Electrical Connector Shield Case Design for Impedance Control
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Solution Overview
Problem
Conventional 4-pole electrical connectors with die-cast housings are costly due to the need for precise dimensioning to stabilize characteristic impedance.
Innovation Solution
An electrical connector with a plurality of contact pins and an insulating housing, where at least one contact pin has a projecting part that reduces the spacing between adjacent pins, allowing for reduced production costs while maintaining desired characteristic impedance, using a shield case formed by machining a sheet metal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a die-cast housing is used to precisely control the spacing between contact pins, then the characteristic impedance is stabilized, but the production cost increases significantly
Solution Approach 1:
The patent applies local quality by providing projecting parts only on specific contact pins (first and second contact pins) rather than all pins. These localized projections adjust the spacing between adjacent pins to maintain characteristic impedance, while the housing itself can be made from lower-cost materials with less precise dimensional control. This selective approach achieves the necessary precision only where electrically critical.
Solution Approach 2:
The patent changes the physical parameter of contact pin spacing by adding projecting parts that extend from the housing surface. This modifies the effective spacing between contact pins without requiring the housing itself to be manufactured with high precision. The projecting parts compensate for variations in housing dimensions, allowing use of cheaper materials and manufacturing processes.
2Reliability
If the spacing between contact pins is reduced to achieve desired characteristic impedance, then the electrical performance is improved, but the housing dimensions become more difficult to control
Solution Approach 1:
The projecting parts act as intermediary elements between the housing and the contact pins. They provide the necessary spacing adjustment without requiring the housing itself to have precise dimensions. The projecting parts mediate the relationship between the housing structure and the electrical requirements, allowing independent optimization of mechanical manufacturing and electrical performance.
3Manufacturing precision
If conventional die-casting is used for the housing, then the production cost is high, but the dimensional accuracy is excellent
Solution Approach 1:
The patent replaces the expensive die-cast housing with a cheaper alternative housing made from materials such as plastic or other insulating materials. The housing is not required to maintain precise dimensions, as the projecting parts on the contact pins provide the necessary spacing control. This substitution of a costly component with a cheaper one, compensated by a simple structural modification, reduces overall manufacturing cost.
Data Source
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AI summary
There is provided an electrical connector including a plurality of contact pins, which electrical connector can realize reduced reduction costs. A jack (10), as this electrical connector, includes a plurality of contact pins (110) arranged at a predetermined spacing from each other within a shield case (160). At least one of the plurality of contact pins (110) includes a projecting part (120) projecting toward another adjacent contact pin (110). The projecting part (120) makes the spacing between the plurality of contact pins (110) smaller than the predetermined spacing so as to change capacitance.