Cable Connector Spacer Supporting Copper Foil

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Solution Overview

Problem

The existing USB 3.0 POWER-B cable connector assemblies face issues with the copper foil breaking due to lack of effective support during the over-molding process, which compromises the shielding effect.

Innovation Solution

A cable connector assembly design that includes a spacer with a sustaining portion extending into the slit of the metal case to support the copper foil, ensuring it remains intact during over-molding and maintains the shielding effect.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If copper foil is used to enclose the metal case to enhance shielding effect, then shielding performance is improved, but the copper foil is easily broken during over-molding due to lack of support

Engineering Contradiction:

Improveshielding effectVSAvoidcopper foil integrity

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent introduces a spacer as an intermediary component between the metal case and copper foil. The spacer includes a sustaining portion that extends into the slit to provide support to the copper foil, preventing it from breaking during the over-molding process while maintaining the shielding effect.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The spacer is assembled to the insulative housing before the over-molding process. The sustaining portion of the spacer preliminarily supports the copper foil in position, ensuring it remains intact during subsequent manufacturing steps.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If a slit is formed on the metal case due to manufacturing limits, then manufacturing feasibility is improved, but the slit causes copper foil breakage and reduces shielding effectiveness

Engineering Contradiction:

Improvemetal case fabricationVSAvoidshielding effect

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The spacer acts as a mediator that bridges the gap created by the slit in the metal case. It provides structural support within the slit area, allowing the copper foil to maintain its shielding function despite the presence of the manufacturing-necessary slit.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If insulative member is over-molded around the electrical connector and cable, then structural integration is improved, but the copper foil located at the slit breaks due to lack of support

Engineering Contradiction:

Improvestructural integrationVSAvoidcopper foil integrity

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The spacer is assembled before the over-molding process to preliminarily support the copper foil. This preliminary action ensures that when the insulative member is over-molded, the copper foil remains intact despite the lack of support from the metal case at the slit location.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The spacer provides beforehand cushioning support to the copper foil at the vulnerable slit location, preventing breakage during the over-molding process that would otherwise compromise the shielding effect.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS9419382B2Cable connector assembly with improved spacer

Publication Date: 2016.08.16 FOXCONN INTERCONNECT TECHNOLOGY LTD

AI summary

A cable connector assembly including: a cable including a number of wires, an insulative housing, a number of contacts retained in the insulative housing and soldered to corresponding wires of the cable, a spacer assembled to the insulative housing and retaining respective rear portions of the contacts, a metal case enclosing the insulative housing and having a slit, a copper foil enclosing the metal case and covering the slit, and an insulative member over-molded on the copper foil and a front end of the cable, wherein the spacer defines a sustaining portion extending into the slit for supporting a portion of the copper foil located above the slit.