Connector Shield Crimp Structure for Precise Beam Compression
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Solution Overview
Problem
The existing connector systems face challenges in achieving precise positional tolerances and secure electrical connections due to difficulties in manufacturing single-piece diecasts and the complexity of crimping two-piece diecasts, leading to impaired shield functioning.
Innovation Solution
A connector system design featuring a diecast composed of two identical halves that deform the outer contact's beam upon crimping, ensuring a secure and precise mechanical and electrical connection by abutting bottoming surfaces, preventing over-compression and under-compression issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single piece diecast is used to receive the outer contact, then the shield structure is simplified, but difficult positional tolerances in manufacturing occur and an imprecise fit results
Solution Approach 1:
The diecast is divided into two separate halves that can be manufactured independently with relaxed tolerances, then joined together to form the complete shield structure. This segmentation allows each half to be produced with easier positional tolerances while the final assembled structure achieves the required precision through the joining mechanism.
2Manufacturing precision
If a two piece diecast is crimped together, then positional tolerances are improved, but under-compression or over-compression occurs which impairs shield functioning
Solution Approach 1:
The diecast halves are pre-formed with specific geometries and features that guide their assembly and compression. The preliminary shaping of the halves includes provisions for controlled deformation that ensures proper compression of the outer contact without under-compression or over-compression, thereby maintaining reliable shield functioning.
Solution Approach 2:
The compression parameters are controlled through the design of the crimping mechanism and the geometry of the diecast halves. By adjusting the compression force, duration, and distribution through appropriate structural features, the outer contact achieves optimal compression that ensures reliable electrical connection without damage.
3Productivity
If a single piece diecast is used, then manufacturing steps are reduced, but an imprecise fit between the diecast and outer contact results
Solution Approach 1:
The diecast is segmented into two halves that are joined together, allowing for better fit precision on the outer contact while maintaining efficient manufacturing. The segmentation enables each half to be optimized for specific functional requirements, improving the overall fit precision without significantly increasing manufacturing complexity.
4Manufacturing precision
If a two piece diecast is crimped together, then fit precision is improved, but the process becomes difficult to control
Solution Approach 1:
The diecast halves are pre-formed with alignment features and controlled geometry that simplify the crimping process. The preliminary preparation includes provisions for easy alignment and controlled compression, reducing the complexity of the assembly process while maintaining high fit precision between the diecast and outer contact.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design achieves a strong, precise mechanical and electrical connection between the diecast and outer contact, enhancing the shield's performance by ensuring consistent deformation of the beams without over-deformation, thus improving the overall functioning of the connector system.
Implementation Method 1
The first diecast half and the second diecast half deform a beam of the outer contact between the first diecast half and the second diecast half in the terminated position
Implementation Method 2
A first bottoming surface of the first diecast half abuts a second bottoming surface of the second diecast half in the terminated position
Data Source
AI summary
A shield of a connector system includes an outer contact and a diecast disposed around the outer contact. The diecast has a first diecast half and a second diecast half that are attached together around the outer contact in a terminated position of the diecast. The first diecast half and the second diecast half deform a beam of the outer contact between the first diecast half and the second diecast half in the terminated position. A first bottoming surface of the first diecast half abuts a second bottoming surface of the second diecast half in the terminated position.