Electrical Connector Shielding and Sealing Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The electrical car industry faces challenges in achieving high electromagnetic shielding efficiency and moisture endurance in electrical connector assemblies, which can lead to electromagnetic disturbances and infiltration of moisture and foreign particles, compromising the sealing and shielding properties of electrical connections.
Innovation Solution
An electrical connection system featuring an electrically conductive core, insulating layer, conductive shielding layer, and external insulating sheath, with a shield part between the front and sealing parts, utilizing a conductive shield with metallic shells, a clip for conductivity, and a sealing device with elastomeric rings and a clamp to maintain shielding and sealing integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional electrical connector assembly is used, then electrical connection is achieved, but electromagnetic shielding efficiency is insufficient and moisture infiltration occurs
Solution Approach 1:
The patent implements nested shielding structures where an inner conductive shield is placed within the connector, surrounded by an outer conductive shield. This multi-layer nested configuration creates successive barriers against electromagnetic interference, significantly improving shielding efficiency compared to conventional single-layer approaches.
Solution Approach 2:
The patent employs composite material structures combining different conductive materials for inner and outer shields, along with insulating materials positioned between them. This composite approach optimizes both electromagnetic shielding performance and electrical insulation properties, addressing the dual requirements of high shielding efficiency and moisture protection.
2Reliability
If shielding structures are added to improve electromagnetic protection, then shielding efficiency increases, but device complexity increases
Solution Approach 1:
The patent designs the conductive shields to serve multiple functions simultaneously: providing electromagnetic shielding, acting as structural support elements, and facilitating assembly through integrated attachment features. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity despite enhanced protection capabilities.
Solution Approach 2:
The patent merges the shielding function with the connector's structural framework by integrating conductive shield elements that also serve as mounting and positioning structures. This consolidation approach maintains structural integrity while providing comprehensive moisture and electromagnetic protection, avoiding the need for additional separate protective components.
3Reliability
If multiple shielding layers are implemented, then electromagnetic shielding efficiency improves, but manufacturing cost increases
Solution Approach 1:
The patent incorporates pre-assembled shield units with pre-attached insulating elements and sealing components. These pre-prepared subassemblies are designed to be installed as complete units into the connector, reducing the number of discrete assembly steps required during final assembly and simplifying the manufacturing process despite the multi-layer shielding configuration.
Solution Approach 2:
The patent utilizes flexible conductive shield materials that can be easily deformed and positioned during assembly, allowing for simple snap-fit or clamp-based installation methods. This flexibility enables rapid assembly of multiple shielding layers without requiring complex fastening operations, thereby maintaining ease of manufacture while achieving high shielding efficiency.
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 a reliable, cost-effective, and time-resistant sealed shielding connection that minimizes electromagnetic interference and prevents moisture infiltration, ensuring safer and more durable electrical connections.
Implementation Method 1
an electrically conductive shielding layer and an external insulating sheath. The shield part may be provided in the electrically conductive shielding layer
Implementation Method 2
two elastomeric rings, arranged between the adapter and electrical wire
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to an Electrical wire (16) extending along a longitudinal axis and comprising a front end portion (33), a shield part (34) and a sealing part (39), the shield part (34) being arranged between the front end portion (33) and the sealing part (34), along the longitudinal axis. The present invention also relates to an electrical connection System comprising: - a cable comprising at least one electrical wire (16), - an electrical connector (28) having an internal cover (8) comprising a reception portion (10) suitable to receive the front end portion (33) of the electrical wire (16), - an electrically conductive shield (9) surrounding the reception portion (10), - an electrically conductive shielding element (3) surrounding the electrical wires (16) from its shield part (34) to the electrically conductive shield ( 9), and - a sealing device (40) extending between the sealing part (39) of the electrical wires (16) and the internal cover (8).