Laser-Joined Dual Metal Shell Electrical Connector
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Solution Overview
Problem
Existing electrical connectors with a latching mode assembly are not firmly fixed, leading to shifting during external forces, causing issues with soldering, stress distribution, and increased through-holes on circuit boards, which affects signal transmission and wiring layout.
Innovation Solution
The electrical connection device features an inner and outer metal shell firmly fixed together using laser joints, ensuring coplanarity of soldering surfaces and reducing the number of through-holes on the circuit board, with the outer metal shell being securely attached via SMT-type soldering plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the first shell and the second shell are assembled by a latching mode, then the assembly process is simple, but the connection is not firm and the shells shift during soldering
Solution Approach 1:
The patent merges the first shell and second shell into a unified structure by having the connecting legs of the second shell pass through the first shell and be soldered to the circuit board together with the terminals. This integration ensures both shells are firmly fixed during the soldering process, eliminating relative shifting while maintaining manufacturing simplicity.
2Reliability
If through-holes are used for connecting legs, then the connector can be firmly fixed, but the wiring layout complexity increases
Solution Approach 1:
The connecting legs of the second shell serve multiple functions: they act as both mechanical support structures and electrical connection elements. By integrating these functions into a single component that passes through the first shell and soldered to the circuit board, the patent reduces wiring layout complexity while maintaining firm fixation.
3Productivity
If SMT-type connecting legs are used, then the through-hole count is reduced, but the soldering surfaces may not be coplanar causing missing solder
Solution Approach 1:
The first shell acts as an intermediary structure that provides a common reference plane for both the terminals and the connecting legs of the second shell. By having both components soldered to the circuit board while maintained in the same plane through the first shell's structure, the patent ensures coplanarity of soldering surfaces and prevents missing solder issues.
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
This solution prevents missing solder issues, enhances connector stability during mating cycles, and reduces the number of through-holes on the circuit board, improving signal transmission and wiring layout efficiency.
Implementation Method 1
the top plate of the inner metal shell and the top plate of the outer metal shell are firmly fixed as a whole by a plurality of laser joints
Data Source
AI summary
A connector comprises an outer shell, an insulating body, a plurality of terminals provided in the insulating body, and an inner metal shell shielding the insulating body. The outer metal shell is sheathed outside the inner metal shell and has a top plate, wherein a top plate of the inner metal shell and a top plate of the outer metal shell can be firmly fixed together by a plurality of laser joints. The outer metal shell can include transverse soldering plates respectively at two sides thereof that are coplanar with a soldering surface associated with the plurality of terminals.