Electrical Connector Central Grounding Plate Structural Integrity
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Solution Overview
Problem
Existing electrical connectors have low engagement force and structural strength due to inadequate design, which limits their effectiveness in connecting mating connectors.
Innovation Solution
The electrical connector design includes a housing assembly with a first and second terminal module, a grounding plate, and an outer shell, featuring engagement columns on the first tongue and locking holes on the second tongue that are stamped for firm engagement, along with ultrasonic welding of protrusions to enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the electrical connector uses a simple terminal module structure, then the device complexity is reduced, but the engagement force and structural strength are insufficient
Solution Approach 1:
The electrical connector is divided into multiple terminal modules (first terminal module and second terminal module), each with its own body and terminals. This segmentation allows each module to be optimized independently for strength while maintaining overall connector functionality, resolving the contradiction between structural strength and device complexity.
Solution Approach 2:
The first terminal module and second terminal module are nested within a common housing assembly, with the grounding plate interposed between them. This nested structure provides structural strength through the combined assembly while keeping individual modules relatively simple, addressing the contradiction between strength and complexity.
2Force
If the electrical connector uses a simple connection method, then the ease of manufacture is improved, but the engagement force between terminal modules is insufficient
Solution Approach 1:
The engagement columns are pre-formed on the first terminal module body, and the locking holes are pre-formed on the second terminal module body before assembly. This preliminary preparation allows for strong engagement force through stamping and ultrasonic welding while maintaining ease of manufacture by avoiding complex assembly operations during final assembly.
Solution Approach 2:
The patent replaces traditional mechanical fastening methods with ultrasonic welding to join the engagement columns to the locking holes. This substitution provides superior engagement force while actually simplifying the assembly process, as ultrasonic welding is a rapid, automated process that eliminates the need for screws, clips, or other mechanical fasteners.
3Reliability
If the electrical connector lacks a grounding plate, then the device complexity is reduced, but the signal integrity and EMC performance deteriorate
Solution Approach 1:
The grounding plate serves multiple functions simultaneously: it provides electrical grounding for signal reference, acts as a shield for EMC protection, and serves as a structural element within the housing assembly. This multi-functionality improves signal integrity and reliability while minimizing the increase in device complexity, as a single component accomplishes multiple goals.
4Strength
If the electrical connector uses traditional joining methods, then the ease of manufacture is maintained, but the structural strength and engagement force are insufficient
Solution Approach 1:
The patent replaces traditional mechanical joining methods (such as screws, rivets, or clips) with ultrasonic welding and stamping processes. These methods create stronger, more reliable joints between the engagement columns and locking holes while actually simplifying the manufacturing process through automation and elimination of multiple fastening components.
Solution Approach 2:
The patent changes the physical state and properties of the engagement columns through ultrasonic welding, creating a metallurgical bond that is stronger than mechanical fastening. This parameter change in the joining method (from mechanical to thermal/metallurgical) dramatically improves structural strength while maintaining ease of manufacture through process integration.
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 significantly increases the engagement force and structural strength of the electrical connector, preventing cracking and improving signal integrity and EMC performance.
Implementation Method 1
The at least one engagement column can correspondingly be inserted into the at least one locking hole and then can be stamped so that the first tongue and the second tongue are firmly engaged together
Implementation Method 2
ultrasonic welding of protrusions to enhance structural integrity
Data Source
AI summary
An electrical connector comprises a housing assembly and an outer shell surrounding the housing assembly, the housing assembly comprises a first terminal module and a second terminal module; the first terminal module comprises a first body and a group of first terminals fixed to the first body, the first body has a first tongue; the second terminal module comprises a second body and a group of second terminals fixed to the second body, the second body has a second tongue; the first body and the second body oppose each other and are fixed together by at least one engagement column in the first tongue that is locked to at least one locking hole in the second tongue.