Electronic Module Cover With Integral Shielded Connector
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Solution Overview
Problem
Conventional electronic module assemblies face alignment issues with header connectors, leading to misalignment and contact stubbing, which increases assembly time and costs due to tight tolerances, and can result in connector vibration and failure over time.
Innovation Solution
A cover plate with a dielectric body and conductive layers for electrical shielding, featuring a unitary connector portion with contact channels and a shroud to receive a plug connector, where contacts are spring-biased for secure mounting to the circuit board, reducing the need for precise manufacturing and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the header connector is aligned with the opening in the cover to pass into the shroud for electrical connection, then electrical connection is achieved, but misalignment leads to contact stubbing and alignment problems
Solution Approach 1:
The cover is divided into two functional portions: a cover plate that provides electrical shielding and a connector portion that houses the contacts. This segmentation allows the connector portion to be precisely positioned within the shroud while the cover plate provides overall structural support and shielding, thereby improving alignment reliability without requiring extremely tight tolerances across the entire cover.
Solution Approach 2:
The connector portion is pre-formed as an integral part of the cover plate with contacts already positioned in the shroud. This preliminary positioning ensures proper alignment before the cover is assembled to the housing, eliminating alignment problems during final assembly and preventing contact stubbing.
2Reliability
If tight tolerances are applied to the location and sizing of the header connector and shroud for sealing, then sealing is achieved, but assembly time and costs increase
Solution Approach 1:
The connector portion is formed integrally with the cover plate as a unitary structure. This merging of the connector and cover plate eliminates the need for separate sealing components and reduces the number of parts requiring tight tolerances, thereby maintaining sealing reliability while reducing assembly time and costs.
3Manufacturing precision
If the header connector is attached to the cover prior to coupling the cover to the enclosure, then alignment is improved, but assembly time increases and parts require tight tolerances
Solution Approach 1:
The connector portion is formed integrally with the cover plate as a unitary structure during manufacturing. This eliminates the need for separate attachment steps and reduces assembly time while maintaining precise alignment through integral formation.
Solution Approach 2:
The connector portion is pre-formed with contacts precisely positioned in the shroud during the cover plate manufacturing process. This preliminary positioning ensures proper alignment is built-in during manufacturing rather than requiring tight tolerances during assembly, thereby improving both alignment and assembly efficiency.
4Object-affected harmful factors
If conventional lamp assemblies use a metal housing for electrical shielding, then electrical shielding is provided, but the cover plate requires conductive layer application
Solution Approach 1:
The cover plate is made from a non-conductive material (such as plastic) and is provided with a conductive layer applied to its exterior surface. This composite structure provides the necessary electrical shielding against electromagnetic interference while allowing for easier manufacturing and forming compared to metal housings, and the conductive layer can be applied through standard coating processes.
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 provides improved alignment and sealing of the connector, reduces assembly time and costs, and enhances the durability of the electronic module by ensuring consistent electrical contact and shielding against electromagnetic interference.
Implementation Method 1
A majority of at least one of the interior surface and the exterior surface includes a conductive layer to provide electrical shielding for the cover plate
Implementation Method 2
the contacts having mounting ends exposed beyond the interior surface for mounting to the circuit board
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A cover (130) for an electronic module (100) that has a housing (110) holding a electrical component (112) and a circuit board (114) for operating the electrical component includes a cover plate (132) having an interior surface (140) and an exterior surface (142). The cover plate has a dielectric body (170). A majority of at least one of the interior surface and the exterior surface includes a conductive layer (160) to provide electrical shielding for the cover plate. A connector portion (134) is formed integrally with the cover plate defining a unitary structure. The connector portion includes a plurality of contact channels (186) and a shroud (144) extending from the exterior surface that surrounds a receptacle (146) configured to receive a plug connector (104) therein. Contacts (136) are held in corresponding contact channels that have mating ends (150) positioned in the receptacle and mounting ends (152) exposed beyond the interior surface for mounting to the circuit board.