Electrical Connector Double Metal Shell Grounding
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Solution Overview
Problem
Existing electrical connectors face issues with smooth insertion and structural strength due to dimension control limitations in metal shell manufacturing, leading to potential cracking and unnecessary soldering leg increases.
Innovation Solution
The electrical connector design features a metal inner shell forming a first frame with wing plates, a metal outer shell forming a second frame with soldering legs, and an insulating outer shell with a receiving cavity, ensuring secure engagement and grounding, while reducing electromagnetic leakage through a double surrounding metal shell structure and precise insertion opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If metal shell is formed by traditional punching process, then manufacturing is simpler, but dimensional precision is poor causing insertion problems and cracking
Solution Approach 1:
The metal shell is divided into an inner shell and an outer shell that are assembled together. The inner shell provides precise dimensional control for the insertion opening, while the outer shell provides structural strength. This segmentation allows each component to be optimized for its specific function, resolving the contradiction between precision and ease of manufacture.
Solution Approach 2:
The inner shell is nested within the outer shell, with the inner shell's precise insertion opening formed by the outer shell's inner surface. This nested structure enables the precise insertion opening to be achieved without requiring complex punching processes, as the precision is provided by the molded outer shell rather than metal forming.
2Reliability
If soldering legs extend from rear portion of metal shell for grounding, then grounding is provided, but soldering pads on circuit board increase unnecessarily
Solution Approach 1:
The grounding function is extracted from the metal shell's soldering legs and transferred to the insulating outer shell's grounding legs. This allows the metal shell to focus on its primary structural and shielding functions, while the grounding function is provided separately through the insulating shell's integrated grounding legs, reducing the need for additional soldering pads on the circuit board.
Solution Approach 2:
The insulating outer shell is designed to provide multiple functions: it provides insulation, structural support, and grounding capability through its integrated grounding legs. This multi-functionality eliminates the need for separate grounding components and reduces circuit board complexity while maintaining reliable grounding.
3Object-affected harmful factors
If single metal shell structure is used, then structure is simpler, but electromagnetic leakage increases and structural strength decreases
Solution Approach 1:
The metal shell is segmented into an inner shell and an outer shell that work together to provide electromagnetic shielding. The inner shell provides the primary shielding layer, while the outer shell provides additional shielding and structural support. This segmentation improves electromagnetic leakage protection while distributing the structural requirements across two components.
Solution Approach 2:
The connector uses a composite structure combining metal inner shell, metal outer shell, and insulating outer shell. This composite design provides both electromagnetic shielding (through the metal shells) and insulation (through the insulating shell), reducing electromagnetic leakage while maintaining structural strength through the combination of different materials.
Data Source
AI summary
An electrical connector has an insulating body which comprises a housing and a tongue; a plurality of conductive terminals, each conductive terminal has a mating portion and a soldering portion; a metal inner shell which surrounds to form a first frame, the first frame is fixed on the insulating body and surrounds a rear portion of the tongue to form a mating cavity; a metal outer shell which surrounds to form a second frame, the second frame encircles an outside of the first frame, a plurality of soldering legs extend out from two sides of the metal outer shell; and an insulating outer shell which is engaged with the metal outer shell integrally, a rear portion of the insulating outer shell is formed with a receiving cavity; the metal inner shell is correspondingly inserted in the receiving cavity, the insulating outer shell surrounds a front portion of the tongue and forms an insertion opening, the insertion opening is integrally communicated with the mating cavity along a front-rear direction. The present disclosure can increase the overall structure strength and facilitate the smooth insertion of another mating connector.