Shielded High-Current Connector With Cap-Closed Screw Access
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Solution Overview
Problem
High-current connectors in the automotive sector face challenges in establishing secure screw fittings due to shielding holes in electromagnetic shields, leading to cumbersome and cost-intensive connections, especially in environments with high currents and voltages.
Innovation Solution
An electrical high-current connector with an electrically insulating connector housing, an electromagnetically shielded contact device, and a clamping screw, featuring a protective cap that closes the shielding hole electromagnetically, allowing for secure and efficient connection of high-current lines, including stranded or solid material lines, and busbars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a screwable connection is made in a layer of the structure of an electrical high-current connector, then mechanical bracing and electrical contact are achieved, but shielding holes are created that compromise electromagnetic shielding
Solution Approach 1:
A shielding cap is introduced as an intermediary component that fills the shielding hole created by the screwable connection. The shielding cap acts as a mediator between the mechanical bracing requirement (screw connection) and the electromagnetic shielding requirement, blocking electromagnetic fields while allowing mechanical fastening to proceed through the cap structure.
Solution Approach 2:
The connector structure is segmented into separate functional components: the main connector body, the shielding hole, and the removable shielding cap. This segmentation allows the shielding function to be independently addressed and maintained even when mechanical connections require openings in the shielding layer.
2Object-affected harmful factors
If a protective cap is added to close shielding holes, then electromagnetic shielding is improved, but device complexity increases
Solution Approach 1:
The shielding cap is merged with the protective cap function, combining electromagnetic shielding and safety protection into a single integrated component. This reduces overall device complexity by eliminating the need for separate shielding and protective elements.
Solution Approach 2:
The protective cap serves multiple functions simultaneously: it closes shielding holes to maintain electromagnetic shielding, provides physical protection for the connector contacts, and ensures safety by preventing accidental contact with live electrical components. This multi-functionality reduces the need for additional separate 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 robust, cost-effective, and flexible high-current connector capable of handling high currents and voltages, ensuring reliable electrical contact while being safe to touch and easy to diagnose, repair, and recycle, with enhanced electromagnetic shielding and vibration resistance.
Implementation Method 1
at least one shielding hole in an electromagnetic shield of the contact device can be closed and/or is closed electromagnetically by means of the protective cap
Implementation Method 2
at least one clamping screw for mechanically bracing an electrical contact means of the contact device
Implementation Method 3
the electrical path is used as a low-resistance electrical contact connection
Data Source
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AI summary
The invention relates to an electrical high-current connector (10) for a high-current line (20) consisting of copper or aluminium, in particular for the automotive sector, comprising an electrically insulating connector housing (100), at least one electromagnetically shielded (136) contact device (130) and at least one clamping screw (120) for mechanically bracing an electrical contact means (110) of the contact device (130), wherein an electrically insulating protective cap (1000) of the high-current connector (10) can be provided or is provided at/on the connector housing (100), wherein at least one shielding hole (135) in an electromagnetic shield (136) of the contact device (130) can be closed and/or is closed electromagnetically by means of the protective cap (1000).