Shielded Plug Connector Assembly for High-Current EMI Control
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Solution Overview
Problem
Existing plug connectors do not provide sufficient electromagnetic shielding for high voltage and high current transmissions, allowing electromagnetic interference to affect surrounding electronic appliances.
Innovation Solution
A plug connector design with conductive shielding elements that establish electrical contact with the electromagnetic shielding layer of the cable, providing additional electromagnetic shielding within the connector and between the plug connector and mating plug, using materials like stainless metal, aluminum alloy, and copper for enhanced shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a conventional plug connector design is used for high voltage and high current transmission, then the current transmission capability is achieved, but electromagnetic shielding is insufficient causing interference to surrounding electronic appliances
Solution Approach 1:
The electromagnetic shielding function is divided into multiple segments: the cable's existing electromagnetic shielding layer, the first shielding element inside the plug connector, and the second shielding element between the plug connector and mating plug. Each segment handles a specific zone of electromagnetic interference, collectively providing comprehensive shielding without requiring a complete redesign of the entire system.
Solution Approach 2:
The first shielding element is nested within the plug connector housing, while the second shielding element is nested between the plug connector and mating plug assembly. This nested arrangement allows multiple shielding layers to be integrated into the existing connector structure without significantly increasing the overall size or complexity of the system.
2Reliability
If additional shielding elements are added to the plug connector, then electromagnetic shielding function is improved, but device complexity increases
Solution Approach 1:
The conductive outer housing serves multiple functions: it provides structural support for the connector, acts as a mounting surface for the shielding elements, and contributes to the overall electromagnetic shielding. The first and second shielding elements also serve dual purposes by providing both electromagnetic shielding and establishing electrical continuity with the conductive housing and cable shielding layer.
Solution Approach 2:
The shielding function is merged with the existing structural components of the plug connector. The conductive outer housing integrates the mounting function for shielding elements while maintaining its structural role. The first shielding element combines shielding functionality with electrical connection to the cable's electromagnetic shielding layer, eliminating the need for separate connection components.
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 ensures reliable and stable high-current transmission with minimal electromagnetic interference, protecting electronic appliances in the vicinity.
Implementation Method 1
a first shielding element, electrically connected to the conductive outer housing, which can contact an insulating outer layer of the cable connected to the plug connector and hence establishes an electrical contact with the electromagnetic shielding layer in the insulating outer layer of the cable in order to provide a further electromagnetic shielding function for the cable
Implementation Method 2
a second shielding element, accommodated in the conductive outer housing, which can be in electrical contact with the conductive outer housing of the plug connector and the conductive outer housing of a mating plug connected to the plug connector in order to provide a further electromagnetic shielding function for the cable
Data Source
AI summary
A plug connector for electrically connecting an electrical cable, attached thereto, to a mating connector has at least one electrically conductive contact an insulating inner housing which has a fastening portion for fastening the contact a conductive outer housing which has a fastening portion for fastening the inner housing; wherein the plug connector also including a first shielding element, which is electrically connected to the conductive outer housing and can penetrate an insulating outer layer of a cable connected the plug connector and establishes electrical contact with the electromagnetic shielding layer in the insulating outer layer of the cable, in order to provide for an additional electromagnetic shielding function for the cable.