Conductive Elastic Sheet Riveted to Connector Housing

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Solution Overview

Problem

Small form factor connectors face challenges in managing heat dissipation and electromagnetic interference, leading to increased manufacturing complexity and cost due to the need for heat radiators and anti-electromagnetic interference sheets.

Innovation Solution

A conductive housing with a conductive elastic sheet riveted onto its peripheral wall using rivets, forming electrical contact spots for improved electromagnetic shielding without the need for a split-type housing or direct welding, thereby simplifying manufacturing and reducing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a heat radiator is mounted on the connector housing to dissipate heat, then heat dissipation capability is improved, but electromagnetic interference is generated

Engineering Contradiction:

Improveheat dissipation capabilityVSAvoidelectromagnetic interference

Core Design Contradiction:

TemperatureVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful electromagnetic interference generated by the heat radiator into a beneficial shielding function by wrapping a conductive elastic sheet around the housing. The same heat radiator structure that generates EMI is now surrounded by a material that utilizes electrical conduction to block electromagnetic fields, transforming the harmful effect into a protective shielding mechanism

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Object-affected harmful factors

If an anti-electromagnetic interference elastic sheet is directly welded onto the housing periphery wall, then electromagnetic shielding capability is improved, but manufacturing difficulty and cost increase

Engineering Contradiction:

Improveelectromagnetic shielding capabilityVSAvoidmanufacturing difficulty and cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical joining) with a mechanical attachment method using clips or fasteners. The conductive elastic sheet is attached to the housing periphery wall through mechanical means rather than welding, significantly reducing manufacturing complexity and cost while maintaining electromagnetic shielding effectiveness

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes the inherent flexibility of the conductive elastic sheet to enable simple mechanical attachment. The elastic nature of the sheet allows it to be easily secured to the housing using clips or fasteners without requiring complex welding procedures, thereby improving ease of manufacture while maintaining shielding capability

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If a split-type housing with upper and lower housings welded together is used, then structural flexibility is improved, but manufacturing cost and process complexity increase

Engineering Contradiction:

Improvestructural flexibilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the upper and lower housing components into a single integrated housing structure. This unification eliminates the need for welding between separate housing parts, reducing manufacturing process complexity and cost while maintaining the necessary structural flexibility through the overall design of the single-piece housing

Inventive Principle:

Principle #5Merging (Combining)

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 enhances anti-electromagnetic interference capabilities while reducing manufacturing costs and complexity by using a one-piece conductive housing with a riveted conductive elastic sheet for effective heat dissipation and electromagnetic shielding.

Implementation Method 1

In small form factor (hereinafter 'SFF') connectors known in the prior art, heat is produced in the connector when it is working. In order to dissipate heat from the connector, a heat radiator must be mounted on a housing of the connector.

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

In order to prevent electromagnetic interference from the heat radiator interfering with the signal terminal provided inside the SFF connector, it is generally required to mount a circle of an anti-electromagnetic interference elastic sheet on a periphery wall of a port of the housing of the connector.

Methodology Applied

Scientific EffectElectromagnetic shielding: Faraday Cage

Implementation Method 3

The housing and elastic sheets are electrically connected by the plurality of contact spots when the elastic sheet is riveted on the housing.

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS9590362B2Connector having a conductive elastic sheet riveted to a conductive housing

Publication Date: 2017.03.07 TYCO ELECTRONICS (SHANGHAI) CO LTD

AI summary

A connector is disclosed. The connector includes a conductive housing having a port and a peripheral wall surrounding the port, a conductive elastic sheet riveted on the peripheral wall of the port of the housing by a plurality of rivets, and a plurality of contact spots formed on at least one of the housing and the elastic sheet. The housing and elastic sheets are electrically connected by the plurality of contact spots when the elastic sheet is riveted on the housing.