Conductive Outer Connector Body for Right Angle Header Shielding

Solution Overview

Problem

Existing shielded electrical header designs for high voltage applications, particularly in electric vehicles, face challenges in manufacturing right angle headers that provide electromagnetic shielding without increasing costs, as they require complex sheet metal boxes with multiple parts.

Innovation Solution

A shielded electrical header assembly featuring a conductive element with dielectric and conductive components, including a flexible contact for grounding and a thermoplastic outer connector body, which allows for a right angle configuration without the need for a multi-part sheet metal box, ensuring electromagnetic shielding and environmental sealing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a sheet metal box is used to surround conductive elements for electromagnetic shielding in a right angle header, then electromagnetic shielding is provided, but the manufacturing complexity and cost increase significantly

Engineering Contradiction:

Improveelectromagnetic interferenceVSAvoidheader structure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent combines the electromagnetic shielding function with the connector body structure by making the outer connector body itself conductive. This eliminates the need for a separate sheet metal box shield, as the outer connector body performs both structural and shielding functions simultaneously, reducing part count and manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The outer connector body is designed to serve multiple functions: it provides mechanical support, environmental sealing, and electromagnetic shielding. By making the outer connector body conductive, it simultaneously acts as both a structural component and an electromagnetic shield, eliminating the need for separate shielding components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Object-affected harmful factors

If a sheet metal box is used to surround conductive elements for electromagnetic shielding, then shielding is provided, but the manufacturing process becomes more complex and costly

Engineering Contradiction:

Improveelectromagnetic interferenceVSAvoidheader manufacturing ease

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent combines the electromagnetic shielding function with the connector body structure by making the outer connector body itself conductive. This eliminates the need for a separate sheet metal box shield, as the outer connector body performs both structural and shielding functions simultaneously, reducing part count and manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs a conductive material for the outer connector body that provides both structural integrity and electromagnetic shielding properties. This composite approach allows a single material to fulfill multiple requirements, simplifying manufacturing compared to assembling separate metal shield components.

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If a right angle header configuration is implemented with traditional sheet metal shielding, then connector mating parallel to bulkhead is enabled, but the shield becomes more complex requiring multiple parts

Engineering Contradiction:

Improveconnector mating orientationVSAvoidshield structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines the electromagnetic shielding function with the connector body structure by making the outer connector body itself conductive. This eliminates the need for a separate sheet metal box shield, as the outer connector body performs both structural and shielding functions simultaneously, reducing part count and manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent divides the header into functional segments: the inner connector body for terminal support and the outer connector body for shielding and environmental protection. This segmentation allows each part to be optimized for its specific function while maintaining overall simplicity through the conductive outer body's multi-functionality.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS9099814B2Shielded electrical header assembly

Publication Date: 2015.08.04 APTIV TECHNOLOGIES AG

AI summary

A shielded electrical header assembly is provided. The header is configured to be coupled to a first connector connected to a shielded electrical cable and second connector. The header is also configured to be attached to an electrically conductive panel, such as an aluminum battery pack in a hybrid or electric vehicle. The header includes a conductive shield contact that connects the outer conductor of the shielded cable to the panel and a conductive outer connector body that is also connected to the panel and surrounds the terminals and the shield contact of the header, thus providing electromagnetic shielding to the terminals of the header and the connectors. The shield contact is formed of a sheet metal to provide a lower resistance connection between the outer conductor and the panel. A method of manufacturing such a header is also provided.