Ceramic Isolative Block for Electrical Connector Shielding
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Solution Overview
Problem
Existing electrical connectors face challenges in achieving effective electromagnetic shielding while avoiding the risk of fire, particularly due to high-temperature conditions that can lead to melting and short circuits.
Innovation Solution
The electrical connector design incorporates an insulative housing with conductive terminals, a shielding plate sandwiched between upper and lower terminals, an isolative block to isolate the terminals from the shielding plate, and a shielding shell to enclose the housing, utilizing a ceramic isolative block for enhanced mechanical and thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a shielding plate is sandwiched between upper and lower terminals to achieve electromagnetic shielding, then electromagnetic shielding effect is improved, but the risk of short circuit and fire increases due to potential contact between conductive terminals and shielding plate at high temperature
Solution Approach 1:
An isolative block made of ceramic material is introduced as an intermediary component between the conductive terminals and the shielding plate. This ceramic block serves as a thermal and electrical insulator, preventing direct contact and potential short circuits while maintaining the electromagnetic shielding function of the shielding plate.
Solution Approach 2:
The patent uses ceramic material for the isolative block, combining it with metal shielding plate and plastic housing to create a composite structure. The ceramic material provides high temperature resistance and electrical insulation, while the metal shielding plate provides electromagnetic shielding, and the plastic housing provides structural support, creating a multi-material system that addresses both shielding and fire safety requirements.
2Temperature
If ceramic material is used to replace insulative layers to avoid fire risk, then thermal stability and fire resistance are improved, but manufacturing complexity increases due to high sintering temperature requirements
Solution Approach 1:
The ceramic component is segmented into a specific block shape that fits precisely between the terminals and shielding plate. This segmentation allows the ceramic to be manufactured separately using standard ceramic sintering processes, then integrated into the assembly, simplifying the overall manufacturing workflow despite the high temperature sintering requirement.
Solution Approach 2:
The ceramic isolative block serves as a mediator that can be pre-manufactured using established ceramic sintering techniques, then integrated into the connector assembly. This approach allows the benefits of ceramic thermal stability to be achieved without requiring the entire manufacturing process to accommodate high temperature sintering, as the ceramic component is prepared separately and then assembled with other components.
3Reliability
If insulative layers are applied to terminal surfaces facing the shielding plate, then electrical insulation is improved, but mechanical strength and fire resistance deteriorate due to the limitations of plastic insulative layers at high temperature
Solution Approach 1:
The patent replaces plastic insulative layers with a ceramic isolative block. The ceramic material provides both superior electrical insulation properties and enhanced mechanical strength, particularly at high temperatures where plastic materials would degrade. This material substitution maintains electrical insulation while significantly improving mechanical strength and thermal resistance.
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 configuration effectively provides electromagnetic shielding while minimizing the risk of fire by isolating conductive terminals from the shielding plate, ensuring mechanical and thermal stability, and preventing short circuits.
Implementation Method 1
an isolative block isolating the conductive terminals from the shielding plate
Implementation Method 2
utilizing a ceramic isolative block for enhanced mechanical and thermal stability
Data Source
AI summary
An electrical connector includes an insulative housing, a number of conductive terminals affixed to the insulative housing, a shielding plate affixed to the insulative housing, a shielding shell enclosing the insulative housing, and an isolative block isolating the conductive terminals from the shielding plate.