Shielded Connector Assembly Using Conductive Plastic for Lighter EV Cables
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Solution Overview
Problem
The existing connector assemblies in new energy automobiles face challenges due to the high current requirements, leading to heavy and expensive multi-core copper cables that are prone to damage from friction with the vehicle shell, and the high cost of shielding cables due to the need for expensive braiding equipment.
Innovation Solution
The use of an electrical connection skeleton instead of multi-core copper cables, combined with conductive plastics or paint to replace braided shielding nets, reduces cable diameter and weight, minimizes friction, and lowers production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multi-core copper cables are used to meet high current requirements, then current carrying capacity is improved, but cable weight and diameter increase
Solution Approach 1:
The patent uses composite materials including aluminum core, copper shielding layer, and polymer insulation to create a cable that meets high current requirements while reducing weight. The aluminum core provides current carrying capacity, the copper shielding layer enables electromagnetic interference shielding, and the polymer materials reduce overall density compared to traditional multi-core copper cables.
Solution Approach 2:
The patent changes material parameters by substituting copper with aluminum for the conductor core, which has lower density but sufficient conductivity for high current applications. This parameter change reduces cable weight while maintaining current carrying capacity through optimized cross-sectional area and material properties.
2Power
If multi-core copper cables are used to meet high current requirements, then current carrying capacity is improved, but cable diameter increases
Solution Approach 1:
The composite cable structure with aluminum core and polymer insulation achieves higher current carrying capacity per unit diameter compared to traditional copper cables. The optimized material combination allows for more efficient space utilization and reduced overall cable diameter.
Solution Approach 2:
By changing from copper to aluminum and optimizing the cross-sectional parameters, the patent reduces cable diameter while maintaining current carrying capacity. The aluminum conductor with optimized gauge and the efficient insulation layer contribute to reduced overall diameter.
3Object-affected harmful factors
If braided shielding net is used for electromagnetic interference shielding, then shielding effect is improved, but equipment complexity and production cost increase
Solution Approach 1:
The patent changes the shielding approach from mechanical braiding to a coating process. The conductive paint or metallic coating is applied directly to the cable surface, eliminating the need for complex braiding machinery while achieving effective electromagnetic interference shielding through the conductive layer.
Solution Approach 2:
The patent replaces the mechanical braiding system with a coating system. Instead of using mechanical processes to braid metal wires into a shielding net, the invention uses painting or coating processes to deposit a conductive layer, simplifying the equipment and production process.
4Object-affected harmful factors
If braided shielding net is used for electromagnetic interference shielding, then shielding effect is improved, but production cost increases
Solution Approach 1:
The patent replaces expensive mechanical braiding equipment with simpler coating equipment. The conductive paint or metallic coating can be applied using standard painting or deposition machinery, significantly reducing capital investment and production costs while maintaining shielding effectiveness.
Solution Approach 2:
The patent uses conductive paint or coating materials that are cheaper than braided metal wire shielding nets. The coating process uses relatively inexpensive conductive materials applied in thin layers, reducing material costs compared to traditional braided copper or aluminum shielding nets.
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
This solution reduces the weight and diameter of the cables, facilitates easier installation, extends the service life of the connector assembly, and lowers production costs while maintaining effective electromagnetic shielding.
Implementation Method 1
the conductive medium layer is made of conductive polymer material... the conductive medium layer is electrically connected to the inner shell
Data Source
AI summary
The disclosure discloses a connector assembly using a new shielding material, and a vehicle, and relates to the technical field of automotive electrical appliances. The connector assembly includes an electrical connection skeleton and connectors, in which each of the connectors includes a connection terminal and an inner shell, two ends of the electrical connection skeleton are electrically connected to connection terminals respectively, periphery of the electrical connection skeleton is covered with an insulation layer and a conductive medium layer from the inside to the outside, the conductive medium layer is electrically connected to the inner shell, and the conductive medium layer is made of conductive plastic or conductive paint.