Dual Port Cable Connector Floating Alignment EMI Shielding
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Solution Overview
Problem
Existing electrical plug connector assemblies face challenges in achieving precise mating of connectors while maintaining effective EMI shielding, as existing solutions require expensive resilient members and compromise on manufacturing tolerance.
Innovation Solution
The use of a rubber ring surrounding the second connector for a floating effect, combined with a conductive sponge for sealing and shielding, allows for transverse movement while maintaining EMI shielding and accommodating manufacturing deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If resilient members are used to provide floating effect for connector, then manufacturing tolerance can be compromised, but the cost of material and manufacturing procedure increases
Solution Approach 1:
The patent replaces expensive resilient members with a combination of a rubber ring (providing floating effect) and conductive sponge (providing EMI shielding). The rubber ring is a simple, low-cost component that can be easily molded, while the conductive sponge provides both structural support and EMI shielding functionality. This substitution significantly reduces material and manufacturing costs while maintaining the required floating effect and connector alignment tolerance compensation.
Solution Approach 2:
The patent uses a composite structure combining rubber ring and conductive sponge materials. The rubber ring provides elastic deformation for floating effect, while the conductive sponge provides EMI shielding and additional structural support. This composite approach achieves both mechanical flexibility and electromagnetic shielding with low-cost materials, avoiding the need for expensive resilient members alone.
2Manufacturing precision
If connectors are made moveable relative to each other for compromising manufacturing tolerance, then connector alignment is improved, but EMI shielding effect is jeopardized
Solution Approach 1:
The conductive sponge acts as an intermediary element between the rubber ring and the shielding case. It provides continuous EMI shielding while allowing the rubber ring to enable connector movement. The conductive sponge fills the gap between the movable connector and the shielding case, ensuring EMI shielding is maintained even when the connector moves within its floating range. This intermediary solution resolves the conflict between movement capability and shielding effectiveness.
Solution Approach 2:
The patent uses a flexible conductive sponge that can deform to accommodate connector movement while maintaining EMI shielding. The sponge's flexible nature allows it to conform to the moving connector's position, ensuring continuous shielding coverage. This flexible shielding approach maintains EMI protection while permitting the necessary connector movement for tolerance compensation.
3Object-affected harmful factors
If conductive sponge is added for EMI shielding, then EMI shielding effect is improved, but device complexity increases
Solution Approach 1:
The conductive sponge serves multiple functions simultaneously: it provides EMI shielding, supports the rubber ring structure, fills gaps between components, and allows for connector movement. By combining these functions into a single component, the patent avoids increasing assembly complexity while achieving effective EMI shielding. The sponge's multi-functionality eliminates the need for additional separate shielding components.
Solution Approach 2:
The patent merges the EMI shielding function with the structural support function by integrating the conductive sponge into the existing rubber ring assembly. Instead of adding a separate shielding component, the sponge is combined with the rubber ring structure, creating a unified assembly that provides both mechanical support and electromagnetic shielding. This merging approach maintains simplicity while achieving dual functionality.
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
This solution provides a low-cost, effective way to ensure precise connector mating and robust EMI shielding by allowing for flexible alignment of connectors while preventing EMI, thus addressing manufacturing tolerance and cost concerns.
Implementation Method 1
the second connector is equipped with a rubber ring transversely confronting the housing shroud for obtaining the floating effect
Implementation Method 2
A conductive sponge surrounds the second connector and intimately shield the front opening in a compressed manner
Data Source
AI summary
An electrical connector assembly includes a housing shroud enclosing the respective first and second connectors spaced and distinct from each other with the corresponding ports exposed outside of the housing shroud. A cable is connected to the first connector and the second connector respectively and extends out of the housing shroud opposite to the mating ports. The first connector is fixed within the housing shroud while the second connector is disposed in the housing shroud in a floating manner wherein the second connector is equipped with a rubber ring transversely confronting the housing shroud for obtaining the floating effect.