Wiring system architecture

Patent metadata

Field	Value
Publication number	US-11260809-B2
Application number	US-201816231314-A
Country	US
Kind code	B2
Filing date	Dec 21, 2018
Priority date	Jan 18, 2018
Publication date	Mar 1, 2022
Grant date	Mar 1, 2022

Abstract

A new wiring and power and communications system for an automobile that includes a plurality of devices, wherein the devices are connected to a backbone section that has an outer sheathing, a first conductor disposed within the outer sheathing, a second conductor disposed within the outer sheathing, a pair of inner sheathing members disposed within the outer sheathing and located on opposing sides of the at least one conductor, the inner sheathing members configured to electrically insulate the first conductor from the second conductor, and a shield member disposed within the outer sheathing.

First claim

What is claimed is:

1. A backbone section comprising:
an outer sheathing;
a first conductor disposed within the outer sheathing, wherein the first conductor is adjacent to a first wall of the outer sheathing;
a second conductor disposed within the outer sheathing, wherein the second conductor is adjacent to a second wall of the outer sheathing, the second wall opposite the first wall of the outer sheathing;
a pair of inner sheathing members disposed within the outer sheathing, one end of the pair of inner sheathing members disposed adjacent to the first wall of the outer sheathing and an opposite end of the pair of inner sheathing extending away from the first wall perpendicularly, the inner sheathing members located on opposing sides of at least one of the first and second conductors, the pair of inner sheathing members configured to electrically insulate the first conductor and the second conductor; and
a shield member disposed within the outer sheathing.

2. A backbone connector comprising:
a base plate;
a sheathed conductor comprising a sheath and one or more conductors, wherein the sheath encompasses the one or more conductors;
a PCBA itself comprising a seal gasket and EMI shield, the PCBA configured to electrically connect to the one or more conductors;
at least one window comprising a hole cut into the sheath of the sheathed conductor to expose at least one of the one or more conductors, wherein the one or more conductors are configured to electrically connect to the PCBA through the window; and
multiple posts each engaged with a nut to hold the PCBA to the base plate, wherein the multiple posts align the base plate, sheathed conductor, and the PCBA and electrically connect the one or more conductors of the sheathed conductor and the PCBA.

3. The backbone connector of claim 2 wherein the multiple posts are incorporated into the base plate in a single piece.

4. The backbone connector of claim 3 wherein the EMI shield comprises a conductive polymer.

5. The backbone connector of claim 3 wherein the EMI shield comprises metallic nanoparticles dispersed within a polymeric matrix.

6. A backbone connector comprising:
a base plate;
a tentacle cable comprising a sheath and one or more conductors, wherein the sheath encompasses the one or more conductors;
a PCBA attached to an umbilical cable, wherein the PCBA is configured to electrically connect to the tentacle cable;
at least one window, a window comprising a cut into the sheath of the tentacle cable, wherein at least one of the one or more of the one or more conductors is exposed by the at least one window;
an upper cover; and
multiple posts that hold and align the base plate, tentacle cable, and the PCBA attached to the umbilical cable, wherein the alignment makes the electrical connection between the tentacle cable and the PCBA through the at least one window.

7. The backbone connector of claim 6 , wherein the upper cover comprises a receptacle ring.

8. The backbone connector of claim 6 , wherein the base plate further comprises a sealing gasket and the multiple posts.

9. The backbone connector of claim 6 , wherein the upper cover comprises the multiple posts, a shield layer made of a conductive material, and a gasket.

10. The backbone connector of claim 9 , wherein the shield layer is on an exterior of the upper cover.

11. The backbone connector of claim 9 , wherein the shield layer is on an interior of the upper cover.

12. The backbone connector of claim 9 , wherein the gasket is made of a conductive material.

13. A method of assembling a backbone connector to connect a backbone section to an umbilical cable in a vehicle, comprising:
installing a base plate to a location in the vehicle, wherein the base plate comprises multiple posts;
installing a sheathed conductor comprising a sheath and one or more conductors, wherein the sheath encompasses the one or more conductors;
installing at least one window on the sheathed conductor, the window comprising a hole cut into the sheath of the sheathed conductor to expose at least one of the one or more conductors;
installing the backbone section that contains an alignment hole such that the alignment hole aligns with one or more of the multiple posts;
installing a PCBA over the multiple posts such that at least a portion of the posts passes through the PCBA, the PCBA configured to electrically connect to the one or more conductors through the window; and
attaching nuts to the posts for securing the PCBA to the base plate.

14. The method of claim 13 , wherein after the nuts have secured the PCBA to the base plate, the assembled backbone connector meets IP67 ingress protection.

15. A method of assembling a backbone connector to connect a backbone section to an umbilical cable in a vehicle, comprising:
installing a base plate to a location in the vehicle, the base plate comprising multiple posts;
installing a sheathed conductor comprising a sheath and one or more conductors, wherein the sheath encompasses the one or more conductors;
installing at least one window on the sheathed conductor, the window comprising a hole cut into the sheath of the sheathed conductor to expose at least one of the one or more conductors, wherein an electrical connection between the one or more conductors and a PCBA can be made through the window;
installing the backbone section that contains an alignment hole such that the alignment hole aligns with one or more of the multiple posts;
installing the PCBA over the multiple posts such that at least a portion of the posts passes through the PCBA, the PCBA configured to electrically connect to the one or more conductors; and
attaching an upper cover that comprises a snap receptacle ring and a shield layer.

16. The method of claim 15 wherein after nuts have secured the PCBA to the base plate, the assembled backbone connector meets IP67 ingress protection.

17. A method of assembling a backbone connector to connect a backbone section to an umbilical cable in a vehicle, comprising:
installing a base plate to a location in the vehicle;
installing a sheathed conductor comprising a sheath and one or more conductors, wherein the sheath encompasses the one or more conductors;
installing at least one window on the sheathed conductor, the window comprising a hole cut into the sheath of the sheathed conductor to expose at least one of the one or more conductors, wherein an electrical connection between the one or more conductors and a PCBA can be made through the window;
installing the backbone section that contains an alignment hole such that the alignment hole aligns with one or multiple posts;
installing the PCBA over the multiple posts such that at least a portion of the posts passes through the PCBA, the PCBA configured to electrically connect to the one or more conductors; and
attaching an upper cover that comprises multiple posts, a gasket, multiple snap hooks, and a shield layer.

18. The method of claim 17 , wherein after nuts have secured the PCBA to the base plate, the assembled backbone connector meets IP67 ingress protection.

Assignees

• Tesla Inc

Inventors

• Chandra Satyan
• Chung In Jae
• Esmail Adnan
• Blum Matthew
• Bhandari Rishabh

Classifications

• B60R16/03 Primary

  for supply of electrical power to vehicle subsystems {or for (circuit arrangements for charging batteries H02J7/00)} · CPC title

• H05K9/0098

  for shielding electrical cables · CPC title

• H05K1/0216

  Reduction of cross-talk, noise or electromagnetic interference (grounding H05K1/0215) · CPC title

• H01R12/62

  connecting to rigid printed circuits or like structures · CPC title

• H05K9/003

  made from non-conductive materials comprising an electro-conductive coating (H05K9/0031 takes precedence) · CPC title