Interface Connector Ground Path Welding in Cutout Housing
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Solution Overview
Problem
Existing interface connectors face difficulties in forming a ground path due to a small abutting area between the metal plate and housing, making it challenging to weld them together effectively.
Innovation Solution
The interface connector design includes a housing with cutouts of varying thicknesses and a contact assembly where the metal plate protrudes from an insulating member to be welded to a flat part of the housing, facilitating easy formation of a ground path through insert-molding and welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the metal plate protrudes from the insulating member to abut the housing, then a ground path can be formed, but the abutting area is small making welding difficult
Solution Approach 1:
The housing is pre-formed with a protrusion that extends into the cutout, creating a preliminary structural feature that guides and supports the metal plate positioning before welding occurs. This preliminary action ensures proper alignment and increases the effective abutting area during the welding process
Solution Approach 2:
The housing structure is designed with localized variations in thickness and geometry - specifically a protrusion with different thickness regions (first thickness larger than second thickness) - to create optimal welding surfaces in specific locations while maintaining overall structural integrity
2Area of stationary object
If the housing is designed with varying thickness parts, then welding surface area is increased, but manufacturing complexity increases
Solution Approach 1:
The protrusion structure combining multiple thickness regions is integrated directly into the housing body as a single formed feature rather than separate components. This merging approach increases the welding surface area while avoiding the complexity of assembling multiple separate housing parts
Solution Approach 2:
The protrusion structure serves multiple functions simultaneously: it provides the welding surface for the metal plate, acts as a positioning feature for the contact assembly, and maintains structural support for the housing. This multi-functionality reduces the need for additional separate features
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 allows for the easy formation of a ground path, enhancing electrical connectivity and reducing manufacturing complexity.
Implementation Method 1
insert-molding contacts including first electric contacts electrically connected to the connection connector and second electric contacts electrically connected to the connection substrate and a metal plate into an insulating member to form a contact assembly
Implementation Method 2
welding a protruding part of the metal plate protruded from the insulating member in a width direction of the housing to a first flat part of a cutout of the housing
Data Source
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AI summary
An interface connector where a ground path can be easily formed is provided. An interface connector (1) according to the present disclosure includes a housing (11) and a contact assembly (13). The housing (11) is a shell block including a plurality of parts having different thicknesses and has a cutout (11b) which accommodates the contact assembly (13). The contact assembly (13) includes contacts, a metal plate, and an insulating member (24) that holds the contacts and the metal plate. A protruding part of the metal plate protruded from the insulating member (24) is welded to a first flat part (11g) of the cutout (11b) of the housing (11) in a state in which the protruding part of the metal plate is placed on the first flat part (11g) of the cutout (11b) of the housing (11).