Electrical Connector Side Arms Shell Integration
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Solution Overview
Problem
Existing electrical connectors suffer from diminished waterproof performance due to minor gaps between the main and sub-shells, which compromise their electromagnetic interference shielding and reliability.
Innovation Solution
An electrical connector design featuring a metallic inner shell with unitarily formed or discretely soldered side arms that extend through an insulative outer shell, ensuring a secure seal and improved waterproof performance by integrating the inner and outer shells via an insert-molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a metallic main shell is enclosed within a metallic sub-shell with openings for mounting legs, then electromagnetic interference shielding is improved, but waterproof performance deteriorates due to gaps between shells
Solution Approach 1:
The patent applies nesting by placing the metallic inner shell with side arms inside the insulative outer shell, creating a nested structure where the inner shell's side arms extend through the outer shell to form mounting legs. This nested configuration allows the inner shell to provide EMI shielding while the outer shell maintains waterproof sealing, eliminating the need for gaps between separate shell components.
Solution Approach 2:
The patent uses composite materials by combining a metallic inner shell (for EMI shielding) with an insulative outer shell (for waterproofing and structural support). The metallic inner shell provides electromagnetic interference shielding while the insulative outer shell ensures waterproof performance, and together they form a unified connector structure that resolves the contradiction between EMI shielding and waterproofing.
2Object-affected harmful factors
If separate main and sub-shells are used with mounting legs, then electromagnetic shielding is achieved, but manufacturing complexity increases and sealing reliability decreases
Solution Approach 1:
The patent merges the inner shell and outer shell into a unified structure where the inner shell's side arms are integrally formed with the outer shell. This merging eliminates the need for separate assembly of multiple shell components, reducing manufacturing complexity while maintaining EMI shielding effectiveness. The integrated structure also eliminates gaps that would compromise sealing reliability.
Solution Approach 2:
The nested configuration of the inner shell within the outer shell, with side arms extending through the outer shell, creates a streamlined structure that reduces overall complexity compared to separate shell assemblies. The nesting allows both EMI shielding and mounting functionality to be achieved within a single integrated design.
3Ease of operation
If separate main and sub-shells are assembled, then mounting legs can be formed, but gaps between shells compromise waterproof performance
Solution Approach 1:
The patent combines the formation of mounting legs with the integral structure of the inner shell, where side arms extend through the outer shell to form mounting legs. This merging of functions allows mounting leg formation without requiring separate shell assembly, thereby eliminating gaps that would compromise waterproof performance while maintaining ease of mounting operation.
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
The solution enhances waterproof performance and maintains effective electromagnetic interference shielding by eliminating gaps between the shells, thereby ensuring reliable operation and durability.
Implementation Method 1
integrating the inner and outer shells via an insert-molding process
Data Source
AI summary
An electrical connector includes a contact module enclosed within a metallic inner shell. The inner shell is formed by stamping and forming, and includes opposite first and second side walls in a vertical direction, and a pair of end walls opposite to each other in the transverse direction and linking the opposite first and second side walls in the vertical direction. Each end wall includes a first arm extending rearwardly from a rear edge and a second arm intimately located beside the first arm either in a unitarily folded manner or a discretely soldered manner. The second arm is located outside of the corresponding first arm in the transverse direction wherein the first arm forms a first mounting leg and the second arm forms a second mounting leg extending through an insulative outer shell which is overmolded upon the inner shell.