Embedded Grounding in Electrical Connectors
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Solution Overview
Problem
Existing electrical connectors with grounding mechanisms face reliability issues due to manufacturing tolerances and environmental impacts, leading to unstable grounding effects and disassembly problems.
Innovation Solution
An electrical connector design featuring an insulative housing with a contact module that includes insulators, signal contacts, and grounding contacts, where conductive plastic blocks are mechanically and electrically connected to the grounding contacts, enhancing the grounding and shielding performance by maximizing contact area and integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If discrete grounding bar is assembled to housing, then grounding contacts are mechanically and electrically connected, but grounding effect becomes unreliable and unstable due to manufacturing tolerance and environment impact
Solution Approach 1:
The grounding bar is integrated into the housing as a unified structure, eliminating the separate assembly step. The conductive plastic is embedded directly into the housing cavity, creating an integrated grounding mechanism that removes assembly tolerance issues and improves reliability.
Solution Approach 2:
The housing is formed as a composite structure combining insulative material with conductive plastic material. The conductive plastic is embedded within the insulative housing to create a hybrid structure that provides both electrical insulation and grounding functionality, improving grounding stability.
2Stability of the object's composition
If discrete conductive plastic is disposed in housing cavity, then grounding contacts are connected, but connector lacks integrity and tends to disassemble
Solution Approach 1:
The conductive plastic is merged with the housing through embedding, creating a unified structure where the grounding bar becomes an integral part of the housing rather than a separate component, preventing disassembly and improving structural integrity.
Solution Approach 2:
The housing structure has different local properties: insulative material in most areas for electrical isolation, and conductive plastic in specific grounding areas for electrical connection. This localized differentiation maintains connector integrity while providing grounding functionality.
3Reliability
If contact area between conductive plastic and grounding contacts is increased, then grounding performance is enhanced, but manufacturing complexity increases
Solution Approach 1:
The conductive plastic is formed with a porous or mesh-like structure that increases the contact area with grounding contacts while maintaining a relatively simple manufacturing process. The porous structure provides extensive surface area for electrical connection without requiring complex assembly.
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 stable and reliable grounding mechanism that enhances high-frequency performance and maintains connector integrity, ensuring effective electrical and mechanical connections between conductive plastic and grounding contacts.
Implementation Method 1
conductive plastic block mechanically and electrically connected to the corresponding grounding contacts
Data Source
AI summary
An electrical connector includes an insulative housing forming a mating slot, and the contact module assembled thereto. The contact module includes the insulator and the contacts secured thereto. The insulator is secured to the housing. The contact includes a retaining section secured to the insulator, a contact section extending from one end of the retaining section into a mating slot, a soldering section extending from the other end of the retaining section out of the housing. The contacts include the signal contacts and the grounding contacts. Each contact module further includes at least one conductive plastic block mechanically and electrically connected to the corresponding grounding contacts.