Shielded Connector Assembly Using Conductive-Particle Insulation
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Solution Overview
Problem
Current connector assemblies for new energy vehicles face challenges due to the high weight and cost of multi-core copper cables, which are prone to damage from rubbing against the vehicle shell, leading to high-voltage discharges and potential traffic accidents. Additionally, the use of braided metal wire shielding nets is costly and inefficient.
Innovation Solution
A connector assembly made of a novel shielding material, featuring an electric connection skeleton coated with an insulating layer containing conductive particles in a radial direction, which provides a shielding effect without the need for a braided shielding net. This design reduces cable weight, simplifies production, and enhances electromagnetic compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multi-core copper cables are used to transmit high current, then the current transmission capability is improved, but the weight and cost of the cables increase significantly
Solution Approach 1:
The patent changes the material parameters of the cable core from copper to aluminum alloy, which has lower density and weight. The insulating layer is modified by adding conductive particles to achieve shielding effects. This parameter change allows the cable to maintain current transmission capability while significantly reducing weight.
Solution Approach 2:
The patent uses composite materials: aluminum alloy for the electric connection skeleton to reduce weight, and a composite insulating layer made of base material plus conductive particles (such as metal powder or carbon particles) to provide both insulation and electromagnetic shielding. This composite approach solves both weight and shielding requirements simultaneously.
2Power
If multi-core copper cables with large diameter are used, then high current transmission is achieved, but the cables frequently rub against the vehicle shell causing damage and high-voltage discharge
Solution Approach 1:
By changing from copper to aluminum alloy, the cable diameter is reduced while maintaining the same current transmission capability. This reduced diameter eliminates the rubbing problem against the vehicle shell, improving reliability and preventing high-voltage discharge incidents.
3Object-affected harmful factors
If a braided metal wire shielding net is added to shield electromagnetic interference, then the shielding effectiveness is improved, but the equipment cost and occupied area increase
Solution Approach 1:
The patent merges the shielding function into the insulating layer by adding conductive particles. Instead of having a separate shielding net layer, the shielding capability is integrated directly into the insulating material itself. This eliminates the need for additional braiding equipment and reduces production complexity.
Solution Approach 2:
The insulating layer is given multiple functions: it provides electrical insulation, contains conductive particles for electromagnetic shielding, and maintains structural integrity. This multi-functionality eliminates the need for separate shielding components and simplifies the overall cable structure.
4Object-affected harmful factors
If a braided metal wire shielding net is used, then electromagnetic shielding is achieved, but the production cost and occupied area increase
Solution Approach 1:
The shielding function is merged into the insulating layer formulation. Conductive particles are mixed into the insulating material during manufacturing, eliminating the need for separate shielding net production and assembly processes. This reduces both production cost and occupied area.
Solution Approach 2:
The patent extracts the shielding function from the traditional braided net structure and implements it through conductive particles embedded in the insulating layer. This extraction simplifies the manufacturing process and reduces the need for specialized equipment and materials.
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 proposed solution reduces the weight and cost of cables, prolongs the service life of the connector assembly, and improves electromagnetic shielding, thereby enhancing safety and reducing the risk of traffic accidents.
Implementation Method 1
the insulating layer internally includes conductive particles in a radial direction, and at least one location of the conductive particles is distributed in the insulating layer in a density-unevenness manner
Data Source
AI summary
Disclosed in the present disclosure are a connector assembly made of a novel shielding material and a vehicle. The novel connector assembly includes an electric connection skeleton and connectors connected to two ends of the electric connection skeleton, in which each of the connectors internally includes a connection terminal and an inner shell with shielding effectiveness, the two ends of the electric connection skeleton are electrically connected to connection terminals, respectively, an outer periphery of the electric connection skeleton is coated with an insulating layer, the insulating layer internally includes conductive particles in a radial direction, and at least one location of the conductive particles is distributed in the insulating layer in a density-unevenness manner.