Shielded High-Voltage Connector Structure for EMI Reduction
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Solution Overview
Problem
Existing electrical connectors lack an effective electromagnetic shield, which leads to interference issues when connecting high voltage components.
Innovation Solution
A high voltage electrical connector design featuring a housing shield with a contact shield and lock mechanism that ensures secure electrical communication between the connector and cable outer conductor, using multiple shields and contact arms for enhanced shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a simple shield structure is used in the electrical connector, then the device complexity is reduced, but the electromagnetic interference protection capability deteriorates
Solution Approach 1:
The shield is divided into multiple segments including a first shield portion, a second shield portion, and a contact shield portion. Each segment performs a specific function: the first and second shield portions provide structural support and initial shielding, while the contact shield portion with contact arms provides enhanced electromagnetic interference protection at the contact interface. This segmentation allows the shield to achieve superior EMI protection without requiring a monolithic complex structure.
Solution Approach 2:
The shield structure extends in multiple dimensions with contact arms that protrude from the contact shield portion. These contact arms create a three-dimensional shielding network that intercepts electromagnetic interference from multiple directions. The shield also includes radial extensions that extend radially outward from a central axis, providing omnidirectional protection against electromagnetic interference.
Solution Approach 3:
The contact shield portion is nested within the connector housing, with the contact arms positioned between the shield contact opening and the terminal housing. The first and second shield portions are nested around the terminal housing, creating concentric layers of protection. This nested arrangement maximizes the shielding effect within the available space without significantly increasing the overall connector footprint.
2Object-affected harmful factors
If multiple shields and contact arms are used to enhance shielding, then the electromagnetic interference reduction is improved, but the manufacturing complexity increases
Solution Approach 1:
The first shield portion, second shield portion, and contact shield portion are formed as a single integrated shield structure in one piece. This merging of multiple shield functions into a single component eliminates the need for separate manufacturing and assembly steps for each shield portion, significantly reducing manufacturing complexity while maintaining the multi-layered shielding effect for superior electromagnetic interference reduction.
Solution Approach 2:
The shield structure utilizes thin metallic walls and flexible contact arms that can be formed through standard sheet metal forming processes. The contact arms are designed with sufficient flexibility to engage with the terminal housing during assembly, allowing for tolerance compensation and simplified assembly procedures. This approach enables complex three-dimensional shielding geometries to be manufactured using conventional forming techniques rather than requiring complex multi-step manufacturing processes.
Data Source
AI summary
An electrical connector includes a connector housing that defines a connector cavity. A terminal housing adapted to hold one or more electrical terminals is located within the connector cavity. A housing shield is located around the terminal housing at least partially between the terminal housing and the connector housing. The housing shield includes a connection end that is adapted to be placed into electrical communication with an outer conductor of a cable. The housing shield also includes a shield contact opening. A contact shield includes a shield contact end and a housing end. The contact shield has contact arms located between the shield contact end and the housing end. The housing end is located in the shield contact opening. A housing lock located at the housing end engages the terminal housing to retain the contact shield in place relative to the housing shield.