Wire End Cover for High-Voltage Cables with Integrated EMC Shielding
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Solution Overview
Problem
Current solutions for connecting high-voltage cables in hybrid and electric vehicles lack effective electromagnetic shielding and reliable sealing, leading to inadequate electromagnetic compatibility and mechanical stability.
Innovation Solution
A cable end piece with a shielding sleeve and crimp sleeve design that provides electromagnetic shielding, mechanical connection, and reliable sealing through crimping and environmental sealing, combined with a compact and cost-effective design, including an O-ring and EMC sealing ring for enhanced sealing and attachment to a housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cable lugs and makeshift sealing solutions are used for connecting high-voltage cables, then assembly is simple and quick, but electromagnetic shielding is insufficient and sealing reliability is poor
Solution Approach 1:
The patent combines multiple functions into a single integrated cable end piece: the housing provides both mechanical protection and sealing, the shielding sleeve integrates electromagnetic shielding with the housing structure, and the crimp sleeve combines electrical connection with mechanical strain relief. This integration achieves reliable sealing and EMC protection without significantly increasing assembly complexity.
Solution Approach 2:
The patent employs nested structures where the shielding sleeve is inserted into the housing, the crimp sleeve encloses the cable core and outer sheath, and the O-ring seal is positioned within the housing cavity. This nesting approach allows multiple protective functions to coexist in a compact arrangement, improving sealing reliability while maintaining reasonable structural complexity.
2Object-affected harmful factors
If cable lugs and makeshift sealing solutions are used for connecting high-voltage cables, then assembly is simple and quick, but electromagnetic shielding is insufficient
Solution Approach 1:
The shielding sleeve is integrated directly with the housing structure, forming a unified EMC protection system. The cable shield is connected to the shielding sleeve through the crimping process, creating a continuous electromagnetic shield without requiring separate complex shielding components.
Solution Approach 2:
The shielding sleeve acts as an intermediary component between the cable shield and the housing, providing a dedicated path for electromagnetic shielding. This intermediate structure effectively grounds the cable shield while maintaining electrical isolation where needed, improving EMC without excessive complexity.
3Strength
If double crimping is used to mechanically connect the cable outer sheath, then strain relief and mechanical stability are improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines two crimping operations into a single integrated crimping process. The crimp sleeve is crimped simultaneously at two locations: once to the cable core for electrical connection and once to the outer sheath for mechanical strain relief. This integrated approach improves mechanical stability while minimizing the increase in manufacturing complexity.
4Object-affected harmful factors
If the shielding sleeve extends to the area where the outer cable sheath is severed, then electromagnetic shielding is optimized, but the design becomes more complex
Solution Approach 1:
The shielding sleeve is designed with varying properties along its length: the outer diameter and wall thickness are optimized for different sections to balance shielding effectiveness with ease of assembly. The sleeve extends precisely to where the cable sheath is severed to provide optimal EMC protection without unnecessary complexity in the overall design.
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 ensures electromagnetic compatibility, mechanical stability, and reliable sealing, allowing for efficient and cost-effective connection of high-voltage cables with easy assembly and replacement capabilities.
Implementation Method 1
the crimp sleeve lying over the braided shield and the shielding sleeve is crimped in such a way that the shielded sleeve and braided shield are connected to one another in an electrically conductive manner
Implementation Method 2
the shield sleeve carries an environmental seal. This can particularly preferably be implemented by an O-ring that is inserted into a groove
Implementation Method 3
the shielding sleeve can carry a shield connection. This can be realized particularly preferably by an EMC sealing ring that is inserted into a groove
Implementation Method 4
a groove is provided in the shielding sleeve, in which a fastening element for locking the cable end piece on a housing comes to rest
Implementation Method 5
the cable end piece is overmoulded with a plastic. Silicone is particularly suitable as the plastic. The contact surface to the housing can be defined by the shape of the plastic encapsulation
Data Source
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AI summary
The invention relates to a wire end cover (1), particularly for high-voltage wires in hybrid and/or electric vehicles, comprising a screening sleeve (2) onto which a braided screen (11) of the wire is pulled. The wire end cover (1) additionally comprises a crimped sleeve (12) which is crimped in such a way at a first crimped point that the screening sleeve (2) and the braided screen (11) are connected in an electrically conducting manner as a result thereof. The crimped sleeve (12) is crimped with the outer sheath (10) of the wire at a second crimped point.