Electrical Connector Ground Routing to Reduce Width
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Solution Overview
Problem
Existing electrical connectors have a larger left-to-right width due to ground wires being bent on the sides of the metal frame, requiring a larger motherboard or transmission line space for installation.
Innovation Solution
The ground wires are bent at the top and bottom parts of the metal frame, connected to the metal frame, and covered by a fixing base formed through injection molding, with a metal housing and insulating layer to reduce width and enhance noise isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If ground wires are bent on the left side and right side of the metal frame, then noise isolation and ground connection are achieved, but the left-to-right width of the electrical connector increases
Solution Approach 1:
The ground wires are bent from the traditional left-right configuration to a top-bottom configuration, changing the spatial dimension in which the ground isolation function is achieved. This allows the ground wires to extend to the top and bottom surfaces of the metal frame rather than to the left and right sides, thereby reducing the left-to-right width while maintaining noise isolation effectiveness through the metal frame's grounding path.
2Reliability
If ground wires are bent to the left and right sides, then ground connection is established, but the electrical connector requires larger motherboard space for installation
Solution Approach 1:
The ground wire routing is reconfigured from a horizontal (left-right) arrangement to a vertical (top-bottom) arrangement, utilizing the vertical dimension of the metal frame structure. This dimensional change allows the ground connection to be established through the metal frame's top and bottom surfaces, significantly reducing the horizontal footprint required on the motherboard while preserving the electrical ground connection functionality.
3Shape
If ground wires are bent onto the outer coverings of conductive wires, then wire organization is improved, but manufacturing complexity increases
Solution Approach 1:
The ground wires are pre-bent onto the outer coverings of the conductive wires during the cable assembly process before the connector housing is assembled. This preliminary action organizes the wires in a neat, structured manner that simplifies subsequent assembly operations, as the wires are already positioned and secured in their final configuration, reducing the complexity of the overall manufacturing process despite the additional bending step.
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
The new design reduces the left-to-right width of the electrical connector while maintaining effective noise isolation and signal integrity.
Implementation Method 1
a plastic material covers the conductive wires through an injection molding technology to form a fixing base
Data Source
AI summary
An electrical connector manufacturing method includes following steps. At least one conductive-wire set is provided. The conductive-wire set is composed of conductive wires. The conductive wires include core wires and ground wires. A metal frame is installed on the conductive wires. The ground wires are bent and electrically connected onto a top part and a bottom part of the metal frame. A plastic material covers the conductive wires through an injection molding technology. A circuit board is electrically connected to the core wires. At least one metal housing is provided and is installed on the top part of the metal frame. The metal housing is electrically connected to the metal frame and the circuit board. Since the ground wires are bent and electrically connected onto the top part and the bottom part, a left-to-right width of the electrical connector is reduced after the electrical connector is assembled.