Integrated Insulation Insert Shielding Element
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Solution Overview
Problem
Existing plug-in connectors with insulation inserts are time-consuming to package due to the large number of parts and are prone to errors during crimp ring insertion, which can lead to unreliable shielding of contact elements against electromagnetic radiation.
Innovation Solution
An integral insulation insert and shielding element are formed as a single component through two-component injection molding with a conductive coating, allowing for simplified packaging and reliable shielding by eliminating separate components and using clamping means for secure contact with the connector housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate insulation insert and shielding element components are used, then the shielding function can be provided, but the packaging process becomes time-consuming and error-prone
Solution Approach 1:
The patent combines the insulation insert and shielding element into a single integrated component. The insulation insert includes both the insulating body and the shielding element as integral parts, eliminating the need for separate assembly steps. This merging of components directly resolves the contradiction by reducing packaging time while ensuring reliable shielding transfer through the integrated structure.
2Reliability
If a crimp ring is used to fasten the shielding braid, then the shielding can be secured, but the crimp ring can easily slip during insertion causing errors
Solution Approach 1:
The shielding element is integrated directly into the insulation insert structure, eliminating the separate crimp ring component. The shielding element provides both the shielding function and the fastening function through its integrated design with the insulation insert, removing the slipping issue associated with separate crimp rings while maintaining secure shielding braid fastening.
Solution Approach 2:
The patent extracts the problematic crimp ring component from the assembly and replaces it with an integrated shielding element that is part of the insulation insert. This extraction eliminates the source of errors (slipping crimp ring) while preserving the essential function of securing the shielding braid through the integrated structure.
3Adaptability or versatility
If multiple separate components are used in the plug-in connector, then specific functions can be provided, but the number of parts increases making packaging complex
Solution Approach 1:
The patent merges multiple functional components (insulation insert and shielding element) into a single integrated part. The insulation insert incorporates both insulating and shielding functions within one component, reducing the total number of parts while maintaining all necessary functional capabilities through the integrated design.
Solution Approach 2:
The insulation insert is designed as a multi-functional component that simultaneously provides insulation, shielding, and structural support functions. By making the insulation insert universal and multi-functional, the patent reduces the number of separate parts needed while maintaining adaptability and versatility of the plug-in connector system.
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
This approach significantly reduces packaging time and enhances the reliability of shielding transfer to the connector housing, ensuring efficient assembly and improved signal integrity by integrating the shielding and clamping functions within the insulation insert.
Implementation Method 1
a plastic body is produced in a two-component injection moulding procedure and is subsequently, at least partially by means of an MID process, provided with a conductive coating
Implementation Method 2
The shielding element at the same time also contacts the electrically conducting housing of the plug-in connector and therefore transfers the cable shielding to the latter
Data Source
AI summary
The invention relates to an insulation insert that can be inserted into a plug-in connector housing (11) of a plug-in connector (10), wherein in the insulation insert (1), at least one contacting element for electrically contacting a conductor core of a cable (12) to be connected may be provided, wherein the insulation insert (1) is provided in one area with a conductive coating, wherein the coated area forms a shielding element (3) that can be electrically contacted with a shielding braid of the cable (12) to be connected and at the same time with the plug-in connector housing (11), and wherein the insulation insert (1) and the shielding element (3) are integrally formed in.