Cable shielding with conductive resin

Patent metadata

Field	Value
Publication number	US-12347976-B2
Application number	US-202018010785-A
Country	US
Kind code	B2
Filing date	Jun 26, 2020
Priority date	Jun 26, 2020
Publication date	Jul 1, 2025
Grant date	Jul 1, 2025

Abstract

A cable assembly includes a connector head electrically coupled to a plurality of conductors disposed in a cable, the connector head having a plug and a conductor interface; an outer shell including a first portion encasing the plug of the connector head, and a second portion encasing the conductor interface of the connector end; an inner shell including a connector end encasing the second portion of the outer shell, and a cable end encasing a portion of the cable and including an injection gate; and conductive resin including a first portion disposed inside the connector end of the inner shell, and a second portion disposed inside and outside the cable end of the inner shell; wherein inside and outside portions of the second portion of the conductive resin are connected through the injection gate.

First claim

What is claimed is:

1. A cable assembly, comprising:
a connector head electrically coupled to a plurality of conductors disposed in a cable, the connector head having a plug and a conductor interface;
an outer shell including:
a first portion encasing the plug of the connector head, and
a second portion encasing the conductor interface of the connector head;

an inner shell including:
a connector end encasing the second portion of the outer shell, and
a cable end encasing a portion of the cable and including an injection gate;

and conductive resin including:
a first portion disposed inside the connector end of the inner shell, and
a second portion disposed inside and outside the cable end of the inner shell;

wherein inside and outside portions of the second portion of the conductive resin are connected through the injection gate; and
wherein the connector end of the inner shell and the second portion of the conductive resin form a contiguous surface.

2. The cable assembly of claim 1 , further comprising:
an overmold encasing the conductor interface of the connector head, the second portion of the outer shell, the connector end and the cable end of the inner shell, and the first portion and the second portion of the conductive resin.

3. The cable assembly of claim 1 , further comprising:
a ground bar electrically coupled to shielding of the plurality of conductors and the cable end of the inner shell.

4. The cable assembly of claim 1 , further comprising:
an inner mold disposed inside the second portion of the outer shell.

5. The cable assembly of claim 1 , wherein:
the inner shell further includes an injection monitoring region exposing a portion of the first portion of the conductive resin; and
the connector end of the inner shell and the exposed portion of the first portion of the conductive resin form a contiguous surface.

6. The cable assembly of claim 1 , wherein:
the inner shell further includes an injection monitoring region exposing a portion of the first portion of the conductive resin;
a surface of the inner shell in which the injection monitoring region is disposed comprises a first surface area; and
the injection monitoring region comprises a total area that is less than 25% of the first surface area.

7. The cable assembly of claim 1 , wherein the cable end of the inner shell includes two injection gates disposed at opposite lateral ends of the conductor interface.

8. The cable assembly of claim 1 , wherein the second portion of the conductive resin is in contact with the cable end of the inner shell and the cable.

9. The cable assembly of claim 1 , wherein the plug of the connector head is a high definition multimedia interface (HDMI) connector.

10. The cable assembly of claim 1 , wherein the inner shell comprises carbon steel.

11. A method of manufacturing a cable assembly, comprising:
coupling a plurality of conductors disposed in a cable to a conductor interface of a connector head;
encasing a plug of the connector head in an outer shell, the outer shell including a first portion encasing the plug of the connector head and a second portion encasing the conductor interface of the connector head;
encasing the second portion of the outer shell in an inner shell, the inner shell including a connector end encasing the second portion of the outer shell, a cable end encasing a portion of the cable and including an injection gate, and an injection monitoring region disposed between the connector end of the inner shell and the cable end of the inner shell;
injecting conductive resin into the injection gate of the cable end of the inner shell; and
ceasing the injecting of the conductive resin when a first portion of the conductive resin is disposed in the injection monitoring region of the inner shell and a second portion of the conductive resin is disposed inside and outside the cable end of the inner shell.

12. The method of claim 11 , further comprising:
encasing the conductor interface of the connector head, the second portion of the outer shell, the connector end and the cable end of the inner shell, and the first portion and the second portion of the conductive resin with an overmold.

13. The method of claim 11 , further comprising:
coupling a ground bar to shielding of the plurality of conductors and the cable end of the inner shell.

14. The method of claim 11 , further comprising:
applying an inner mold inside the second portion of the outer shell prior to injecting the conductive resin into the injection gate.

15. The method of claim 11 , further comprising:
prior to injecting the conductive resin into the injection gate, placing an injection mold over the cable end of the inner shell leaving the injection monitoring region exposed; and
after injecting the conductive resin into the injection gate, removing the injection mold;
wherein the connector end of the inner shell and the second portion of the conductive resin form a contiguous surface shaped by the injection mold.

Assignees

• Google Llc

Inventors

• Chen Andrew
• Liu Billy
• Fong Hj
• Lee Jay

Classifications

• H01R43/24

  Assembling by moulding on contact members · CPC title

• H01R13/6599 Primary

  Dielectric material made conductive, e.g. plastic material coated with metal · CPC title

• H01R13/65914

  Connection of shield to additional grounding conductors · CPC title

• B29K2995/0005

  Conductive · CPC title

• B29C2045/14557

  coating spliced fibres or cables, e.g. optical fiber splices or junctions · CPC title