Plug Connector Assembly Seamless Housing Design
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Solution Overview
Problem
Existing plug connector assemblies are not suitable for larger components and are inconvenient to assemble, especially when trying to insert the front and attraction plates after mounting the subassembly and circuit board, due to their design limitations.
Innovation Solution
A plug connector assembly featuring an insulative cover with a channel connecting the front and rear ports, a magnetic member electrically connected to a printed circuit board, and a front stopple that fills the channel, eliminating the need for strain relief and allowing for a seamless assembly without seams, enabling easier insertion and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional plug connector assembly is used with strain relief and multiple plates, then the assembly can accommodate various components, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent combines the strain relief function and the insulative cover into a single integrated component. The insulative cover is designed with a recessed portion that directly receives and secures the cable, eliminating the need for a separate strain relief component. This merging reduces the total number of parts and simplifies the assembly process while maintaining the structural integrity and organizational functions of the original multi-component design.
Solution Approach 2:
The insulative cover serves multiple functions simultaneously: it provides electrical insulation, organizes cables and connectors, provides strain relief through its recessed portion, and maintains structural support. By designing the insulative cover to perform multiple functions that were previously distributed across several separate components, the patent reduces assembly complexity while preserving all necessary functionalities.
2Ease of manufacture
If strain relief is used to secure cable and components, then the assembly is more secure, but production cost increases
Solution Approach 1:
The strain relief function is merged into the insulative cover structure itself. The recessed portion of the insulative cover is designed to directly receive and secure the cable, eliminating the need for a separate strain relief component. This integration maintains cable security and assembly reliability while reducing the total number of parts and production costs.
3Shape
If multiple separate components are used for assembly, then each component can be optimized for its specific function, but the final assembly has visible seams and less aesthetic appearance
Solution Approach 1:
The patent merges multiple functional components into a single integrated insulative cover structure. The recessed portion is formed as an integral part of the insulative cover, creating a seamless appearance without visible joints or seams. This integration maintains the aesthetic advantages of a unified structure while preserving the functional optimization of having dedicated areas for cable management, connector organization, and strain relief.
4Adaptability or versatility
If larger components are used in plug connector assembly, then the assembly can accommodate more functionality, but the assembly process becomes more difficult
Solution Approach 1:
The insulative cover is segmented into functional zones including a recessed portion for cable reception, areas for connector organization, and integrated strain relief features. This segmentation allows larger, more versatile components to be designed with built-in organizational features that guide proper assembly and reduce insertion difficulty, making it easier to handle larger components while maintaining adaptability for various cable and connector configurations.
Data Source
AI summary
A plug connector assembly for mating with a mating connector including a plug connector comprising an insulative cover defining a receiving space, a printed circuit board (PCB) received in the insulative cover, a mating member mounted on the insulative cover and electrically connected with the PCB, and a front stopple; and a cable connected to the plug connector; wherein the insulative cover comprises a front port and an opposite rear port for the cable to extend through, a channel extends from the front port to the rear port and is connected with the receiving space to extend the mating member out of the insulative cover, and the front stopple fills the front port and the channel.