Electrical Connector Protruding Metal Shell Fit Clearance
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Solution Overview
Problem
Existing electrical connectors often experience issues with loose or tight fits, leading to unstable connections, wear, and interference, which affect both the appearance and electrical performance, and make insertion and removal difficult.
Innovation Solution
The electrical connector design includes a metal shell with protruding portions that control the fit clearance between the connector and mating parts, ensuring a stable and secure connection while allowing easy insertion and removal, by adjusting the height and positioning of these protrusions to minimize shaking and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the clearance between the shielding shell and the metal shell is increased to allow easy insertion and removal, then the ease of operation is improved, but the connection becomes unstable and the plug connector shakes at high amplitude
Solution Approach 1:
The patent applies parameter changes by precisely controlling the height of protruding portions on the metal shell (0.02-0.08mm) to optimize the clearance between the shielding shell and metal shell. This parameter optimization allows the connector to be easily inserted and removed while maintaining stable connection, resolving the contradiction between ease of operation and connection stability.
2Reliability
If the fit between the plug connector and the socket connector is made tighter to improve connection stability, then the reliability is improved, but the ease of operation deteriorates and the shielding shell surface is easily worn
Solution Approach 1:
The patent optimizes the height parameter of protruding portions (0.02-0.08mm) to achieve the optimal fit between connectors. This parameter control ensures stable connection while preventing excessive tightness that would cause wear and difficult insertion, resolving the contradiction between reliability and ease of operation.
3Reliability
If the protruding portions on the metal shell are increased in height to reduce clearance and stabilize connection, then the reliability is improved, but the manufacturing precision requirements increase and material costs increase
Solution Approach 1:
The patent establishes an optimal height range (0.02-0.08mm) for protruding portions that achieves connection stability without excessive manufacturing precision requirements. This parameter optimization balances reliability improvement with manufacturability, avoiding the need for extremely precise or costly manufacturing processes.
Data Source
AI summary
An electrical connector includes an insulating body having a base and a tongue extending forward from the base, multiple terminals fixed in the base and extending to the tongue, and a metal shell. An insertion space is formed between the metal shell and the tongue. The metal shell has first protruding portions protruding toward the insertion space. Each first protruding portion has a first height along the vertical direction. The first height is greater than or equal to 0.02 mm and less than or equal to 0.08 mm. Thus, the corresponding fit clearance in the vertical direction between the electrical connector and a mating connector can be controlled within a range from 0.059 mm to 0.001 mm.