Electrical Connector Rear-Wall Opening to Reduce Cable Compression
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Solution Overview
Problem
The miniaturization of electrical connectors reduces the reliability due to excessive compression of the cable by the second insulating body, which affects the stability and integrity of the connection.
Innovation Solution
The design includes a rear wall with an opening communicating with a filling cavity, where the cable's longitudinal portion extends into, and a filling block encapsulates the connection point, reducing cable compression and enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the second insulating body is designed to press against the cable as much as possible to shorten the overall length, then the overall length is reduced, but the reliability of the electrical connector is greatly reduced
Solution Approach 1:
The patent introduces a filling cavity and filling block that segment the internal space of the second insulating body. The filling block is specifically positioned to fill the space between the cable and the rear wall, separating the cable from direct compression by the insulating body walls. This segmentation allows the overall length to be shortened while the filling block prevents excessive compression of the cable, maintaining reliability.
2Volume of moving object
If the second insulating body compresses the cable excessively to minimize overall length, then miniaturization is achieved, but the connection stability is compromised
Solution Approach 1:
The filling block acts as an intermediary element between the cable and the rear wall of the second insulating body. It mediates the spatial relationship by occupying the void space, preventing the cable from being directly compressed by the insulating body walls. This intermediary structure maintains connection stability while enabling miniaturization of the overall connector volume.
3Device complexity
If the cable connection position is placed in a compact arrangement to reduce size, then miniaturization is achieved, but the risk of loosening or detachment increases
Solution Approach 1:
The filling block provides beforehand cushioning by pre-occupying the space between the cable connection position and the rear wall. This prevents any potential loosening or detachment by maintaining constant supportive contact with the cable, even in the compact miniaturized structure. The filling block acts as a protective cushion that compensates for the reduced structural margin in miniaturized designs.
Data Source
AI summary
An electrical connector includes a first insulating body, a conductive unit, a cable and a second insulating body. The cable includes a transverse portion fixed to the conductive unit and a longitudinal portion bent from the transverse portion. The second insulating body includes a rear wall. The electrical connector includes a filling cavity between the first insulating body and the rear wall. A connection position of the cable and the conductive unit is located in the filling cavity. The rear wall includes an opening communicating with the filling cavity. The longitudinal portion of the cable at least partially corresponds to the opening, so as to reduce the compression of the cable by the rear wall and improve reliability. The electrical connector includes a filling block filled in the filling cavity. A method for manufacturing the electrical connector is also disclosed.