Method for electromagnetic interference (EMI) protection of a high voltage connector assembly having a high voltage vertical disc ferrule

Abstract

A method for reducing the effects of electromagnetic interference (EMI) to provide EMI protection to a connector assembly using at least one vertical disc-shaped ferrule. The method includes the steps of providing a flared portion, a first portion, of a wire shield to at least one vertical disc-shaped ferrule, or securing the flared portion between two of the vertical disc-shaped ferrules. Furthermore, one of the steps of providing a ferrule having a surface that directly contacts a metal connector housing, or providing a flared portion of the wire shield that directly contacts the metal connector housing, wherein the EMI is conducted from the metal connector housing to the ferrule or flared portion, further to the flared portion of the wire shield, further through the second portion of the wire shield, and further to ground, wherein the EMI is generated by at least the metal connector housing.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This patent application claims priority to U.S. Provisional Patent Application No. 63 / 051,517, filed on July 14, 2020, which is incorporated herein by reference in its entirety. Background Art

[0003] Electromagnetic interference (EMI) affects circuits due to interference from a source, either through electromagnetic induction, electrostatic coupling, or conduction. EMI can degrade the performance of a circuit or even cause it to cease functioning. Where the circuit includes a data path, EMI can impact the effectiveness of the data path by increasing the error rate relative to the overall loss of data. Sources that can generate currents and voltages that can cause EMI include, for example, automotive injection systems, mobile phone cellular networks, and the like. Therefore, it is necessary to manage the generation of EMI to avoid the adverse effects caused thereby; thereby maximizing the effectiveness of circuits that may be susceptible to the adverse effects of EMI.

[0004] Ways to avoid or reduce the adverse effects of EMI include conduction, shielding, and the like. EMI protection through conduction is achieved by conducting EMI between conductive elements or conductors that are in physical contact, while EMI protection through shielding is achieved by shielding radiated EMI by induction (i.e., the absence of physical contact between conductors). In a connector assembly, conducted EMI is directed through the path of adjacent conductive elements or conductors toward the device to which the connector assembly is attached or mounted, which serves as a ground.

[0005] It is therefore desirable that the structure or structural arrangement of the ferrule employed in the high voltage connector of the present invention can provide complete or substantial EMI coverage by covering the apertures in the corresponding housing, which allows for complete coverage of the interior of the opening of the corresponding connector housing used with the ferrule, and that no secondary cutting is required when the ferrule is attached to the wire braid shield, thereby minimizing or reducing the likelihood of stray strands of the wire braid shield (ground circuit) contacting the wire core (power circuit), and providing a forgiving take up or tolerance to enhance the ferrule's assembly method. Summary of the Invention

[0006] The present invention relates to a method for reducing the effects of electromagnetic interference (EMI) by providing EMI protection to a high-voltage connector assembly, the high-voltage connector assembly using a high-voltage vertical disc-shaped collar with different embodiments. The high-voltage vertical disc-shaped collar of the high-voltage connector assembly is a vertical (or vertical) disc-shaped structure; the disc-shaped structure is mainly made of a flat surface, and its outer edge, edge or vertical shape or constraint is not necessarily circular or does not necessarily have any roundness. The high-voltage vertical disc-shaped collar of the high-voltage connector is a conductive device having a hole or opening at its center. The hole or hole is located above the wire core and the wire braided shield, and the end of the wire braided shield is fixed to the high-voltage vertical disc-shaped collar or fixed between the collars so that a portion of the wire braided shield is open and substantially perpendicular to the direction of the wire core. The hole or hole at the center of the high-voltage vertical disc-shaped collar accommodates the wire core, the wire core insulation part and / or the wire braided shield therein; the wire braided shield is located above the wire core insulation part.

[0007] Once the vertical disc-shaped ferrule of the high-voltage connector assembly is fixed to the wire braid shield, it slides on the core insulation toward the point or position where the outer insulation is cut (the vertical (or vertical) surface of the outer insulation). The wire braid shield is pushed back and allows the wire braid shield to generate a natural spring force against the vertical disc-shaped ferrule, and the wire braid shield becomes a condition or state in which it has been compressed, bent, pleated or folded against itself, and thus pushes the wire braid shield back (pushes backward) against the direction of travel of the ferrule along the wire core when the wire is pushed so as to push the vertical disc-shaped ferrule forward (toward the cut end of the wire or terminal attached thereto). This force will allow the high-voltage vertical disc-shaped ferrule or wire braid shield of the high-voltage connector assembly (if between them) to maintain contact with the ground structure of the high-voltage connector assembly when in use, or when used as a single high-voltage vertical disc-shaped ferrule, the force pushes the wire braid shield against the housing or ferrule when in use.

[0008] In various embodiments, the structural arrangement of the high voltage disc structure of the high voltage vertical disc ferrule of the high voltage connector assembly presents the ability to be stamped into any shape allowing it to provide complete or near complete electromagnetic interference (EMI) coverage when used with a corresponding metal connector housing that may require a specific shape, and unlike conventional ferrules and conventional stamped shields that may allow EMI to escape, when used with such a corresponding metal connector housing into which the wires or terminals are inserted, it further allows little or no path for EMI to escape by covering the apertures or holes into which the wires or terminals are placed.

[0009] The high voltage vertical disc-shaped collar of the high voltage connector assembly of the present invention also provides sufficient clearance between the wire core or terminal (power circuit) and the wire braided shield or collar (ground circuit), while also limiting the possibility of contact between the power circuit and the ground circuit in the process by also limiting the possibility of stray strands of the wire braided shield contacting the power circuit. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is a side view illustrating an EMI path along a high voltage connector assembly employing a first embodiment of a high voltage vertical disc ferrule;

[0011] Figure 2 is a side view illustrating an EMI path along a high voltage connector assembly employing a second embodiment of a high voltage vertical disc ferrule;

[0012] Figure 3 is a flow chart illustrating the path taken by EMI along a high voltage connector assembly employing the first embodiment or the second embodiment of the high voltage vertical disc ferrule;

[0013] Figure 4 is a side view illustrating an EMI path along a high voltage connector assembly employing a third embodiment of a high voltage vertical disc ferrule;

[0014] Figure 5 is a flow chart illustrating the path taken by EMI along a high voltage connector assembly employing a third embodiment of a high voltage vertical disc ferrule;

[0015] Figure 6 is a front view of a high voltage vertical disc-shaped ferrule used in the high voltage connector of the present invention;

[0016] Figure 7 is a perspective view of a high voltage vertical disc-shaped ferrule employed in a high voltage connector of the present invention, wherein two high voltage vertical disc-shaped ferrules of the high voltage connector of the present invention are used which are fully assembled with electrical wires. DETAILED DESCRIPTION

[0017] The high voltage connector assembly of the present invention (in Figure 11 ), a first embodiment of a high voltage vertical disc ferrule 3 is employed. The first embodiment of the high voltage vertical (or vertical) disc ferrule 3 includes at least a first high voltage vertical (or vertical) disc ferrule 5 having a front surface 5a and a second high voltage vertical (or vertical) disc ferrule 7 having a rear surface 7a. As discussed more fully below, the first high voltage vertical disc ferrule 5 and the second high voltage vertical disc ferrule 7 are mounted on a core insulation 9 that extends into a metal container shell 12. In addition to the core insulation 9, also inside the metal container shell 12 are a core 15 and a terminal 18 connected to the core 15. Adjacent to the first embodiment of the high voltage vertical disc ferrule 3 is a wire braid shield 23 that includes a compressed, bent, pleated, or folded portion 20 of the wire braid shield 23 as discussed more fully below. The outer insulator 25 of the wire 30 is at one end of the compressed, folded, pleated, or folded portion 20 of the wire braid shield 23. The terminal 18, the wire core 15, the wire core insulation 9, the vertical disc-shaped ferrule 3 of the first embodiment (having the first high-voltage disc-shaped ferrule 5 and the second high-voltage disc-shaped ferrule 7), the outer insulator 25, and the wire 30 are all connected together to form the high-voltage connector assembly 1.

[0018] The high voltage vertical disc ferrule 3 (5, 7) can be made of any conductive material such as but not limited to copper, tinned copper, steel, brass alloy, bronze, etc., or any similar type of conductive metal known in metallurgy. Figure 6 As shown, the high-voltage vertical disc-shaped ferrule 3 (5, 7) includes an outer edge 102, an inner edge 104 defining an opening or hole 106, and an additional flat front surface 5a and a also flat rear surface 7a. The first high-voltage vertical disc-shaped ferrule 5 and the second high-voltage vertical disc-shaped ferrule 7 constituting the high-voltage vertical disc-shaped ferrule 7 of the first embodiment of the high-voltage connector assembly 1 of the present invention may be substantially identical in structure. Preferably, the outer edge 102 and the front surface 5a meet vertically, and similarly, the outer edge 102 and the rear surface 7a meet vertically. Furthermore, the inner edge 104 and the front surface 5a meet vertically, and similarly, the inner edge 104 and the rear surface 7a meet vertically. Therefore, the distance or length between the outer edge 102 and the inner edge 104 in a direction parallel to or axial to the electric wire 30 defines the thickness or length of the high-voltage vertical disc-shaped ferrule 100 employed in the high-voltage connector assembly 1 (30, 60) of the present invention (see Figure 1 、 Figure 2 and Figure 4 ).

[0019] Furthermore, the high voltage vertical disc-shaped ferrule 3 (5, 7) used in the high voltage connector 1 (30, 60) of the present invention is preferably a circular vertical (or vertical) disc-shaped structure, but its form is not limited thereto. The disc-shaped structure is mainly made of vertical (or vertical) flat surfaces of the front surface 5a and the rear surface 7a, and the periphery (or outer edge), edge or vertical (or vertical) shape constraint of the outer edge 102 is not necessarily formed as a circle or does not necessarily have any roundness, and can also present any shape into which it can be stamped. For example, the shape of the vertical disc-shaped ferrule 3 (5, 7) can take the form of an oval, an ellipse or any other shape allowed by the stamping device that defines the outer edge 102. Preferably, the shape of the vertical disc-shaped ferrule 3 (5, 7) will provide complete or substantial coverage on the corresponding hole or orifice (not shown) in the connector housing, where the associated wire 30 or terminal 18 (see Figure 1 、 Figure 2 and Figure 4 ) is connected to the connector housing and needs to pass through the connector housing, wherein the vertical disc-shaped ring 3 (5, 7) is used in conjunction with the connector housing. Therefore, when used with the corresponding metal connector housing 12 (see Figure 1 、 Figure 2 and Figure 4 ), the shape of the vertical disc-shaped collar 3 (5, 7) will allow it to provide complete or substantial electromagnetic interference (EMI) suppression or coverage. The corresponding metal connector housing 12 itself may require the vertical disc-shaped collar 3 (5, 7) to be a specific shape to fit into the metal connector housing 12 recess or cavity (not shown). (See Figure 6 and Figure 7 , which shows a vertical disc-shaped collar 3 (5, 7) of generally circular shape, with the front surface 5a and the rear surface 7a of the vertical disc-shaped collar 3 (5, 7) radiating vertically outward from its opening 106, and the corresponding wire 30 being inserted and accommodated through the opening 106).

[0020] like Figure 1 、 Figure 2 and Figure 4As shown, the wire 30 includes a wire core 15, a wire core insulation 9, a wire braid shield 23, and an outer wire insulation 25. As previously described, the front surface 5a and the rear surface 7a of the vertical disc-shaped ferrule 3 (5, 7) are preferably substantially perpendicular to the axial direction of the wire 30. The diameter or size of the front surface 5a and the rear surface 7a is such that the vertical disc-shaped ferrule 3 (5, 7) is large enough to cover the hole in the corresponding metal connector housing 12, wherein the hole is large enough to accommodate the terminal 18 and the corresponding portion of the wire core 15 and / or the wire core insulation 9. Therefore, the size of the front surface 5a and the rear surface 7a of the high voltage vertical disc-shaped ferrule 3 (5, 7) is not limited, however, their respective sizes will need to be such that they are not smaller than the size of the outer insulation 25 of the wire 30, so that the vertical disc-shaped ferrule 3 (5, 7) can have an inner edge 104 defining the opening 106 of the vertical disc-shaped ferrule 3 (5, 7) that is large enough to be properly used with the corresponding wire 30 size. While the vertical disc-shaped ferrule 3 (5, 7) has sufficient surface area on the front and rear surfaces 5a, 7a for proper grounding via the grounding features and for proper functioning when in use, the wire 30 remains flexible behind the ferrule 3 (5, 7). The size of the opening 106 of the vertical disc-shaped ferrule 3 (5, 7) also allows the vertical disc-shaped ferrule 3 (5, 7) to move freely over the wire braid shield 23 of the wire 30, if desired, as will be discussed later.

[0021] The vertical disc-shaped ferrule 3 (5, 7) contacts the corresponding grounding element in the corresponding metal connector housing 12 at its front vertical surface 5a, or when used as a single ferrule 3, the vertical disc-shaped ferrule 3 (5, 7) contacts the corresponding grounding element in the corresponding metal connector housing 12 in combination with its front vertical surface 5a and the wire braided shield 23 when the single ferrule 3 has a flared portion F of the wire braided shield 23 between the front vertical surface 5a of the single ferrule 3. The grounding element in the corresponding metal connector housing 12 can be, for example, a plated surface, a conventional stamped shield, a foil-lined surface, or other conductive material used for grounding purposes within, on, or by the metal connector housing 12. If desired, the outer edge 102 of the vertical disc-shaped ferrule 3 (5, 7) can also contact the grounding element of the corresponding metal connector housing 12.

[0022] The thickness of the vertical disc-shaped ferrule 3 (5, 7) in the axial direction is defined by the length of the outer edge 102 and is preferably no more than 1 mm (however, its size and / or length are not limited thereto); and the preferred thickness of the vertical disc-shaped ferrule 3 (5, 7) in the axial direction is kept thin enough to provide less required space in the corresponding connector housing than conventional crimp ferrules, the vertical disc-shaped ferrule 3 (5, 7) being thinner or shorter than conventional crimp ferrules and also allowing for sufficient take-up of the wire 30, as will be discussed further below. The thickness of the vertical disc-shaped ferrule 3 (5, 7) also preferably accommodates the vertical disc-shaped ferrule 3 (5, 7) within a recess in the corresponding metal shell connector housing 12, so that if necessary, the vertical disc-shaped ferrule 3 (5, 7) is located within a portion of the corresponding metal connector housing 12, thereby providing a much shorter design for the metal connector housing 12 than conventional ferrules when the connector assembly 1 (30, 60) of the present invention is assembled. The vertical disc-shaped ferrule 3 (5, 7) can also be received on the exterior of the corresponding metal connector housing 12 by substantially abutting the surface or side of the metal connector housing 12 (see Figure 1 、 Figure 2 and Figure 4 ).

[0023] When the high voltage connector assembly 1 (30, 60) of the present invention is assembled, the wire 30 is pushed into and through the vertical disc-shaped ring 3 (5, 7), whereby the wire braided shield 23 is pushed back and the wire braided shield 23 is allowed to generate a natural spring force against the vertical disc-shaped ring 3 (as in the first embodiment, if two vertical disc-shaped rings 5, 7 are used, it is the second vertical disc-shaped ring (or the last vertical disc-shaped ring) 7), and the wire braided shield 23 becomes a condition or state in which it has formed a bent, pleated or folded portion 20 against itself, and therefore when pushing the wire 30, it is pushed backward against the direction of travel of the vertical disc-shaped ring 3 (5, 7) along the wire core 15 so as to push the vertical disc-shaped ring 3 (5, 7) forward (or toward the cut end of the wire 30 or the terminal 18 attached thereto). This force will allow the vertical disc ferrule 3 (5, 7) and / or the wire braided shield 23 (if between the vertical disc ferrule 3 and the metal connector housing 12) to maintain contact with the ground structure of the connector housing 12. Figure 4 ), if a single vertical disc-shaped ferrule 3 is used, this force pushes the vertical disc-shaped ferrule 3 against the wire braid shield 23 which rests against the ground feature or metal connector housing 12.

[0024] Figure 1, and preferably uses two vertical disc-shaped ferrules 5, 7. The use of two vertical disc-shaped ferrules 5, 7 (a first vertical disc-shaped ferrule 5 and a second vertical disc-shaped ferrule 7) provides the ability to sandwich the flared portion F of the wire braided shield 23 of the electric wire 30 between the front surface 5a of the first vertical disc-shaped ferrule 5 and the rear surface 7a of the second vertical disc-shaped ferrule 7. The first vertical disc-shaped ferrule 5 has been placed on the wire braided shield 23 so that the first vertical disc-shaped ferrule 5 and the second vertical disc-shaped ferrule 7 contact the flared portion F of the wire braided shield 23. The above structural arrangement provides sufficient contact between the flared portion F of the wire braided shield 23, the first vertical disc-shaped ferrule 5, and the second vertical disc-shaped ferrule 7. Solder or other mechanical or electromechanical means (not shown) may be used to further stabilize or facilitate the sandwiching or insertion of the flared portion F between the first vertical disc-shaped collar 5 and the second vertical disc-shaped collar 7 and to ensure the structural arrangement or relationship of these portions to achieve complete continuity of the EMI path therethrough, as further discussed below.

[0025] When two vertical disc-shaped ferrules 5 and 7 are used as the vertical disc-shaped ferrule 3, it may be further or optimally desirable to securely fasten the two vertical disc-shaped ferrules 5 and 7 together so as to maintain and hold the flared portion F of the wire braided shield 23 inserted or sandwiched therebetween, as described above. Preferably, a mechanical or electromechanical device is used to connect the two vertical disc-shaped ferrules 5 and 7 so as to fully operate the two vertical disc-shaped ferrules 5 and 7. For example, solder, welding (resistance welding, spot welding, ultrasonic welding, etc.), or brazing are electromechanical methods that can be used to connect the respective metals comprising the two vertical disc-shaped ferrules 5 and 7. Furthermore, a mechanical bond using a press fit or snap fit can be used. The means for securing the two vertical disc-shaped ferrules 5, 7 together provides and facilitates sufficient conductive and / or physical substrate to connect the second vertical disc-shaped ferrule 7 to the first vertical disc-shaped ferrule 5, thereby ensuring conductive connection and contact of the two vertical disc-shaped ferrules 5, 7 (which comprise the vertical disc-shaped ferrule 3) with the flared portion F or the wire braided shield 23 when or if the first vertical disc-shaped ferrule 5 makes contact with a ground structure in the corresponding metal connector housing 12. Alternatively, when a single vertical disc-shaped ferrule 3 (5, 7) is used (as in the second and third embodiments of the present invention, respectively, as Figure 2 and Figure 4 As shown), the flared portion F of the wire braided shield 23 and the vertical disc-shaped collar 3 (5, 7) can be welded together to ensure that they are fixed and firmly together. Figure 1 and Figure 2 , the use of a terminal 18 on an electric wire 30 is shown. The terminal 18 is fixed to the end of the electric wire 30 by being fixedly attached (e.g., soldered) to the wire core 15 of the electric wire 30. Figure 1The vertical disc-shaped collar is shown using two vertical disc-shaped collars 5, 7; however, the second and third embodiments of the connector assembly 30, 60 used in the present invention are not limited to this, and the replacement and use of a single vertical disc-shaped collar 5, 7 can be similarly applied to the structure, structural arrangement or method of the present invention, as shown in the figure and as further discussed below.

[0026] In the first embodiment ( Figure 1 ), when two vertical disc-shaped ferrules 5, 7 are used, one ferrule (the second vertical disc-shaped ferrule 7) straddles the wire shield 23, and the other ferrule (the first vertical disc-shaped ferrule 5) straddles the core insulation 9. Here, the flared portion F of the wire braided shield 23 is sandwiched between the first disc-shaped ferrule 5 and the second disc-shaped ferrule 7. In the second embodiment ( Figure 2 ), when a single vertical disc-shaped ferrule 3 is used and the flared portion F of the wire braided shield 23 is fixed or abutted against the rear surface 7a of the vertical disc-shaped ferrule 3, the vertical disc-shaped ferrule 3 rides on the wire core insulating portion 9. In the third embodiment ( Figure 4 ), when a single vertical disc-shaped ferrule 3 is used and the wire shield 23 is fixed or abutted against the front surface 5a of the vertical disc-shaped ferrule 3, the vertical disc-shaped ferrule 3 rides on the wire braided shield 23.

[0027] like Figure 1As shown, in the first embodiment of the present invention, the wire braided shield 23 of the electric wire 30 is fixed between two vertical disc-shaped ferrules 5, 7. The vertical disc-shaped ferrule 3, consisting of the first vertical disc-shaped ferrule 5 and the second vertical disc-shaped ferrule 7, cannot move along the electric wire 30 toward the terminal 18 in the axial direction along the electric wire 30 because the wire shield 23 is fully extended in such a direction that a portion of the wire shield 23 is flat along the insulation 9 of the core 15, and the flared end F of the wire braided shield 23 is fixed and affixed to prevent movement from its position between the two vertical disc-shaped ferrules 5, 7. The second vertical disc-shaped ferrule 7 straddles the wire braided shield 23, and the first vertical disc-shaped ferrule 5 straddles the core insulation 9. The wire 30 extends through the opening 106 of the two vertical disc-shaped ferrules 5, 7 during what is considered a "take-up," which includes bunching or folding of the wire braid shield 23 (see section 20 of the wire braid shield 23) due to slack or tolerance in the movement of the wire core 15, as it further relates to the exposed length of the wire braid shield 23. The wire braid shield 23 bunches on the side of the two vertical disc-shaped ferrules 5, 7 opposite the side on which the terminal 18 and the wire core 15 extend. As the two vertical disc-shaped ferrules 5, 7 move in the axial direction of the wire 30 and parallel to the wire 30, the wire core 15 extends, moves, and passes through the opening 106 of the two vertical disc-shaped ferrules 5, 7. Therefore, when the "take-up" of the wire 30 occurs, the wire braid shield 23 bunches or folds itself, as shown by reference numeral 20. The wire braided shield 23 is bunched from a position where it is exposed at the outer insulator 25 of the wire 30 to a position where it can contact the rear surface 7 a of the second vertical disc-shaped ferrule 7 .

[0028] like Figure 2 As shown, once the wire braided shield 23 has been bunched or folded, this bunched or folded portion 20 of the wire shield 23 provides a force against the rear surface 7a of the vertical disc-shaped ferrule 3 because the wire braided shield 23 is pressed against itself and compressed while abutting against the vertical disc-shaped ferrule 3. Therefore, when the wires 23 are in this structural arrangement, this folded portion 20 of the wire braided shield 23 provides a force against the rear surface 7a of the vertical disc-shaped ferrule 3. Figure 1 The rear surface 7a of the second vertical disc-shaped ring 7 of the vertical disc-shaped ring 3 or abuts against Figure 2 The spring-like force of the rear surface 7a of the vertical disc-shaped collar 3 in the vertical disc-shaped collar 3 is provided or ensured by the force provided by the wire shield 23. Figure 1 The second vertical disc-shaped ring 7 of the vertical disc-shaped ring or Figure 2 The vertical disc-shaped ferrule 3 in the embodiment is pressed against the surface of the metal connector housing 12 and / or against the corresponding shielding means combined with the metal connector housing 12. Figure 1 The rear surface 7a of the second vertical disc-shaped ring 7 of the vertical disc-shaped ring 3 or Figure 2 The rear surface 7 a of the vertical disc-shaped ferrule 3 in FIG. 1 also substantially covers the opening or hole (not shown) in the metal connector housing 12 .

[0029] Figure 3 FIG. 1 is a flow chart showing the path taken by EMI along a high voltage connector assembly 1 that utilizes a first embodiment of a high voltage vertical disc-shaped ferrule 3 (5, 7). Figure 3 As shown (see also Figure 1 ), EMI travels from the metal connector housing 12 to the first high-voltage disc ferrule 5 of the high-voltage disc ferrule 3 in step 1 (S1), and then travels to the flared portion F of the wire braided shield 23 in step 2 (S2). Here, because the flared portion F of the wire braided shield 23 is connected to the compressed portion 20 of the wire braided shield 23, in step 3 (S3), EMI travels directly from the flared portion F of the wire braided shield 23 to the compressed portion 20. Thereafter, in step 4 (S4), EMI travels from the compressed portion 20 of the wire braided shield 23 to the ground.

[0030] In the second embodiment of the high voltage connector assembly 30 of the present invention, as shown in FIG. Figure 2 As shown, the flared portion F of the wire braided shield 23 of the electric wire 30 is fixed to the rear surface 7a of the single vertical disc-shaped collar 3. Once the flared portion F of the wire braided shield 23 is attached, the vertical disc-shaped collar 3 cannot move further forward along the electric wire 30 toward the terminal 18 in the axial direction along the electric wire 30 because the wire braided shield 23 is fully extended or stretched in such a direction that a portion of the wire braided shield 23 is tightened and flat along the wire core insulation 9 of the wire core 15, and the flared portion F of the wire braided shield 23 is fixed and attached to prevent movement from its position on the vertical disc-shaped collar 3, and the flared portion F can be further attached to the rear surface 7a of the vertical disc-shaped collar 3 using solder. In addition, the wire braided shield 23 may also not be fixed or attached to the vertical disc-shaped collar 3; however, it will also move away from the flared portion F of the wire braided shield 23. However, in the fixed state with the wire shield 23, the single vertical disc-shaped collar 3 (in Figure 215. In the second embodiment shown, the wire braid shield 23 is movable in the axial direction toward the outer wire insulation 25 and away from the cut end of the wire or the attachment terminal 18. Thus, when a single vertical disc-shaped ferrule 3 is used and the wire braid shield 23 is fixed or abutted against the rear surface 7a of the vertical disc-shaped ferrule 3, the vertical disc-shaped ferrule 3 rides on the wire core insulation 9 and does not ride on the wire braid shield 23. Thus, the wire 30 extends through the opening 106 of the vertical disc-shaped ferrule 3 in a process that is considered to be "coiling", which includes bunching or folding of the wire braid shield 23 (portion 20 of the wire braid shield 23) due to slack or tolerance in the movement of the wire core 15 as it further relates to the exposed length of the wire braid shield 23. The wire braid shield 23 is bunched on the side of the vertical disc-shaped ferrule 3 opposite to the side from which the terminal 18 and the wire core 15 extend from the front surface 5a of the high voltage vertical disc-shaped ferrule 3. As the vertical disc-shaped ferrule 3 moves in the axial direction of the wire 30, along the conductor core insulation 9 and parallel to the wire 30, the wire core 15 extends along, moves through and through the opening 106 of the vertical disc-shaped ferrule 3. Thus, when "coiling" of the wire 30 occurs, the wire braid shield 23 bunches or folds into itself (see section 20 of the wire braid shield 23). The wire braid shield 23 is bunched from its position exposed at the outer insulation 25 of the wire 30 to a position where it can contact the rear surface 7 of the vertical disc-shaped ferrule 3. As shown in FIG. Figure 2 As further shown in FIG, once the wire braided shield 23 has been bunched or folded (as in the portion 20 of the wire braided shield 23), this portion 20 of the wire braided shield 23 provides a force against the rear surface 7a of the vertical disc-shaped ferrule 3 because the wire braided shield 23 is now pressed against itself and compressed while abutting the vertical disc-shaped ferrule 3. Therefore, more specifically, the wire braided shield 23 is bunched or folded in the space between the vertical disc-shaped ferrule 3 and the outer insulator 25, whereby the exposed portion of the wire braided shield 23 extends along the wire core insulation 9 and the end portion (or flared portion F) of the wire braided shield 23 is between the vertical disc-shaped ferrule 3 and the folded portion 20 of the wire braided shield 23. Therefore, when the electric wire 30 is in this state, this folded portion 20 of the wire braided shield 23 provides a spring-like force against the vertical disc-shaped ferrule 3. The spring force provided by the wire braided shield 23 provides or ensures that the front surface 5a of the vertical disc-shaped collar 3 is pressed against and contacts the surface of the metal connector housing 12, and is pressed against the interior of the metal connector housing 12 or such corresponding shielding device (not shown) of the metal connector housing 12, while the vertical disc-shaped collar 3 further and also fully covers the opening or hole (not shown) in the metal connector housing 12.

[0031] In the second embodiment of the high voltage connector assembly 30 of the present invention, similarly applicable is Figure 3Regarding the second embodiment of the present invention, Figure 3 The flow chart in FIG. 1 shows the path that EMI takes along the high voltage connector assembly 30 that employs the second embodiment with a single use high voltage vertical disc ferrule 3. Figure 3 As shown (see also Figure 2 ), EMI travels from the metal connector housing 12 to the high-voltage disc-shaped ferrule 3 in step 1 (S1), and then travels to the flared portion F of the wire braided shield 23 in step 2 (S2). Here, because the flared portion F of the wire braided shield 23 is connected to the compressed portion 20 of the wire braided shield 23, EMI travels directly from the flared portion F of the wire braided shield 23 to the compressed portion 20 in step 3 (S3). Thereafter, in step 4 (S4), EMI travels from the compressed portion 20 of the wire braided shield 23 to the ground.

[0032] like Figure 4 As shown, the flared portion F of the braided wire shield 23 of the electric wire 30 is fixed to the front surface 5a of the single vertical disc-shaped ferrule 3. Once the flared portion F of the braided wire shield 23 is attached, the vertical disc-shaped ferrule 3 cannot move further forward along the electric wire 30 toward the terminal 18 in the axial direction along the electric wire 30 because the braided wire shield 23 is fully extended or stretched in such a direction that a portion of the braided wire shield 23 is stretched taut and flat along the wire core insulation 9 of the core 15, and the flared portion F of the braided wire shield 23 is fixed and attached to prevent movement from its position on the vertical disc-shaped ferrule 3, and the flared portion F can be further attached to the front surface 5a of the vertical disc-shaped ferrule 3 using solder or the like. Furthermore, the braided wire shield 23 may not be fixed or attached to the vertical disc-shaped ferrule 3, but it will similarly move away from the flared portion F of the braided wire shield 23. However, in a fixed state with the wire braided shield 23, the single vertical disc-shaped ferrule 3 can be moved in the axial direction toward the vertical portion of the outer wire insulation portion 25 and away from the cut end of the wire or the attachment terminal 18. Therefore, when a single vertical disc-shaped ferrule 3 is used and the wire braided shield 23 is fixed or abutted against the front surface 5a of the vertical disc-shaped ferrule 3, the vertical disc-shaped ferrule 3 straddles the wire braided shield 23. Here, during what is considered to be a "winding" period, the wire extends through the opening 106 of the vertical disc-shaped ferrule 3 (see Figure 6), the "coiling" includes bunching or folding of the portion 20 of the wire braid shield 23 due to slack or tolerance in the movement of the wire core 15, as it further relates to the exposed length of the wire braid shield 23. The wire braid shield 23 is bunched on the side of the vertical disc-shaped ferrule 3 opposite to the side on which the terminal 18 and the wire core 15 extend from the front surface 5a of the vertical disc-shaped ferrule 3. When the vertical disc-shaped ferrule 3 moves along the axial direction of the wire 30, along the wire braid shield 23, and parallel to the wire 30, the wire core 15 extends, moves, and passes through the opening 106 of the vertical disc-shaped ferrule 3. Therefore, when "coiling" of the wire 30 occurs, as shown in the portion 20 of the wire braid shield 23, the wire braid shield 23 is bunched or folded into itself. The wire braided shield 23 is bunched from a position where it is exposed at the outer insulator 25 of the electric wire 30 to a position where it can contact the rear surface 7a of the vertical disc-shaped ferrule 3. Figure 4 As shown, once the wire braided shield 23 has become bunched or folded, as in portion 20 thereof, this portion 20 of the wire braided shield 23 provides a force against the rear surface 7a of the vertical disc-shaped ferrule 3 because the wire braided shield 23 is now pressed against itself and compressed while abutting against the vertical disc-shaped ferrule 3. Therefore, more specifically, the wire braided shield 23 is bunched or folded in the space between the vertical disc-shaped ferrule 3 and the outer insulator 25, whereby the exposed portion of the wire braided shield 23 extends along the wire core insulation 9, and the flared portion F of the wire braided shield 23 is between the vertical disc-shaped ferrule 3 and the metal connector housing 12. Therefore, when the electric wire 30 is in this state, this folded portion 20 of the wire braided shield 23 provides a spring-like force against the vertical disc-shaped ferrule 3. The spring force provided by the wire braided shield 23 provides or ensures that the front surface 5a of the vertical disc-shaped collar 3 is pressed against and contacts the flared portion F of the wire braided shield 23, or if the wire braided shield 23 is further fixed or welded using a fixing device, then ensures that the wire braided shield 23 is in full contact with the surface of the metal connector housing 12 and abuts against the interior of the metal connector housing 12 or such corresponding shielding device of the metal connector housing 12 (not shown), while the vertical disc-shaped collar 3 further and also fully covers the opening or hole (not shown) in the metal connector housing 12.

[0033] Figure 5 FIG. 1 is a flow chart illustrating the path taken by EMI along a high voltage connector assembly 60 that utilizes a third embodiment of a high voltage vertical disc-shaped ferrule 3. Figure 5As shown, in step 1' (S1'), EMI travels directly from the metal connector housing 12 to the flared portion F of the wire braided shield 23, which abuts and contacts the metal connector housing 12. In step 2' (S2'), EMI then travels directly from the flared portion F to the compressed portion 20 of the wire braided shield 23, which is connected to the compressed portion 20 of the wire braided shield 23. In step 3' (S3'), EMI travels directly from the compressed portion 20 of the wire braided shield 23 to ground.

[0034] The high voltage vertical disc-shaped ferrule 3 (5, 7) used in the high voltage connector 1, 30, 60 of the present invention also increases electrical clearance during operation. In other words, compared to conventional ferrule structural arrangements and assemblies having conventional ferrules closer to the attached terminals, the electrical clearance between the two components is increased by allowing the vertical disc-shaped ferrule 3 (5, 7) and the wire braided shield 23 (ground circuit) to be further away from the terminal 18 or the wire core 15 (power circuit) due to the travel distance of the wire 30 into the metal connector housing 12 and the extension of the terminal 18 or the wire core 15 away from the vertical disc-shaped ferrule 3 (5, 7).

[0035] The present invention is not limited to the embodiments described above; various modifications in design, structural arrangement, etc. may be used without departing from the scope of the present invention or its equivalents. Although the foregoing description is directed to preferred embodiments of the present invention, it should be noted that other changes and modifications will be apparent to those skilled in the art and may be made without departing from the spirit or scope of the present invention. In addition, even if not explicitly stated above, the structural arrangement or features described in conjunction with one embodiment of the present invention may also be used in conjunction with other embodiments.

Claims

1. A method for reducing the effects of electromagnetic interference (EMI) to provide EMI protection to a connector assembly having at least one vertical disc-shaped ferrule, the method being characterized by the following steps: EMI protection of a connector assembly having at least one vertical disc-shaped ferrule, the method being characterized by the following steps: providing the connector assembly with a wire braid shield between an outer insulation of the electrical wire and the at least the vertical disc-shaped ferrule, and the at least the vertical disc-shaped ferrule between the wire braid shield and a metal connector housing housing a core of the electrical wire; conducting the EMI generated by at least the metal connector housing to the at least one vertical disc-shaped ferrule; conducting the EMI from the at least one vertical disc-shaped ferrule to the wire braid shield, a first portion of the wire braid shield being secured against a substantially flat surface of the at least one vertical disc-shaped ferrule; as well as Thereafter, conducting the EMI from the wire braid shield to ground; The method is further characterized by the steps of allowing spring force to press the at least one vertical disc-shaped ferrule against the metal connector housing; said step of providing said connector assembly with said braided shield comprises the steps of providing said wire braided shield with at least said first portion and a second portion; The first portion of the wire braid shield is a flared portion, and wherein the second portion of the wire braid shield is a folded, pleated, or folded portion.

2. The method for reducing the effects of electromagnetic interference (EMI) to provide EMI protection to a connector assembly having at least one vertical disc-shaped ferrule according to claim 1, wherein: The step of conducting the EMI generated by at least the metal connector housing to the at least one vertical disc-shaped ferrule includes the step of conducting the EMI from the metal connector housing to a first of two vertical disc-shaped ferrules.

3. The method for reducing the effects of electromagnetic interference (EMI) to provide EMI protection to a connector assembly having at least one vertical disc-shaped ferrule according to claim 2, further characterized by The step of conducting the EMI from the first disc ferrule to the wire braid shield.

4. The method for reducing the effects of electromagnetic interference (EMI) to provide EMI protection to a connector assembly having at least one vertical disc-shaped ferrule according to claim 1, wherein: The step of conducting the EMI from the at least one of the vertical disc-shaped collars includes the step of conducting the EMI from the at least one of the vertical disc-shaped collars to the flared portion of the wire braid shield and then to the bent, pleated or folded portion of the wire braid shield.

5. The method for reducing the effects of electromagnetic interference (EMI) to provide EMI protection to a connector assembly having at least one vertical disc-shaped ferrule according to claim 1, wherein: The step of conducting the EMI from the wire braid shield to the ground includes the step of conducting the EMI from the folded, pleated, or folded portion of the wire braid shield to the ground.

6. The method for reducing the effects of electromagnetic interference (EMI) to provide EMI protection to a connector assembly having at least one vertical disc-shaped ferrule according to claim 1, wherein: The step of providing the connector assembly includes the steps of sandwiching the flared portion of the wire braid shield between two vertical disc-shaped ferrules, and providing the bent, pleated or folded portion of the wire braid shield between the vertical disc-shaped ferrules and the outer insulation of the wire.

7. The method for reducing the effects of electromagnetic interference (EMI) to provide EMI protection to a connector assembly having at least one vertical disc-shaped ferrule according to claim 6, wherein: The two vertical disc-shaped ferrules sandwiching the flared portion of the wire braid shield contact or abut the metal connector housing and are disposed between the metal connector housing and the bent, pleated, or folded portion of the wire braid shield.

8. The method for reducing the effects of electromagnetic interference (EMI) to provide EMI protection to a connector assembly having at least one vertical disc-shaped ferrule according to claim 1, wherein: The step of providing the connector assembly includes the steps of contacting or abutting the vertical disc-shaped collar to the metal connector housing, and placing the flared portion of the wire braid shield between the vertical disc-shaped collar and the bent, pleated or folded portion of the wire braid shield, and the bent, pleated or folded portion of the wire braid shield is placed between the flared portion of the wire braid shield and the outer insulation of the wire.

9. The method for reducing the effects of electromagnetic interference (EMI) to provide EMI protection to a connector assembly having at least one vertical disc-shaped ferrule according to claim 1, further characterized by The step of providing the spring force through the wire braided shield to ensure that the vertical disc-shaped ferrule is pressed against and contacts the metal connector housing.

10. The method for reducing the effects of electromagnetic interference (EMI) to provide EMI protection to a connector assembly having at least one vertical disc-shaped ferrule according to claim 1, further characterized by The step of providing a spring force through the wire braided shield to ensure that the flared portion of the wire braided shield is pressed against and contacts the vertical disc-shaped ferrule.

11. A method for reducing the effects of electromagnetic interference (EMI) to provide EMI protection to a connector assembly having at least one vertical disc-shaped ferrule, the method being characterized by the following steps: providing the connector assembly with a first portion of a wire braid shield between the vertical disc-shaped ferrule and a metal connector housing housing a core of an electrical wire, and a second portion of the wire braid shield between the vertical disc-shaped ferrule and an outer insulation of the electrical wire; conducting the EMI generated by at least the metal connector housing to the first portion of the wire braid shield, the first portion of the wire braid shield being secured against a substantially flat surface of the at least one vertical disc-shaped ferrule; conducting the EMI from the first portion of the wire braid shield to the second portion of the wire braid shield; as well as thereafter, conducting the EMI from the second portion of the wire braid shield to ground; wherein the first portion of the wire braid shield is a flared portion, and wherein the second portion of the wire braid shield is a folded, pleated, or folded portion.

12. The method for reducing the effects of electromagnetic interference (EMI) to provide EMI protection to a connector assembly having at least one vertical disc-shaped ferrule according to claim 11, further characterized by The step of providing a spring force through the wire braid shield to ensure that the flared portion of the wire braid shield is pressed against and contacts the metal connector housing.

13. The method for reducing the effects of electromagnetic interference (EMI) to provide EMI protection to a connector assembly having at least one vertical disc-shaped ferrule according to claim 11, further characterized by The step of providing a spring force through the wire braided shield to ensure that the vertical disc-shaped ferrule is pressed against and contacts the flared portion of the wire braided shield.

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