Interlocked Shell and Housing Electrical Connector
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Solution Overview
Problem
Existing electrical connectors, such as reversible USB Type-C connectors, face challenges in automated production due to lack of interference fit between the contact module and metal shell, leading to insufficient molding and production inefficiencies.
Innovation Solution
An electrical connector design featuring a contact module with an insulative housing and conductive terminals, and a metal shell with locking grooves, where the insulative housing's mounting portions engage with the metal shell's locking grooves, ensuring interference fit and stability during assembly, facilitating automated production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If no interference fit is provided between contact module and metal shell, then assembly is simplified, but molding becomes insufficient and automated production is compromised
Solution Approach 1:
The contact module is segmented into distinct functional parts: insulative housing with mounting portions, grounding terminals with engaging portions, and signal terminals. The metal shell is segmented with dedicated locking grooves. This segmentation allows each component to have specific engagement features that enable automated assembly while maintaining secure connection.
Solution Approach 2:
The contact module is nested within the metal shell, with the insulative housing positioned inside the metal shell cavity. The grounding terminals are nested within the insulative housing, with their engaging portions fitting into the locking grooves of the metal shell. This nested structure ensures proper positioning and secure assembly suitable for automated production.
2Stability of the object's composition
If interference fit is provided between mounting portions and locking grooves, then assembly stability is improved, but device complexity increases
Solution Approach 1:
The interference fit feature is applied locally only at specific mounting portions of the insulative housing and corresponding locking grooves in the metal shell, rather than throughout the entire assembly. This localized approach provides necessary assembly stability while keeping the overall device structure simple and manageable.
Solution Approach 2:
The mounting portions are integrated into the insulative housing structure, and the locking grooves are formed as part of the metal shell geometry. This merging of functions into existing structural elements provides assembly stability without adding separate complex components or mechanisms.
Data Source
AI summary
An electrical connector includes: a contact module comprising an insulative housing having a base portion and a tongue portion, and a number of conductive terminals affixed to the insulative housing and each comprising a contacting portion exposed to a surface of the tongue portion, a soldering portion and a connecting portion connecting the contacting portion and the soldering portion; and a metal shell comprising a pair of locking grooves depressed forwardly from a rear surface thereof; wherein the insulative housing comprises a pair of mounting portions located at two lateral sides of a rear end thereof, the mounting portions are stuck in the locking grooves when the contact module is assembled to the metal shell along a rear-to-front direction, and a lower portion of each mounting portion is resisted against the rear surface of the metal shell.