Plug Connector Assembly with Telescoped Metal Shells for Anti-EMI Shielding

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Solution Overview

Problem

Existing plug connector assemblies suffer from poor anti-EMI performance and structural strength due to gaps between metal shell connecting portions.

Innovation Solution

A plug connector assembly design featuring shells with closed circumferences, where the first shell is telescoped with the rear mating end and the second shell is telescoped on the cable, providing a seamless connection and improved sealing, anti-EMI performance, and structural strength through sheet metal drawing or similar manufacturing methods.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If metal shells are connected with gaps to allow assembly, then ease of manufacture is improved, but anti-EMI performance deteriorates

Engineering Contradiction:

Improveease of assemblyVSAvoidEMI shielding performance

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

A contact plate is introduced as an intermediary component between the first and second metal shells. The contact plate includes a first contact portion electrically connected to the first metal shell and a second contact portion electrically connected to the second metal shell, creating an electrical bridge that maintains EMI shielding continuity while allowing the shells to be assembled separately with gaps.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If metal shells are connected with gaps for assembly flexibility, then device complexity is reduced, but structural strength deteriorates

Engineering Contradiction:

Improvestructural complexityVSAvoidstructural strength

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The contact plate merges the electrical and mechanical connection functions between the two metal shells. By combining the electrical contact function with the structural bridging function in a single component, the overall structural strength is enhanced while maintaining assembly flexibility and not increasing device complexity.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If metal shells are connected with gaps to simplify assembly, then ease of manufacture is improved, but seal performance deteriorates

Engineering Contradiction:

Improveease of assemblyVSAvoidseal performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The contact plate acts as a flexible electrical bridge that can accommodate the gaps between metal shells during assembly while maintaining continuous electrical connection. This flexible intermediate structure allows the shells to be assembled separately without compromising the overall sealing effectiveness of the EMI shield.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS9450342B2Plug connector assembly having improved anti-EMI performance

Publication Date: 2016.09.20 FOXCONN INTERCONNECT TECHNOLOGY LTD

AI summary

An plug connector assembly (1) includes a mating member (10) including a front mating end (101) and a rear mating end (102), a cable (30) electrically connected with the mating member, a first shell (50) formed by sheet metal drawing and having a closed circumference, a second shell (60) formed by sheet metal drawing and having a closed circumference. The first shell includes a first front end (51) telescoped with the rear mating end, and a first rear end (52) opposite to the first front end. The second shell (60) includes a second front end (61) telescoped with the first rear end, and a second rear end (62) opposite to the second front end and telescoped on the cable.