Compact Connector Shell Structure for Twist-Resistant Mating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Miniaturized electrical connectors are prone to damage from off-axis forces during mating and are at risk of inadvertent disconnection due to twisting and external forces, leading to signal integrity issues and costly troubleshooting.
Innovation Solution
The design features a shell with conforming and spaced-apart portions that guide proper alignment and secure the plug connector, preventing misalignment and twisting, and includes hook portions to engage with the housing edge, ensuring reliable mating and reducing the risk of damage during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the connector is miniaturized to reduce size, then the volume of the connector is reduced, but the connector becomes more prone to damage from off-axis forces during mating
Solution Approach 1:
The shell is divided into multiple functional portions: conforming portions that contact the housing, spaced-apart portions that create alignment spaces, and hook portions that engage with the housing edge. This segmentation allows each portion to independently address specific protection needs, enabling the compact connector to resist off-axis forces effectively despite its small size.
Solution Approach 2:
The shell portions are pre-configured to counteract potential misalignment and twisting forces before they can damage the connector. The conforming portions preemptively guide alignment, while the hook portions prepare to engage and prevent twisting, thus preventing damage before it occurs during the mating process.
2Device complexity
If the connector design is simplified to reduce complexity, then the device complexity is reduced, but the connector becomes susceptible to inadvertent disconnection due to twisting and external forces
Solution Approach 1:
The shell serves multiple functions simultaneously: it provides structural support, guides alignment through conforming portions, creates alignment spaces through spaced-apart portions, and prevents twisting through hook portions. This multi-functionality allows a single component to address multiple reliability concerns without proportionally increasing complexity.
Solution Approach 2:
The shell is designed with a configuration that allows it to flex and adapt during mating while maintaining its protective function. The spaced-apart portions create flexibility that enables the shell to accommodate minor misalignments while still providing rigid protection against twisting forces, balancing flexibility and strength in a compact design.
Data Source
AI summary
An electrical connector includes a housing having a bottom and a wall bounding an opening adjacent the bottom, and a shell configured to encircle an outer surface of the wall. The shell may include: first shell corners configured to conform with first housing corners of the housing, second shell corners configured to be spaced apart from second housing corners of the housing in a first direction, a plurality of first portions configured to conform with the outer surface of the wall, and a plurality of second portions configured to be spaced apart from the outer surface of the wall. The first and second shell corners have a height greater than a maximum height of the housing. Such a connector may be miniaturized, yet provide for robust operation and resist unintentional demating as a result of twisting forces on a plug inserted into the connector.