Cable Connector Assembly Grounding Lug Design
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Solution Overview
Problem
Current cable connector assemblies face challenges in transmitting high currents efficiently due to power loss and heat generation, particularly when trying to maintain a slim and flexible design, as they often require additional components for grounding which complicates assembly.
Innovation Solution
A cable connector assembly that includes an electrical connector with a circuit board and a metal housing connected to a shield layer, where the circuit board has a grounding lug that electrically connects the metal housing for reduced resistance and improved current transmission, allowing for higher current transmission with reduced heat and power loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the diameter of the cable is increased to reduce power loss during high current transmission, then power loss is reduced, but the cable becomes less slim and flexible
Solution Approach 1:
The patent segments the power transmission function by adding a dedicated power ground wire separate from the signal shielding structure. This allows the main cable to remain thin and flexible while the power transmission path uses larger gauge wires for reduced resistance and power loss.
Solution Approach 2:
The patent introduces an additional dimensional element by adding a separate power ground wire that runs parallel to the existing signal wires. This adds a dedicated power return path without increasing the overall cable diameter significantly, maintaining flexibility while reducing power loss through lower resistance connections.
2Reliability
If an extra hook member is added for grounding the shield casing, then grounding effectiveness is improved, but device complexity increases and assembly becomes difficult
Solution Approach 1:
The patent merges the grounding function into the existing connector housing structure by integrating the power ground wire directly into the housing. This eliminates the need for separate hook members or additional grounding components, reducing assembly steps while maintaining effective grounding and shielding.
Solution Approach 2:
The connector housing is designed to serve multiple functions: it provides structural support, houses the shielding, and integrates the power ground wire connection. This multi-functionality eliminates the need for separate dedicated grounding components, simplifying the overall assembly while maintaining grounding effectiveness.
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 solution effectively reduces power circuit resistance, minimizing heat generation and enabling the transmission of higher currents with lower voltage drop and temperature rise, while maintaining a slim and flexible design.
Implementation Method 1
the circuit board has a lug disposed thereon, the lug including a grounding portion, the metal housing electrically connected with the grounding portion of the lug for grounding
Data Source
AI summary
A cable connector assembly includes an electrical connector and a cable connected with the electrical connector, the electrical connector including a mating plug for mating with a mating connector, a circuit board mated with the mating plug and the cable, and a metal housing disposed outside the circuit board, the cable including a plurality of core wires and a shield layer disposed outside thereof, the metal housing electrically connected with the shield layer. The circuit board has a lug disposed thereon that has a grounding portion, the metal housing electrically connected with the grounding portion of the lug for grounding.