Differential-Strength Connector Structure for Compact Engagement
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Solution Overview
Problem
Existing connectors face challenges in maintaining robustness during size and height reduction, as components like metal fittings and insulators tend to break easily upon engagement due to uniform strength distribution, making it difficult to enhance strength selectively and prevent breakage.
Innovation Solution
A connector design featuring separate first and second metal fittings with different strengths, attached to an insulator with distinct engagement and peripheral wall structures, allowing for differential material selection and thickness to enhance robustness without compromising electrical continuity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the connector size and height are reduced, then the electronic apparatus weight and size are reduced, but the connector components become more prone to breaking during engagement
Solution Approach 1:
The patent applies local quality by making the metal fitting have non-uniform thickness, with a first thickness at the engagement projection area and a second thickness at the peripheral wall area, where the thickness ratio is between 0.5 and 2.0. This allows different regions of the same component to have different strength levels, providing enhanced protection to critical areas while maintaining overall size reduction.
2Strength
If the metal fitting strength is increased to prevent breakage, then the connector robustness is improved, but the connector size and height cannot be reduced
Solution Approach 1:
The metal fitting is designed with localized thickness variations rather than uniform thickening, allowing strength enhancement only where needed during engagement while maintaining overall compact dimensions.
Solution Approach 2:
The connector combines different materials with complementary properties: the insulator provides structural support and electrical insulation, while the metal fitting provides electrical conductivity and mechanical strength at critical interfaces, achieving robustness through material synergy rather than sheer size.
3Reliability
If the connector components are made more robust, then the breakage risk is reduced, but the manufacturing complexity increases
Solution Approach 1:
The non-uniform thickness design is achieved through efficient molding processes that can create variable thickness profiles in a single manufacturing step, avoiding the need for complex assembly of multiple components and maintaining manufacturing simplicity.
Data Source
AI summary
According to the present disclosure, a connector (10) configured to engage a connection object (50) includes i) an insulator (20) including an engagement projection (22) and a peripheral wall (23) surrounding the engagement projection (22), ii) a first metal fitting (40a) attached to the engagement projection (22), and iii) a second metal fitting (40b) attached to the peripheral wall (23). The first metal fitting (40a) and the second metal fitting (40b) are separate members. A strength of the first metal fitting (40a) and a strength of the second metal fitting (40b) are different from each other.