Shield Connector Structure with Integrated Connection Member
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Solution Overview
Problem
The existing shield connector structure faces issues with galvanic corrosion between dissimilar metals, deformation during disassembly, and degradation of waterproof performance due to increased parts and complex assembly processes.
Innovation Solution
A shield connector structure with a connection member that includes a second extension portion protruding from the insertion hole to fix the shield wire, a concave groove for the second seal member, and a large-diameter portion for the first seal member, reducing the need for a shield member and simplifying the sealing configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shield member is used to electrically connect the shield portion and the metal case, then electrical connection is achieved, but the number of parts increases and assembly complexity increases
Solution Approach 1:
The connection member integrates both mechanical connection and electrical connection functions into a single component. The connection member includes a connection portion that mechanically connects to the metal case and an extension portion that electrically connects to the shield portion, eliminating the need for a separate shield member and reducing the total number of parts.
Solution Approach 2:
The connection member serves multiple functions: it provides mechanical support for the shield wire, establishes electrical connection between the shield portion and metal case, and provides sealing support. This multi-functional design replaces what would traditionally require multiple separate components including a dedicated shield member.
2Reliability
If a shield member is used to electrically connect the shield portion and the metal case, then electrical connection is achieved, but the number of assembly processes increases
Solution Approach 1:
The connection member combines mechanical assembly and electrical connection into a single assembly operation. By integrating the electrical connection function into the connection member itself, the patent eliminates the need for a separate assembly step to install a shield member, thereby reducing the total number of assembly processes.
3Reliability
If dissimilar metals (brass shield member and aluminum alloy metal case) are in close contact, then electrical connection is achieved, but galvanic corrosion occurs and fixation happens
Solution Approach 1:
The connection member and metal case are both made of aluminum alloy, creating a homogeneous material system that eliminates galvanic corrosion. This material homogeneity ensures that electrical connection is achieved without the harmful effects of dissimilar metal contact, preventing both corrosion and unwanted fixation.
4Adaptability or versatility
If the shield member is made of thin brass with low rigidity, then flexibility is achieved, but deformation occurs during disassembly maintenance
Solution Approach 1:
The connection member is made of aluminum alloy matching the metal case, providing sufficient rigidity to prevent deformation during assembly and disassembly operations. This material selection eliminates the weakness of using thin brass while maintaining compatibility with the metal case structure.
5Reliability
If the second seal member is interposed and held between the shield pipe and stepped portion of the shield member, then waterproofing is achieved, but misalignment or damage occurs degrading waterproof performance
Solution Approach 1:
The patent removes the shield member from the structure, thereby eliminating the complex stepped portion interface where the second seal member was previously positioned. The seal member is now directly installed between the connection member and metal case, simplifying the assembly process and eliminating misalignment issues caused by the multi-step interface.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A shield connector structure (10) includes: a connection member (11) fixed to the outer surface of a metal case (6); a first seal member (12) interposed between an inner surface of the connection member (11) and an outer surface of an outer insulation coating (5) of a shield wire (1); a second seal member (13) interposed between the connection member (11) and an inner surface of an insertion hole (7) of the metal case (6); and an annular fixing member (14) that fixes the shield portion (4) of the shield wire (1) to the connection member (11) by crimping. The connection member (11) includes a first cylindrical extension portion (24) extending from the connection member body (21) to the inside of the insertion hole (7) of the metal case (6) and a second cylindrical extension portion (25) further extending from the tip of the first extension portion (24) and having an outer diameter smaller than the outer diameter of the first extension portion (24). The shield portion (4) of the shield wire (1) is clamped by the fixing member (14) from the outside in the radial direction so that the shield portion (4) is fixed to the second extension portion (25).