Electrical Connector Assembly Segmentation for Case Aperture
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Solution Overview
Problem
The assembly of electrical connector assemblies is hindered by the length of wires requiring extended assembly times and the difficulty in mating pin terminals with PCB contacts due to the entire assembly being fixed from the outside, leading to increased time and complexity.
Innovation Solution
The method involves an outer connector with a flange and attachment holes, an electromagnetic shield with ground and retention tabs, and an inner connector with alignment and retention features, allowing for efficient assembly by positioning and securing the components from the outside while ensuring proper orientation and electrical grounding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the conductor is a wire that is fed through an aperture in the case, then the electrical connector assembly can be assembled, but the assembly time is extended due to the time required to feed the wire through the aperture
Solution Approach 1:
The electrical connector assembly is divided into two separate assemblies: a first electrical connector assembly attached to the outside of the case, and a second electrical connector assembly attached to the inside of the case. The conductor connects these two separate assemblies, eliminating the need to feed the conductor through the case aperture during assembly. This segmentation allows each assembly to be constructed independently and attached separately, significantly reducing assembly time and complexity.
2Productivity
If the entire electrical connector assembly is fixed to the case from the outside, then the assembly is secure, but it becomes difficult and time consuming to mate the pin terminal to the electrical contact of the PCB
Solution Approach 1:
The electrical connector assembly is segmented into an outer connector portion that is fixed to the case from the outside, and an inner connector portion that remains accessible from the inside for mating with the PCB. This segmentation allows the outer assembly to be securely attached while the inner assembly remains accessible for easy mating operations.
Solution Approach 2:
The conductor acts as an intermediary element that connects the first electrical connector assembly (attached to the outside of the case) with the second electrical connector assembly (attached to the inside of the case). This intermediary approach allows secure external attachment while maintaining internal accessibility for PCB mating, eliminating the contradiction between secure fixation and ease of mating.
Data Source
Figure 1
Figure 1A~2
Figure 3
AI summary
A method is provided for assembling a connector assembly (10, 110) to a case (12, 112). The case (12, 112) includes an inside surface (14, 114) defining an inside of the case (12, 112), an outside surface (16, 116) defining an outside of the case (12, 112), and an aperture (18, 118) therethrough providing communication from the inside surface (14, 114) to the outside surface (16, 116). The connector assembly (10, 110) includes an outer connector (20, 120) having a body (30, 130) with a passage (36, 136) therethrough, an electromagnetic shield (24, 124), and an inner connector (22, 122) with a terminal (74, 174) therein with a conductor (75, 175) extending from the inner connector (22, 122) in electrical communication with the terminal (74, 174). The method includes positioning the outer connector (20, 120) on the outside of the case (12, 112) to align the passage (36, 136) of the outer connector (20, 120) with the aperture (18, 118) of the case (12, 112). The method also includes positioning the inner connector (22, 122) on the inside of the case (12, 112). The method also includes inserting the inner connector (22, 122) into the passage (36, 136) of the outer connector (20, 120) from the inside of the case (12, 112).