Shielded Electrical Connector With Nested Insert Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for an improved matched-impedance, shielded-pair interconnection system for high-speed data transmission in harsh environments that can be packaged in a minimal form factor, capable of withstanding vibration, temperature swings, moisture, and chemical contaminants while maintaining high-quality electrical characteristics and being field repairable.
Innovation Solution
An electrical connector with a conductive shell and insert assembly providing peripheral electrical shielding around channels, featuring insulator housings for each pair of contacts and a cable support system that ensures electrical continuity and shields the contacts from each other, allowing for removability and easy replacement of individual contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If electrical connectors are made compact to reduce the number of individual pieces, then the volume and device complexity are reduced, but it becomes more difficult to provide adequate shielding and maintain matched impedance for high-speed data transmission
Solution Approach 1:
The patent implements nesting by placing the insert assembly containing contact carriers within the shell, and further nesting cable support elements within the insert assembly. The contact carriers are positioned within channels of the insert assembly, which itself is received in the shell chamber. This nested arrangement achieves compact volume while maintaining adequate shielding through the concentric placement of conductive elements at multiple levels.
Solution Approach 2:
The patent utilizes three-dimensional spatial arrangement by positioning contact carriers at different heights and angles within the compact shell. The cable support elements extend in multiple directions, and the shielding structure employs vertical and radial dimensions to achieve comprehensive electromagnetic shielding within a minimized footprint, transforming a two-dimensional layout problem into a three-dimensional solution.
2Ease of repair
If individual contacts are made replaceable for field repairability, then ease of repair is improved, but device complexity increases due to additional mechanisms needed for removable coupling
Solution Approach 1:
The patent segments the connector into distinct replaceable components: contacts are separate from contact carriers, and contact carriers are separate from the insert assembly. This segmentation allows individual contacts to be replaced without replacing the entire connector. The modular contact carrier design enables field repairability while keeping the coupling mechanisms simple and standardized.
3Object-generated harmful factors
If peripheral electrical shielding is provided entirely around each channel for the entire length of channels, then crosstalk between pairs is reduced, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The insert assembly serves multiple functions simultaneously: it provides the structural framework for contact carriers, creates the channels that guide cables and contacts, and forms the peripheral shielding around each channel. The conductive material of the insert assembly performs both mechanical support and electromagnetic shielding functions, eliminating the need for separate shielding components and simplifying manufacturing.
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 solution provides a compact, reliable, and field-repairable connector system with low signal loss and minimal crosstalk, capable of maintaining high-speed data transmission in harsh environments, reducing the number of individual pieces and allowing for efficient assembly and maintenance.
Implementation Method 1
The shell is conductive and provides electrical shielding. The module is conductive and provides peripheral electrical shielding entirely around each of the channels
Implementation Method 2
The insulator housings are received in corresponding channels and electrically insulating the contacts from the module
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An electrical connector (102) includes a conductive shell (200) having a chamber (210) and having a mating end (212) and a cable end (214). An insert assembly (202) is received in the chamber (210) and includes a module (230) having a plurality of channels (238). The module (230) is conductive and provides peripheral electrical shielding entirely around each of the channels (238) for an entire length of each of the channels (238). The module (230) engages and is electrically commoned with the shell (200). The insert assembly (202) also includes insulator housings (240) each holding a pair of contacts (122). The insulator housings (240) are received in corresponding channels (238) and electrically insulate the contacts from the module (230). Each pair of contacts is electrically shielded from each other pair of contacts by the module (230). A back shell (204) is coupled to the cable end (214) of the shell (200) and holds the insert assembly (202) in the chamber (210) of the shell (200).