Shielded Connector Assembly for Shell Ring Gap Closure

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Solution Overview

Problem

Connectors used in vehicles face challenges in maintaining electromagnetic shielding performance as they are required to handle larger currents, leading to gaps between crimp rings that allow electromagnetic noise to leak out.

Innovation Solution

A connector design with a shield attachment that covers gaps between shell rings, pressing them together to ensure electromagnetic shielding, using a conductive shield shell and shell rings connected via a shield attachment with a covering portion and pressing portion to stabilize the connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If larger diameter wires and terminals are used to carry larger currents, then current carrying capacity is improved, but distance between adjacent terminals and wires increases creating gaps that reduce electromagnetic shielding performance

Engineering Contradiction:

Improvecurrent carrying capacityVSAvoidelectromagnetic shielding performance

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

A shield attachment is introduced as an intermediary component between adjacent shell rings. This shield attachment includes a covering portion that fills the gap between shell rings and a pressing portion that applies force to maintain contact. The shield attachment mediates between the conflicting requirements of larger wire spacing (for current capacity) and gap closure (for shielding performance), enabling both larger currents and maintained electromagnetic shielding to coexist.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If distance between adjacent terminals is increased to insulate them for larger currents, then insulation reliability is improved, but gap between crimp rings increases allowing electromagnetic noise to leak

Engineering Contradiction:

Improveinsulation reliabilityVSAvoidelectromagnetic noise leakage

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The shield attachment serves as a mediator that closes the gap between shell rings without reducing the insulation distance between terminals. The covering portion fills the gap while the pressing portion maintains contact with adjacent shell rings, thereby blocking electromagnetic noise leakage while preserving the insulation reliability achieved through increased terminal spacing.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The shielding structure is segmented into multiple components: shell rings mounted on individual wires, and shield attachments positioned between adjacent shell rings. This segmentation allows the insulation distance between terminals to be increased for safety while the shield attachments independently fill the gaps between shell rings to prevent electromagnetic noise leakage.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If shell rings are mounted on adjacent wires with larger spacing, then compatibility with larger currents is improved, but gap between shell rings forms reducing electromagnetic shielding

Engineering Contradiction:

Improvecompatibility with larger currentsVSAvoidelectromagnetic shielding performance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The shield attachment acts as a mediator that enables shell rings to be spaced further apart (for current compatibility) while simultaneously maintaining electromagnetic shielding. The covering portion fills the gap created by larger spacing, and the pressing portion ensures continuous electrical contact, allowing the system to adapt to larger currents without sacrificing shielding reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Ensures effective electromagnetic shielding while accommodating larger currents by stabilizing the connection between shell rings and reducing noise leakage.

Implementation Method 1

a pressing portion to be held in contact with the contact surface adjacent to the shield attachment in the first direction, the pressing portion pressing the contact surface with a force including a component in a direction parallel to the first direction

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

an electrically conductive shield attachment to be arranged between the shell rings adjacent in the first direction... each of the plurality of shell rings electrically connecting the electromagnetic shield member of the wire having the shell ring mounted thereon and the shield shell

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Data Source

PatentUS20260045744A1connector

Publication Date: 2026.02.12 AUTONETWORKS TECH LTD

AI summary

A plurality of wires each including an electromagnetic shield member are electrically connected to a plurality of terminals arranged in a first direction. A plurality of shell rings respectively mounted on the plurality of wires are arranged in the first direction. An electrically conductive attachment is arranged between the shell rings adjacent in the first direction. Each shell ring electrically connects the electromagnetic shield member of the wire having the shell ring mounted thereon and a shield shell for covering the plurality of terminals. The attachment includes a covering portion for covering a gap between the shell rings adjacent in the first direction. Further, the attachment includes first and second pressing portions to be held in contact with contact surfaces adjacent to the attachment in the first direction and configured to press the contact surfaces with forces including components in a direction.