Multi-piece Backshell Jackscrew Fastening Design
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Solution Overview
Problem
Traditional electrical connector assemblies with two-piece backshells require additional mechanical fasteners like threaded screws, which increase assembly time, cost, and are prone to reliability issues due to their small size and tendency to strip during assembly.
Innovation Solution
A backshell design that uses a jackscrew and guide pin as fasteners to secure the upper and lower shells together, eliminating the need for additional threaded fasteners by utilizing existing components for multiple functions, such as securing and guiding the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional threaded screws are used to secure the upper and lower shell halves, then the backshell can be assembled, but the part count increases and assembly time increases
Solution Approach 1:
The patent combines the fastening function with the existing shell structure by integrating a fastening member that is formed as an integral part of either the upper or lower shell half. This eliminates the need for separate traditional screws, reducing part count while maintaining the backshell assembly's structural integrity and reliability.
Solution Approach 2:
The integrated fastening member serves multiple functions: it provides structural support as part of the shell and simultaneously performs the fastening function to secure the upper and lower shell halves together. This multi-functionality reduces the overall component count and simplifies the assembly structure.
2Reliability
If traditional threaded screws are used to secure the upper and lower shell halves, then the backshell can be assembled, but assembly time increases
Solution Approach 1:
By integrating the fastening member as an integral part of the shell structure, the patent eliminates the need for separate fastening operations. The shell halves can be directly assembled without additional steps for installing traditional screws, significantly reducing assembly time while maintaining assembly reliability.
Solution Approach 2:
The fastening member is pre-formed as an integral part of the shell during manufacturing, rather than being added as a separate component during assembly. This preliminary integration eliminates the need for additional fastening operations during the assembly process, reducing assembly time while ensuring reliable connection.
3Device complexity
If small threaded screws are used to secure the upper and lower shell halves, then the overall size of the shells is not unnecessarily increased, but the screws tend to strip easily during assembly
Solution Approach 1:
The patent integrates the fastening function into the shell structure itself, eliminating the need for separate small screws. The integrated fastening member provides sufficient fastening strength without requiring additional threaded bores, maintaining the compact size of the backshell while avoiding the reliability issues of small separate fasteners.
Solution Approach 2:
The fastening member features a curved or angled configuration that allows it to engage with the opposing shell half at an optimal angle, distributing stress more effectively and preventing the stripping issues associated with small straight screws. The curved design maintains compact dimensions while improving fastening reliability.
Data Source
AI summary
A backshell includes an upper shell, a lower shell and a fastener coupled to the upper shell and coupled to the lower shell to hold the upper shell and the lower shell together and resist separation of the upper shell from the lower shell. The upper shell defines a portion of a cavity of the backshell and includes a top wall and an upper shell side wall extending from the top wall to a bottom of the upper shell. The lower shell defines another portion of the cavity of the backshell. The lower shell includes a bottom wall and a lower shell side wall extending from the bottom wall to a top of the lower shell. The top of the lower shell generally mates with the bottom of the upper shell at a mating plane. The fastener extends along a longitudinal axis generally parallel to the mating plane.