Shielded Conductor Connector Housing with Integrated Clamping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing solutions for connecting shielded electrical conductors in high-voltage applications, such as in automobiles, are complex and costly due to the use of multiple parts, which compromises electromagnetic compatibility and increases assembly effort and space requirements.
Innovation Solution
A device with an electrically conductive housing that allows shielded conductors to be connected by folding back the shielding layer over a contact section, secured with a single one-piece clamp, minimizing additional components and maintaining electromagnetic compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple individual parts (sleeves, washers, additional housings) are used to connect shielding layers to housing, then electromagnetic compatibility is ensured, but device complexity and assembly effort increase significantly
Solution Approach 1:
The patent integrates multiple separate components (shielding layer contact elements, clamping elements, and housing) into a single integrated housing structure. The housing itself is designed with integrated contact sections and clamping mechanisms that directly engage the shielding layers, eliminating the need for separate sleeves, washers, and additional housings. This merging maintains electromagnetic compatibility while significantly reducing device complexity.
2Reliability
If multiple individual parts are used for connecting shielding layers, then reliable electrical contact is achieved, but assembly effort and space requirements increase
Solution Approach 1:
The housing combines contact and clamping functions into a single integrated structure. The contact sections with clamping mechanisms are built directly into the housing, allowing shielded conductors to be connected in a single assembly operation without requiring multiple separate components to be installed sequentially.
Solution Approach 2:
The housing serves multiple functions simultaneously: it provides mechanical support, establishes electrical contact with shielding layers, and secures the connections through integrated clamping mechanisms. This multi-functionality reduces the number of assembly steps and simplifies the overall connection process while maintaining reliable electrical contact.
3Reliability
If additional housings or protective structures are added to maintain electromagnetic compatibility, then shielding effectiveness is improved, but the space requirement and cost increase
Solution Approach 1:
The patent eliminates the need for additional separate housings or protective structures by integrating all electromagnetic compatibility functions into the main housing. The housing itself is designed with conductive contact sections that maintain shielding continuity, removing the need for extra spatial volume that would be required for separate protective components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a simple, cost-effective structure with low electrical contact resistance, enhancing aging behavior and resistance to environmental influences while maintaining electromagnetic compatibility, allowing for efficient connection of multiple conductors.
Implementation Method 1
They consist, for example, of two electrically conductive wires, each of which is encased in an electrical insulation layer made of plastic. This is followed, for example, by another common plastic layer, which encases both cable strands, which are already insulated. This layer, in turn, is surrounded by a shielding layer, which can have the form of a conductive metallic foil or a mesh, for example, and represents a shield against the interference fields described above.
Implementation Method 2
the part of the shielding layer of the respective conductor that is put over the contact section is fastened there with a single one-piece clamp, with the connection being able to be force-fit, form-fit or a mixture of both types of connection.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a device for connecting electrical conductors (31, 32, 3n) having shielding layers (21, 22, 2<sb />) in a electromagnetically compatible manner against interference fields, particularly in motor vehicles. The conductors (31, 32, 3n) to be connected are guided in a housing (5) of the device, which is also referred to as high-voltage distributor. In order to ensure the electromagnetic shielding, the shielding layers (21, 22, 2n), of the stripped cables are turned inside out and are pulled over contact segments (11, 12, 1n) of the housing (5) provided therefor, as a result of which an electrical contacting takes place. The fixing of the shielding layers (21, 22, 2n) is realized by one terminal (41, 42, 4n) each.