Communication Connector Shield Layout for Faster Stamping
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Solution Overview
Problem
Existing communication connector shields face challenges in reducing process takt time and material cost while maintaining effective anti-noise shielding and resistance to loads during mating operations.
Innovation Solution
The shield is designed with multiple shield portions and lead portions that are strategically aligned and dimensioned to provide resistance against separation and noise, using a shortened feed pitch in progressive processing to reduce material usage and process time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional T-shaped shield blank is used with standard feed pitch, then the shield structure is simple and easy to manufacture, but the process takt time is long and material usage is excessive
Solution Approach 1:
The shield blank is segmented into multiple functional portions (first shield portion, second shield portion, third shield portion, fourth shield portion, and lead portions) with distinct orientations and functions. This segmentation allows each portion to be optimized independently for its specific role, enabling shorter feed pitch and reduced material usage while maintaining structural integrity and shielding effectiveness.
Solution Approach 2:
The shield blank transitions from a conventional two-dimensional T-shaped layout to a three-dimensional multi-portion structure with portions extending in different directions and orientations. This dimensional transformation enables more efficient material utilization and shorter feed pitch by arranging shield portions in spatial configurations that reduce overall blank length while maintaining coverage.
2Quantity of substance
If material quantity is reduced to lower cost, then material cost decreases, but resistance to separation loads and anti-noise shielding effectiveness may deteriorate
Solution Approach 1:
Different portions of the shield blank are designed with locally optimized properties: the first shield portion has specific dimensions for front face coverage, the second and fourth portions are configured for side face coverage with appropriate widths, and the third portion is designed for rear face coverage. The lead portions are specifically dimensioned to provide separation resistance. This local optimization ensures each area uses only the necessary material quantity for its function, reducing overall material usage while maintaining required strength and shielding effectiveness.
3Productivity
If feed pitch is shortened to increase stamping frequency, then productivity increases and material usage reduces, but manufacturing precision and shield quality may be compromised
Solution Approach 1:
The shield blank is pre-configured with all necessary portions (first, second, third, and fourth shield portions along with lead portions) in their correct spatial relationships and orientations before the stamping process. This preliminary arrangement of the blank geometry ensures that subsequent stamping operations can proceed with shorter feed pitch while maintaining manufacturing precision, as the pre-positioned portions guide the forming process and ensure proper alignment and quality of the final shield structure.
Data Source
AI summary
A shield formed by bending a metal plate includes a first shield portion, a second shield portion adjacent to the first shield portion, a fourth shield portion adjacent to the first shield portion and opposite to the second shield portion, and a third shield portion adjacent to each of the first shield portion, the second shield portion, and the fourth shield portion. The third shield portion includes a first shield sub-portion contiguous to the second shield portion and a second shield sub-portion contiguous to the fourth shield portion.