High-current flexible conductive circuits with connectors
A flexible conductive assembly includes a flexible shielded high-current circuit having first and second circuit portions, each with conductive layers and an electromagnetic shield. Contacts are mechanically and electrically coupled to the conductive layers and extend into a connector housing. The housing incorporates electromagnetic shield portions electrically joined to the circuit shields, and a wire seal that protects against environmental ingress while maintaining electrical isolation. By combining flat conductor layers, integrated shielding, and sealed connector structures, the assembly provides a compact, lightweight, and reliable flexible shielded circuit for transmitting high currents with reduced electromagnetic emissions.
1 . A flexible conductive assembly comprising:
a flexible shielded high-current circuit comprising a first circuit portion and a second circuit portion, wherein each of the first circuit portion and the second circuit portion comprises a first conductive layer, which is a metal sheet, a circuit electromagnetic shield, a first contact mechanically and electrically coupled to the first conductive layer of the first circuit portion, and a second contact mechanically and electrically coupled to the first conductive layer of the second circuit portion; and
a connector comprising a housing comprising a first housing portion, a first electromagnetic shield portion, and a wire seal, wherein:
the first electromagnetic shield portion is electrically coupled to the circuit electromagnetic shield of each of the first circuit portion and the second circuit portion and at least partially surrounds the first contact and the second contact, and
each of the first circuit portion and the second circuit portion at least partially protrudes into the housing and is sealed, relative to the housing, by the wire seal.
2 . The flexible conductive assembly of claim 1 , wherein:
each of the first circuit portion and the second circuit portion further comprises a first insulating layer, a second insulating layer, a third insulating layer, and a second conductive layer,
the first insulating layer, the first conductive layer, the second conductive layer, the second insulating layer, the electromagnetic shield, and the third insulating layer are stacked along a stacking axis,
the first conductive layer and the second conductive layer directly interface and form a stack positioned between the first insulating layer and the second insulating layer, and
the electromagnetic shield is positioned between the second insulating layer and the third insulating layer and is configured to block electromagnetic emissions produced by the stack while transmitting an electric current.
3 . The flexible conductive assembly of claim 2 , wherein the stack is configured to transmit an electric current of more than 400 Amperes.
4 . The flexible conductive assembly of claim 2 , wherein each of the first conductive layer and the second conductive layer comprises aluminum.
5 . The flexible conductive assembly of claim 2 , wherein each of the first conductive layer and the second conductive layer has a thickness, measured along the stacking axis, of at least 400 micrometers.
6 . The flexible conductive assembly of claim 2 , wherein the first conductive layer and the second conductive layer have the same thickness.
7 . The flexible conductive assembly of claim 2 , wherein each of the first insulating layer and the second insulating layer comprises polypropylene (PP).
8 . The flexible conductive assembly of claim 7 , wherein each of the first insulating layer and the second insulating layer further comprises polyethylene (PE) such that the polypropylene (PP) forms a first sublayer while the polyethylene (PE) forms a second sublayer directly interfacing the first sublayer.
9 . The flexible conductive assembly of claim 2 , wherein the electromagnetic shield is a metal sheet having a thickness, measured along the stacking axis, of 20-150 micrometers.
10 . The flexible conductive assembly of claim 2 , wherein the electromagnetic shield of the first circuit portion is mechanically and electrically coupled with the first electromagnetic shield portion.
11 . The flexible conductive assembly of claim 1 , wherein at least a portion of the first contact extends away from the first circuit portion in a direction perpendicular to a plane parallel with a portion of the first circuit portion.
12 . The flexible conductive assembly of claim 1 , wherein each of the first contact and the second contact is formed from copper.
13 . The flexible conductive assembly of claim 1 , wherein:
the connector further comprises a blocker positioned between the first contact and the wire seal,
the first contact is welded to the first conductive layer of the first circuit portion of the flexible shielded high-current circuit, and
the second contact is welded to the first conductive layer of the second circuit portion of the flexible shielded high-current circuit.
14 . The flexible conductive assembly of claim 1 , wherein the housing comprises a first housing portion and a second housing portion removably attached to each other and enclosing the first contact, the second contact, the first electromagnetic shield portion, and a portion of each of the first circuit portion and the second circuit portion extending into the connector.
15 . The flexible conductive assembly of claim 14 , wherein the housing further comprises a circuit seal enclosing a portion of each of the first housing portion, the second housing portion, the first circuit portion, and the second circuit portion.
16 . The flexible conductive assembly of claim 15 , wherein:
the circuit seal comprises a blocker and a wire seal, and
a portion of the blocker is positioned between the first circuit portion and the second circuit portion and a portion of the blocker extends from the first housing portion to the second housing portion.
17 . The flexible conductive assembly of claim 16 , wherein the first housing portion, the second housing portion, and blocker each comprise a set of ribs interfacing and compressed against the first circuit portion or the second circuit portion.
18 . The flexible conductive assembly of claim 1 , wherein:
the first housing portion comprises connector alignment protrusions,
the first contact comprises connector alignment notches, and
the connector alignment protrusions protrude into a volume defined by the connector alignment notches.
19 . The flexible conductive assembly of claim 1 , wherein the flexible conductive assembly further comprises a first terminal position assurance (TPA) device positioned between the first contact and the second circuit portion and mechanically coupled with the first housing portion, thereby securing the first contact to the first housing portion.
20 . A method of forming a flexible conductive assembly comprising a flexible shielded high-current circuit, the method comprising:
welding a first contact to a first conductive layer of a first circuit portion comprising an electromagnetic shield, a first insulating layer, a second insulating layer a third insulating layer, and a second conductive layer, wherein the first insulating layer, the first conductive layer, the second conductive layer, the second insulating layer, the electromagnetic shield, and the third insulating layer are stacked along a stacking axis;
welding a second contact to a first conductive layer of a second circuit portion comprising an electromagnetic shield, a first insulating layer, a second insulating layer, a third insulating layer and a second conductive layer, wherein the first insulating layer, the first conductive layer, the second conductive layer, the second insulating layer, the electromagnetic shield, and the third insulating layer are stacked along a stacking axis;
positioning the first contact within a first housing portion comprising a first electromagnetic shield portion, a first connector opening, and a second connector opening such that a portion of the first contact extends into the first connector opening and a portion of the first circuit portion extends out of the first housing portion;
welding the electromagnetic shield of the first circuit portion to the first electromagnetic shield portion;
positioning the second contact within the first housing portion such that a portion of the second contact extends into the second connector opening and a portion of the second circuit portion extends out of the first housing portion;
welding the electromagnetic shield of the second circuit portion to the first electromagnetic shield portion; and
attaching a second housing portion comprising a second electromagnetic shield portion with first housing portion such that the second electromagnetic shield portion is positioned between a portion of the second circuit portion and the second housing portion and the second electromagnetic shield portion electrically contacts the first electromagnetic shield portion.