Internal Spring Shielded Connector for Heat and Vibration Stability
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Solution Overview
Problem
Conventional electrical connector assemblies for motor vehicles are prone to failure due to harsh operating conditions, including high temperatures, vibration, and electromagnetic interference, which can lead to mechanical and electrical disconnections, resulting in significant repair and warranty costs.
Innovation Solution
A shielded electrical connector system with a spring actuated electrical connector assembly housed within a conductive and non-conductive material assembly, providing enhanced mechanical and electrical connectivity while suppressing electromagnetic interference. The connector system features a male and female terminal assembly with an internal spring actuator that ensures a secure connection, even under elevated temperatures and power loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a peripheral spring element is used in the connector assembly, then the engagement of components is made obvious to the worker assembling the part, but the spring becomes prone to premature failure due to high temperatures and thermal expansion
Solution Approach 1:
The spring element is extracted from the peripheral location and repositioned to an internal location within the connector assembly, removing it from the harmful thermal environment while preserving its functional visibility through other means
Solution Approach 2:
A non-conductive housing is introduced as an intermediary structure that provides a thermal barrier between the spring element and the high-temperature environment, allowing the spring to maintain retention force while the connector operates in harsh conditions
2Ease of operation
If the spring element is placed on the exterior surface of the connector, then assembly engagement is made obvious, but the spring steel undergoes thermal expansion and returns to its original shape after temperature cycling, reducing retention force
Solution Approach 1:
The spring element is extracted from the exterior surface and relocated to an internal position within the connector assembly, removing it from direct exposure to temperature cycling that causes shape memory effects
Solution Approach 2:
The design anticipates the shape memory effect of spring steel and counteracts it by positioning the spring in a thermally protected environment, preventing the harmful thermal expansion and contraction cycles from occurring
3Adaptability or versatility
If conventional connector assemblies are used in harsh operating conditions, then the connector can be installed in motor vehicles, but the connectors are prone to mechanical and electrical disconnections due to vibration and heat
Solution Approach 1:
The connector assembly uses a composite structure combining conductive and non-conductive materials, where the non-conductive housing provides thermal and mechanical stability while the conductive components maintain electrical connectivity, enabling reliable operation in harsh automotive environments
Solution Approach 2:
The design incorporates protective features that cushion against the effects of vibration and heat before they can cause failure, including the thermally isolated spring element that maintains constant retention force despite temperature fluctuations and vibrational stresses
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 shielded connector system significantly reduces the risk of mechanical and electrical failures, maintaining connectivity under harsh conditions and minimizing repair costs. It effectively suppresses electromagnetic interference, ensuring reliable performance in high-power, high-current, and high-voltage applications.
Implementation Method 1
A spring member is nested inside the male terminal body. The spring member resists inward deflection and applies outwardly directed force on the contact arms
Implementation Method 2
The male housing assembly is configured to: (i) suppress EMF noise that is emitted from the shielded connector system
Data Source
AI summary
A shielded electrical connector system is disclosed. A male connector assembly includes a male terminal, a non-conductive internal male, and a conductive external male housing that receives an extent of the internal male housing. The male terminal includes a side wall arrangement defining a receiver and including at least one contact arm. An internal spring member resides within the male terminal receiver. A female connector assembly includes a female terminal with a receptacle that receives the male terminal and the spring member. Wherein in a connected position, the male terminal, the spring member, and the female terminal reside within an external female housing; the male terminal and the spring member reside within an internal female housing; the male terminal and the spring member reside within the internal male housing; and a major extent of both the male terminal and the spring member extend beyond the external male housing.