Method for shielding and grounding a connector

Abstract

A method for shielding and grounding a connector assembly from electromagnetic interference (EMI), the method including at least one of directing EMI to at least one conductive seal and directing EMI to at least one male / female mating stamped shield, wherein EMI generated by, for example, at least one battery cable assembly housed within at least one male or female connector assembly of the connector assembly has a flow path that is directed through at least the conductive seal and the male / female mating stamped shield of the connector assembly.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims priority to U.S. Provisional Patent Application No. 62 / 810,107, filed February 25, 2019, which is incorporated herein by reference in its entirety. [Background technology]

[0002] It is desirable for connector assemblies, preferably high voltage connector assemblies, to be subject to reduced or suppressed electromagnetic interference (EMI).

[0003] 1 and 2 show a conventional connector assembly, generally designated by the reference numeral 1, that uses stamped shielding for EMI shielding or containment. The conventional assembly 1 includes a mating female connector assembly 20 and a male connector assembly 25. Housed within the female connector assembly 20 and the male connector assembly 25 are battery cable assemblies 28, 30, respectively. Surrounding the battery cable assembly 28 housed within the female connector assembly 20 is a corresponding female wire shield 5 secured thereabout by a corresponding ferrule 8, which is housed in and contacts the female inner housing 10. A female stamped shield 13 partially surrounds the female inner housing 10, and the female stamped shield 13 is surrounded by a female outer housing 15. The female stamped shield 13 extends toward and connects with an intermediate stamped shield 28, which in turn connects with a male stamped shield 32. The male stamped shield 32 extends between a male inner housing 35 and a male outer housing 40, which partially contacts and surrounds a ferrule 44, which in turn contacts and surrounds a corresponding male wire shield 48.

[0004] 1 further includes a female terminal position assurance (TPA) device 50 and a male terminal position assurance (TPA) device 55 inserted into the female connector assembly 20 and the male connector assembly 25, respectively, to secure the respective terminals therein. Plastic back covers 58, 60 are secured to the ends of the female connector assembly 20 and the male connector assembly 25, respectively. A silicone wire seal 63 is located near the plastic back cover 58 of the female connector assembly 20, and a silicone wire seal 65 is located near the plastic back cover 60 of the male connector assembly 25. The joint between the female outer housing 15 and the male outer housing 40 is sealed with a silicone ring seal 70.

[0005] In conventional connector assembly 1, the associated female inner housing 10, female outer housing 15, male inner housing 35, and male outer housing 40 are made of plastic, resin, nylon, or a non-conductive material. Similarly, in conventional connector assembly 1, the associated seals (including silicone wire seal 63 of female connector assembly 20, silicone wire seal 65 of male connector assembly 25, and silicone ring seal 70 at the junction between female connector assembly 20 and male connector assembly 25) are made of a non-conductive material.

[0006] Due to the female connector assembly 20's female inner housing 10 and female outer housing 15 made of conventional non-conductive resin, nylon or plastic, the male connector assembly 25's male inner housing 35 and male outer housing 40 made of conventional non-conductive resin, nylon or plastic, and the non-conductive silicone seals 63, 65, 70, the EMI generated in the conventional connector assembly 1 using the female stamped shield 13, middle stamped shield 28, and male stamped shield 32 has limited EMI ground paths, as will be further discussed below with reference to Figures 2 and 3.

[0007] 2 and 3, EMI generated by, for example, conductive battery cable assembly 28 (housed within female connector assembly 20) and conductive battery cable assembly 30 housed within male connector assembly 25 has flow paths 80, 88 that travel within conventional connector assembly 1 between female wire shield 5 and male wire shield 48. More specifically, EMI generated in conventional connector assembly 1 travels between female wire shield 5 and male wire shield 48 through each female wire shield 5 and adjacent ferrule 8, female stamped shield 13, male stamped shield 32, adjacent ferrule 44, and each male wire shield 48. Summary of the Invention [Means for solving the problem]

[0008] The present invention provides such a high-voltage connector assembly for connection to a device that experiences reduced or suppressed EMI during operation. An EMI flow path created by, for example, a battery cable assembly housed within the male connector assembly is directed to, for example, but not limited to, at least the male wire shield, the male conductive seal, the male / female mating press-fit shield, the female conductive seal, and ultimately the female wire shield. Additionally, an EMI flow path created by, for example, another cable assembly at the opposite end of the connector assembly within the female connector assembly is directed to, for example, but not limited to, at least the female wire shield, the female conductive seal, the male / female mating press-fit shield, the male conductive seal, and ultimately the male wire shield. [Brief explanation of the drawings]

[0009] [Figure 1] 1A and 1B show a conventional connector assembly having a male connector assembly and a female connector assembly that uses a stamped shield. [Figure 2] FIG. 1 illustrates EMI paths in a conventional connector assembly that uses a stamped shield for EMI containment. [Figure 3]1 is a flow chart of at least one path of EMI through a conventional connector assembly. [Figure 4] FIG. 1 is a perspective view showing the male and female portions of a male / female combined stamped shield. [Figure 5] FIG. 1 illustrates a structural layout of a connector assembly having a male connector and a female connector, showing shielding and grounding of the connector assembly from EMI using at least a male conductive seal, a male / female combined stamped shield, and a female conductive seal. [Figure 6] 5 illustrates the shielding and grounding of the EMI path of the present invention in the connector assembly of FIG. 4 using at least a male conductive seal, a mating male / female stamped shield, and a female conductive seal. [Figure 7] 7 is a flow chart of at least one flow path of EMI of the present invention through a connector assembly using at least a male conductive seal, a male / female mating pressed-in shied, and a female conductive seal as shown in FIGS. 5 and 6 for EMI shielding and grounding. DETAILED DESCRIPTION OF THE INVENTION

[0010] 4 and utilized in the present invention is a combined male / female stamped shield 90 that includes a male portion 92 and a female portion 94. The male portion 92 and the female portion 94 have openings 96, 98, respectively.

[0011] Illustrated in Figure 5 is a first embodiment of a connector assembly of the present invention, generally designated by the reference numeral 100. The connector assembly 100 of the present invention is preferably a high-voltage connector assembly having a male connector assembly 103 and a female connector assembly 105. The male connector assembly 103 receives a battery cable assembly 108, and on the opposite side of the connector assembly 100, the female connector assembly 105 receives another battery cable assembly 110. Surrounding the battery cable assembly 108 is inner wire insulation 115, and the other battery cable assembly 110 is surrounded by another wire insulation 117.

[0012] In the male connector assembly 103, a wire shield 120 surrounds an internal wire insulation 115, while in the female connector assembly 105, a wire shield 123 surrounds another internal wire insulation 117. Outside the wire shield 120, near the end of the male connector assembly 103, is an external wire insulation 130. Outside the wire shield 123, near the end of the female connector assembly 105, is an external wire insulation 132. Another portion of the wire shield 120 in the male connector assembly 103 may contact a ferrule 150 (i.e., the wire shield 120 / ferrule 150 interface). At the other end of the connector assembly 100, in the female connector assembly 105, another portion of the wire shield 123 may contact a ferrule 155 (i.e., the wire shield 123 / ferrule 155 interface). The ferrules 150, 155 are preferably metal, a conductive material, or the like.

[0013] As further shown in Figure 5, conductive seal 160 surrounds wire shield 120 and ferrule 150 (i.e., surrounds the wire shield 120 / ferrule 150 interface) of male connector assembly 103. Also shown in Figure 5, conductive seal 165 surrounds wire shield 123 and ferrule 155 (i.e., surrounds the wire shield 123 / ferrule 155 interface) of female connector assembly 105. In male connector assembly 103, conductive seal 160 is disposed between wire shield 120 / ferrule 150 interface and male / female mating stamped shield 170. In female connector assembly 105, conductive seal 165 is disposed between wire shield 123 / ferrule 155 interface and male / female mating stamped shield 170.

[0014] At the end of male connector assembly 103, a plastic back cover 180 shields conductive seal 160, male end 92 of stamped shield 170, and its opening 96. At the end of female connector assembly 105, a plastic back cover 185 shields conductive seal 165, female end 94 of stamped shield 170, and its opening 98.

[0015] The interface between male conductive seal 160 and female conductive seal 165 is a combined male / female stamped shield 170 having male end 92 and female end 94 .

[0016] The conductive seal 160 of the male connector assembly 103 and the conductive seal 165 of the female connector assembly 105 are each made of conductive metal-injected silicone, conductive metal-filled silicone, or the like, and the metal may be, for example, stainless steel.

[0017] Generally, contained within male outer housing 170 and female outer housing 175 are a male terminal position assurance (TPA) device 190, a female terminal position assurance (TPA) device 195, and male terminal 200 / female terminal 210 interfaces extending from battery cable assembly 108 of male connector assembly 103 and battery cable assembly 110 of female connector assembly 105, respectively.

[0018] Methods for shielding and grounding the connector assembly 100 of the present invention from electromagnetic interference (EMI) are described below and illustrated in Figures 6 and 7. EMI flow paths 300, 320 (or 300', 320'), each shown as a single dashed line in Figure 6 for illustrative purposes only, travel throughout the connector assembly 100 through various elements of the connector assembly 100, including, but not limited to, through at least the male conductive seal 160, the mating male / female stamped shield 170, and the female conductive seal 165.

[0019] 6 and 7, for example, EMI generated from the high voltage battery cable assembly 108 of the male connector assembly 103 has a flow path 300 that directs it through the male conductive seal 160 (made, for example, of fiber-filled or fiber-infused silicone, such as stainless steel) to the male wire shield 120 and adjacent ferrule 150 (made of metal). The EMI then travels through the combined male / female stamped shield 170, through the female conductive seal 165, through the adjacent ferrule 155 (made of metal), and then further through the female wire shield 123.

[0020] In another embodiment of the above invention, the ferrule 150 at the male wire shield 120 / ferrule 150 interface of the male connector assembly 103 and the ferrule 155 at the female wire shield 123 / ferrule 155 interface of the female connector assembly 105 may be eliminated and are optional components. In such a case, the EMI flow path 300' passes through the male wire shield 120 directly to the male conductive seal 160. In such a case, the EMI flow path 300' passes through the female conductive seal 165 directly to the female wire shield 123.

[0021] A method for shielding and grounding the connector assembly 100 of the present invention from EMI will be further described in connection with Figures 6 and 7. Here, EMI generated, for example, from a high-voltage battery cable assembly 110 of the female connector assembly 105 has a flow path 320 that directs it through the female conductive seal 165 (made, for example, of fiber-filled or fiber-infused silicone such as stainless steel) to the female wire shield 123 and the adjacent ferrule 155 (made of metal). The EMI is then further directed through the male / female combined stamped shield 170. After passing through the male / female combined stamped shield 170, the EMI is further directed through the male conductive seal 160 of the male connector assembly 103, through the adjacent ferrule 150, and finally to the male wire shield 120.

[0022] In another embodiment of the present invention, the ferrule 155 at the female wire shield 123 / ferrule 155 interface of the female connector assembly 105 and the ferrule 150 at the male wire shield 120 / ferrule 150 interface of the male connector assembly 103 may be eliminated and are optional components. In such a case, the EMI flow path 320 passes through the female wire shield 123 directly to the female conductive seal 165 (see EMI flow path 320' in FIG. 7). In such a case, the EMI flow path 320 passes through the male conductive seal 160 directly to the male wire shield 120 (see EMI flow path 320' in FIG. 7).

[0023] It should be noted that while the foregoing description is directed to preferred embodiments of the invention, other variations and modifications will be apparent to those skilled in the art and may be made without departing from the spirit or scope of the invention. Furthermore, structures, structural arrangements, or features described in connection with one embodiment of the invention may be used in conjunction with other embodiments, even if not explicitly described above.

Claims

1. 1. A method for shielding and grounding a connector assembly from electromagnetic interference (EMI), comprising: (a) directing the EMI to at least one conductive seal; (b) directing the EMI into at least one mating male / female stamped shield, The step of directing the EMI to at least one conductive seal comprises: directing the EMI from the male / female mating stamped shield to a first conductive seal, and then directing the EMI from the first conductive seal to a wire shield; directing the EMI from the male / female mating stamped shield to a second conductive seal, and then directing the EMI from the second conductive seal to a wire shield; directing the EMI from the wire shield to the first conductive seal, and then directing the EMI from the first conductive seal to the male / female mating stamped shield; and directing the EMI from the wire shield to the second conductive seal, and then directing the EMI from the second conductive seal to the male / female mating stamped shield; The step of directing the EMI to at least one male / female mating stamped shield comprises: directing the EMI from the wire shield to the first conductive seal and from the first conductive seal to the male / female mating stamped shield; and directing the EMI from the wire shield to the second conductive seal and directing the EMI from the second conductive seal to the male / female mating press-formed shield. A method characterized by:

2. directing the EMI to at least one of the male / female mating stamped shields; (i) directing the EMI into the male portion of the male / female combined stamped shield; (ii) directing the EMI into the female portion of the male / female combined stamped shield; 2. The method for shielding and grounding the connector assembly from the EMI of claim 1, comprising at least one of:

3. 2. The method for shielding and grounding the connector assembly from the EMI of claim 1, wherein the first conductive seal and / or the second conductive seal is a metal-injected or metal-filled material.

4. 4. The method for shielding and grounding the connector assembly from EMI as recited in claim 3, wherein the metal injection material or metal fill material of the first conductive seal and / or the second conductive seal contains a metal, the metal being a conductive metal including stainless steel.

5. 2. The method for shielding and grounding said connector assembly from said EMI as recited in claim 1, wherein said male / female mating stamped shield is made of metal.

6. 1. A method for shielding and grounding a connector assembly from electromagnetic interference (EMI) using at least a conductive seal and a male / female mating stamped shield, comprising: directing the EMI generated by at least one battery cable assembly in a male connector assembly of the connector assembly to a male wire shield; directing the EMI to a first conductive seal; directing the EMI from the first conductive seal to a mating male / female stamped shield having a center portion, a first end, and a second end, the center portion being larger in size than each of the first and second ends, the stamped shield accommodating mated first and second terminals and extending the EMI flow path outward; directing the EMI from the male / female mating stamped shield to a second conductive seal; and thereafter directing the EMI to a female wire shield; A method characterized by:

7. directing the EMI generated by at least one battery cable assembly in a female connector assembly of the connector assembly to a female wire shield; directing the EMI to the second conductive seal; directing the EMI to the male / female mating stamped shield; directing the EMI to a first conductive seal; and thereafter: directing the EMI to the male wire shield; 7. The method for shielding and grounding the connector assembly from the EMI of claim 6, further characterized by:

8. directing the EMI to the first conductive seal includes directing the EMI to a male wire shield / ferrule interface; 10. The method of claim 9, wherein the step of directing the EMI to the female wire shield includes directing the EMI to a female wire shield / ferrule interface.

7. The method for shielding and grounding the connector assembly from the EMI of claim 6.

9. wherein the step of directing the EMI to the second conductive seal includes directing the EMI to a female wire shield / ferrule interface; 10. The method of claim 9, wherein the step of directing the EMI to the male wire shield includes directing the EMI to a male wire shield / ferrule interface.

8. The method for shielding and grounding the connector assembly from the EMI of claim 7.

10. 7. The method for shielding and grounding the connector assembly from EMI of claim 6, wherein at least one of the first conductive seal and the second conductive seal is a metal injected material or a metal filled material.

11. 11. The method for shielding and grounding the connector assembly from EMI of claim 10, wherein the metal injection material or metal fill material of at least one of the first conductive seal and the second conductive seal contains a metal, the metal being a conductive metal including stainless steel.

12. 7. The method for shielding and grounding the connector assembly from EMI as recited in claim 6, wherein the mating male / female stamped shield is made of metal.

13. 4. The method for shielding and grounding the connector assembly from EMI of claim 3, wherein the metal-injected or metal-filled material is silicone infused or filled with a conductive metal including stainless steel.

14. 11. The method for shielding and grounding the connector assembly from EMI of claim 10, wherein the metal-injected or metal-filled material is silicone infused or filled with a conductive metal including stainless steel.

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