Electrical Connector Sleeve and Outer Cover Design
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Solution Overview
Problem
Existing electrical connectors lack versatility in color, material, and finish, and do not provide sufficient structural strength, particularly at the mating part and receiving chamber.
Innovation Solution
The design includes a sleeve that extends beyond the front mating end to define a receiving chamber and an outer cover made of a softer material, providing structural strength while allowing for versatility in color, material, and finish, with reinforcing ribs and a separate inner mold or divider for enhanced bonding and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connector housing is formed from two inter engaging halves, then the manufacturing complexity is reduced and assembly is simplified, but the structural strength at the mating part is insufficient
Solution Approach 1:
The connector is divided into three main segments: the connector unit, the sleeve, and the outer cover. The sleeve is further segmented into a rear portion that fits within the connector unit and a front portion that extends forward. This segmentation allows each part to be manufactured separately with optimized structures, then assembled together to achieve both ease of manufacture and sufficient structural strength through the combined system.
Solution Approach 2:
The connector employs composite construction by combining multiple materials with different properties. The sleeve is made of a material softer than the outer cover, creating a composite structure where each material contributes its advantageous properties. This composite approach allows the softer sleeve material to provide cushioning and protection at the mating interface while the harder outer cover provides overall structural strength and durability.
2Ease of manufacture
If a single material is used for the connector housing, then the manufacturing process is simplified, but the versatility in color, material, and finish is limited
Solution Approach 1:
The connector housing is segmented into the sleeve and the outer cover as separate components. This segmentation enables each component to be manufactured from different materials with different properties, allowing for versatility in color, material selection, and surface finish. Each segment can be independently manufactured and then assembled, maintaining manufacturing efficiency while achieving design flexibility.
Solution Approach 2:
Different portions of the connector housing are made from different materials with different properties. The sleeve uses a softer material suitable for the mating interface, while the outer cover uses a harder material for structural protection. This local differentiation of material properties allows each region to be optimized for its specific function while maintaining overall manufacturing efficiency through modular construction.
3Strength
If the sleeve material is harder, then the structural strength is improved, but the bonding and sealing with the outer cover is compromised
Solution Approach 1:
The connector uses composite materials where the sleeve is made of a softer material than the outer cover. This material selection ensures that the softer sleeve material can be effectively bonded to and sealed with the harder outer cover material. The softer sleeve material provides compliance for reliable sealing while the harder outer cover provides overall structural strength, resolving the contradiction between strength and bonding reliability.
Data Source
AI summary
An electrical connector includes: a connector unit having a mating part, the mating part defining a front mating end; a sleeve enclosing the mating part and extending forwardly beyond the front mating end to define a receiving chamber; and an outer cover enclosing the sleeve and the connector unit, wherein the sleeve has a front portion containing the receiving chamber, and the outer cover is made of a material softer than the sleeve.