Compact Connector With Metal Frame For High Force Mating
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Solution Overview
Problem
Existing electrical connectors face challenges in reducing size while maintaining reliability, particularly with high insertion forces that can lead to misalignment and damage during mating, especially with combo connectors having thin housing walls.
Innovation Solution
A connector design featuring a robust metal frame mounted to a thin insulative housing member with interlocking features, such as latches and chamfered edges, to protect the housing from damage and ensure proper alignment during mating, using a frame made of die-cast metal for added strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the housing walls are made thin to reduce connector size, then the connector compactness is improved, but the housing becomes more susceptible to damage during mating
Solution Approach 1:
The connector housing is divided into two distinct parts: a thin insulative member and a separate robust metal frame. The thin insulative member provides compactness and electrical insulation, while the separately attached metal frame provides structural strength and damage protection during mating operations.
Solution Approach 2:
The connector combines two different materials with complementary properties: an insulative material (such as plastic or polymer) for the housing member that enables compact design, and a metallic material for the frame that provides high strength and durability. This composite structure allows both thin walls and high strength to coexist.
2Reliability
If high insertion forces are used to ensure reliable connection, then the connection reliability is improved, but misalignment and damage during mating increase
Solution Approach 1:
The robust metal frame is attached to the insulative member beforehand to create a protective structure that absorbs and distributes insertion forces. This pre-reinforced structure prevents misalignment damage before it can affect the thin housing walls or conductive elements during the mating process.
Solution Approach 2:
The metal frame acts as an intermediary structure between the thin insulative housing member and the external mating forces. It mediates the high insertion forces by providing a strong interface that protects the vulnerable insulative member and conductive elements while still enabling reliable electrical connection.
3Strength
If a robust metal frame is added to protect the housing, then the housing strength is improved, but the device complexity increases
Solution Approach 1:
The metal frame and insulative member are designed to be attached together to form an integrated housing structure. This merging of components achieves robust protection while maintaining a unified connector design that does not significantly increase overall complexity compared to a single-piece housing.
Data Source
AI summary
A compact connector that mates with a complementary connector at high mating force. The connector (100) may have a housing (102) with a member (104) having a plurality of sides (106) and an opening (108) at a first side (110), and a frame (114) mounted to the member (104) from the first side (110) and having a plurality of walls (116) so as to bound the opening (108). The frame (114) may be made of a material that withstands forces to which the connector (100) may be exposed during mating. The member (104) may be made of a less robust material, such as plastic with thin walls (116) so as to enable a compact connector. The frame (114) and the member (104) may have engagement features, including latches, complementary chamfer and bevel features that may aid in mounting the frame (114) to the member (104) and locking features that resist dis-engagement of the frame (114) and the member (104).