Electrical Connector With Embedded Metallic Bracket
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Solution Overview
Problem
Existing electrical connectors require labor-intensive and costly soldering of inner and outer metallic shells, which can lead to improper interference during signal transmission due to direct metallic contact in the mating cavity.
Innovation Solution
An electrical connector design featuring an insulative shell with a metallic reinforcement bracket embedded within, forming both the mating cavity and mounting legs, allowing for insert-molding to simplify manufacturing and prevent interference, with a contact module assembled into the mating case for plug mating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If inner and outer metallic shells are soldered together, then structural strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the inner metallic shell and outer metallic shell into a single integrated metallic shell structure. The mounting legs extend from the same metallic shell that forms the mating cavity, eliminating the need for separate shells and soldering operations. This integration maintains structural strength while significantly simplifying manufacturing.
Solution Approach 2:
The single metallic shell serves multiple functions: it provides structural support, forms the mating cavity for connector engagement, and includes integrated mounting legs for PCB attachment. This multi-functionality replaces the previous multi-component design, reducing assembly steps and manufacturing complexity.
2Stability of the object's composition
If inner and outer metallic shells are soldered together, then structural integrity is improved, but manufacturing cost increases
Solution Approach 1:
The patent combines what were previously two separate metallic shells into one monolithic structure. This single metallic shell is molded as one piece with integrated mounting legs, eliminating the soldering process entirely. The structural integrity is maintained through the unified design while manufacturing costs decrease due to reduced labor and material waste.
Solution Approach 2:
The patent extracts the soldering operation from the manufacturing process by designing a structure that achieves structural integrity through integrated molding rather than post-assembly joining. This eliminates the need for soldering materials and the associated labor costs while maintaining the required structural strength.
3Ease of manufacture
If inner metallic shell directly faces mating cavity, then manufacturing is simplified, but signal interference occurs
Solution Approach 1:
The patent introduces an insulating material as an intermediary layer between the metallic shell and the mating cavity. This insulating layer is molded into the metallic shell structure, creating a barrier that prevents signal interference while allowing the metallic shell to maintain its simplified single-piece construction. The insulating material acts as a mediator that preserves both manufacturing simplicity and electrical performance.
4Strength
If separate inner and outer shells are used, then structural support is improved, but assembly complexity increases
Solution Approach 1:
The patent merges the separate inner and outer shells into a single metallic shell component with integrated mounting legs. This unified structure provides the necessary structural support through its monolithic construction, eliminating the need for assembly operations to join multiple shell components. The structural support function is maintained while assembly complexity is reduced to zero for the shell assembly.
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
This design simplifies manufacturing, prevents signal interference, and enhances waterproofing by using an insulative shell with a metallic reinforcement bracket, reducing labor and costs while ensuring proper connector functionality.
Implementation Method 1
an insulative shell forms opposite inner and outer surfaces wherein the inner surface forms a mating cavity... and the bracket is essentially located between the outer surface and the inner surface
Implementation Method 2
the metallic reinforcement bracket is insert-molded within the insulative shell to commonly form the mating case
Data Source
AI summary
An electrical connector includes a contact module and a mating/outer case enclosing the contact module. The mating case includes an insulative shell with a metallic reinforcement bracket embedded therein. The insulative shell forms opposite inner and outer surfaces wherein the inner surface forms a mating cavity for receiving a complementary plug connector therein, and the bracket is essentially located between the outer surface and the inner surface except the corresponding mounting legs extending out of the insulative shell for mounting to a printed circuit board.