Shielded Electrical Terminal With Nested Outer Shield

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Solution Overview

Problem

Shielded electrical terminals experience leakage of the electrical field due to openings associated with contact springs, which affects radio frequency performance.

Innovation Solution

A method of forming a shielded electrical terminal with an inner shield defining a plurality of contact springs and an outer shield that covers these openings, reducing field leakage by radially offsetting seams and using a cylindrical shape to integrate the inner and outer shields.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If contact springs are used to establish electrical contact, then electrical connectivity is achieved, but openings in the shield allow electrical field leakage

Engineering Contradiction:

Improveelectrical connectivityVSAvoidelectrical field leakage

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent implements a nested shield structure where an inner shield and outer shield are positioned concentrically. The inner shield contains the contact springs and defines openings for electrical contact, while the outer shield is positioned to cover these openings when the connector is assembled. This nested arrangement allows the contact springs to function while the outer shield blocks the harmful electrical field leakage through the openings.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Strength

If traditional machining or casting methods are used to form shielded terminals, then structural integrity is achieved, but manufacturing costs increase

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent divides the shielded terminal into multiple segments or components including an inner shield, outer shield, and contact springs that can be formed separately and then assembled. This segmentation allows each component to be manufactured using cost-effective processes while maintaining the overall structural integrity of the assembled terminal, reducing total manufacturing cost compared to forming the entire structure as a single piece through expensive machining or casting.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines multiple functional elements (shielding structure, contact springs, and terminal body) into an integrated assembly where the inner and outer shields work together to provide both structural support and electromagnetic shielding. This merging of functions into a unified design reduces the number of separate manufacturing steps and assembly operations required, thereby lowering manufacturing costs while preserving structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10516238B2Method for forming a shielded electrical terminal and an electrical terminal formed by said method

Publication Date: 2019.12.24 APTIV TECHNOLOGIES AG

AI summary

A method of forming a shielded electrical terminal configured to receive a corresponding shielded electrical terminal. The terminal includes an inner shield defining a shield cavity about a longitudinal axis. The shield cavity is configured to receive the corresponding shielded electrical terminal. The inner shield has a longitudinal inner seam substantially that is parallel to the longitudinal axis. The inner shield defines a plurality of resilient contact springs that protrude into the shield cavity. The contact springs are configured to contact the corresponding shielded electrical terminal. The terminal also includes an outer shield integrally formed with the inner shield and covering at least a portion of the inner shield. The terminal formed by this method is also presented.