Seamless Metallic Shell With Curvilinear And Springy Flaps
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Solution Overview
Problem
Existing electrical connectors with metallic shells often have seams, which can compromise structural strength and mating reliability, and traditional manufacturing methods limit the production of connectors to single rows rather than matrix configurations.
Innovation Solution
An electrical connector design featuring a seamless metallic shell with a sleeve and upper part containing curvilinear and springy flaps, formed via metal drawing and insert-molding, allowing for matrix production of connectors with enhanced structural strength and reliable mating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods are used to form metallic shells, then production can be done in single rows, but manufacturing efficiency is limited and cannot achieve matrix configurations
Solution Approach 1:
The metallic shell is divided into multiple curvilinear flaps and springy flaps that can be independently formed and positioned. This segmentation allows the shell to be manufactured in a matrix configuration where multiple connectors can be produced simultaneously, greatly improving productivity while maintaining structural integrity through the interlocking flap design
2Strength
If seams are present in the metallic shell, then manufacturing may be simpler, but structural strength and mating reliability are compromised
Solution Approach 1:
The metallic shell incorporates springy flaps that can elastically deform during the forming process and mating operations. This dynamic characteristic allows the shell to achieve a seamless, high-strength structure while accommodating manufacturing variations and assembly tolerances, improving both structural strength and mating reliability without significantly complicating the manufacturing process
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 seamless metallic shell provides increased structural strength and reliable mating, enabling efficient matrix production of electrical connectors with improved retention force and manufacturing efficiency.
Implementation Method 1
a plurality of springy flaps interposed between adjacent curvilinear flaps and extending upwardly beyond the plurality of curvilinear flaps
Implementation Method 2
formed via metal drawing and insert-molding
Data Source
AI summary
An electrical connector includes: an insulative housing having a base; a center conductor secured to the insulative housing; and a metallic shell secured to the insulative housing and surrounding the center conductor, the metallic shell including a sleeve having a lower part secured to the base of the insulative housing and an upper part extending upwardly beyond the base of the insulative housing; wherein the upper part includes plural curvilinear flaps coplanar with the lower part of the sleeve and plural springy flaps interposed between adjacent curvilinear flaps and extending upwardly beyond the curvilinear flaps.