Angled Cable Connector Housing for Compact High-Strength Assembly
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Solution Overview
Problem
Existing electrical connectors, such as those disclosed in China Patent No. 217281302U, are not strong enough for automotive and industrial applications, necessitating an improvement in structural design for enhanced durability and performance.
Innovation Solution
An angled cable connector design featuring a wire cable component with an inner and outer conductor, a first outer housing with a lower and rear end face, and a second outer housing with a hollow barrel and rear cover, assembled via laser welding for enhanced structural integrity, using materials like PBT-I-GF30 and opaque insulating materials with light absorption properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a stamping process is used to make the shielding shell, then the production cost is reduced and the size is minimized, but the structural strength is insufficient for automotive and industrial applications
Solution Approach 1:
The connector is divided into multiple components: a thermoplastic housing, a metal shield, and a cable assembly. The metal shield is segmented into a barrier shield and a drain shield, each performing specific functions. This segmentation allows each part to be optimized for its specific role while maintaining overall structural integrity.
Solution Approach 2:
The connector combines different materials with complementary properties: thermoplastic material for the housing (providing insulation and structural form), metal material for the shield (providing electromagnetic shielding and structural strength), and conductive material for the cables (providing electrical connection). This composite structure resolves the contradiction by allowing the metal shield to provide the necessary strength while the thermoplastic housing provides cost-effective manufacturing.
2Device complexity
If a stamping process is used to make the shielding shell, then the manufacturing complexity is reduced, but the durability is insufficient for harsh environments
Solution Approach 1:
The connector is divided into multiple components: a thermoplastic housing, a metal shield, and a cable assembly. The metal shield is segmented into a barrier shield and a drain shield, each performing specific functions. This segmentation allows each part to be optimized for its specific role while maintaining overall structural integrity.
Solution Approach 2:
The connector combines different materials with complementary properties: thermoplastic material for the housing (providing insulation and structural form), metal material for the shield (providing electromagnetic shielding and structural strength), and conductive material for the cables (providing electrical connection). This composite structure resolves the contradiction by allowing the metal shield to provide the necessary strength while the thermoplastic housing provides cost-effective manufacturing.
3Volume of stationary object
If the connector size is minimized, then the space requirement is reduced, but the structural strength is compromised
Solution Approach 1:
The connector employs a nested structure where the metal shield is positioned within the thermoplastic housing, and the cable assembly is routed through the housing. The barrier shield and drain shield are nested concentrically, with the drain shield surrounding the barrier shield. This nesting maximizes the use of internal space while maintaining a compact external dimensions.
Solution Approach 2:
The connector combines different materials with complementary properties: thermoplastic material for the housing (providing insulation and structural form), metal material for the shield (providing electromagnetic shielding and structural strength), and conductive material for the cables (providing electrical connection). This composite structure resolves the contradiction by allowing the metal shield to provide the necessary strength while the thermoplastic housing provides cost-effective manufacturing.
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 angled connector provides improved structural strength and durability, suitable for automotive and industrial applications, while maintaining a compact size and potentially offering waterproof capabilities.
Implementation Method 1
an opaque insulating material with light absorption properties
Implementation Method 2
assembled via laser welding for enhanced structural integrity
Data Source
AI summary
An angled cable connector includes: a wire cable component having an inner conductor, an outer conductor, and a cable electrically connected with the inner conductor; a first outer housing; and a second outer housing; the first outer housing and the second outer housing cooperate with each other and form a complete outer housing to receive the wire cable component; the first outer housing has a lower end face facing downward and a rear end face facing rearward, and the second outer housing comprises a hollow barrel portion through which the cable passes and a rear cover extending upward from a rear part of the barrel portion, the barrel portion abutting the lower end face and the rear cover forwardly abutting the rear end face in a front and rear direction; and a mating edge of the first outer housing and the second outer housing is L-shaped.