Backshell Assembly for Bulkhead Connector EMI Shielding
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Solution Overview
Problem
Conventional electrical connection assemblies for bulkhead connectors are bulky and lack efficient electromagnetic shielding, leading to increased volume and component count, as well as inadequate protection against electromagnetic interference.
Innovation Solution
A compact backshell assembly comprising a lug, nut, and ring, where the ring is retained within the lug and nut bores, providing a conical surface engagement to securely position and compress electromagnetic shielding between the ring and lug surfaces, ensuring electrical grounding and shielding of the wire assembly to the bulkhead connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional electrical connection assemblies are used, then electromagnetic shielding is provided, but the assembly volume and component count increase
Solution Approach 1:
The patent combines multiple separate components (lug, ring, and electromagnetic shielding elements) into an integrated backshell assembly where the ring is retained within the lug structure, reducing overall assembly volume while maintaining shielding effectiveness through the integrated design
Solution Approach 2:
The ring is nested within the lug structure, with the ring being retained by the lug in a configuration where one component is positioned inside or within the structure of another, reducing the overall footprint and assembly volume while maintaining functional separation
2Reliability
If conventional electrical connection assemblies are used, then connection functionality is provided, but the component count increases
Solution Approach 1:
The backshell assembly merges the lug, ring, and electromagnetic shielding components into a single integrated assembly that provides both mechanical connection and electromagnetic shielding functions, reducing the total component count while maintaining reliability
Solution Approach 2:
The integrated backshell assembly performs multiple functions simultaneously: the lug provides mechanical attachment, the ring provides structural support and retention, and the integrated electromagnetic shielding provides EMI protection, all within a single assembly unit
3Object-affected harmful factors
If electromagnetic shielding is added to wire assemblies, then protection against electromagnetic interference is improved, but the assembly volume increases
Solution Approach 1:
The electromagnetic shielding is integrated within the backshell assembly structure, with the ring nested within the lug and the shielding positioned within this nested structure, minimizing the additional volume required while maintaining effective electromagnetic protection
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces the volume and part count of the assembly while maintaining effective electromagnetic shielding and grounding, ensuring reliable transmission of electrical power and data while protecting against electromagnetic interference.
Implementation Method 1
the ring has a radially outward ring surface that is conical, the lug has a radially inward lug surface that is conical, and at least a portion of the electromagnetic shielding of the wire assembly is configured to be disposed between the conical, radially outward ring surface and the conical, radially inward lug surface
Implementation Method 2
A wire assembly to be coupled to the bulkhead electrical connector includes electromagnetic shielding, and such electromagnetic shielding is electrically grounded to the bulkhead electrical connector via the backshell assembly
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A backshell assembly (102) for a bulkhead electrical connector (101) may include a lug (110) defining a central lug bore (115), a nut (120) defining a central nut bore (125), and a ring (130) defining a central ring bore (135). The lug (110) may be configured to be coupled to the bulkhead electrical connector (101), the nut (120) may be configured to be coupled to the lug (110), and the ring (130) may be configured to be retained by the nut (120) at least partially within at least one of the central lug bore (115) and the central nut bore (125). A wire assembly to be coupled to the bulkhead electrical connector (101) may include electromagnetic shielding (144), and such electromagnetic shielding (144) may be configured to be electrically grounded to the bulkhead electrical connector (101) via the backshell assembly (102).