Electrical Connector Shell Structure for Wrong-Angle Insertion Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors with fool-proof protrusions suffer from deformation issues during manufacturing, affecting the sensitive dimensions of the frame opening and leading to a high defect rate, while also failing to prevent incorrect insertion angles effectively.
Innovation Solution
An electrical connector design featuring a shielding shell with a fool-proof protrusion that is integrally stamped from the first shell portion, positioned adjacent to the mating surface, and configured to prevent incorrect insertion angles by being located beyond the first outer surface, with the first end surface and end edge arranged one behind the other to minimize impact on sensitive dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fool-proof protrusion is made flush with the front surface of the shell, then the fool-proof function is achieved, but large deformation occurs on the front end of the shell during forming, affecting the sensitive dimensions of the frame opening
Solution Approach 1:
The fool-proof protrusion is repositioned from the front surface (first direction) to the side surface (second direction perpendicular to the first direction) of the shielding shell. This dimensional relocation allows the protrusion to maintain its fool-proof function while eliminating the deformation problem caused by forming operations on the front end of the shell, thereby preserving the dimensional accuracy of the frame opening.
2Reliability
If the fool-proof protrusion is positioned to abut against the plug connector at wrong angle, then incorrect insertion is prevented, but the structural stability of the shell is reduced due to forming deformation
Solution Approach 1:
The fool-proof protrusion is relocated from the front surface to the side surface of the shielding shell, changing its spatial dimension. This relocation maintains the insertion prevention function while avoiding the structural instability caused by forming deformation on the front end of the shell.
Solution Approach 2:
The fool-proof protrusion function is extracted from the front surface structure and implemented separately on the side surface of the shielding shell. This separation allows the protrusion to perform its function independently without compromising the structural integrity and stability of the main shell body.
3Ease of manufacture
If the fool-proof protrusion is formed by stamping on the front end of the shell, then the protrusion structure is created, but the sensitive dimensions of the frame opening are affected resulting in high defect rate
Solution Approach 1:
The fool-proof protrusion is relocated from the front surface to the side surface of the shielding shell. This dimensional change allows the protrusion to be formed without affecting the sensitive dimensions of the frame opening, thereby reducing the defect rate while maintaining ease of manufacture.
Solution Approach 2:
The shielding shell is divided into different functional zones: the front end maintains its structural integrity for frame opening formation, while the side surface accommodates the fool-proof protrusion. This segmentation allows each zone to be optimized independently, preventing interference between protrusion formation and frame opening dimensional accuracy.
Data Source
AI summary
An electrical connector includes an insulating body, a number of conductive terminals and a shielding shell. The insulating body includes a mating surface and a slot extending through the mating surface. Each conductive terminal includes a contact portion extending into the slot. A receiving groove for accommodating a mating connector is formed between the shielding shell and the insulating body. The shielding shell includes a first shell portion. The first shell portion includes a first outer surface, a first end surface and a fool-proof protrusion. The fool-proof protrusion has a first edge located at a most end thereof. The first end surface and the first end edge are disposed one behind the other. The fool-proof protrusion is configured to prevent the mating connector from being inserted into the electrical connector at a wrong angle.