Face-to-Face Contact Assembly with Shielding Spring
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Solution Overview
Problem
Face-to-face electrical contacts in aerospace and automotive applications require reliable and robust connections, but existing solutions often fail to provide adequate shielding and electrical isolation, leading to interference from electromagnetic waves and environmental signals.
Innovation Solution
A face-to-face contact assembly comprising an inner electrically conductive spring element and an outer shielding spring element separated by a dielectric spacing element, where the conductive spring connects two faces and the shielding spring at least partially shields the connection, with the spacing element made from dielectric material to ensure electrical isolation and the shielding spring configured to prevent EM wave interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single electrically conductive spring element is used to connect two faces, then electrical connection is established, but electromagnetic interference and environmental signal interference occur due to lack of shielding
Solution Approach 1:
The contact assembly is segmented into multiple functional components: an inner electrically conductive spring element for signal transmission and an outer shielding spring element for electromagnetic protection. This segmentation allows the electrical connection and shielding functions to be performed by separate elements, resolving the contradiction between establishing reliable electrical connection and preventing electromagnetic interference.
Solution Approach 2:
The inner electrically conductive spring element is nested within the outer shielding spring element, with both elements contained within the housing structure. This nested arrangement allows the conductive element to perform its electrical function while being protected by the surrounding shielding element, effectively blocking electromagnetic interference from reaching the signal transmission path.
2Object-affected harmful factors
If an outer shielding spring element is added around the inner conductive spring element, then electromagnetic shielding is provided, but device complexity increases
Solution Approach 1:
Both the inner conductive spring element and the outer shielding spring element serve multiple functions: they provide electrical connection, mechanical compliance, and structural support. The spring elements also define flow paths and sealing surfaces when combined with the housing. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity despite adding shielding capability.
Solution Approach 2:
The shielding spring element is merged with the housing structure through integrated sealing surfaces and engagement features, eliminating the need for separate sealing components or mounting hardware. The spring elements are directly received by the housing with minimal additional parts, combining multiple functions into unified components and preventing excessive complexity.
3Reliability
If multiple spring elements (inner conductive and outer shielding) are used, then both electrical connection and shielding are achieved, but manufacturing complexity increases
Solution Approach 1:
The housing is pre-formed with integrated spring receptacles, sealing surfaces, and engagement features before the spring elements are installed. This preliminary preparation allows the spring elements to be directly inserted and secured without requiring complex assembly operations or additional machining steps, thereby maintaining ease of manufacture despite the presence of multiple spring components.
4Reliability
If the spacing element is made of dielectric material, then electrical isolation between spring elements is ensured, but manufacturing precision requirements increase
Solution Approach 1:
The housing features localized conductive regions and insulating regions with distinct material properties or surface treatments. Conductive paths are precisely defined only where needed for electrical connection, while insulating properties are provided in specific areas for isolation. This local differentiation allows standard manufacturing tolerances to suffice, as precision is required only at critical interface locations rather than throughout the entire component.
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 and robust electrical connection while effectively shielding against electromagnetic interference, ensuring reliable signal transfer and preventing interference from external EM waves, thus enhancing the performance and reliability of electrical contacts in demanding applications.
Implementation Method 1
separated by a spacing element made from dielectric material to ensure electrical isolation
Implementation Method 2
the shielding spring configured to prevent EM wave interference
Data Source
AI summary
A face to face contact assembly having at least one electrically conductive spring element and at least one shielding spring element separated from one another by a spacing element. From the perspective of a centerline and extending radially outwardly, electrically conductive spring element is located closest to the centerline, then the spacing element, and then the shielding spring element. The electrically conductive spring element electrically connects two adjacent faces, which in one example can be adjacent printed circuit boards, and the shielding spring element at least partially shields such electrical connection. Other face to face contact assembly arrangements are also disclosed.