Conductive Spikes for EMC Housing Connections
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Solution Overview
Problem
Existing electronic assembly solutions for achieving electromagnetic compatibility (EMC) face challenges such as complexity, cost, temperature sensitivity, corrosion, and mechanical instability, particularly with painted, anodized, or insulated metal parts, which hinder secure low-impedance connections.
Innovation Solution
The use of tapered spikes on the joining surfaces of metal housing parts to penetrate through insulating layers and establish secure electrical connections, ensuring a low-impedance connection between housing parts, with the spikes being made of a stronger material than the mating surface to ensure penetration and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If insulating layers (paint, anodization, coating) are applied to metal housing parts, then corrosion protection and aesthetic appearance are improved, but electrical conductivity and low-impedance connection are worsened
Solution Approach 1:
The contact means is segmented into multiple point contacts (protrusions) distributed across the joining surface. Each protrusion independently penetrates the insulating layer to create multiple electrical connection paths, ensuring reliable electrical contact while maintaining the insulating coating on the overall housing surface.
Solution Approach 2:
The protrusions act as intermediary elements that bridge the insulating layer and the underlying conductive metal housing. These protrusions penetrate through the insulating barrier to establish direct metal-to-metal electrical contact, thereby mediating between the insulated exterior and the required conductive connection.
2Reliability
If traditional EMC solutions (screw connections, springs, wire mesh, adhesives) are used, then electromagnetic compatibility is improved, but device complexity and construction cost increase
Solution Approach 1:
The invention merges the mechanical fastening function and the electrical connection function into a single integrated structure. The protrusions on the joining surface simultaneously provide mechanical attachment and electrical conductivity, eliminating the need for separate EMC seals, grounding wires, or additional connection components.
Solution Approach 2:
The contact means with protrusions serves multiple functions: it provides mechanical joining of the housing parts, ensures electrical conductivity for EMC compliance, and maintains structural integrity. This multi-functional design replaces multiple specialized components with a single universal solution.
3Reliability
If traditional EMC solutions (screw connections, springs, wire mesh) are used, then electromagnetic compatibility is improved, but manufacturing cost increases
Solution Approach 1:
The invention merges the mechanical fastening function and the electrical connection function into a single integrated structure. The protrusions on the joining surface simultaneously provide mechanical attachment and electrical conductivity, eliminating the need for separate EMC seals, grounding wires, or additional connection components.
Solution Approach 2:
The protrusions on the joining surface automatically establish electrical contact when the housing parts are assembled together. The design self-ensures EMC compliance without requiring additional grounding wires, separate connection elements, or complex assembly procedures, thereby reducing manufacturing costs.
4Strength
If insulating layers are present on housing parts, then surface quality and corrosion resistance are improved, but mechanical penetration and electrical contact are worsened
Solution Approach 1:
The contact means is segmented into multiple point contacts (protrusions) distributed across the joining surface. Each protrusion independently penetrates the insulating layer to create multiple electrical connection paths, ensuring reliable electrical contact while maintaining the insulating coating on the overall housing surface.
Solution Approach 2:
The insulating layer is selectively removed or penetrated only at the locations of the protrusions where electrical contact is required. The rest of the housing surface maintains its insulating coating for corrosion protection and aesthetic appearance, achieving local optimization of both electrical conductivity and surface integrity.
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 enhances EMC compatibility by providing a secure, low-impedance connection that meets legal requirements, is cost-effective, and does not require additional components or seals, while ensuring mechanical stability and compliance with EMC standards.
Implementation Method 1
contact means in the joining surface being designed as embossments tapering to a point from the joining surface... By penetrating into the counter-joining surface of another metal housing part, these spikes produce a secure electrical connection
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to an electronic assembly (1) comprising at least a first metallic housing part (11) and a second metallic housing part (12), which are configured such that they form a housing (10) for the assembly (1) in an assembled state, wherein the first housing part (11) has at least one joining surface (21, 21') and the second housing part has at least one counter joining surface (22, 22') which are in contact with each other in the assembled state, wherein the at least one joining surface (21, 21') has a contact means (2) which is configured to interact with the counter joining surface (22, 22') in the assembled state such that an insulating layer surrounding the housing parts (11, 12) is penetrated at the location of the contact means (2) and an electrical contact exists between the two housing parts (11, 12).