How to Use Conductive Seals to Protect Connector Assemblies from Electromagnetic Interference (EMI)

Abstract

To provide a method for reducing the effect of electromagnetic interference (EMI) to provide EMI protection in a connector assembly having at least one electrically conductive seal, a female connector assembly, and a male connector assembly.SOLUTION: A method for reducing the effect of EMI in a connector assembly includes the steps of: conducting the EMI generated by at least a wire 10 housed within a connector assembly 1 (or another source) to a corresponding wire shielding 13 that respectively surrounds the wire 10 and to a corresponding crimped ferrule 15 that surrounds the wire shielding 13; conducting the EMI through a female connector assembly 3 and through a male connector assembly 5; and ultimately conducting the EMI to a housing of a device onto which the conductor assembly 1 is connected or mounted.SELECTED DRAWING: Figure 2A

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This patent application claims priority to U.S. Provisional Patent Application No. 62 / 811,873, filed February 28, 2019, which is incorporated herein by reference in its entirety. [Background technology]

[0002] Electromagnetic interference (EMI) affects electrical circuits due to disturbances from sources through electromagnetic induction, capacitive coupling, or conduction. EMI can degrade the performance of a circuit or even cause it to stop functioning. If the circuit includes a data path, EMI can affect the effectiveness of the data path due to increased error rates up to total data loss. Sources that can generate varying currents and voltages that can cause EMI can include, for example, automobile injectors, cell phone cellular networks, etc. Therefore, it is essential to manage EMI generation to avoid the harmful effects caused by it and, as a result, maximize the effectiveness of electrical circuits that may be vulnerable to the harmful effects of EMI.

[0003] Methods of avoiding or reducing the harmful effects of EMI include conduction, shielding, etc. Conducted EMI protection is achieved by conducting EMI between conductive elements or conductors in physical contact, while shielded EMI protection is achieved by shielding radiated EMI through induction (i.e., when there is no physical contact between conductors). In a connector assembly, conducted EMI is directed through the paths of adjacent conductive elements or conductors toward the device to which the connector assembly is attached. Summary of the Invention

[0004] The present invention relates to a method for reducing the effects of electromagnetic interference (EMI) and providing EMI protection to a connector assembly having a conductive seal, a female connector assembly, and a male connector assembly. The method of reducing the effects of EMI in a connector assembly includes the steps of conducting EMI generated by at least wires housed within the connector assembly to corresponding wire shields surrounding the wires and corresponding crimp ferrules surrounding the wire shields, conducting the EMI to corresponding silicone back seals in contact with the crimp ferrules, the silicone back seals being housed within the female housing connector assembly and in contact with at least a portion of the female housing connector assembly, and conducting the EMI to the female connector assembly, a portion of which is in contact with another silicone seal, the other silicone seal being positioned between a portion of the female connector assembly and a portion of the male connector assembly and in contact with a portion of the female connector assembly and a portion of the male connector assembly. The method of the present invention for reducing the effects of EMI in a connector assembly further includes conducting EMI to a portion of the male connector assembly surrounding and in contact with another silicone seal, where the EMI is further conducted to the male connector assembly and toward a flange member of the male connector assembly, the flange containing at least a limiter further containing a respective bolt therein that connects or attaches the connector assembly to a device. The method of the present invention for reducing the effects of EMI in a connector assembly additionally includes conducting EMI from the flange member of the male connector assembly to the limiter surrounding and in contact with the corresponding bolt, and to the corresponding bolt, and subsequently conducting the EMI through the bolt and ultimately to the device. [Brief explanation of the drawings]

[0005] [Figure 1A] FIG. 1A is a cross-sectional view of a connector assembly showing the various elements that make up the female and male connector assemblies of the connector assembly. [Figure 1B] FIG. 1B is a cross-sectional view that is a continuation of the view shown in FIG. 1A for the completed connector assembly, showing in more detail the device to which the connector assembly is connected or attached. [Figure 2A] FIG. 2A is a cross-sectional view of a connector assembly, as in FIG. 1A, further illustrating the paths that EMI takes as it is conducted from the wire shield, through various conductive elements within the connector assembly, and toward the housing of an associated device to which the connector assembly is connected or attached. [Figure 2B] FIG. 2B is a continuation of the cross-sectional view shown in FIG. 1B to complete the connector assembly, as in FIG. 1B, further illustrating in more detail the path that EMI takes as it is conducted from the connector assembly to the device to which the connector assembly is connected or attached. [Figure 3] FIG. 3 is a flow diagram of the path EMI takes as it is conducted from the wire shield, through the various conductive elements within the connector assembly, and toward the housing of the associated device to which the conductor assembly is connected or attached. DETAILED DESCRIPTION OF THE INVENTION

[0006] 1A and 1B, the connector assembly generally referred to as 1 includes a female connector assembly 3 and a male connector assembly 5, which are coupled together, and FIG. 1B is a continuation of FIG. 1A to complete the connector assembly 1. The connector assembly 1 is preferably a high-voltage connector assembly that houses high-voltage wires 10 having respective wire shields 13 therein. Surrounding each of the wire shields 13 is a corresponding crimp ferrule 15, and surrounding the crimp ferrules 15 and the corresponding wire shields 13 is a corresponding conductive silicone back seal 18 that is inserted into a rear portion 20 of a female outer housing 25 of the female connector assembly 3.

[0007] The wire shield 13 is made of a metal, a conductive material, or the like. The crimp ferrule 15 is made of a metal (e.g., copper, stainless steel, or the like). The conductive silicone back seal 18 is made of a conductive metal-infused silicone, or the like. The female outer housing 25 is made of a metal-infused conductive plastic, resin, nylon, or the like. The female outer housing 25 can also be made of a stainless steel fiber-filled plastic, resin, nylon, or the like.

[0008] The rear portion 20 of the female outer housing 25 includes a rear opening 28 that accommodates at least one of the high voltage wires 10, each surrounded by a corresponding wire shield 13, which in turn is surrounded by a corresponding crimp ferrule 15 that is protected or sealed around by a corresponding conductive silicone back seal 18.

[0009] Extending along a portion of opening 28 is an extension member 30 that extends from the rear portion 20 of the female outer housing 25 of female connector assembly 3 toward an opening 35 in the male outer housing 38 of male connector assembly 5. A portion 42 of the male outer housing 38 surrounds a conductive silicone ring seal 40 that is positioned between the extension member 30 of the female outer housing 25 and the male outer housing 38. The conductive silicone ring seal 40 provides a seal between the extension member 30 of the female outer housing 25 and the male outer housing 38. The male outer housing 38 has a peripheral flange 45 extending therefrom at its end remote from the female connector assembly 3 (see also FIG. 1B, a continued view of the male connector assembly 5).

[0010] The conductive silicone ring seal 40 is made from metal-infused silicone. The male outer housing 38 is made from a metal-infused conductive plastic, resin, nylon, etc. The male outer housing 38 can also be made from a stainless steel fiber-filled plastic, resin, nylon, etc.

[0011] Shown in Figure 1A or 1b is a non-conductive overmolded silicone seal 50 that surrounds (preferably the entire exposed side of) the exposed side of flange 45 of male connector assembly 5. While Figure 1A shows bolt heads 55 (made from stainless steel or the like) of bolts 58, Figure 1B shows bolts 58 in more detail, passing through holes 60 that respectively pass through flange 45 and surrounding overmolded silicone seal 50. Bolts 58 include respective threads 65 that allow threaded bolts 58 to fasten flange 45, surrounded by overmolded silicone seal 50, to device 70, which ultimately attaches connector assembly 1 to device 70.

[0012] Also shown in FIG. 1B are conductive compression limiters or rings 75 (made from aluminum or the like) that fit within the holes 60, which in turn receive the bodies 78 of the bolts 58 therein, such that each conductive compression limiter or ring 75 is located between a corresponding one of the bolt bodies 78 and a corresponding side of the flange 45.

[0013] 1B, the overmolded silicone seal 50 has a first set of pads 80, each located in a recess 85 beneath the head 55 of each of the corresponding bolts 58. The overmolded silicone seal 50 further has a second set of pads 90, each located in a corresponding recess 95 on an adjacent side 98 of the device 70.

[0014] The following describes how conducted EMI is directed through paths of conductive elements within connector assembly 1. The paths of conducted EMI are represented in Figures 2A and 2B as line arrows that begin at wire shield 13, extend through various conductive elements within connector assembly 1, and ultimately terminate at device 70.

[0015] 2A , EMI generated, for example, by conductive high-voltage wires 10 (or other sources) is conducted to the corresponding wire shield 13. The crimp ferrules 15 are in physical contact with and surround the corresponding wire shields 13, so that EMI generated, for example, by wires 10 (or other sources) is conducted to the corresponding wire shield 13 and through the crimp ferrules 15. The crimp ferrules 15 are metallic and conductive, preferably made of copper, stainless steel, or the like. The conducted EMI travels from the crimp ferrules 15 to the corresponding silicone back seals 18, each of which is a metal-infused silicone back seal 18. The conducted EMI further travels from the silicone back seals 18 to the rear portion 20 of the female outer housing 25. The conducted EMI is further conducted to the female outer housing 25 and the conductive silicone ring seal 40 surrounding the extension member 30 extending from the rear portion 20 of the female outer housing 25, where the silicone ring seal 40 is a metal-infused silicone ring seal 40. The conducted EMI then travels toward the portion 42 of the male outer housing 38 surrounding the metal-infused silicone ring seal 40, and further through the male outer housing 38 toward the conductive compression limiters or rings 75 that respectively surround the corresponding bodies 78 of the bolts 58. The conducted EMI thus travels to the bolts 58 and is emitted to a device 70 (e.g., a compressor housing) that is made of metal.

[0016] 3 shows a flow diagram of the path of conducted EMI, which was described with reference to FIGS. 2A and 2B. As shown in FIG. 3, in step S1, EMI is generated by the high-voltage wire 10 and conducted to the corresponding wire shield 13. The crimp ferrule 15 is in physical contact with and surrounds the corresponding wire shield 13, so in step S2, EMI generated from the wire 10 is conducted to the corresponding wire shield 13 and through the crimp ferrule 15. In step S3, the conducted EMI travels from the crimp ferrule 15 to the corresponding silicone back seal 18. The conducted EMI further travels from the silicone back seal 18 to the rear portion 20 of the female outer housing 25 in step S4.

[0017] 3, the conducted EMI is further conducted to the female outer housing 25 and, in step S5, to the conductive silicone ring seal 40 surrounding the extension member 30 extending from the rear portion 20 of the female outer housing 25. In step S6, the conducted EMI then travels toward the portion 42 of the male outer housing 38 surrounding the metal-infused silicone ring seal 40, and further travels through the male outer housing 38 toward the conductive compression limiters or rings 75 each surrounding a corresponding body 78 of the bolts 58 (in step S7). The conducted EMI thus travels to the bolts 58 (in step S8) and is emitted to the device 70 (in step S9).

[0018] The present invention is not limited to the embodiments described above, and various changes in design, structural arrangement, etc. can be used without departing from the scope or equivalent of the present invention.

Claims

1. 1. A method for reducing the effects of electromagnetic interference (EMI) and providing EMI protection to a connector assembly having at least one conductive seal, a female connector assembly, and a male connector assembly, comprising: conducting the EMI generated by at least wires housed within the connector assembly to corresponding wire shields surrounding the wires and corresponding crimp ferrules surrounding the wire shields; conducting the EMI through the female connector assembly and through the male connector assembly, (a) the step of conducting the EMI through the female connector assembly includes the step of conducting the EMI through a conductive silicone seal inserted into the female connector assembly and sealing around the crimp ferrule, the conductive silicone seal being a metal-infused conductive silicone seal; and (b) the step of conducting the EMI through the male connector assembly includes the step of conducting the EMI through a conductive silicone seal that seals between the female connector assembly and the male connector assembly, and the conductive silicone seal is a metal-infused conductive silicone seal. conducting the EMI through the female and male connector assembly, Finally, conducting the EMI to a housing of a device to which the connector assembly is connected or attached; It is characterized by A method for reducing the effects of electromagnetic interference (EMI) and providing EMI protection to a connector assembly having at least one conductive seal, a female connector assembly, and a male connector assembly, wherein the male connector assembly includes a male housing, the male housing being made from a metal-infused material, the material being made from at least one of plastic, resin, and nylon.

2. conducting the EMI through the female connector assembly includes conducting the EMI through at least a silicone back seal; 10. The method of reducing the effects of electromagnetic interference (EMI) and providing EMI protection to a connector assembly as recited in claim 1, wherein the step of conducting the EMI through the male connector assembly includes the step of conducting the EMI through at least a silicone ring seal.

3. the step of conducting the EMI through the female connector assembly includes the step of conducting the EMI through at least a conductive silicone back seal, the conductive silicone back seal being a metal-infused conductive silicone back seal; 2. The method for reducing the effects of electromagnetic interference (EMI) and providing EMI protection to a connector assembly as recited in claim 1, wherein the step of conducting the EMI through the male connector assembly includes the step of conducting the EMI through at least a conductive silicone ring seal, the conductive silicone ring seal being a metal-infused conductive silicone ring seal.

Images