Shielded Electric Interface Overmoulding Conductive Composite
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Solution Overview
Problem
The production of shielded electrical interfaces, such as plug connections, is complex and expensive due to the difficulty in achieving 360° shielding, especially in connectors with complicated geometries, requiring costly processes like crimping, soldering, and manual assembly.
Innovation Solution
A method involving the overmoulding of shielding elements with an electrically conductive composite material, incorporating an insulating plastic body produced by injection molding, which integrates electrical contacts and simplifies the manufacturing process by eliminating the need for crimping or soldering, using a composite material with metallic components and low-melting metals for conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods (crimping, soldering, manual assembly) are used to achieve 360° shielding in shielded electrical interfaces, then effective shielding is achieved, but production complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple separate production steps (crimping, soldering, manual assembly) into a single injection molding process. The electrically conductive composite material is molded directly onto the cable shielding and electrical contacts, integrating electrical contacting and shielding formation in one operation, thereby reducing production complexity while maintaining shielding effectiveness
Solution Approach 2:
The patent uses an electrically conductive composite material consisting of a thermoplastic matrix with metallic particles or fibers dispersed throughout. This composite material provides both the mechanical properties needed for molding and the electrical conductivity required for shielding and electrical contacting, eliminating the need for separate metallic components and complex assembly processes
2Reliability
If conventional methods (crimping, soldering, manual assembly) are used to achieve 360° shielding in shielded electrical interfaces, then effective shielding is achieved, but production cost increases significantly
Solution Approach 1:
The patent combines multiple separate production steps (crimping, soldering, manual assembly) into a single injection molding process. The electrically conductive composite material is molded directly onto the cable shielding and electrical contacts, integrating electrical contacting and shielding formation in one operation, thereby reducing production complexity while maintaining shielding effectiveness
Solution Approach 2:
The injection molding process automatically performs electrical contacting and shielding formation without requiring manual intervention. The molten electrically conductive composite material flows and conforms to the cable shielding and contact areas, creating electrical connections and shielding structures self-automatically through the molding process, thereby reducing labor costs and increasing manufacturing efficiency
3Volume of moving object
If interfaces are miniaturized to reduce size, then compactness is improved, but production complexity and cost increase due to difficulty in completing shielding
Solution Approach 1:
The patent replaces manual mechanical operations (crimping, soldering, assembly) with an automated injection molding process. The molten electrically conductive composite material is injected under pressure and automatically conforms to the miniaturized cable shielding and contact areas, creating precise electrical connections and shielding structures without requiring manual dexterity or complex tooling, thereby enabling cost-effective production of miniaturized interfaces
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
This method simplifies the production of shielded electrical interfaces by automating the electrical contacting and shaping of shielding elements, reducing production costs and complexity, while achieving effective shielding without the need for conventional crimping or soldering processes.
Implementation Method 1
the shielding of the cable or cables and at least one area adjacent to the shielding around the electrical contacts is overmoulded with an electrically conductive composite material
Implementation Method 2
the insulating body is produced by overmoulding the contacts, the contacts being at least partially integrated into the insulating body by injection molding
Implementation Method 3
using a composite material with metallic components and low-melting metals for conductivity
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
The invention relates to a method for producing a preferably multi-pole, shielded electric interface, in particular a plug connection, preferably a plug, a socket, a Y piece, T piece or similar, comprising at least one cable (2) and protector (1), which is connected to the electric interface comprising electric contacts (4) and the cable (2) provided with wires (3) which are to be connected to the electric contacts (4) and a protector (1) which surrounds the wires (3). The protector extends from the cable (2) to the or into the interface. Said method is characterised by virtue of the fact that to form a protection element (6), the cable (2) protector (1) or the cable and at least one area around the electric contacts (4) and bordering the protector (1) is extrusion coated with an electrically conductive composite material. Said protection element (6) is insulated against the electric contacts (4) at a distance or by integrating an insulating body (5). An interface is correspondingly produced.