Integrated Connector Shield Structure for AC/DC Cable Isolation
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Solution Overview
Problem
Existing connectors lack an efficient and simplified design for simultaneously shielding alternating current (AC) and direct current (DC) power cables, leading to complex manufacturing processes and potential quality risks due to manual wiring challenges.
Innovation Solution
A connector design featuring a shield structure with a shield shell base and body connected to both AC and DC cables, utilizing ferrules and a ground terminal to electrically connect the cables to earth and chassis grounds, simplifying the manufacturing process and reducing manual wiring complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate shielding designs are used for AC and DC cables, then each cable can be shielded individually, but the manufacturing process becomes complex and manual wiring challenges arise
Solution Approach 1:
The patent combines the shielding structures for AC and DC cables into a single integrated shield assembly. The shield housing contains both AC cable shielding portions and DC cable shielding portions, with a common ground connection structure. This merging eliminates the need for separate manual wiring operations while maintaining individual cable shielding effectiveness, thus resolving the contradiction between reliable shielding and manufacturing complexity.
Solution Approach 2:
The ground terminal structure serves multiple functions simultaneously: it provides ground connections for both AC and DC cable shields, acts as a mounting structure for the shield assembly, and provides electrical isolation between AC and DC ground paths. This multi-functionality reduces the number of separate components needed and simplifies the manufacturing process while ensuring proper shielding for both cable types.
2Ease of operation
If manual wiring is used for connecting shields to grounds, then flexibility in connection is achieved, but productivity decreases and quality risks increase
Solution Approach 1:
The shield housing is pre-assembled with integrated ground terminals and connection points during manufacturing. The AC and DC cable shielding portions are pre-configured with their respective ground paths within the housing before installation. This preliminary assembly eliminates the need for complex manual wiring operations during final installation, thereby increasing productivity while maintaining proper electrical connections.
Solution Approach 2:
The ground terminal acts as an intermediary component that provides standardized connection points for both AC and DC cable shields. Instead of requiring direct manual wiring from each cable shield to ground, the terminal serves as a mediator with pre-established electrical paths, simplifying the connection process while ensuring reliable ground connections for both cable types.
3Productivity
If integrated shield structure is used for AC and DC cables, then manufacturing is simplified and productivity improves, but electrical isolation between grounds must be ensured
Solution Approach 1:
The shield housing is segmented into distinct AC cable shielding portions and DC cable shielding portions, with separate ground terminals for each system. This segmentation maintains electrical isolation between AC and DC ground paths while being manufactured as an integrated assembly. The physical separation within the unified structure ensures that productivity benefits are achieved without compromising electrical isolation requirements.
Solution Approach 2:
Different regions of the shield housing are designed with different electrical properties: the AC cable shielding portion is connected to an AC ground terminal with specific electrical characteristics, while the DC cable shielding portion is connected to a DC ground terminal with different electrical characteristics. This local differentiation ensures proper electrical isolation and grounding for each cable type while maintaining an integrated manufacturing structure.
Data Source
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AI summary
A connector (100) including a housing (93), an outer case (91) connected to the housing (93), an inner case (92) disposed between the housing (93) and the outer case (91), a shield shell base (2) surrounding at least a portion of the inner case (92), and provided to be electrically connected to a shield (413) of a first cable (41), a shield shell body (3) connected to the shield shell base (2) and provided to be electrically connected to a shield (423) of a second cable (42), and a ground terminal (43) connected to the housing (93), in contact with the shield shell base (2), and configured to electrically connect each of the shield shell base (2) and the shield shell body (3) to two grounds (C, E).