EMI Shielded Connector Shunt Member Design
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Solution Overview
Problem
Hybrid vehicles require EMI shielded electrical connections to prevent short circuits between high voltage components and the vehicle chassis, necessitating effective isolation of electrical terminals and shield components.
Innovation Solution
A shielded electrical connector system with conductive inner and outer housings, featuring a shunt member of conductive material to enhance electrical continuity between the conductive shield and outer housing, and a shielded electric cable with a conductive core, inner and outer insulation jackets, and a terminal in electrical contact with the core, ensuring electrical isolation and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrical terminals and shield components are isolated from each other electrically to prevent short circuits, then safety and reliability are improved, but electrical continuity between the shield and outer housing deteriorates
Solution Approach 1:
The connector is divided into two distinct electrical zones: an inner housing containing electrical terminals isolated for safety, and an outer housing containing shield components for EMI protection. This segmentation allows each zone to perform its specific function independently while maintaining overall system reliability and EMI shielding effectiveness.
2Reliability
If the inner housing is made of non-conductive material to isolate terminals, then electrical isolation is improved, but EMI shielding effectiveness deteriorates
Solution Approach 1:
The housing structure is segmented into an inner non-conductive housing for electrical isolation and an outer conductive housing for EMI shielding. This allows the non-conductive inner housing to prevent short circuits while the conductive outer housing maintains effective EMI shielding, resolving the contradiction between electrical isolation and shielding effectiveness.
Solution Approach 2:
A shunt member acts as an intermediary component that provides a controlled electrical path between the inner and outer housings. This allows the inner housing to remain electrically isolated for safety while the outer housing maintains its EMI shielding function, with the shunt member mediating the electrical relationship between the two housings.
3Object-affected harmful factors
If the outer housing is made of conductive plastic material for EMI shielding, then EMI protection is improved, but electrical continuity with the shield deteriorates
Solution Approach 1:
The shunt member serves as a conductive intermediary that bridges the gap between the conductive plastic outer housing and the metallic shield. It provides a reliable electrical continuity path while allowing the outer housing to maintain its conductive plastic construction for optimal EMI shielding performance.
Solution Approach 2:
The shunt member changes the electrical conductivity parameter at the interface between the outer housing and shield. By introducing this highly conductive element, the system achieves both the EMI shielding benefits of conductive plastic housing and the electrical continuity required for effective shield grounding.
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 effectively prevents electromagnetic interference and short circuits by ensuring electrical continuity and isolation, enhancing the reliability and safety of high voltage electrical connections in hybrid vehicles.
Implementation Method 1
A shunt member of conductive material contacts the conductive shield of the cable and the outer housing of conductive plastic material to enhance electrical continuity between the conductive shield and the outer housing of conductive plastic material.
Implementation Method 2
This connector may have a second shunt chamber communicating with the terminal inlet, and a second shunt member that is disposed in the second shunt chamber engaging the conductive shield of the cable and the connector's outer housing of conductive plastic material.
Data Source
AI summary
A shielded electrical connection system has a pair of electrical connectors each comprising an inner insulator housing and an outer housing of conductive material. A shunt member of conductive material contacts conductive plug and socket portions of the respective electrical connectors when mated, to enhance electrical continuity between the outer housings. The shunt member is disposed in a shunt chamber and a connector seal seals the chamber at one end. A terminal attached to a shielded electric cable is disposed in a terminal passage in electrical connector that has a second shunt chamber at an inlet of the terminal passage. A second shunt member engages the conductive shield of the cable in the second shunt chamber and the outer housing of the connector. A cable seal seals an inlet of the second shunt chamber. The outer housing of electrical connector is adapted for connection to a conductive casing for grounding the shielded electrical connection. This outer housing carries a second connector seal for sealing an interface between the outer housing and the conductive casing.