Compact Electrical Connector Shell With Integral Latch Arms
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Solution Overview
Problem
Existing electrical connectors face challenges in achieving high reliability and compactness, particularly in small form factors, due to limitations in traditional manufacturing methods that hinder complex design features.
Innovation Solution
The use of additive manufacturing techniques, such as stereolithography and selective laser sintering, allows for the creation of integral shell designs with innovative latch arm and soldering pin/fin structures, enhancing retention force and reducing the connector's footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods are used, then manufacturing simplicity is maintained, but manufacturing precision and design complexity are limited
Solution Approach 1:
The shell and latch arms are merged into a single integral component manufactured via additive manufacturing. This integration enables complex geometries and precise features that would be difficult to achieve with traditional separate-part manufacturing methods, directly resolving the contradiction between manufacturing precision and design complexity.
Solution Approach 2:
The patent employs additive manufacturing parameters (layer thickness, infill density, material selection) to achieve precise dimensional control and complex geometries. This manufacturing parameter change enables high manufacturing precision while accommodating design complexity that traditional methods cannot achieve.
2Volume of moving object
If connector size is reduced for compactness, then volume is decreased, but reliability may be compromised
Solution Approach 1:
The latch arms are nested within the shell structure, with the contact blocks positioned within the opening. This nesting arrangement maximizes the use of internal space, achieving compact volume while maintaining functional integrity and reliability through proper structural integration.
Solution Approach 2:
By integrating the latch arms and shell into a single piece, the patent eliminates potential failure points from assembly interfaces while maintaining compact dimensions. The integral structure ensures reliable latch engagement despite the reduced overall size.
3Ease of operation
If latch arm flexibility is increased for easier engagement, then ease of operation improves, but retention force may be reduced
Solution Approach 1:
The latch arms feature localized flexibility at the tip region for easy engagement, while the base region maintains higher stiffness for strong retention. This spatial variation in mechanical properties, achieved through additive manufacturing geometry optimization, simultaneously provides ease of operation and adequate retention force.
Solution Approach 2:
The latch arms are designed with dynamic characteristics that allow flexible deflection during insertion and engagement, then transition to a stable retained position. The additive manufacturing process enables optimized cross-sectional geometry that provides the necessary dynamic response for both easy operation and strong retention.
Data Source
AI summary
An electrical connector assembly includes an electrical connector. The electrical connector includes a shell, contact block and at least one electrical contact. The shell includes an opening at a first end, and a channel extending from the opening and toward a second end. The shell includes one or more latch arms that extend from an anchor and continue toward the first end to a tip. The latch arms have a contact region at an intermediate position between the anchor and the tip and are flexible about the anchor and flexible about the contact region in response to the contact region engaging a contact portion of the shell. The contact block is positioned at least partially within the opening and includes a mating interface. The shell may also include a mounting fin having ridges that cooperate with the mounting fin to form a solder channel when mounted to a circuit board.