Connector Assembly Sealing Plug for EMI and Contaminant Protection
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Solution Overview
Problem
High voltage connectors in the automotive industry face issues with contaminants entering through empty cavities and inadequate restriction of electromagnetic interference (EMI) emission, as existing sealing plugs fail to provide a comprehensive seal.
Innovation Solution
A connector assembly featuring an outer housing with an electromagnetic shield and a plug that seals both the housing and the shield's aperture, preventing contaminant ingress and EMI emission by engaging with the shield's extensions and a cable seal, ensuring a secure environmental and EMI seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a sealing plug is installed to seal the empty cavity, then contaminant ingress is prevented, but electromagnetic interference emission is not adequately restricted
Solution Approach 1:
The sealing plug is merged with an electromagnetic shield to create a single component that simultaneously provides both environmental sealing and EMI shielding. The plug includes a body portion that seals the cavity opening and a shield portion with conductive material that restricts EMI emission, combining two previously separate functions into one integrated component.
Solution Approach 2:
The sealing plug is designed as a multi-functional component that performs both sealing and electromagnetic shielding functions. The plug body provides mechanical sealing to prevent contaminant ingress, while the integrated conductive shield portion provides electromagnetic interference restriction, allowing a single component to address multiple harmful effects.
2Ease of manufacture
If the cavity is left open for access, then installation is simplified, but contaminants can enter the connector interior
Solution Approach 1:
The sealing plug is pre-installed in the empty cavity position during connector assembly, providing immediate sealing protection. This preliminary sealing action prevents contaminant ingress from the outset while maintaining the appearance of an open cavity configuration, eliminating the need for additional sealing steps.
3Ease of manufacture
If a traditional sealing plug is used, then manufacturing is simple, but electromagnetic interference is not restricted
Solution Approach 1:
The sealing plug utilizes composite construction combining non-conductive sealing material with conductive shielding material. The plug body is formed from non-conductive material for sealing, while the shield portion incorporates conductive material or conductive coating, creating a composite component that provides both sealing and EMI restriction functions.
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 prevents contaminants from entering the connector while restricting EMI emission, enhancing the reliability and performance of high voltage connectors in harsh environments.
Implementation Method 1
The plug seals the opening in the outer housing and the aperture in the shield to prevent ingress of contaminants into the interior chamber of the outer housing
Implementation Method 2
The electromagnetic shield is disposed within the outer housing and includes a conductive body having an interior compartment with an aperture. The plug also restricts emission of electromagnetic interference from the interior compartment of the shield
Data Source
AI summary
A connector assembly includes an outer housing, an electromagnetic shield, and a plug. The outer housing includes an interior chamber and an opening. The electromagnetic shield is disposed within the outer housing and includes a conductive body having an interior compartment with an aperture. The plug is disposed in the opening of the outer housing and is engaged with the shield around the aperture of the shield. The plug seals the opening in the outer housing and the aperture in the shield to prevent ingress of contaminants into the interior chamber of the outer housing. The plug also restricts emission of electromagnetic interference from the interior compartment of the shield.