Electrical Plug Connector EMC Shielding via Thin Film and Overlapping Walls
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Solution Overview
Problem
Existing electrical connectors in the motor vehicle field face challenges in achieving adequate electromagnetic compatibility (EMC) without the need for a thick, electrically conductive shell coating.
Innovation Solution
A multi-part contact chamber with a thin, electrically conductive layer on its outer surface and overlapping wall sections that intercept electromagnetic waves, combined with conductive coatings on abutting faces and flexible locking arms for enhanced shielding, allows for effective EMC without a thick shell coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick electrically conductive shell coating is applied to achieve adequate shielding for EMC, then electromagnetic compatibility is improved, but the weight and complexity of the connector increase
Solution Approach 1:
The patent applies a thin electrically conductive coating (layer 5) on the outer surface of the contact chamber instead of a thick shell. This thin film provides adequate electromagnetic shielding while maintaining lightweight construction, directly resolving the contradiction between EMC performance and weight reduction.
Solution Approach 2:
The patent introduces overlapping wall sections (27) that extend beyond the abutting faces to create a three-dimensional shielding structure. This dimensional extension provides effective electromagnetic shielding without requiring increased coating thickness, thus improving EMC without increasing weight.
2Reliability
If a thick electrically conductive shell coating is applied to achieve adequate shielding for EMC, then electromagnetic compatibility is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The thin conductive coating (layer 5) is easier to manufacture and apply than a thick shell coating. The reduced material thickness simplifies the coating process and reduces manufacturing complexity while maintaining adequate EMC performance.
Solution Approach 2:
The overlapping wall sections provide a structural solution for EMC shielding that can be integrated into the molding process, avoiding the need for complex post-manufacturing assembly steps required by thick shell coatings.
3Adaptability or versatility
If multiple chamber parts are assembled to form the contact chamber, then adaptability and modular design are improved, but shielding effectiveness deteriorates due to slits between abutting faces
Solution Approach 1:
The overlapping wall sections (27) extend in the third dimension beyond the abutting faces, creating a labyrinthine path for electromagnetic waves. This three-dimensional structure effectively blocks radiation despite the presence of slits between modular components, maintaining shielding effectiveness while preserving modular design benefits.
Solution Approach 2:
The overlapping wall sections act as intermediary shielding elements that bridge the gap between modular components. These sections intercept electromagnetic waves before they can pass through the slits between abutting faces, mediating between the need for modular assembly and the requirement for continuous shielding.
4Weight of stationary object
If the contact chamber outer surface is coated with a thin conductive layer, then weight is reduced and manufacturing is simplified, but shielding effectiveness may be compromised
Solution Approach 1:
The overlapping wall sections add a three-dimensional shielding dimension that compensates for the reduced shielding capability of the thin coating. This structural extension provides the additional shielding effectiveness needed to maintain reliability while using a lightweight thin layer coating.
Solution Approach 2:
The solution combines a thin electrically conductive coating (layer 5) with the structural shielding provided by overlapping wall sections (27). This composite approach integrates both the weight-saving benefits of thin coating and the shielding effectiveness of three-dimensional structure.
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 effective shielding against electromagnetic interference, ensuring improved EMC in motor vehicle applications while maintaining a lightweight and efficient design.
Implementation Method 1
The outer surface (5) of the cover part (3) and of the base part (4) are coated with an extremely thin, electrically conductive layer. Laterally from the abutting faces (24, 25), the contact chamber (2) is shielded on the outside with overlapping wall sections (27), which are also coated with an electrically conductive layer on their inside (28).
Data Source
AI summary
The invention relates to an electrical plug-type connector (1) having a socket-like contact element (6), which is arranged in a contact chamber (2), which comprises at least two chamber parts (3, 4), which bear against one another with in each case at least one abutting face (24, 25), is made from plastic and has a plug-in opening (8). The invention provides for the outer face (5) of the contact chamber (2) to be completely coated with a conductive layer and for the abutting faces (24, 25) to be overlapped laterally by an overlapping wall section (27) on the outside of the contact chambers (2), and for that side of the overlapping wall section (27) which faces the abutting faces (24, 25) to likewise be coated with a conductive layer.