Electrical Connector Metal Frame Reinforcement
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Solution Overview
Problem
Existing electrical connectors lack reliability in withstanding large insertion forces and do not offer a simple manufacturing process while maintaining a satisfactory waterproof effect.
Innovation Solution
An electrical connector design featuring an insulative housing with contacts, a metal shield, an insulative cover, and a metal frame with transverse and vertical arms that reinforce the metal shield from three sides, along with a waterproof ring and glue block for enhanced durability and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the metal shield is reinforced to withstand large insertion forces, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The metal frame is nested inside the insulative cover, which itself covers the metal shield. This nested structure allows the reinforcing elements to be integrated within the existing components without adding external complexity, while still providing the necessary structural support to withstand large insertion forces.
Solution Approach 2:
The metal frame extends in multiple dimensions with transverse and vertical arms that reinforce the metal shield from three sides. This multi-dimensional reinforcement approach provides comprehensive structural support without requiring a complete redesign of the connector architecture.
2Strength
If additional reinforcing structures are added to the metal shield, then the strength is improved, but the manufacturing complexity increases
Solution Approach 1:
The metal frame is combined with the insulative cover through insert molding, merging two components into a single integrated assembly. This reduces the number of separate manufacturing steps and assembly operations, thereby improving ease of manufacture while maintaining the reinforcing strength.
Solution Approach 2:
The connector employs composite material construction with a metal frame providing structural reinforcement, an insulative cover providing electrical isolation, and a metal shield providing electromagnetic shielding. This composite approach allows each material to be optimized for its specific function while being manufactured efficiently as an integrated unit.
3Reliability
If the metal shield is reinforced with additional structures, then the reliability is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The metal frame is pre-formed and then inserted into the insulative cover during the molding process. This preliminary preparation of the reinforcing structure allows it to be integrated seamlessly without requiring post-assembly operations, thereby improving reliability while keeping the manufacturing process straightforward.
Solution Approach 2:
The mechanical assembly of the metal frame into the insulative cover is replaced by an insert molding process, where the frame is embedded directly during the molding operation. This substitution eliminates the need for separate mechanical fastening steps, reducing manufacturing process complexity while ensuring reliable integration.
Data Source
AI summary
An electrical connector (100) includes an insulative housing (2), a number of contacts (3) retained in the insulative housing, a metal shield (4) covering the insulative housing for defining a receiving space, an insulative cover (5) insert-molded outside of the metal shield, and a metal frame (6) retained in the insulative cover. The metal frame includes a transverse arm (61) and a pair of vertical arms (62) extending downwardly from two distal ends of the transverse arm for reinforcing the metal shield from three sides of the metal shield.