Electrical Connector Forward Stopper Retention
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Solution Overview
Problem
Existing electrical connectors face issues with strong rearward movement of the contact module during mating due to high insertion forces, leading to inadequate retention between the shell and the contact module.
Innovation Solution
The electrical connector design includes a metallic inner shell with a mating cavity and a metallic outer shell featuring a rear cover with abutment sections that prevent rearward movement of the contact module, combined with securing grooves and legs for stable positioning within the inner and outer shells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the contact module is retained within the inner shell using conventional securing structures, then the assembly is simple, but the retention force is insufficient to resist high insertion forces during mating
Solution Approach 1:
The patent introduces a rearward extension of the inner shell that protrudes into the rear cover of the outer shell, creating a new dimensional feature for retention. This third-dimensional protrusion structure provides additional retention force against insertion forces without significantly increasing overall structural complexity
Solution Approach 2:
The retention mechanism is segmented into multiple components: the conventional securing structures on the inner and outer shells, plus the additional rearward extension of the inner shell. This segmentation allows each component to contribute to retention force independently, providing cumulative strength
2Reliability
If the inner shell and outer shell both have securing structures for retaining the contact module, then the retention is improved, but the structure becomes more complex
Solution Approach 1:
The patent merges the retention functions of the inner shell and outer shell by having both components provide securing structures. The inner shell has securing structures that engage with the contact module, while the outer shell also has securing structures that engage with the contact module, creating a combined retention system that improves reliability
Data Source
AI summary
An electrical connector includes a contact module enclosed within a metallic inner shell, and a metallic outer shell attached upon the inner shell. The contact module includes an insulator and a plurality of terminals integrally formed with the insulator. The insulator includes a base and a tongue portion extending forwardly from the base. The inner shell forms a mating cavity in which the tongue portion extends. The outer shell forms a main body covering the inner shell and a rear cover extending rearwardly from the main body to cover the rear side of the base. The rear cover further includes at least an abutment section forwardly extending toward the base and abutting against a rear face of the base so as to prevent further rearward movement of the contact module relative to the inner shell.