Shielded High-Voltage Connector Assembly for EMI and Corrosion
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Solution Overview
Problem
High voltage connectors face challenges with electromagnetic interference (EMI), galvanic corrosion between dissimilar metals, and inadequate electrical grounding, which existing technologies fail to effectively address.
Innovation Solution
A high voltage connector design featuring a metallic braided shield with a conductive clamp, a metal-infused plastic outer housing with an over-molded silicone seal, and a grounding system using stainless steel bolts and aluminum compression limiters, which reduces EMI and prevents galvanic corrosion by providing a conductive path and insulation layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a shielded connector structure is used to reduce EMI, then electromagnetic interference protection is improved, but device complexity increases
Solution Approach 1:
The patent implements a nested shielding structure where an inner shield is placed inside the outer housing, and an outer shield surrounds the inner shield. This multi-layer nested arrangement provides comprehensive EMI protection while efficiently utilizing the internal space of the connector housing.
Solution Approach 2:
The patent employs composite material construction by combining metal shielding layers with plastic housing materials. The outer housing is made of plastic providing insulation, while metal shields provide EMI protection, creating a composite structure that addresses both electrical isolation and electromagnetic interference requirements.
2Reliability
If dissimilar metals are used in the connector, then electrical conductivity and grounding are improved, but galvanic corrosion resistance deteriorates
Solution Approach 1:
The patent introduces plastic isolation components as intermediaries between dissimilar metal parts. The plastic housing and isolation elements physically separate metal components with different electrochemical potentials, preventing direct galvanic contact while maintaining electrical connectivity through controlled pathways.
Solution Approach 2:
The patent applies different material properties to different regions of the connector. Metal materials are used specifically where electrical conductivity and grounding are required, while plastic materials are applied in regions where galvanic corrosion prevention is critical, creating a spatially differentiated material distribution.
3Reliability
If metal components are used for conductivity, then electrical grounding is improved, but corrosion resistance in fluid environments deteriorates
Solution Approach 1:
The patent creates a composite structure where metal components providing electrical conductivity are combined with corrosion-resistant plastic housing. The plastic material acts as a protective barrier against fluid environments, while metal inserts or shields provide the necessary electrical grounding pathways.
Solution Approach 2:
The patent uses plastic isolation elements as intermediaries between metal components and the external fluid environment. These plastic barriers prevent direct exposure of metal parts to corrosive fluids while maintaining the electrical functionality of the metal components through controlled contact points.
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 effectively reduces EMI and prevents galvanic corrosion, ensuring reliable electrical connectivity and durability by establishing a robust grounding system and insulation layer between the connector and the connected device.
Implementation Method 1
a metallic braided shield on top of an inverter outer housing assembly
Implementation Method 2
an over-molded silicone seal to provide the necessary sealing and insulation layer to prevent galvanic corrosion
Implementation Method 3
a metallic clamp that holds the metallic braided shield above the outer housing, and provides a conductive contact between the metallic braided shield and the outer housing
Implementation Method 4
The bolts provide the necessary grounding among the metallic braided shield, metal-infused plastic outer housing, and the device to which the connector of this invention is to be connected
Data Source
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AI summary
A high voltage connector, connected to a device, that experiences reduced electromagnetic interference, avoids galvanic corrosion of dissimilar metals within or without a fluid environment, and provides an effective electrical ground system. The connector includes an inner housing mounted inside an outer housing, a set of cable reinforcement retainer assemblies secured inside the inner housing, a back cover through which cables slide along and cover a central opening of the outer housing, a braided shield covering the cables, and a clamp that connects the shield onto the outer housing.