Injection Molded Sleeve for Electrical Connector Shielding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing electrical connectors with continuous shielding are complex and costly, and there is a risk of the shielding becoming loose due to relative movement of components, especially in vibrating environments.
Innovation Solution
A method involving partial peeling of the cable jacket from the conductor shield, followed by injection molding of a first sleeve part that directly contacts the components and fills gaps, ensuring stable connection and continuous shielding, with a metal sleeve connecting the conductor and housing screens, and an optional handle for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the cable jacket is completely removed from the conductor shield, then the shielding connection is simplified, but the manufacturing precision and reliability of the pre-encapsulation are compromised
Solution Approach 1:
The cable jacket is partially peeled back in advance during cable preparation, exposing a portion of the conductor shield before the connector assembly process. This preliminary exposure ensures that the shield is readily accessible for reliable connection to the housing shield, eliminating the need for complex in-situ shield exposure mechanisms while maintaining manufacturing precision.
2Ease of manufacture
If conventional manufacturing methods are used, then the production process is simpler, but the risk of shielding becoming loose under vibration increases
Solution Approach 1:
The injection molding process combines multiple functions into a single operation: the mold cavity simultaneously forms the housing, the carrier, and the first sleeve part that connects to the conductor shield. This merging ensures that all components are produced as an integrated assembly with consistent tolerances and reliable connections, eliminating the need for separate manufacturing steps that could compromise shielding stability under vibration.
Solution Approach 2:
The connector employs composite material construction with the housing and carrier made from injection-molded plastic materials, while the sleeve parts provide conductive shielding pathways. This composite approach allows the non-conductive housing to be integrated with conductive shielding elements, ensuring both mechanical stability and electrical continuity of the shield even under vibrational stress.
3Adaptability or versatility
If multiple separate components are used for shielding connection, then the assembly flexibility is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The housing serves multiple functions simultaneously: it provides the structural enclosure, contains the carrier and conductors, and acts as the housing shield through its integrated connection to the conductor shield via the first sleeve part. This multi-functionality eliminates the need for separate shield housing components, reducing overall device complexity while maintaining assembly flexibility for different cable and connector configurations.
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 method provides a reliable, inexpensive, and vibration-resistant electrical connector with continuous shielding, ensuring effective electromagnetic radiation protection and easy assembly, suitable for preassembled cables.
Implementation Method 1
At least that part of the sleeve which is in contact with the conductor shield is injection molded. This ensures that the sleeve makes reliable contact with the conductor shield. Particularly in the case of a conductor shield made from a wire mesh, sleeve material penetrates at least partially into interstices of the wire mesh during manufacture of the sleeve, so that the connection between the sleeve and the conductor shield is very firm and is also ensured under vibrations.
Data Source
Figure 1a~1d
Figure 2~3
Figure 4a~4c
AI summary
The invention relates to an electric connector for connecting a cable to an electric assembly, said cable having a conductor shield. The connector further comprises a housing on which a housing shield lies. The connector comprises an electrically conductive sleeve for connecting the housing shield to the conductor shield, said sleeve comprising a first sleeve part and a second sleeve part. At least the first sleeve part is injection molded. The invention further relates to a method for producing an electric connector, in particular according to the invention, said connector being provided for connecting a cable to an electric assembly. The cable comprises at least one electric conductor and has a conductor shield. Said method consists of the following steps: arranging the electric conductor in a housing, and arranging a housing shield on the housing. Said method also consists of further steps: injection molding an electrically insulating support at least between the housing and the cable, and injection molding at least one first electrically conductive sleeve part.