Anti-Interference Water-Resistant High-Voltage Cable Solution for New Energy Vehicles

I. Solution Overview​
With the rapid development of new energy vehicles toward higher voltage and greater intelligence, the performance requirements for internal high-voltage cables have become more stringent than ever. Traditional high-voltage cables commonly suffer from three major drawbacks: susceptibility to electromagnetic interference, poor stability of internal cores, and inadequate protection against water and physical compression. These issues severely impact the safety and reliability of the vehicle.

Based on a utility model patent, this solution proposes a novel anti-interference water-resistant high-voltage cable. Through an innovative three-layer functional structure design, it systematically addresses all the above problems, providing a safer, more stable, and more durable energy and signal transmission carrier for new energy vehicles.

​II. Overall Cable Structure and Core Components​
The core of this solution lies in its innovative design of "one basic framework and three functional structures."

1. ​Basic Framework Structure​
   This framework forms the main body of the cable, providing a foundational platform for functional implementation.
• ​Inner Sheath (1)​: Serves as the basic protective layer inside the cable, uniformly distributing four sets of cores to provide installation space and initial protection.
• ​Cores (3)​: Four sets in total, these are the core components for transmitting energy and signals. Each core is pre-wrapped with a shielding collar, laying the foundation for the cable’s anti-interference capability.
• ​Separation Layer (8)​: Located outside the inner sheath, it separates the internal and external structures and enhances the cable’s overall water resistance.
2. ​Three Functional Structures​
   These three structures target the different shortcomings of traditional cables, delivering precise solutions for comprehensive performance improvement.
• ​​(1) Fixation Structure (2) – Addressing Core Displacement and Wear​
• ​Location: Between the cores and the inner sheath.
• ​Composition: Shielding collar (201), filler particles (202), tooth blocks (203), and connecting blocks (204).
• ​Key Features: All shielding collars are arranged concentrically around the connecting block and interlock via tooth blocks on the outer side of the shielding collars and connecting blocks.
• ​Function: The four cores are precisely assembled into a stable unit through the interlocking tooth blocks. Combined with the filler particles in the inner sheath, this eliminates displacement, mutual friction, and compression of the cores during installation or vibration, significantly enhancing structural stability and durability.
• ​​(2) Anti-Interference Structure (4) – Addressing Signal Interference​
• ​Location: Between the separation layer and the inner sheath.
• ​Composition: Buffer material (401), insulation layer (402), braided shield (403), grooves (404), and covering strips (405).
• ​Key Features: The braided shield is spirally wrapped around the insulation layer and securely fixed via grooves on the inner side of the covering strips, ensuring it remains flush with the insulation layer.
• ​Function: The insulation layer provides basic insulation protection. The spirally braided shield forms a robust electromagnetic barrier. The covering strips prevent misalignment or detachment of the shield. The buffer material enhances structural strength and prevents deformation of the shielding layer. This structure works in synergy with the shielding collars on the cores to create a dual-shielding effect, ensuring pure and stable transmission of energy and signals in complex electromagnetic environments.
• ​​(3) Protection Structure – Addressing Physical Compression and Moisture Ingress​
• ​Location: Outermost layer of the separation layer, serving as the first line of defense against external damage.
• ​Composition: Water-blocking strips (5), chambers (9), sealing layer (6), foaming adhesive (7), and friction particles (10).
• ​Key Features: The water-blocking strips contain multiple chambers filled with foaming adhesive, and their outer surface is evenly spaced with friction particles.
• ​Function:
• ​Smart Self-Healing Protection: When the cable is subjected to sharp external force causing the water-blocking strip to rupture, the foaming adhesive in the chambers rapidly expands and solidifies instantly, preventing further penetration and significantly reducing the risk of damage to internal components.
• ​Excellent Water Resistance: The water-blocking strips work in synergy with the internal separation layer to form a tight waterproof system, effectively blocking moisture ingress and preventing internal short circuits and corrosion.
• ​Easy Installation: The friction particles on the outer wall increase the cable’s grip with external contact surfaces, facilitating easier routing and fixation within the vehicle body.

​III. Addressing Three Traditional Technical Challenges​
This solution directly tackles industry pain points, perfectly resolving three core issues that have long plagued traditional high-voltage cables:

1. ​Effective Resistance to External Force and Moisture: Through an innovative protection structure integrating smart self-healing (foaming adhesive) and physical water resistance (water-blocking strips), it fundamentally transforms the passive protection approach of traditional cables, actively safeguarding internal components.
2. ​Elimination of Internal Core Damage: The fixation structure’s interlocking tooth blocks and filler particles integrate the four loose cores into a solid, stable unit, preventing internal wear caused by vibration and compression, thereby extending lifespan.
3. ​Superior Electromagnetic Interference Resistance: The dual-shielding combination of the anti-interference structure’s spirally braided shield and the cores’ built-in shielding collars delivers far better performance than traditional single-layer shielding, adapting to the extremely complex signal environment within the vehicle and ensuring transmission quality.

​IV. Conclusion​
This high-voltage cable solution achieves three major breakthroughs in protection capability, structural stability, and anti-interference performance through systematic structural innovation. It is a comprehensive solution tailored for the high-voltage platform requirements of future new energy vehicles. Its application will significantly enhance vehicle safety, reliability, and performance, providing a solid foundation for the continued development of new energy vehicles.