Ceramic Insulator Electrical Connector High-Temperature Shielding
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Solution Overview
Problem
Existing electrical connectors face issues with plastic melting at high temperatures and inability to shield high-frequency interference effectively.
Innovation Solution
The electrical connector features a contact module with a ceramic flat portion and insulator, replacing insulative materials with ceramic for the tongue portion and using a metal layer between conductive terminals to prevent melting and shield interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If insulative materials (plastic) are used for the tongue portion, then the device complexity is reduced and ease of manufacture is improved, but the reliability deteriorates due to melting at high temperatures
Solution Approach 1:
The patent applies composite materials by combining ceramic material for the tongue portion with metal shielding plates and insulative housings. The ceramic material provides high-temperature resistance while the metal components provide shielding and structural support, creating a composite structure that solves both the manufacturing ease and high-temperature reliability requirements.
Solution Approach 2:
The patent changes the material parameter from plastic to ceramic for the tongue portion. This parameter change increases the melting point and thermal stability of the component, allowing it to withstand high temperatures during high-current transmission without deforming or melting.
2Reliability
If ceramic materials are used to replace insulative materials, then the reliability is improved by preventing melting at high temperatures, but the ability to shield high frequency signal interference deteriorates
Solution Approach 1:
The patent introduces metal shielding plates as intermediary elements between the ceramic tongue portion and the external environment. These shielding plates act as mediators that block high-frequency electromagnetic interference while allowing the ceramic material to maintain its high-temperature resistance function.
Solution Approach 2:
The patent creates a composite structure where ceramic material provides thermal stability and metal shielding plates provide electromagnetic interference protection. This composite approach allows both high-temperature reliability and high-frequency shielding to be achieved simultaneously.
3Object-affected harmful factors
If metal shielding plates are added to shield high frequency interference, then the shielding capability is improved, but the device complexity increases
Solution Approach 1:
The patent merges the shielding function with the existing structural components by integrating metal shielding plates into the housing and contact module assembly. This combining approach provides shielding capability while minimizing the increase in device complexity through functional integration.
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
This design prevents plastic melting at high temperatures and effectively shields high-frequency interference, enhancing the safety and performance of the electrical connector.
Implementation Method 1
The electrical connector replaces the tongue portion affixing with the conductive terminals from insulative materials to ceramic materials, thereby preventing the shortcoming of the plastic being easily melted at a high temperature caused by a large temperature increase during use
Implementation Method 2
using a metal layer between conductive terminals to prevent melting and shield interference
Data Source
AI summary
An electrical connector includes: a contact module having a base portion, a tongue portion extending forwardly from the base portion, and two rows of conductive terminals, the tongue portion including a front mating portion and a rear thickened portion, each conductive terminal including a contacting portion exposed to two surfaces of the front mating portion and a soldering portion extending outwardly from the base portion, wherein the contact module is constructed of a ceramic flat portion and an insulator.