CN112533796A

CN112533796A - Electromagnetic interference (EMI) ground protection method for connectors using multidirectional conductive housings

Info

Publication number: CN112533796A
Application number: CN202080002778.XA
Authority: CN
Inventors: V·阿扎德
Original assignee: JST Corp
Current assignee: JST Corp
Priority date: 2019-02-08
Filing date: 2020-02-03
Publication date: 2021-03-19
Also published as: CN112534656A; JP2022511587A; JP2022511586A; JP7460542B2; JP7460543B2; CN112534656B

Abstract

An electromagnetic interference (EMI) ground protection method for a connector assembly using a multidirectional conductive housing. The method comprises the following steps: conducting EMI generated by a source toward a metallic braided shield secured and mounted to a multidirectional conductive housing by a metallic clip; conducting EMI from the metal braided shield to the metal clip and to the multidirectional conductive housing, the multidirectional conductive housing being mounted to a metal fixture by at least metal bolts, and the bolts being received within corresponding metal compression limiters; and thereafter conducting EMI (1) from the metal braided shield to the multidirectional conductive housing, through the metal compression limiter and through its respective bolt, and ultimately to the metal device; and (2) from the metallic braided shield to the multidirectional conductive housing, directly through the conductive pads of the multidirectional conductive housing, and ultimately to the metallic device.

Description

Electromagnetic interference (EMI) ground protection method for connectors using multidirectional conductive housings

Cross Reference to Related Applications

This patent application claims priority from U.S. provisional patent application No. 62/775,103 filed on 12/4/2018 and U.S. provisional patent application No. 62/802,829 filed on 2/8/2019, which are incorporated herein by reference in their entirety.

Background

It is desirable to provide a high voltage connector assembly for connection to a device. It is further desirable that the high voltage connector assembly experience reduced or suppressed electromagnetic interference (EMI) through the conductive seal and the multi-directional conductive housing.

Disclosure of Invention

The present invention provides a high voltage connector for connection to a device that reduces or inhibits EMI when in operation. This is achieved by providing the connector with a metal braided shield over the inverter outer housing assembly or the like. The connector of the present invention is further provided with a metal clip that holds the metallic braided shield layer on the multidirectional conductive outer housing and provides conductive contact between the metallic braided shield and the multidirectional conductive outer housing. A multidirectional conductive outer housing made of metal impregnated plastic, resin, nylon, or the like, includes an overmolded silicone seal to provide the necessary sealing and insulating layers to prevent galvanic corrosion between the connector and the device to which the connector is connected. The outer housing may also be made of plastic, resin, nylon, etc. filled with stainless steel fibers. The metal-impregnated or stainless steel fiber-filled outer housing with the overmolded silicone shield includes holes through which bolts pass to secure the connector of the present invention to the device. The bolt provides the necessary ground between the metal braided shield, the metal impregnated plastic outer housing and the device to which the connector of the present invention is to be connected. Each bolt is preferably inserted into a corresponding metal compression limiter within a respective one of the apertures of the outer housing. The connector of the present invention is provided with a grounding system by establishing contact between the connector and the device by connecting the connector to the device using bolts and metal compression limiters. Furthermore, the steel bolts are housed within metal compression limiters, which in turn are housed within side holes of the outer casing. The overmolded silicone seal, along with the structural arrangement of dissimilar metals described above, provides corrosion resistance characteristics on the outer periphery of the base of the metal-impregnated outer housing.

The connector of the present invention further includes an inner housing disposed within the outer housing, the inner housing also having a cable reinforcement holder assembly securely inserted therein. The inner housing contains a cable therein that is directed in a desired direction in combination with a conductive outer housing having an angled or multi-directional portion.

The connector of the present invention further includes a back cover that serves as a Terminal Position Assurance (TPA) device through which the cable slides and is secured in the back cover during assembly of the connector. The rear cover comprises an overmolded silicone seal for isolating the connection interface of the cable. During assembly of the connector, the back cover ensures that the inner housing is properly positioned within the outer housing. The outer housing is inclined (i.e., a portion thereof extends in one direction and another portion extends in another direction) so as to accommodate therein a cable extending in any direction. In this case, the outer case has one portion extending in one direction and another portion extending in another direction, which are orthogonal to each other, but the shape of the outer case is not limited thereto.

Typically, in assembling the connector of the present invention, an inverter outer housing assembly having a metal-impregnated plastic outer housing with an overmolded silicone seal is mounted to the associated device using bolts received within corresponding metal compression limiters; the inner shell is positioned in the outer shell and on the base of the outer shell; a rear cover with associated cable and cable tie-down retainer assembly mounted within the angled outer housing and mounted on the inner housing, the cable sliding upwardly through the rear cover; the metal braided shield is mounted to the outer housing while covering the exposed cable; and the clip is slid along the braided shield to secure it to the outer housing.

In, for example, electric or hybrid vehicles, EMI is noise generated by, for example, a high voltage source, such as a battery or a set of conductive high voltage cables connected to a battery. Electrical shielding is important to reduce, suppress or eliminate EMI noise between components within a vehicle to avoid any loss of any or all vehicle functions. Proper grounding of all shielding components is important to suppress, reduce, or eliminate all EMI noise from the system. The present invention uses, for example, a conductive housing (made of gold-impregnated metal conductive plastic, resin, nylon, or the like, or made of stainless steel fiber filled plastic, resin, nylon, or the like), a metal compression limiter, a metal clamp, a metal braided shield, and a metal bolt to ground the connector assembly of the present invention and suppress, reduce, or eliminate EMI noise. EMI electrical noise generated by, for example, a vehicle battery, flows through the metal braided shield, then conducts to the metal clip, conducts to the electrically conductive housing including portions angled relative to each other, conducts to the metal compression limiter, conducts to the metal bolt, and then conducts to the associated metal device to which the connector assembly is mounted. Alternatively, EMI electrical noise generated by, for example, a vehicle battery or a conductive cable connected thereto, flows through the metal braided shield, then conducts to the metal clip, to the multidirectional conductive housing that includes portions that are angled relative to one another, and then directly to the associated metal device to which the connector assembly is mounted.

Drawings

FIG. 1 is a drawing of the present invention generally indicated by the reference numeral1An exploded view of the high voltage connector is shown showing the different components of the high voltage connector arranged in a horizontal direction ready to be mounted on an associated device.

FIG. 2A is a perspective view of the fully assembled connector of the present invention, without the braided shield, and with the cable exposed; fig. 2B is a perspective view of the fully assembled connector of the present invention showing the braided shield fully secured to the outer housing with a metal clip.

Fig. 3A is a top perspective view of the outer housing, and fig. 3B is a bottom perspective view of the outer housing.

FIG. 4A is a top perspective view of an outer housing surrounded at its bottom periphery by a corresponding overmolded silicone seal; FIG. 4B is an exploded view of the outer housing and corresponding overmolded silicone seal with the compression limiter fitted within the overlapping apertures of the outer housing and silicone seal.

FIG. 5A is a bottom view of the base end of the outer housing assembly showing the gasket of the outer housing passing through the elongated slot of the base of the overmolded silicone seal; fig. 5B is a bottom view of the base end of the outer housing assembly showing another embodiment or pattern of pads of the outer housing passing through corresponding elongated slits of another embodiment or pattern of bases of the overmolded silicone seal.

Fig. 6 is a front perspective view of the outer housing, showing its inner surface through its central opening.

Fig. 7A is a top perspective view of the inner housing showing the rear and top thereof, and fig. 7B is a bottom perspective view of the inner housing.

Fig. 8 shows a further top perspective view of the inner housing, illustrating the front and top thereof.

Fig. 9 shows an exploded perspective view of a cable strength retainer assembly having a clamp (or retainer) mounted on and surrounding an end terminal.

Fig. 10 illustrates a side view of the cable holder assembly when the cable holder assembly is fully assembled and the end of the end terminal of the clamp is coupled to the terminal of the cable.

Fig. 11A is a front view of a first side of an end terminal and a first side of a clip of a cable retention strength assembly, and fig. 11B is a front view of a second side of an end terminal and a second side of a clip of a cable retention assembly.

Fig. 12A illustrates a perspective view of the bottom and the rear of the rear cover, and fig. 12B illustrates a perspective view of the rear cover.

FIG. 13A is a perspective view of the top and front of the back cover; and fig. 13B is a front view of the front of the rear cover.

FIG. 14A is a perspective view of a braided shield; fig. 14B is a perspective view of the metal clip.

Fig. 15 is a fully assembled horizontal high voltage connector of the present invention showing a wedge (or bump) mechanism for securing a cable in an inner housing received in an outer housing.

Fig. 16 is a fully assembled horizontal high voltage connector of the present invention showing a wedge (or bump) mechanism for securing a cable in an inner housing received in an outer housing and also showing terminals extending from a corresponding device to which the connector is mounted for connection with end terminals of a cable retention and reinforcement assembly.

Fig. 17 is a fully assembled multi-directional, angled or horizontal high voltage connector of the present invention, showing the electrical ground path for EMI noise generated by the source, which is then conducted through the metal braided shield, through the connector assembly, and ultimately to the corresponding metal device to which the connector assembly is mounted.

Fig. 18 is a flow chart of the electrical ground path of EMI noise flowing through the metal braided shield, through the multi-directional, angled or horizontal connector assembly and ultimately conducted to the corresponding metal device to which the connector assembly is mounted.

Detailed Description

As shown in fig. 1, the high voltage connector 1 comprises an outer housing assembly 3, the outer housing assembly 3 comprising an angled, multidirectional or horizontal electrically conductive outer housing 5, the outer housing 5 having an accompanying overmolded silicone seal 7. In this case, the multidirectional conductive outer housing 5 includes a portion extending vertically and another portion extending in a horizontal direction orthogonal to the vertically extending portion, but the multidirectional conductive outer housing 5 of the present invention is not limited thereto. The multidirectional conductive outer casing 5 is preferably made of a metal-impregnated casing and comprises a side extension 62 of its base 32 for housing therein a respective bolt 12 (made of stainless steel or the like) for fixing the connector 1 to an associated device 210 (see fig. 15; for example, an inverter or the like made of, for example, aluminum).

The inner housing 14 is received in the outer housing 5 and mounted to its base 32. Connector 1 further includes a set of cable strength retainer assemblies 16 (specifically referred to as reference numeral 108 in fig. 9, 10, 11A, and 11B) for coupling with inner housing 14 and a set of cables 18. The set of cables 18 is preferably a high voltage cable (e.g. 25 mm)²Cable), but the type of cable is not limited thereto. Although a set of 3-way high voltage cables is shown in fig. 1, this embodiment is not so limited. The cable 18 is slidably received within the rear cover 20. The connector 1 further comprises a metallic (e.g. stainless steel) braided shield 22, the braided shield 22 forming an outer layer of the connector 1 when the connector 1 is fully assembled as shown in fig. 2B. As also shown in fig. 2B, when the connector 1 is fully assembled, the metal clip 25 secures the braided shield 22 to the outer housing 5.

Fig. 2A illustrates the connector 1 lacking the braided shield 22 when fully assembled, and fig. 2B illustrates the connector in which the braided shield 22 is fixed to the outer housing 5 by the metal jig 25 when fully assembled. In fig. 2A is further shown an outer housing assembly 3 with an outer housing 5, the outer housing 5 being firmly seated on and within an overmolded silicone seal 7 through which bolt 12 is fastened with a metal compression limiter 28 made of aluminum or the like. As discussed later, a set of cables 18 extend through the upper portion 30 of the outer housing 5.

In fig. 2B, a group of cables 18 is covered by a metallic braided shield 22. The metal clip 25 ensures that the bottom part 33 of the metal braided shield 22 is connected to the upper part 30 of the outer housing 5.

As shown in fig. 3A, the outer case 5 having the base 32 extends in a horizontal direction, and the horizontal rib 34 extends from one side of the base 32 toward the central portion 36 of the outer case 5. As far as the outer casing 5 is concerned, and as previously mentioned, also shown in fig. 3A are the extended sides or ribs 9 and the side holes 38 for receiving therein, together with the silicone seal 7, the corresponding bolts 12 and the corresponding metal compression limiters 28. The outer housing 5 is preferably made of metal-impregnated plastic, while the bolt 12 is preferably made of stainless steel or the like.

A central opening 40 extends through central portion 36 of outer housing 5 for receiving inner housing 14 and cable strength retainer assembly 16 completely therein and further receiving a set of cables 18 partially therein. A hole 42 passes through the upper portion of the outer housing 5.

The bottom end 45 of the outer housing 5 is shown in fig. 3B. Bottom end 45 is substantially flat and includes at least a pad 48 extending therefrom. Pad 48 surrounds a bottom opening or hole 50 through bottom end 45 of base 32 of outer housing 5. The pads 48 provide a means for substantially reducing or substantially eliminating any generation of EMI when the outer housing 5 is mounted to an associated device 210 (see fig. 15). The bottom opening or aperture 50 is preferably smaller in size than the central aperture 40 of the outer housing 5 and communicates therewith.

Fig. 4A shows the outer housing assembly 3, the outer housing assembly 3 comprising an outer housing 5 and an overmolded silicone seal 7, the base 32 of the outer housing 5 being located on and within the overmolded silicone seal 7. The overmolded silicone seal 7 provides a seal and insulation layer for galvanic corrosion protection between the connector 1 and the device 210.

In fig. 4B, an exploded view of the outer housing assembly 3 is illustrated showing the outer housing 5 and its corresponding overmolded silicone seal 7. As previously discussed with respect to the outer housing 5 shown in fig. 3A and 3B, the outer housing 5 includes a base 32 having a bottom end 45. As also described with respect to fig. 3B, base end 45 includes a pad 48 that fits through an elongated slit 51, which slit 51 passes through a base 52 of overmolded silicone seal 7 (see fig. 4B). As further described with respect to fig. 3B, the substantially flat bottom end 45 of the outer housing 5 is located and mounted on the base portion 52 of the overmolded silicone seal 7, as shown in fig. 4A and 4B. In the overmolded silicone seal 7 shown in fig. 4B, the base portion 52 includes side holes 53, while the upper portion 55 of the silicone seal 7 includes side members 57, each side member 57 having a hole 60 therethrough. As shown in fig. 4A, each upper portion 55 of the silicone seal 7 is fitted to one of the side extensions 62 of the base 32 of the outer housing 5. Thus, each hole 60 of each side member 57 of the silicone seal 7 corresponds to a corresponding one of the holes 38 of the base 32 of the outer housing 5 to respectively receive the metal compression limiters 28 therein.

Fig. 5A illustrates the bottom end 45 of the outer housing component 3 with the gasket 48 of the outer housing 5 passing through the elongated slit 51 of the silicone seal 7 when the outer housing 5 is seated and mounted on the overmolded silicone seal 7. Fig. 5B illustrates the bottom end 45 of the outer housing component 3 with a different embodiment or style of gasket 48 passing through a corresponding elongated slit 51 of a different embodiment or style of silicone seal 7 when the outer housing 5 is seated and mounted on the overmolded silicone seal 7.

Fig. 6 is a top perspective view of the outer housing 5, showing the inner surface through its central opening 40. As can be seen in fig. 6, through the central opening 40 of the outer housing 5, a bottom opening or hole 50 is substantially orthogonal to and in communication with the central opening 40, the bottom opening or hole 50 passing through the end 45 substantially orthogonal to the base 32 of the outer housing 5. As further shown in fig. 6, an internal shoulder 95 extends from an inner surface 97 of the outer housing 5. Although not shown in fig. 6, a similar type of internal shoulder 95 extends from the opposite side of the inner surface of the outer housing 5. Also shown in fig. 6 are

external shoulders

98a and 98b extending from the upper portion of outer housing 5.

The inner housing 14, which is accommodated within the outer housing 5 and is located on its base 32, will be described in detail below. The inner housing 14 is preferably made of nylon or the like. The inner housing 14 (preferably made of nylon or the like) provides isolation between conductive portions (e.g., the outer housing 5 made of metal-impregnated plastic or the like and the cable terminal 107 fixed within the inner housing 14). Fig. 7A is a top perspective view of the inner housing 14 showing the rear 70 and top 72 thereof. The rear portion 70 of the inner housing 14 has

flexible members

75, 76, 77. The top 72 of the inner housing 14 has a first portion 80, a second portion 82, and a third portion 84 extending from the top 72. As shown in fig. 7A, the inner housing 14 is an upside down (or inverted) substantially L-shaped structure having a downward extending member 83 and a front extending member 87.

Fig. 7B is a bottom perspective view of the inner housing 14. In fig. 7B, a bottom end 85 of the inner housing 14 is shown, the bottom end 85 having

slots

88, 89, 90 therethrough. The front extension member 87 of the inner housing 14 is similarly shown in fig. 7B as having a bottom surface 92.

Fig. 8 shows a further top perspective view of the inner housing 14 illustrating the front 101 and the top 72 thereof. The front 101 of the inner housing 14 is opposite the rear 70 of the inner housing 14 shown in fig. 7A. Similarly shown in fig. 8 are

flexible members

75, 76, 77 in the rear portion 70 of the inner housing 14. Each of the

flexible members

75, 76, 77 has an inclined shoulder 103. Extending from the rear portion 70 are a first portion 80, a second portion 82, and a third portion 84 (see also fig. 7A). Each second portion 82 extends obliquely relative to the substantially flat and substantially horizontal first portion 80. The top 72 of the inner housing 14 is preferably similarly flat and horizontal. Between the second portion 82 and the third portion 84 is a substantially concave portion or depression 105. Also shown in FIG. 8 are

upper slots

188, 189, 190, the

upper slots

188, 189, 190 communicating with the

lower slots

88, 89, 90, respectively, of the inner housing 14 shown in FIG. 7B.

Fig. 9 shows an exploded perspective view of cable strength retainer assemblies 108 (also referred to as reference numeral 16 in fig. 1), each cable strength retainer assembly 108 having a clamp (or retainer) 105, the clamp 105 being mounted on and surrounding a preferably flexible (although not limited to) end terminal 107. The end terminal 107 has a substantially flat and substantially bent end portion 110, the end portion 110 being attached to a cable terminal 113, the cable terminal 113 being attached to the cable 18. The terminal 107 includes a first side portion 115 and a second side portion 117. The first side 115 includes a plurality of preferably flexible fingers 119 and the second side 117 also includes a plurality of preferably flexible fingers 121. Although not limited thereto, flexible finger 119 and flexible finger 121 are substantially symmetrical. At least the extension member 120 is attached to the second side 117, the extension member 120 extending towards the first side 115. Each of the first and

second sides

115, 117 of the end terminal 107 includes at least a recess or

hole

122, 123, respectively.

The clamp (or holder) 105 of the cable strength retainer assembly 108 includes a first side 125 and a second side 127. Each of the first and

second sides

125, 127 of the clamp 105 includes at least an inwardly projecting

member

130, 132, respectively. When the end terminal 107 is received within the clamp 105 during assembly thereof, the projecting

members

130, 132 enter the recesses or

holes

122, 123, respectively. Further shown in fig. 9 is at least a flexible member 133 in the second side portion 127 of the clip 105. Although the flexible members 133 are illustrated as a pair of flexible members 133 in fig. 9, it is not limited thereto.

At least the side portions 134 of the terminals 107 are prevented from passing over the inwardly projecting members 136 at least at the side portions 137 of the clip 105. Preferably, each of the opposing sides 137 of the clamp 105 includes an inwardly projecting member 136 and the end terminal 107 includes an opposing side 134.

The cable strength retainer assembly 108 is shown fully assembled in fig. 10, and the end 110 of the end terminal 107 of the clamp 105 is coupled to the end 113 of the cable 18. As shown in fig. 10, the cable tie-down retainer assembly 108 shows an end of at least one of the flexible members 121 of the second side 117 of the end terminal 107 and an end of at least one of the flexible members 119 of the first side 115 of the end terminal 107. See also fig. 9.

Fig. 11A is a front view of the second side 117 of the end terminal 107 and the second side 127 of the clamp 105 of the cable retention strength assembly 108. The second side 127 of the clamp 105 includes at least a flexible member 133. Although not limited thereto, a pair of flexible members 133 having an elongated slit 138 therebetween is shown in fig. 11A. Also shown in fig. 11A is an inwardly projecting member 130 in the second side 127 of the clamp 105, which is preferably inclined so as to easily enter the recess or hole 122 of the end terminal 107 when the end terminal 10 is moved inside the clamp 105 (see fig. 9). Once the inwardly projecting members 130 have been received in the recesses or holes 122, the end terminals 107 are retained inside the clip 105. That is, the inwardly projecting

members

130, 132 of the clip 105 are preferably inclined to allow the terminal 107 to be inserted into the clip 105; and prevents the terminals 107 from being pulled out of the clamp 105 once the inwardly projecting

members

130, 132 have been received within the recesses or

apertures

122, 123, respectively, of the end terminals 107. As previously described with respect to fig. 9, the opposing sides 134 of the end terminal 107 are retained by the inwardly projecting members 136 of the clip 105 and prevent the retainer 107 from being pushed further forward into the clip 105. When so assembled, the cable holder assembly 108 extends the ends of the

flexible members

119, 121 of the terminals 107 to the exterior of the clamp 105, as shown in fig. 10, 11A and 11B.

Fig. 11B illustrates a front view of the cable holder assembly 108 showing the first side 115 of the end terminal 107 and the first side 125 of the clamp 105. Here exemplified the inwardly projecting member 132 and the pair of flexible members 135 of the clamp 105, the ends of the flexible members 119 of the first side portion 115 of the terminal 107 extend outside the clamp 105 when the cable tie holder assembly 108 is assembled as shown.

Further illustrated in fig. 11B is an elongated slot 140 (shown here as passing entirely through the first side 125 of the clamp 105) between the pair of flexible members 135.

Fig. 12A illustrates a perspective view of bottom 142 and back 145 of rear cover 20. There is shown an at least substantially semi-circular tubular member 148 having a bottom 149 and extending from the rear 145 of the rear cover 20. For strength and stability, the semicircular tubular members 148 are coupled to bridge (or rib) members 150 respectively connected to the rear cover 20 and extending to the sides 153 of the rear cover 20. The opening 155 of the tubular member 148 extends toward the middle portion 160 of the rear cover 20. Within the intermediate portion 160 are substantially circular apertures 162 that respectively communicate with the tubular members 148. A circular fitting silicone seal 165 is in each circular hole 162; and an overmolded silicone seal 168 is provided on the outer periphery of the middle portion 160 of the rear cover 20. The rear cover 20 has a circular fitting silicone seal 165 for engaging the cable 18 and an overmolded silicone seal 168 for engaging the inner surface of the outer housing 5. The rear cover 20 serves as a Terminal Position Assurance (TPA) means of the high-voltage connector 1 of the present invention in a state where the cables 18 are respectively accommodated in the circular fitting silicone seals 165. Shoulder 173 surrounds lower portion 170 of rear cover 20; and the inclined projecting member 175 between the shoulders 173 as shown in fig. 12A.

As shown in fig. 12A, the above-described elements of the rear cover 20 are similarly shown in the front view of the rear portion 145 of the rear cover 10 as illustrated in fig. 12B. Here, a tubular member 148 and a bridge (rib) member 150 connected to a side 153 are shown. Also shown in fig. 12B are respective openings 155 of the tubular member 148 that communicate with the circular apertures 162 of the tubular member 148, respective circular fitting silicone seals 165 that fit within the circular apertures 162, and silicone seals 168 that surround the outer periphery of the intermediate portion 160 of the rear cover 20. Shoulder 173 is shown in fig. 12B surrounding lower portion 170 of back cover 20 on all sides of lower portion 170 of back cover 20 (see fig. 12A), and inclined projecting members 175 extend on opposite sides of back cover 20, as shown in fig. 12B.

Fig. 13A is a perspective view of the top 180 and front 182 of the rear cover 20. An inclined projecting member 175 is shown on the top 180. The top 180 of the rear cover 20 is opposite the bottom 142 thereof. A top tubular member 185 having respective openings 188 extends from the front 182, the openings 188 each communicating with a circular aperture 162 extending through the middle portion 160 of the rear cover. Top tubular member 185 is similarly surrounded by bridge (or rib) members 190, as is semi-circular tubular member 148 extending from rear portion 145. A silicone seal 168 surrounds the outer periphery of the intermediate portion 160.

Fig. 13B is a front view of the front portion 182 of the rear cover 20, showing the various openings 188 and associated bridge (or rib) formations 190 of the top tubular member 185. Fig. 13B also shows the corresponding circular fitting silicone seal 165 discussed earlier with respect to fig. 13A, and the angled projecting members 175 located in the front portion 182 at opposite sides of the front portion 182.

Fig. 14A is a perspective view of the braided shield 22 having an interior opening 192 extending along its entire length. The braided shield 22 is made of metal, preferably stainless steel or the like. Fig. 14B is a perspective view of the metal jig 25, the metal jig 25 being substantially annular in shape and made of stainless steel or the like.

In the high voltage horizontal connector 1 of the present invention, the connection of the connector 1 to the associated aluminum device 210 is provided to a grounding system by establishing contact between the metal impregnated conductive plastic outer housing 5, the aluminum compression limiter 28, the stainless steel bolt 12 and the associated aluminum device 210. EMI is substantially reduced or eliminated by the metal-impregnated pads 48 of the outer housing 5 in combination with the braided shield 22 extending along the path of the cable 18, the metal-impregnated pads 48 being in contact with the associated aluminum device 210. The present invention further provides galvanic corrosion protection by shielding the metal impregnated conductive plastic outer housing 5 and associated aluminum device 210 from electrolytic fluids using the base 52 of the non-conductive overmolded silicone seal 7. The metal impregnated conductive plastic outer housing 5 and aluminum compression limiter 28 are protected from the electrolytic fluid and further the stainless steel bolt 12 and associated aluminum device 210 from the electrolytic fluid with the side member 57 of the upper portion 55 of the silicone seal 7 to prevent galvanic corrosion which is further prevented.

The method of assembling the high voltage connector of the present invention is described in detail below. The bolts 12 are respectively fixed into the compression limiters 28 in the side holes 38 of the outer housing 5, and then the outer housing 5 together with the over-molded silicone seal 7 is mounted to the outer housing 5 and then the device 210 to which the connector 1 is to be mounted (see fig. 15). The bolt 12 securely fastens the connector 1 to the device 210 and provides a ground connection between the woven shield 22, the outer housing 5 and the device 210. Preferably, stainless steel bolts 12 and aluminum compression limiters 28 provide contact between the connector 1 and the device 210 to ground the system.

With the outer housing 5 already mounted to the device, together with the overmolded silicone seal 7, the inner housing 14 is then inserted or slid into the central opening 40 of the outer housing 5 until the inner housing 14 is about to reach or reach the end 45 (see fig. 6) of the outer housing 5, and the inner housing 14 is then inserted or slid down into the bottom opening or hole 50 (see fig. 6) of the outer housing 5 to mount the inner housing 14 to the base 32 of the outer housing 5 until a click or the like is heard, which ensures that the inner housing 14 is secured within the outer housing 5. The overmolded silicone seal 7 provides a seal and insulation layer for galvanic corrosion protection between the connector 1 and the device 210. Preferably, the plurality of pre-assembled cable reinforcing retainer assemblies 108 with their respective cables 18 are inserted first into the central opening 40 of the outer housing 5 and then downwardly into the inner housing 14 until a click or the like is heard, in which case the rear cover 20 is then slid along the cables 18 through the central opening 40 and into the outer housing 5 until a click or the like is heard again once the rear cover 20 is secured within the outer housing 5. At this time, the partially assembled connector 1 is as shown in fig. 2A. Thereafter, the braided shield 22 is mounted onto the outer housing 5, and the clamp 25 is slid down over the braided shield 22 toward the rear end of the braided shield 22 and placed on the braided shield 22 (see fig. 2B), and provides conductive contact between the braided shield 22 and the outer housing 5.

More specifically, when the inner housing 14 is inserted into the central opening 40 of the outer housing 5, the inner housing 14 will reach or reach the end 45 of the outer housing 5 and then be inserted into the opening or hole 50 and lowered toward the base 32 of the outer housing 5, with the downwardly extending member 83 of the inner housing 14 downwardly entering (or sliding) into the bottom opening or hole 50 of the outer housing 5. Then, the bottom surface 92 of the front extension member 87 of the inner housing 14 is mounted to the inner portion 41 (see fig. 3A and 6) of the outer housing 5. Substantially immediately, the upper portions 201 (see fig. 8) of the flexible latch members 200 on opposite sides of the inner housing 14 enter the recesses 99 (see fig. 6) on opposite inner sides of the outer housing 5, respectively, at which time a click or the like is heard. A click or the like thus indicates that the inner housing 14 is securely mounted within the outer housing 5. The inner housing 14 (preferably made of nylon or the like) provides isolation between electrically conductive portions (e.g., the outer housing 5 made of metal-impregnated plastic or the like and the cable terminal 107 fixed within the inner housing 14).

Thereafter, preferably a plurality of pre-assembled cable reinforcement holder assemblies 108 (see fig. 10) with their respective cables 18 have their respective cables 18 inserted into respective circular fitting silicone seals 165 of the respective circular apertures 162 of the rear cover 20.

The preferably preassembled cable strength retainer assembly 108 is then inserted or slid into the central opening 40 of the outer housing 5 and lowered toward the

upper notches

188, 189, 190 (see fig. 8) of the inner housing 14. More specifically, with the second side 125 of the clamp 105 facing the front 70 of the inner housing 14, respectively, the cable strength retainer assembly 108 is inserted or slid substantially horizontally through the central opening 40 of the outer housing 5 and then lowered through the

upper notches

188, 189, 190, respectively, but not beyond the

notches

88, 89, 90 of the bottom end 85 of the inner housing 14 (see fig. 7B). The cable tie-down retainer assemblies 108 travel down through the

upper notches

188, 189, 190, respectively, of the inner housing 14, and the clamps 105 push the angled shoulders 103 of the

flexible members

75, 76, 77 (see fig. 8), respectively, while traveling down until each upper end 128 (see fig. 10) of each clamp 105 is positioned below one of the angled shoulders 103 of the inner housing 14 (see fig. 8), respectively; thereupon, a click or the like is heard, indicating that the clamp 105, and thus the cable reinforcing retainer assembly 108, is securely fastened within the inner housing 14. At this time, the substantially flat and substantially bent portion 110 (see fig. 10) of the end terminal 107 is located or mounted on the substantially flat and substantially horizontal first portion 80 of the front extension member 87 of the inner housing 14. The second portions 82 of the front extension members 87 of the inner housing 14 respectively isolate the substantially flat and substantially bent portions 110 of the end terminals 107.

Thereafter, the rear cover 20 is slid substantially horizontally along the cable 18 toward the outer housing 5 and through the central opening 40 thereof until the inclined projecting members 175 (see fig. 13A and 13B) on opposite sides of the rear cover 20 enter the holes 42 (see fig. 3A and 3B) through the front portion of the outer housing 5, respectively, whereupon a click or the like is heard, indicating that the rear cover 20 has been securely fixed to the outer housing 5, and the cable reinforcing retainer assembly 108 is similarly fully fixed within the outer housing 5. That is, rear cover 20 pushes inner housing 14 into place and ensures that inner housing 14 is properly positioned within outer housing 5.

As shown in fig. 15, the horizontal high-voltage connector 1 of the present invention is mounted to a device 210 (for example, an inverter or the like) using bolts 12. The downwardly extending member 83 of the inner housing 14 is shown as having passed through the bottom opening or aperture 50 of the bottom end 45 of the base 32 of the outer housing 5 and through the overmolded silicone seal 7. The pad 48 of the bottom end 45 of the base 32 of the outer housing 5 is shown within the elongate slot 51 of the overmolded silicone seal 7.

As further shown in fig. 15, a substantially flat and substantially bent portion 110 (see fig. 10) of the end terminal 107 of the cable strength retainer assembly 108 is located or mounted on the substantially flat and substantially horizontal first portion 80 of the front extension member 87 of the inner housing 14. The bottom surface 92 of the front extension member 87 of the inner housing 14 is placed on or mounted to the inner side 41 of the outer housing 5 (see fig. 3B and 6).

Also shown in fig. 15 is a wedge or bumping mechanism a for securing the cable 18 within the inner housing 14. More specifically, when the rear cover 20 is inserted or slid substantially horizontally along the cable 18 through the central opening 40 and into the outer housing 5, the bottom 149 of the substantially semicircular tubular member 148 (see fig. 12A) of the rear cover 20 presses or strikes the top surface portion 111 (see fig. 10 and 11A)7, respectively, of the end portion 110 of the end terminal 107 of the cable reinforcing holder assembly 108, thereby securing the cable 18 within the inner housing 14. As shown in fig. 16, the ends of the

flexible members

119, 121 of the terminals 107 that extend outside the clip 105 (see, e.g., fig. 10) are connected with a set of terminals 220 of an associated device 210.

Thereafter, to shield the exposed cable 18, the braided shield 22 is slid substantially horizontally toward the outer housing component 3, whereby the rear of the braided shield 22 extends from the portion of the outer housing 3 proximate its central opening 40 past the

outer shoulders

98a, 98b (see fig. 6). The clip 25 then slides substantially horizontally along the braided shield 22 past the

external shoulders

98a, 98b and approximately past the

external shoulders

98a, 98b, the clip 25 connecting and securing the braided shield 22 to the external housing 5.

When fully assembled, the horizontal high voltage connector 1 of the present invention comprises a grounding system provided with the connection of the connector 1 to the associated aluminum device 210 by establishing contact between the metal-impregnated conductive plastic outer shell 5, the aluminum compression limiter 28, the stainless steel bolt 12 and the associated aluminum device 210. EMI may be substantially reduced or substantially eliminated by shielding the braided shield 22 extending along the path of the cable 18 or otherwise transferring EMI from the braided shield 22 to the metal-impregnated pad 48 for EMI grounding, contacting the associated aluminum device 210. That is, EMI is transferred to a path from the stainless steel braided shield 22 connected to the metal-impregnated plastic outer case 5 by the stainless steel clip 25 to the metal-impregnated plastic outer case 5 mounted to, for example, the aluminum inverter 210. The present invention further provides galvanic corrosion protection by shielding the metal-impregnated conductive plastic outer housing 5 and associated aluminum inverter 210 from electrolytic fluids using the base 52 of the non-conductive overmolded silicone seal 7. The metal-impregnated pad 48 protruding through the silicone seal 7 and abutting the silicone seal 7 prevents electrochemical corrosion between the metal-impregnated outer case 5 and the aluminum inverter 210. The metal impregnated conductive plastic outer housing 5 and aluminum compression limiter 28 are protected from the electrolytic fluid and further the stainless steel bolt 12 and associated aluminum inverter 210 from the electrolytic fluid with the side member 57 of the upper portion 55 of the silicone seal 7 to prevent galvanic corrosion which is further prevented.

Fig. 17 is a fully assembled vertical high voltage connector assembly 1 of the present invention showing

electrical grounding paths

220, 230, 240, 250 for EMI noise generated by a source (e.g., the electrically conductive high voltage cable 18, the electrically conductive cable reinforcement holder assembly 16, 108, the battery itself, etc., or any other source) that is then conducted through the metal braided shield 22, through the high voltage connector 1, and ultimately to the corresponding metal fitting 210 to which the high voltage connector 1 is secured. Fig. 18 is a corresponding flow diagram of the

electrical grounding paths

220, 230, 240, 250 of EMI noise that flows through the metallic braided shield 22, through the high voltage connector 1, and ultimately to the corresponding metallic device 210 to which the high voltage connector 1 is mounted.

More specifically, in, for example, an electric vehicle or a hybrid vehicle, when EMI noise is generated, for example, by a vehicle high voltage battery, a conductive cable 18 connected to the battery, a cable reinforcement assembly 16, 108, etc., and any other source, it is desirable to reduce, suppress, or eliminate the EMI noise for the reasons discussed above. Electrically grounded EMI

noise flow paths

220, 230, 240, 250 are illustrated in fig. 17. As shown in fig. 17, the EMI noise flow path 220 initially flows through the metallic braided shield 22 (made of stainless steel or the like). The EMI noise flow path 220 then flows through the metal clip 25, and the metal clip 25 (as previously discussed) secures the metallic braided shield 22 to the multidirectional conductive outer housing 5. The outer case 5 is made of metal-impregnated conductive plastic, resin, nylon, or the like. The outer case 5 may also be made of plastic, resin, nylon, etc. filled with stainless steel fiber. The EMI noise flow path 220 is then directed along the angled or multi-directional portion of the electrically-conductive outer housing 5 to the EMI noise flow path 230, the EMI noise flow path 230 traveling through a different direction than the EMI noise flow path 220. In this case, the EMI flow path similarly traveling along the electrically-conductive outer housing 5 is orthogonal to the direction in which the EMI noise flow path 220 travels, taking into account the angled or multi-directional configuration of the outer housing 5. The EMI noise flow path 230 continues to travel through the EMI noise flow path 240 and is then conducted to at least one of the metal compression limiters 28 (made of aluminum or the like) surrounding the corresponding bolt (made of stainless steel or the like).

The EMI noise flow path 240 flows from the electrically conductive outer housing 5 to a metal compression limiter 28 (made of aluminum or the like) (see the EMI noise flow path 240 in fig. 17), the metal compression limiter 28 surrounding a corresponding bolt 12 (made of stainless steel or the like), the bolt 12 connecting the connector assembly 1 to the metal fitting 210 to which the connector assembly 1 is mounted. With the structural arrangement discussed above, the EMI noise flow path 240 thus travels from the electrically conductive outer housing 5 to the metal compression limiter 28 to the corresponding stainless steel bolt 12 being surrounded and ultimately conducted to the associated metal fitting 210. The associated metallic device 210 may be, for example, an aluminum automotive transmission.

Further, as discussed above, fig. 5A illustrates the bottom end 45 of the outer housing component 3, with the gasket 48 of the outer housing 5 passing through the elongated slit 51 of the silicone seal 7 when the outer housing 5 is seated and mounted on the overmolded silicone seal 7. Fig. 5B illustrates the bottom end 45 of the outer housing component 3 with a different embodiment or style of gasket 48 passing through a corresponding elongated slit 51 of a different embodiment or style of silicone seal 7 when the outer housing 5 is seated and mounted on the overmolded silicone seal 7.

The pads 48 of the conductive outer housing 5 passing through the elongated slits 51 of the silicone seal 7 contact the corresponding metal means 210. Preferably, although the tightening of the bolt 12 is limited by the compression limiter 28 to ensure that the physical or functional integrity of the silicone seal 7 is maintained, the tightening of the bolt 12 when connecting the connector assembly 1 to the corresponding metal device 210 ensures that physical contact between the pads 48 of the conductive outer housing 5 and the corresponding metal device 210 is maintained.

With the pads 48 of the electrically-conductive outer housing 5 in physical contact with the corresponding metal fittings 210 ensured as described above, the EMI noise flow paths 220 flow from the metal braided shield 22 to the multidirectional electrically-conductive outer housing 5, and then directly to the corresponding metal fittings 210 along the EMI noise flow paths 230 of the angled or orthogonally-directed portions of the multidirectional electrically-conductive outer housing 5 (see EMI noise flow paths 250).

Although only a single metal compression limiter 28 and a single corresponding stainless steel bolt 12 are described above, the EMI noise flow path 240 may proceed to multiple metal compression limiters 28 and corresponding stainless steel bolts 12 shown in fig. 2A and 2B. Also, the EMI noise flow path 250 may travel through different embodiments or styles of the plurality of gaskets 48 of the electrically-conductive outer housing 5, the plurality of gaskets 48 passing through corresponding elongated slits 51 of different embodiments or styles of the silicone seal 7, as discussed above with respect to fig. 5A and 5B.

As discussed further above, the noise flow path 220 of the generated EMI noise flows from the metal braided shield 22 and ultimately to the corresponding metal device 210 as follows: (1) from the metal braided shield 22 to the multidirectional conductive outer housing 5, through the metal compression limiters 28 and through their respective bolts 12 and ultimately to the corresponding metal fittings 210 (see EMI

noise flow paths

220, 230, 240), and (2) from the metal braided shield 22 to the multidirectional conductive outer housing 5, through the conductive pads 48 of the outer housing 5 and ultimately to the corresponding metal fittings 210 (see EMI

noise flow paths

220, 230, 250).

Although fig. 17 shows angled or orthogonally oriented portions of the electrically-conductive outer housing 5 through which the EMI noise flow paths 230 are directed, multi-directional portions of the electrically-conductive outer housing 5 are certainly contemplated by the inventors and may alternatively be paths through which the EMI

noise flow paths

220, 230, 240 may be directed.

Fig. 18 further illustrates EMI

noise flow paths

220, 230, 240, 250 flowing from the metallic braided shield 22 and ultimately to the corresponding metallic device 210.

As discussed above, EMI noise is generated by a source (e.g., a battery of an electric vehicle, a hybrid vehicle, etc., or the electrically conductive cable 18, or the electrically conductive cable-reinforced retainer assembly 16, 108, etc.), and a method for protecting the connector assembly 1 from EMI ground noise is shown in the flow chart of fig. 18. As shown in step 1(S1), EMI noise is conducted through the metal braided shield 22. In step 2(S2), EMI noise continues to flow through the noise flow path 220 to the metal clip 25, and further continues through the EMI noise flow path 220 to the multi-way conductive outer housing 5, through the angled portion or the multi-way portion of the conductive outer housing 5 in the EMI noise flow path 230 in step 3 (S3).

In the EMI

noise flow paths

230, 240, EMI noise is conducted from the angled or multi-directional portion of the electrically-conductive outer housing 5 to the metal compression limiter 28 in step 4A (S4A), continues through the EMI noise flow paths 240 to the corresponding bolts 12 in step 5A (S5A), and is ultimately conducted to the metal fitting 210 to which the connector assembly 1 is mounted in step 6A (S6A).

In the EMI

noise flow paths

230, 250, EMI noise is conducted from the angled or multi-directional portion of the conductive outer housing 5 directly through the conductive pad 48 of the conductive outer housing 5 in step 4B (S4B) and ultimately to the metallic device 210 to which the connector assembly 1 is mounted in step 5B (S5B).

While the foregoing description is directed to the preferred embodiments of the present invention, it is noted that other variations and modifications will be apparent to those skilled in the art, and may be made without departing from the spirit or scope of the invention. Furthermore, features described in connection with one embodiment of the invention may be used in combination with other embodiments, even if not explicitly stated above.

Claims

1. A method of electromagnetic interference (EMI) ground protection for a connector assembly using a multidirectional conductive housing, characterized by the steps of:

conducting the EMI generated by the source toward a metallic braided shield secured and mounted to the electrically-conductive housing by a metallic clip;

conducting the EMI from the metallic braided shield to the metallic clip and to the multi-directional electrically-conductive housing, the electrically-conductive housing having an angled portion or a multi-directional portion, and the multi-directional electrically-conductive housing being mounted to a metallic device at least by bolts, and the bolts being received within corresponding metallic compression limiters; and thereafter

Conducting the EMI from the multidirectional conductive housing to the corresponding metal compression limiter and to the bolt within the corresponding metal compression limiter and ultimately to the metal device, thereby EMI protecting the connector assembly by grounding the EMI.

2. The method of electromagnetic interference (EMI) ground protection for the connector assembly using the multidirectional conductive housing of claim 1, wherein the metal braided shield is made of stainless steel or the like.

3. The method of electromagnetic interference (EMI) ground protection for the connector assembly using the multidirectional conductive housing of claim 1, wherein the conductive housing is made of a metal-impregnated conductive material selected from the group consisting of plastic, resin, and nylon.

4. The method of electromagnetic interference (EMI) ground protection for the connector assembly using the multidirectional conductive housing of claim 1, wherein the multidirectional conductive housing is made of a stainless steel fiber filled material selected from the group consisting of plastic, resin, and nylon.

5. The method of electromagnetic interference (EMI) ground protection for the connector assembly using the multidirectional conductive housing of claim 1, wherein the metal compression limiter is made of aluminum or the like.

6. The method of electromagnetic interference (EMI) ground protection for the connector assembly using the multidirectional conductive housing of claim 1, wherein the bolt is made of stainless steel or the like.

7. The method of claim 1, wherein the metal device to which the multidirectional conductive housing is mounted is made of aluminum or the like.

8. The method of electromagnetic interference (EMI) ground protection for the connector assembly using the multidirectional conductive housing of claim 7, wherein the metal device to which the multidirectional conductive housing is mounted is an aluminum automotive transmission.

9. A method of electromagnetic interference (EMI) ground protection for a connector assembly using a multidirectional conductive housing, characterized by the steps of:

conducting the EMI generated by the source toward a metallic braided shield secured and mounted to the multidirectional conductive housing by a metallic clip;

conducting the EMI from the metallic braided shield to the metal clip and to the multidirectional conductive housing, wherein the multidirectional conductive housing has a base portion with a plurality of pads that pass through slits of a silicone seal and contact a metal device to which the connector assembly is mounted, the silicone seal being located between the multidirectional conductive housing and the metal device; and thereafter

Conducting the EMI from the multidirectional conductive housing through the pads of the base portion of the multidirectional conductive housing and ultimately to the metallic device, thereby EMI protecting the connector assembly by grounding the EMI.

10. The method of electromagnetic interference (EMI) ground protection for the connector assembly using the multidirectional conductive housing of claim 9, wherein the metal braided shield is made of stainless steel or the like.

11. The method of electromagnetic interference (EMI) ground protection for the connector assembly using the multidirectional conductive housing of claim 9, wherein the multidirectional conductive housing is made of a metal-impregnated conductive material selected from the group consisting of plastic, resin, and nylon.

12. The method of electromagnetic interference (EMI) ground protection for the connector assembly using the multidirectional conductive housing of claim 9, wherein the multidirectional conductive housing is made of a stainless steel fiber filled material selected from the group consisting of plastic, resin, and nylon.

13. The method of claim 9, wherein the metal device to which the conductive housing is mounted is made of aluminum or the like.

14. The method of electromagnetic interference (EMI) ground protection for the connector assembly using the multidirectional conductive housing of claim 13, wherein the metal device to which the multidirectional conductive housing is mounted is a metal automotive compressor.