Shielded HV Connector Assembly With Integrated EMI Grounding
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Solution Overview
Problem
Current high-voltage connection mechanisms for electric vehicles have complex structures, high costs, and inadequate electromagnetic shielding, leading to increased assembly time and risk of short-circuits due to the lack of effective shielding devices.
Innovation Solution
A connection mechanism with a shield, featuring an inner shell integrally injection-molded with a functional cable and plug-in terminal, and a protective shielding shell connected to the shielding layer and grounding terminal, providing effective electromagnetic shielding and reducing assembly complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a metal cover is used for shielding, then electromagnetic shielding effect is improved, but device complexity and assembly time increase
Solution Approach 1:
The patent combines the shielding function with the existing connection mechanism structure by integrating a shielding layer into the cable assembly and using the inner shell as a shielding component. This merging approach eliminates the need for separate metal cover components, reducing assembly steps while maintaining electromagnetic shielding effectiveness.
Solution Approach 2:
The patent introduces an inner shell made of electromagnetic shielding material that acts as an intermediary between the cable assembly and the external environment. This inner shell provides the necessary shielding function without requiring additional metal covers, simplifying the overall structure and assembly process.
2Object-affected harmful factors
If a metal cover is used for shielding, then electromagnetic shielding effect is improved, but manufacturing cost increases
Solution Approach 1:
The shielding function is merged into the existing cable assembly and connection mechanism structure. The shielding layer is integrated with the cable insulation, and the inner shell serves dual purposes as both structural support and electromagnetic shield, eliminating the need for separate metal cover components and reducing material and manufacturing costs.
Solution Approach 2:
The patent uses cost-effective shielding materials such as conductive polymers or metalized films instead of expensive solid metal covers. These materials provide adequate shielding performance at lower cost and can be easily applied during the manufacturing process, reducing overall production expenses.
3Object-affected harmful factors
If a metal cover is placed inside the connection mechanism, then shielding effect is improved, but risk of short-circuit increases
Solution Approach 1:
The patent uses an inner shell as an intermediary shielding structure that is properly isolated from conductive cores through insulation layers. This intermediary structure provides electromagnetic shielding while maintaining safe electrical distances, preventing short-circuits between the shielding layer and conductive elements.
Solution Approach 2:
The shielding layer is applied selectively in specific locations where electromagnetic interference is most problematic, rather than using a complete metal cover. The shielding is concentrated around the cable assembly and connection terminals, providing effective protection while maintaining proper insulation and reducing short-circuit risks.
4Adaptability or versatility
If traditional assembled structure is used, then flexibility in design is improved, but assembly time and complexity increase
Solution Approach 1:
The patent merges multiple components including the cable, insulation layer, shielding layer, and connection terminals into an integrated assembly. This unified structure reduces the number of separate parts that need to be assembled, significantly decreasing assembly time and complexity while maintaining design flexibility through modular connection interfaces.
Solution Approach 2:
The shielding layer and connection terminals are pre-assembled and pre-positioned during the cable manufacturing process, rather than being assembled separately at the final assembly stage. This preliminary action reduces on-site assembly steps and time, while the modular design maintains flexibility for different application requirements.
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 simplifies processing, reduces costs, and effectively shields electromagnetic interference, ensuring safer and more reliable high-voltage connections by integrating the shielding function directly into the connection mechanism.
Implementation Method 1
the protective shielding shell is at least partially electrically connected to the shielding layer... effectively shield electromagnetic interference in the connection mechanism, and reduce the electromagnetic interference on other devices
Data Source
AI summary
The present disclosure provides a connection mechanism having a shield, an electric energy transmission apparatus and a motor vehicle, in which the connection mechanism includes a functional cable, a plug-in terminal, a protective conductor, a grounding terminal, an inner shell integrally formed with the functional cable and the plug-in terminal, and a protective shielding shell disposed on at least part of an outer periphery of the inner shell; the functional cable is provided having a shielding layer, one end of the protective shielding shell is at least partially electrically connected to the shielding layer, and the other end thereof is at least partially electrically connected to the protective conductor or the grounding terminal; the connection mechanism having a shield is provided with the inner shell which is integrally injection-molded with the functional cable and the plug-in terminal.