Shielding Sleeve for High-Current Cable EMI Reduction
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Solution Overview
Problem
High-current electrical connection systems face challenges in achieving effective electromagnetic shielding while maintaining mechanical stability and low electrical resistance, particularly due to high demands on robustness and quality of electrical contacting, which often require compromises.
Innovation Solution
A shielding system with a hollow cylindrical conductive shielding sleeve that mechanically and electrically connects to the cable shielding, allowing for radial movement and decoupling, and features a fastening strip for secure contact, reducing wear and electromagnetic field leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the cable shielding is rigidly connected to the shielding housing, then mechanical stability is improved, but wear at contact points increases due to vibrations and movement
Solution Approach 1:
The patent applies the dynamics principle by introducing a flexible coupling mechanism between the cable shielding and shielding housing. The connection allows controlled movement and deformation to accommodate vibrations and relative motion, transforming the rigid static connection into a dynamic adaptive connection that reduces wear while maintaining mechanical stability.
Solution Approach 2:
The patent utilizes flexible shielding materials (such as braided mesh or foil with flexibility) that can deform and move relative to each other while maintaining electrical contact. This flexible connection absorbs mechanical stress from vibrations and movement, preventing excessive wear at contact points while preserving both mechanical stability and electrical conductivity.
2Reliability
If the cable shielding is flexibly connected to the shielding housing, then wear at contact points is reduced, but mechanical stability deteriorates
Solution Approach 1:
The flexible connection is designed with controlled compliance that allows movement within certain limits while maintaining overall structural stability. The coupling mechanism provides dynamic adaptation to vibrations and motion while preserving mechanical integrity through proper design of the flexible element's stiffness and geometry.
Solution Approach 2:
The flexible shielding material is configured to provide both flexibility for movement and sufficient mechanical strength for stability. The braided mesh or foil structure inherently combines flexibility with tensile strength, allowing the connection to accommodate relative motion while maintaining mechanical stability and electrical continuity.
3Stability of the object's composition
If a robust mechanical connection is used between cable shielding and shielding housing, then mechanical stability is improved, but electrical resistance increases
Solution Approach 1:
The flexible shielding material (braided mesh or foil) provides continuous electrical contact through its conductive structure. The flexibility of the material allows it to conform and maintain intimate contact with the connection surfaces, ensuring low electrical resistance while accommodating mechanical movement and vibrations.
Solution Approach 2:
The connection system utilizes composite structures combining conductive materials (such as copper-braided mesh or copper-foil) with mechanically robust configurations. This composite approach ensures both low electrical resistance through high-conductivity materials and mechanical stability through proper structural design and mounting arrangements.
4Reliability
If the connection between cable shielding and shielding housing is rigid, then electrical resistance is reduced, but mechanical stability deteriorates due to vibration-induced stress
Solution Approach 1:
The connection system employs dynamic compliance to maintain electrical contact under varying mechanical conditions. The flexible coupling allows the electrical contact surfaces to remain in intimate contact (low resistance) while accommodating vibrations and relative motion that would otherwise cause stress and instability in a rigid connection.
Solution Approach 2:
The flexible conductive shielding material inherently provides both low electrical resistance through its continuous conductive path and mechanical stability through its ability to deform and absorb vibration-induced stress. The material's flexibility allows it to maintain electrical contact while adapting to mechanical movements.
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 system provides improved mechanical stability, reduced wear at contact points, and effective electromagnetic shielding with lower electrical resistance, while allowing for radial movement to mitigate vibration-induced stress and electromagnetic radiation leaks.
Implementation Method 1
In order to avoid impairment of the environment around the conductor due to these electromagnetic fields, for example a surrounding shielding may be required. In the case of high-current lines, for example a shielding braid can be integrated in the line insulation for this purpose.
Implementation Method 2
The cable shielding is electrically connected to the shielding housing via the shielding sleeve
Data Source
AI summary
A shielding system for high-current applications, having a connecting cable that has an insulated conductor (22) and a cable shielding surrounding the insulated conductor, as well as a shielding housing having a feed-through. In addition, the shielding system has a hollow cylindrical and electrically conductive shielding sleeve. The insulated conductor is fed through the shielding sleeve. The shielding sleeve is situated in the area of the feed-through of the shielding housing, so that the shielding housing abuts a jacket surface of the shielding sleeve. The cable shielding lies against a jacket surface of the shielding sleeve. The cable shielding is electrically connected to the shielding housing via the shielding sleeve.