Connector Grounding Bar for Wire and Shielding Shell

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Solution Overview

Problem

Existing electrical connectors lack enhanced mechanical and electrical connectivity between grounding layers of wires and shielding shells, which limits their performance.

Innovation Solution

An electrical connector design featuring an insulative housing, contacts, a metallic shielding shell, and a cable sub-assembly with a grounding unit that includes a grounding bar mechanically and electrically connected to both the wires' grounding layers and the shielding shell, ensuring robust mechanical and electrical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a grounding bar is used to connect grounding layers of wires, then electrical connectivity is improved, but mechanical strength and stability are insufficient

Engineering Contradiction:

Improveelectrical connectivityVSAvoidmechanical strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent combines multiple grounding bars into a unified grounding structure that integrates both electrical conductivity and mechanical strength. The grounding bars are positioned to contact multiple grounding layers simultaneously, creating a merged structural unit that provides both electrical connectivity and mechanical support.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The grounding structure uses composite construction combining conductive materials for electrical connectivity with structurally robust materials for mechanical strength. The grounding bars are designed with specific cross-sectional geometries that optimize both electrical conductivity and mechanical rigidity.

Inventive Principle:

Principle #40Composite materials

2Reliability

If grounding bars connect only to wire grounding layers, then electrical grounding is achieved, but connection to shielding shell is insufficient

Engineering Contradiction:

Improvegrounding effectivenessVSAvoidconnection structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The grounding bars are designed to serve multiple functions simultaneously: they electrically connect to wire grounding layers, provide mechanical support to the cable assembly, and establish electrical contact with the shielding shell. This multi-functional design eliminates the need for separate components for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The grounding bars act as intermediary elements that bridge the wire grounding layers and the shielding shell. Rather than directly connecting wires to the shell, the grounding bars serve as intermediate conductive pathways that simplify the overall connection structure while maintaining electrical integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If multiple grounding connections are made, then electrical stability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveelectrical stabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The grounding system is segmented into modular grounding bar units that can be independently positioned and connected to different grounding layers. Each segment is designed to perform a specific grounding function, allowing for systematic assembly and simplifying the manufacturing process through modular construction.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The grounding bars are pre-positioned and pre-connected to wire grounding layers during cable assembly manufacturing, before final connector assembly. This preliminary action ensures that electrical stability is established early in the manufacturing process, reducing complexity during final assembly.

Inventive Principle:

Principle #10Preliminary action

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 provides improved mechanical and electrical connectivity, enhancing the overall performance and reliability of the electrical connector by ensuring effective grounding and shielding.

Implementation Method 1

a grounding unit (32) including a grounding bar (33, 34) soldered to the grounding layers (312) of the corresponding wires (31) and to the shielding shell (4)

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS10454222B2Connector having grounding bar connecting to both shielding shell and grounding layers of wires

Publication Date: 2019.10.22 FOXCONN (KUNSHAN) COMPUTER CONNECTOR CO LTD

AI summary

An electrical connector includes an insulative housing, a plurality of contacts retained in the housing, a metallic shielding shell, and a cable sub-assembly. The contact includes a front mating section and a rear connecting section. The cable sub-assembly includes a plurality of wires and a grounding unit. The wire includes an inner/transmission conductor, an inner insulator, an outer/grounding conductor/layer, and an outer insulator sequentially coaxially arranged with one another. The connecting sections of the contacts are mechanically and electrically connected to the inner conductors of the corresponding wires. The grounding unit includes a grounding bar mechanically and electrically connected to the grounding layers of the corresponding wires and with forwardly extending legs for connection to the shielding shell. Also included is a central shielding plate with extensions at opposite ends for connection to the grounding bar.