Shielded Connector Assembly With Integrated Bridge for Low Crosstalk
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Solution Overview
Problem
Existing methods for shielding electrical connectors often require complex assembly, exhibit varying contact resistances due to material aging, and fail to provide effective shielding between individual wires within a cable, leading to signal crosstalk and potential defects.
Innovation Solution
A shielded electrical connector design featuring an outer shielding sleeve, inner shielding sleeves for wire pairs, a shield divider, and a monolithic electrically conductive shielding bridge that integrates the components to form a continuous, gapless, and mechanically robust shielding system, ensuring low contact resistance and effective shielding between wire subsets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If previously known shielding methods are used, then shielding connection is provided, but assembly becomes complex and contact resistance varies due to material aging
Solution Approach 1:
The patent combines multiple shielding components (outer shielding sleeve, inner shielding sleeves, shield divider) into a single integrated shielding bridge structure that is cast as one piece. This merging eliminates complex assembly steps while ensuring consistent electrical contact throughout the shielding system, thereby maintaining low contact resistance without requiring multiple separate components to be assembled together.
Solution Approach 2:
The shielding bridge serves multiple functions simultaneously: it provides electrical connection between the outer shielding sleeve and inner shielding sleeves, acts as a mechanical support structure, and ensures continuous shielding coverage. This multi-functionality reduces the need for separate components and simplifies the overall assembly while maintaining reliable electrical contact.
2Object-affected harmful factors
If previously known shielding methods are used, then outer shielding connection is provided, but wire-level shielding and continuous shielding effect are not maintained
Solution Approach 1:
The patent implements a nested shielding structure where inner shielding sleeves surround individual wire pairs, which are themselves surrounded by the outer shielding sleeve. The shielding bridge integrates these nested levels by providing electrical connection between them, maintaining continuous shielding at both the wire level and cable level, thereby preventing signal crosstalk while managing the complexity through systematic nesting.
Solution Approach 2:
The shielding structure is segmented into functional zones: outer shielding sleeve for cable-level shielding, inner shielding sleeves for wire-pair level shielding, and shield divider for separating different wire groups. The shielding bridge connects these segmented parts, allowing each segment to address specific crosstalk issues while maintaining overall shielding continuity.
3Productivity
If multiple separate shielding components are used, then shielding coverage is provided, but manufacturing and assembly become time-consuming
Solution Approach 1:
The patent merges multiple shielding components into a single casting process. The shielding bridge is produced in one manufacturing step as an integrated structure, eliminating the need to manufacture and assemble multiple separate components. This significantly improves productivity while maintaining the shielding effectiveness that would require complex multi-component assembly in traditional approaches.
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 design simplifies assembly, maintains low contact resistance, reduces signal crosstalk, and enhances signal quality and mechanical stability, particularly in radio-frequency applications, by providing uninterrupted shielding and strain relief.
Implementation Method 1
an electrically conductive shielding bridge is provided, for establishing an electrical connection from the outer shielding sleeve to the inner shielding sleeves and to the shield divider
Implementation Method 2
The shielding bridge is adapted to bond to the outer shielding sleeve, to the inner shielding sleeves, and to the shield divider in a non-releasable manner, in particular in a material bond
Data Source
AI summary
A shielded electrical connector is provided, comprising a plurality of wire elements, a plurality of wire element sheaths, an outer shielding sleeve, at least one inner shielding sleeve, a connector housing for accommodating terminal members, a shield divider for defining at least two shielding sectors, wherein the first subset of wire elements is extended into a first shielding sector and a second subset of wire elements is extended into a second shielding sector, at least one sealing insert for being arranged in one of the shielding sectors for sealing off a cable side from a connector side in the area of the shield divider, and an electrically conductive shielding bridge for electrically connecting the outer shielding sleeve to the at least one inner shielding sleeve and to the shield divider.