Mini FAKRA Connector Tunnel-Pin Assembly for Stronger Housing Fit
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Solution Overview
Problem
Conventional FAKRA connectors face issues with guaranteed tightness and structural strength due to material differences between the front and rear housings, leading to wear and poor durability during assembly.
Innovation Solution
A mini type FAKRA connector design that combines a metal housing and a plastic housing with a pin to form a tunnel structure, eliminating the need for additional buckle structures, enhancing bonding strength and durability by using overlapping portions and protrusions to secure the housings together.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a buckle structure is used to combine the front housing and the rear housing, then the assembly process is simplified, but the tightness and structural strength cannot be guaranteed due to material differences
Solution Approach 1:
The housing is divided into a front housing and a rear housing made of different materials (plastic and zinc alloy respectively), allowing each part to be manufactured separately with optimal material selection while maintaining overall structural integrity through the tunnel connection
Solution Approach 2:
A tunnel structure is introduced as an intermediary element that connects the front housing and rear housing. The tunnel acts as a mediator that transfers and distributes mechanical stresses between the two different materials, resolving the incompatibility issue while maintaining strong bonding
2Adaptability or versatility
If different materials are used for the front housing and the rear housing, then the functional requirements are met, but the tightness and coverage between housings cannot be guaranteed
Solution Approach 1:
Different regions of the housing structure use different materials optimized for their specific functions: the front housing uses plastic for electrical insulation and terminal support, while the rear housing uses zinc alloy for mechanical strength and shielding, achieving both functional requirements and structural reliability
Solution Approach 2:
The tunnel structure serves as an intermediary connection that ensures tightness and coverage between the front and rear housings. It provides a continuous structural path that maintains sealing and mechanical integrity despite the material transition between housing sections
3Device complexity
If a conventional buckle structure is used to fix the housings, then the device complexity is reduced, but wear and poor durability occur
Solution Approach 1:
The tunnel structure is pre-formed as an integral part of the housing assembly, with the pin insertion path and clamping features built in during manufacturing. This preliminary preparation eliminates the need for separate buckle components and assembly steps, reducing complexity while enhancing durability through a more robust fixed connection
Data Source
AI summary
The disclosure provides a mini type FAKRA connector, which includes a metal housing, a plastic housing, a pin, and multiple terminals. The plastic housing is assembled to the metal housing, and a portion structure of the metal housing and a portion structure of the plastic housing are overlapped to form a tunnel. The pin is inserted into the tunnel to fix the metal housing and the plastic housing together. The terminals penetrate the metal housing and the plastic housing.