Conductive Connector Housing for EMI Grounding and Corrosion Isolation
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Solution Overview
Problem
Existing connector assemblies experience significant electromagnetic interference (EMI) noise, particularly in high voltage applications like electric and hybrid vehicles, which can disrupt vehicle functions and require effective shielding and grounding solutions.
Innovation Solution
A connector assembly with a metallic braided shield and a multi-directional conductive outer housing, using metal-infused plastic or stainless steel fiber-filled materials, combined with stainless steel bolts and compression limiters, to establish a grounding path that diverts and suppresses EMI noise, while an over-molded silicone seal provides insulation and corrosion protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a metallic braided shield is added to the connector assembly, then EMI shielding effectiveness is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The metallic braided shield is nested within the outer housing structure, with the shield positioned inside the housing cavity and secured by compression limiters that integrate with the housing walls. This nesting approach allows the shielding function to be incorporated without significantly increasing the external dimensions or overall complexity of the connector assembly.
Solution Approach 2:
Compression limiters serve as intermediary components between the metallic braided shield and the outer housing. These limiters provide a mechanical interface that secures the shield while allowing for controlled compression and electrical connection, simplifying the assembly process and reducing the complexity of directly integrating the shield into the housing structure.
2Reliability
If metal-infused plastic or stainless steel fiber-filled housing is used, then EMI grounding and corrosion resistance are improved, but manufacturing precision and material processing difficulty increase
Solution Approach 1:
The outer housing is constructed using composite materials, specifically metal-infused plastic or stainless steel fiber-filled polymer matrices. These composite materials combine the corrosion resistance and EMI grounding properties of metals with the manufacturing advantages of plastics, such as ease of molding and forming complex geometries. The composite structure allows for integrated features like apertures, ribs, and mounting points to be formed directly during the molding process, reducing subsequent machining requirements.
3Object-affected harmful factors
If multiple grounding paths are established through bolts and compression limiters, then EMI suppression effectiveness is improved, but assembly complexity increases
Solution Approach 1:
The grounding system is segmented into multiple discrete grounding paths, each established through separate bolts and compression limiters positioned at different locations on the connector assembly. This segmentation allows for modular assembly, where each grounding point can be independently installed and verified, simplifying the overall assembly process while maintaining multiple redundant grounding paths for effective EMI suppression.
4Reliability
If an over-molded silicone seal is added, then galvanic corrosion protection is improved, but manufacturing complexity and production time increase
Solution Approach 1:
The over-molded silicone seal is incorporated into the outer housing structure during the initial molding process, rather than being added as a separate post-assembly component. This preliminary action allows the seal to be formed integrally with the housing, creating a unified part that provides both structural support and corrosion protection. The seal's positioning and configuration are predetermined during mold design, eliminating the need for separate installation steps and reducing production time.
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 suppresses EMI noise by grounding it through angled conductive paths, reducing interference and preventing galvanic corrosion, ensuring reliable vehicle function.
Implementation Method 1
An electromagnetic interference (EMI) grounding protection method for a connector assembly connected to a device is provided
Implementation Method 2
The bolts provide the necessary grounding among the metallic braided shield, metal-infused plastic outer housing, and the device
Implementation Method 3
provides the necessary sealing and insulation layer to prevent galvanic corrosion between the connector and the device
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
An electromagnetic interference (EMI) grounding protection method for a connector assembly using a multi-directional conductive housing. The method includes the steps of: conducting the EMI generated by a source towards a metallic braided shield, the metallic braided shield being secured and mounted onto the multi-directional conductive housing by a metallic clamp; conducting the EMI from the metallic braided shield to the metallic clamp and to the multi-directional conductive housing, the multi-directional conductive housing being mounted onto a metallic device by at least a metallic bolt and the bolt being accommodated within a corresponding metallic compression limiter; and thereafter, conducting the EMI: (1) from the metallic braided shield to the multi-directional conductive housing through the metallic compression limiters and through their respective bolts, and ultimately to the metallic device, and (2) from the metallic braided shield to the multi-directional conductive housing directly through conductive pads thereof, and ultimately to the metallic device.