Header Connector Assembly Shielding and Sealing
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Solution Overview
Problem
High voltage connectors in hybrid and electric automobiles face challenges in sealing to prevent contaminants and electromagnetic interference, which can lead to short circuits and fluid leaks due to multiple interfaces in shielded connectors.
Innovation Solution
A header connector assembly with an outer and inner housing, a shield subassembly, and seal bodies that restrict contaminant passage, featuring a conductive shield and elastomeric seal bodies to prevent moisture and fluid ingress while managing electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a shielded connector with multiple sections or nested portions is used to restrict electromagnetic interference, then electromagnetic shielding is improved, but the number of interfaces increases which allows contaminants to pass into the interior of the connector
Solution Approach 1:
The patent employs nested housing sections where an inner housing is positioned within an outer housing, creating a nested structure that provides electromagnetic shielding while maintaining sealing integrity. The nested portions are sealed together to prevent contaminant passage through the interfaces.
Solution Approach 2:
Sealing members are introduced as intermediary elements between the nested housing sections. These sealing members fill and seal the interfaces between housing portions, preventing contaminants from passing through the interfaces while allowing the nested structure to maintain its electromagnetic shielding function.
2Object-affected harmful factors
If multiple sections or nested portions are used in the connector housing, then electromagnetic shielding capability is improved, but the complexity of the connector structure increases
Solution Approach 1:
The nested housing structure allows multiple shielding sections to be integrated within each other, providing comprehensive electromagnetic shielding while organizing the complex structure in a compact, systematic manner that manages the increased complexity through hierarchical arrangement.
3Reliability
If seal bodies are added to restrict contaminant passage, then sealing performance is improved, but the device complexity increases
Solution Approach 1:
The sealing function is merged with the housing structure by integrating sealing members directly into the interfaces between housing sections. This combination approach provides improved sealing performance while minimizing the increase in device complexity by avoiding separate, standalone sealing components.
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 seals contaminants and electromagnetic interference, ensuring reliable high voltage transmission by using a shielded connector assembly with strategically placed seal bodies and conductive shields, preventing short circuits and fluid leaks.
Implementation Method 1
The shield subassembly is disposed between the outer housing and the inner housing. The shield subassembly engages the panel to electrically couple the shield subassembly with the panel.
Implementation Method 2
The seal body is disposed between the panel and at least one of the outer housing and the inner housing. The seal body restricts passage of contaminants between the panel and at least one of the outer housing and the inner housing.
Data Source
AI summary
A header connector assembly includes an outer housing, an inner housing, a shield subassembly, and a seal body. The outer housing is disposed in an opening of a panel and includes a cavity. The inner housing includes a channel and is disposed in the opening of the panel. The inner housing is received in the cavity of the outer housing and includes a channel configured to have a contact disposed therein. The shield subassembly is disposed between the outer housing and the inner housing. The shield subassembly engages the panel to electrically couple the shield subassembly with the panel. The seal body is disposed between the panel and at least one of the outer housing and the inner housing. The seal body restricts passage of contaminants between the panel and at least one of the outer housing and the inner housing.