Process Fieldbus Connector Shielding and Fixing
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Solution Overview
Problem
Current PROFIBUS-DP connectors fail to provide adequate protection against electromagnetic interference and have a loose fit, leading to disconnection issues and incomplete shielding.
Innovation Solution
A connector design featuring a circuit board, two communicating cables with shielding net layers, an inner shell, a shielding layer, and an outer shell, where the inner and outer shells are formed by injection molding to securely fix the circuit board and the shielding layer is electrically connected to the cables' shielding net layers, ensuring complete electromagnetic interference protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the circuit board and connecting port are just mounted in the plastic shell, then the connector structure is simple and easy to manufacture, but the circuit board and connecting port may be loosened and disconnected, leading to poor connector quality
Solution Approach 1:
The patent merges the mounting function and fixing function into a single integrated plastic shell structure. The shell incorporates both the mounting cavity for the circuit board and the fixing mechanism (through holes with fastening elements) as unified components, eliminating the need for separate mounting brackets or additional fastening parts. This integration maintains manufacturing simplicity while ensuring reliable connection.
Solution Approach 2:
The patent introduces through holes with curved or rounded features in the plastic shell that work with fastening elements to secure the circuit board. The curved geometry of these mounting features provides both ease of manufacture (simple mold design) and reliable mechanical interlocking, preventing loosening and disconnection while maintaining structural simplicity.
2Object-affected harmful factors
If a metallic shield is mounted between the circuit board and plastic shell to cover the circuit board, then electromagnetic interference protection is improved, but the shield may not totally cover the circuit board, resulting in incomplete protection
Solution Approach 1:
The patent implements a nested shielding structure where the metallic shield is positioned within the plastic shell and extends to cover the circuit board completely. The shield is nested between the circuit board and the outer plastic shell, creating multiple layers of protection. This nested arrangement ensures complete coverage of the circuit board while maintaining the compact connector structure.
Solution Approach 2:
The patent uses a thin metallic shield film or foil that can conform to the shape of the circuit board and extend to cover all exposed surfaces. This flexible shielding layer is mounted within the plastic shell structure, ensuring complete coverage of the circuit board and connecting port areas, eliminating electromagnetic interference from all directions.
3Ease of operation
If the plastic shell is a flip shell with two half shells pivotally connected, then the connector can be easily assembled, but the circuit board and connecting port are not tightly covered, leading to loosening and disconnection
Solution Approach 1:
The patent divides the plastic shell into two half shells that can be separately assembled around the circuit board and connecting port. This segmentation allows easy assembly by snapping the two halves together, while the design incorporates integrated fastening elements (through holes with securing features) that ensure tight coverage and prevent loosening, combining assembly ease with connection stability.
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 improved connector provides a secure fit and complete shielding against electromagnetic interference, enhancing the reliability and quality of the PROFIBUS-DP connection.
Implementation Method 1
a shielding layer (14) covering the inner shell (13) and the circuit board (11), and being electrically connected to the shielding net layers (122) of the two communicating cables (12)
Implementation Method 2
The inner shell (13) is mounted on the ends of the core wires (121) by injection molding to cover the ends of the core wires (121) of the two communicating cables (12)
Data Source
AI summary
A connector of a process field bus decentralized peripherals has a circuit board, two communicating cables each having two core wires and a shielding net layer, the two core wires coated by the shielding net layer, ends of the two core wires electrically connected to the circuit board, an inner shell mounted on the ends of the core wires by injection molding, a shielding layer covering the inner shell and the circuit board, the shielding layer electrically connected to the shielding net layers, and an outer shell mounted on the shielding layer by injection molding. Since the inner shell and the outer shell are formed by injection molding, the circuit board is tightly fixed in the connector. Further, the shielding layer is mounted between the inner shell and the outer shell to protect the circuit board from electromagnetic interference. Therefore, quality of the connector may be improved.