Die-Cast Outer Conductor Coupling for Connector Retention

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Solution Overview

Problem

Existing connectors with die-casting outer conductors lack reliable locking mechanisms, leading to concerns about the holding performance of the outer conductor within the housing.

Innovation Solution

A connector design that incorporates an electrically conductive coupling member to securely couple the die-casting outer conductor and the housing, enhancing the holding performance through a combination of mechanical and electrical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a resilient lock is provided on the outer conductor made of die casting, then the holding performance is improved, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improveholding performanceVSAvoidlocking structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent introduces a housing as an intermediary component that provides the resilient lock, rather than adding complex locking structures directly to the die-casting outer conductor. The housing's elasticity enables the locking function, simplifying the overall structure while maintaining holding performance.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the housing is made with a resilient lock, then the holding performance is improved, but the resilient lock may be broken

Engineering Contradiction:

Improveholding performanceVSAvoidlock durability

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent applies local quality by providing the resilient lock function only in specific locations where the housing interacts with the outer conductor, rather than making the entire housing resilient. This concentrates the elastic function where needed while maintaining overall structural integrity.

Inventive Principle:

Principle #3Local quality

3Device complexity

If a simple press-fitting structure is used, then the device complexity is reduced, but the holding reliability is insufficient

Engineering Contradiction:

Improvelocking structureVSAvoidholding performance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The housing's resilient property enables self-service locking, where the housing automatically engages with the outer conductor through its elastic deformation during assembly, eliminating the need for separate locking mechanisms while ensuring reliable holding performance.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS12308555B2Connector including inner conductor, outer conductor, and housing holding the outer conductor

Publication Date: 2025.05.20 SUMITOMO WIRING SYSTEMS LTD

AI summary

A connector is provided with electrically conductive inner conductors, an outer conductor made of die casting and configured to surround the inner conductors, and an insulating housing including a holding recess extending in a vertical direction in a front end of the insulating housing and into which the outer conductor is mounted. A lower end of the holding recess is open in a bottom surface of the front end of the insulating housing. Moreover, the connector further includes a coupling member including a holding protrusion fit into the holding recess from below and configured to couple the outer conductor and the housing to each other.