Ruggedized High-Speed Connector Shielding for Vibration Stability
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Solution Overview
Problem
Electrical connectors in harsh environments, such as automobiles, face issues with vibration causing unmating and electrical noise due to relative component movement, which disrupts high-speed signal transmission.
Innovation Solution
The electrical connector design includes a shield with interlocking edges and tabs for secure latching, a dual-shield structure with embossments for electrical connection, and impedance adapters to maintain signal integrity, along with retention features and spacers to stabilize conductors and match impedance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connectors are used in harsh environments with vibration, then connections between assemblies can be made, but vibration causes relative movement of components within connectors leading to electrical noise and signal interference
Solution Approach 1:
The connector is divided into multiple functional segments including a shield member with cavity, terminal assembly with insulative member, and conductor elements. Each segment serves a specific function: the shield provides electromagnetic shielding and structural support, the insulative member isolates conductors, and the conductors transmit signals. This segmentation allows each component to be optimized for its specific function while working together to reduce electrical noise and maintain connection stability under vibration.
Solution Approach 2:
The patent employs a nested structure where the terminal assembly with conductors is positioned within the cavity formed by the shield member. The insulative member is nested within the terminal assembly, providing electrical isolation. This nested arrangement ensures that conductors are protected and positioned stably within the shielded cavity, reducing relative movement and electrical noise while maintaining signal integrity in harsh environments.
2Adaptability or versatility
If cable assemblies are used to connect assemblies at greater distances, then flexibility in system assembly is improved, but cable assemblies with connectors are more susceptible to vibration and electromagnetic radiation from automotive components
Solution Approach 1:
The cable connector uses a nested structure where the terminal assembly is positioned within the shielded cavity, and the insulative member is nested within the terminal assembly. This nested arrangement provides multiple layers of protection against electromagnetic radiation while maintaining assembly flexibility. The shield member encloses the conductors, creating a protected pathway for signals through harsh automotive environments.
Solution Approach 2:
The insulative member acts as an intermediary between the conductors and the external environment, providing electrical isolation and mechanical support. The shield member serves as an intermediary barrier against electromagnetic radiation from automotive components like spark plugs, alternators, and power switches. These intermediary elements protect the signal pathway while allowing cable assemblies to maintain flexibility for connecting assemblies at various distances.
3Ease of manufacture
If traditional connector designs are used, then manufacturing is simpler, but they lack the ruggedization needed to resist vibration and maintain signal integrity in harsh environments
Solution Approach 1:
The connector is segmented into distinct components (shield member, terminal assembly, insulative member, conductors) that can be manufactured separately using standard processes and then assembled. This segmentation maintains manufacturing simplicity while allowing each component to be optimized for vibration resistance and signal integrity. The modular design enables easy assembly and replacement while providing ruggedized performance in harsh environments.
Data Source
AI summary
A modular connector system with components that can be economically assembled to provide high signal integrity in a harsh environment, such as an automobile. In some connectors, electrical conductors serving as signal conductors may be at least partially encircled by a conductive sheet formed into a tube. The tube may be formed by joining opposite edges of the sheet with tab portions extending from the edges. The tab portions may be bent to extend radially outwards from the cavity and crimped together, providing mechanical integrity to the shield, as well as a tab that polarizes the shield to block incorrect insertion into an insulative housing and can engage with components in the insulative housing to latch the shield in the housing. Other disclosed techniques economically and stably position electrical conductors, which may serve as signal terminals relative to ground structures, electrically and mechanically connect shields, or compensate for impedance variations.