Insulating Member With Cruciform Shield For High-Frequency Connectors
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Solution Overview
Problem
Existing multi-pin connectors are complex and expensive to assemble, limiting their versatility and ability to handle high-frequency data transmission effectively.
Innovation Solution
A one-piece insulating body with a conductive coating, produced via a two-component injection molding process, incorporates a shielding element and spring arms for electromagnetic shielding, eliminating the need for additional assembly steps and metallic contact rings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-pin connectors are assembled with multiple individual parts including metallic contact rings and separate shielding elements, then electromagnetic shielding is achieved, but assembly complexity increases and manufacturing costs rise
Solution Approach 1:
The patent combines the insulating body, shielding element, and contact ring into a single integrated component produced via two-component injection molding. The first component forms the insulating body with integrated shielding areas, while the second component forms the contact ring that is simultaneously molded onto the first component, eliminating the need for separate assembly steps and reducing overall device complexity while maintaining electromagnetic shielding effectiveness.
Solution Approach 2:
The patent employs composite materials by incorporating conductive fillers (such as metal powders or carbon-based materials) into the plastic matrix of the insulating body during the injection molding process. This creates a composite material that provides both the insulating properties of plastic and the electromagnetic shielding capabilities of conductive materials, allowing the shielding function to be integrated directly into the insulating body without requiring separate metallic shielding elements.
2Adaptability or versatility
If traditional connectors use separate metallic contact rings and shielding elements requiring multiple assembly steps, then functional requirements are met, but manufacturing time and cost increase
Solution Approach 1:
The patent implements preliminary action by pre-integrating the shielding element and contact ring into the insulating body through a two-component injection molding process. The first component is molded with integrated shielding areas that already contain the necessary conductive structures, and the second component (contact ring) is simultaneously molded onto these areas. This preliminary integration eliminates the need for subsequent assembly steps, significantly improving manufacturing efficiency and productivity while maintaining all required functional characteristics.
Solution Approach 2:
The patent merges multiple functional components (insulating body, shielding element, and contact ring) into a single integrated part produced in one manufacturing cycle. The two-component injection molding process creates a unified structure where the contact ring is permanently attached to the insulating body with integrated shielding, eliminating the need for separate assembly operations and thereby increasing production speed and manufacturer productivity.
3Reliability
If connectors are designed with multiple individual components for shielding and contact elements, then electromagnetic shielding is effective, but manufacturing cost increases
Solution Approach 1:
The patent merges the insulating body, shielding element, and contact ring into a single integrated component produced through a two-component injection molding process. This consolidation reduces the number of separate parts that need to be manufactured, stored, and assembled, thereby reducing overall manufacturing costs while maintaining effective electromagnetic shielding through the integrated conductive structures.
Solution Approach 2:
The patent uses composite materials by incorporating conductive fillers into the plastic matrix during injection molding to create an insulating body with integrated electromagnetic shielding properties. This approach eliminates the need for separate metallic shielding materials and reduces material costs while maintaining shielding effectiveness, and the entire structure is produced in a single manufacturing process.
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 simplifies assembly, reduces costs, and enhances electromagnetic shielding for high-frequency data transmission, making connectors easier to manufacture and more versatile.
Implementation Method 1
The contact ring, in turn, is in conductive (touch) contact with the inner wall of the cavity of the connector housing
Implementation Method 2
A galvanic coating of a metal surface with a tin or a tin alloy layer is known from EP 1 256 981 A1
Data Source
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AI summary
The invention relates to an insulating member (1) which is provided for receiving and/or electrically contacting at least one conductor of a cable to be connected or for fitting same onto a printed circuit board, wherein the insulating member (1) can be introduced into a chamber provided therefor in a plug connector housing and comprises at least one cutout (11) for at least one contact element which can be connected to the individual conductor of the cable to be connected or to a conductive track of the printed circuit board, and has a shielding element by which the contact element is electromagnetically shielded, wherein the insulating member (1) is formed by at least one component and one second component (10), wherein the first component contains a doping, such that the surface of the first component can be provided with a conductive coating (6) by a galvanic process, wherein the shielding element is formed from the first component.