Connector Housing Assembly With Friction-Fit Shield Contact
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors face complexity in manufacturing and unreliable electrical contact between the shielding sleeve and contact sleeve due to the need for spot-welding, which complicates assembly and affects the integrity of the electromagnetic shielding.
Innovation Solution
A housing assembly for electrical connectors featuring a shielding sleeve and contact sleeve modules that are frictionally engaged, eliminating the need for welding and ensuring a reliable electrical connection through a design that includes recesses, projections, and press fits, allowing for easy assembly and improved contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spot-welding is used to connect contact sleeve to outer housing, then electrical contact is achieved, but manufacturing complexity increases and assembly becomes more difficult
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a friction-based mechanical engagement system. The contact sleeve is retained in the outer housing through friction engagement created by radial protrusions on the contact sleeve fitting into corresponding recesses in the housing, eliminating the need for spot-welding while maintaining electrical contact reliability.
Solution Approach 2:
The patent introduces intermediate friction engagement features (radial protrusions and recesses) as mediators between the contact sleeve and outer housing. These features facilitate reliable mechanical and electrical connection without requiring direct welding, thus reducing manufacturing complexity while ensuring good electrical contact.
2Reliability
If spot-welding is used to connect contact sleeve to outer housing, then electrical contact is achieved, but assembly time and production complexity increase
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a friction-based mechanical engagement system. The contact sleeve is retained in the outer housing through friction engagement created by radial protrusions on the contact sleeve fitting into corresponding recesses in the housing, eliminating the need for spot-welding while maintaining electrical contact reliability.
Solution Approach 2:
The friction engagement features (protrusions and recesses) are pre-formed during the molding process of the contact sleeve and housing components. This preliminary action during manufacturing allows for rapid assembly without requiring additional welding steps during final assembly, thereby improving productivity while ensuring reliable electrical contact.
3Ease of manufacture
If frictional engagement is used to affix contact sleeve module in shielding sleeve, then manufacturing is simplified and assembly is easier, but electrical contact reliability must be maintained
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a friction-based mechanical engagement system. The contact sleeve is retained in the outer housing through friction engagement created by radial protrusions on the contact sleeve fitting into corresponding recesses in the housing, eliminating the need for spot-welding while maintaining electrical contact reliability.
Solution Approach 2:
The patent applies local quality by creating concentrated friction engagement zones at specific locations (radial protrusions fitting into recesses) rather than relying on uniform friction across the entire contact surface. This localized approach ensures sufficient frictional force for reliable retention and electrical contact while simplifying the overall manufacturing process.
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 solution simplifies manufacturing, ensures reliable electrical contact, and enhances electromagnetic shielding by using a frictionally engaged design that reduces complexity and improves contact integrity.
Implementation Method 1
the at least one contact sleeve module is inserted into the shielding sleeve and affixed in the shielding sleeve in a frictionally engaged manner
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Housing assembly (1) for an electrical connector (38), wherein the housing assembly (1) comprises a shielding sleeve (2) made of electrically conductive material. The shielding sleeve (2) comprises a central receptacle (6) that axially penetrates the shielding sleeve (2) for receiving at least one shielded cable (16). At least one contact sleeve module (4) made of electrically conductive material is inserted into the central receptacle (6). The at least one contact sleeve module (4) comprises at least one passage opening (10) for the at least one shielded cable (16) and is provided with at least one contact section (22) for contacting a shielding (42) of the at least one shielded cable (16) and is frictionally affixed in the shielding sleeve (2) when in the assembled state. The at least one contact sleeve module (4) is provided, at least in the regions in which it is frictionally engaged with the shielding sleeve (2), with projections (30) spaced from one another on its outer circumference (31). In an advantageous embodiment, the projections (30) are configured as ribs, in particular as wave-shaped ribs, which ensure linear contact with the shielding sleeve (2) and, in the case of at least two contact sleeve modules (4), also with one another, for simple and reliable frictional engaged fixation.