Electrical Connector Shielding Shell with Variable Wall Thickness
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Solution Overview
Problem
The existing electrical connectors, particularly Type C connectors, face challenges in miniaturization as their iron shell thickness is typically 0.2 mm to 0.3 mm, and there is a need for a solution to reduce height while maintaining structural strength.
Innovation Solution
The electrical connector design includes an insulative housing with conductive terminals and a shielding shell with thinner first and second walls, but thicker lateral walls, allowing for reduced height while ensuring strength through a combination of metal injection molding and stamping techniques, which provides flexibility and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the thickness of the iron shell is reduced to minimize height, then the height of the electrical connector is reduced, but the structural strength is compromised
Solution Approach 1:
The shielding shell employs different wall thicknesses in different regions: the first and second walls have a first thickness (0.15mm) while the pair of lateral walls have a second thickness (0.2mm-0.3mm) that is greater than the first thickness. This local differentiation allows the connector to achieve minimal overall height while maintaining structural strength through the thicker lateral walls that bear mechanical loads.
2Length of moving object
If the thickness of the iron shell is reduced to achieve miniaturization, then the height is reduced, but the ability to withstand mating forces is weakened
Solution Approach 1:
The lateral walls are designed with greater thickness to specifically withstand mating forces during connector assembly and usage, while the first and second walls are thinner to minimize overall height. This targeted thickening of load-bearing regions ensures the connector can handle mechanical stress without requiring uniform thickness throughout.
3Length of moving object
If the thickness of the first and second walls is reduced, then the height of the connector is minimized, but the rigidity of the shielding shell is reduced
Solution Approach 1:
The shielding shell structure compensates for the reduced rigidity of the thinner first and second walls through the thicker pair of lateral walls. The lateral walls, being thicker, provide the necessary structural support and rigidity to maintain the overall shape and stability of the shielding shell, allowing the first and second walls to be thinner for height reduction.
Solution Approach 2:
The shielding shell is formed through a combination of metal injection molding and stamping techniques, creating a composite structure that optimizes both rigidity and height. The multi-process manufacturing approach allows for precise control of wall thicknesses and structural properties in different regions.
Data Source
AI summary
An electrical connector includes an insulative housing, plural conductive terminals affixed to the insulative housing, and a shielding shell enclosing the insulative housing for forming a receiving room. The insulative housing includes a base portion and a tongue portion extending forwardly from the base portion. Each conductive terminal has a contacting portion disposed in the tongue portion. The shielding shell has a first wall, a second wall opposite to the first wall, and a pair of lateral walls connecting the first wall and the second wall. The thickness of the first wall is smaller than that of the lateral walls.