Connector Grounding via Insulating Bushings
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Solution Overview
Problem
Electrical connectors designed decades ago are inadequate for use with shielded cables, leading to electromagnetic interference and safety concerns due to improper grounding.
Innovation Solution
A connector design featuring a conductive shell, insert, and face seal with insulating bushings to establish a grounding path, using conductive and elastomeric materials to ensure reliable electrical connections and reduce interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical connectors are designed without grounding mechanisms (as in legacy designs), then device complexity is reduced and ease of manufacture is improved, but electromagnetic interference increases and reliability deteriorates
Solution Approach 1:
The grounding bushing is nested within the connector assembly, with the insulating bushing containing the conductive grounding element. This nested structure provides grounding functionality while maintaining a compact connector design, resolving the contradiction between reliability improvement and device complexity increase.
Solution Approach 2:
The insulating bushing acts as an intermediary component between the conductive grounding element and the connector shell. It provides electrical isolation while allowing mechanical support and grounding current flow through designated paths, enabling reliable grounding without compromising connector integrity or excessive complexity.
2Reliability
If grounding mechanisms are added to legacy electrical connectors, then reliability and electromagnetic interference protection are improved, but ease of manufacture deteriorates
Solution Approach 1:
The grounding bushing serves multiple functions simultaneously: it provides electrical insulation, mechanical support for the grounding element, and establishes grounding current paths. This multi-functionality reduces the need for separate components, thereby improving reliability while maintaining ease of manufacture.
Solution Approach 2:
The grounding mechanism is merged with the existing connector assembly structure. The insulating bushing integrates with the connector shell and the grounding element combines insulation and conduction functions in a single component, simplifying the manufacturing process while ensuring effective grounding.
3Adaptability or versatility
If shielded cables are used with ungrounded connectors, then adaptability to modern electrical systems is improved, but electromagnetic interference increases and safety concerns arise
Solution Approach 1:
The grounding bushing is pre-installed within the connector assembly before cable connection. This preliminary grounding preparation ensures that when shielded cables are connected, the grounding path is already established, preventing electromagnetic interference from the outset while maintaining adaptability to modern electrical systems.
Solution Approach 2:
The grounding mechanism converts the potential harm of electromagnetic interference into a beneficial grounding path. By providing a controlled current flow path through the insulating bushing, electromagnetic energy is directed safely to ground rather than causing interference, thus converting a harmful factor into a protective feature.
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 effectively grounds electrical connectors, reducing electromagnetic interference and enhancing safety and reliability in electrical systems, while being adaptable to various environments and conditions.
Implementation Method 1
at least one electrically insulating bushing disposed within the at least one first aperture in the electrically conductive face seal, wherein the at least one electrically insulating bushing is further disposed between the face seal and the at least one connector pin
Implementation Method 2
an electrically conductive face seal that abuts against a distal end of the insert within the first cavity, wherein the at least one connector pin traverses at least one first aperture in the electrically conductive face seal
Data Source
AI summary
A connector can include a first shell having at least one first wall made of an electrically conductive material, where the at least one first wall forms a first cavity. The connector can also include an insert disposed within the first cavity. The connector can further include at least one connector pin disposed in and traversing the first shell. The connector can also include an electrically conductive face seal that abuts against a distal end of the insert within the first cavity, where the at least one connector pin traverses at least one first aperture in the electrically conductive face seal. The connector can further include at least one electrically insulating bushing disposed within the at least one first aperture in the electrically conductive face seal, where the at least one electrically insulating bushing is further disposed between the face seal and the at least one connector pin.