Integrated Plug Connector Housing for Stable Cable Junctions
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Solution Overview
Problem
Existing plug connectors have unstable structures due to separate front and rear shells, leading to increased size and manufacturing costs, and potential movement during use.
Innovation Solution
A plug connector design with an integrally formed second housing that stabilizes the first housing, cable, and connecting member as a whole, reducing overall size and manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connector uses separate front shell and rear shell assembled together, then the manufacturing flexibility is improved, but the structural stability deteriorates and the overall size increases
Solution Approach 1:
The patent merges the front shell and rear shell into a single integrated housing structure. The housing is formed as one piece that accommodates both the circuit board and cable, eliminating the need for separate assembly of front and rear shells. This integration directly resolves the technical contradiction by providing structural stability through a unified design while maintaining manufacturing efficiency through single-piece molding techniques.
2Ease of manufacture
If the connector uses separate front shell and rear shell assembled together, then the manufacturing flexibility is improved, but the overall size increases
Solution Approach 1:
The integrated housing combines the functions of front shell and rear shell into a single structural element, reducing the overall volume by eliminating the gap and fastening structures required for separate assemblies. The unified housing design allows for more compact arrangement of internal components, directly addressing the size increase issue.
3Productivity
If the connector uses separate front shell and rear shell assembled together, then the manufacturing process is extended, but the manufacturing cost increases
Solution Approach 1:
By integrating the housing into a single piece, the patent eliminates multiple assembly steps, fastening operations, and quality inspection steps required for separate shell assemblies. This reduction in manufacturing steps directly improves productivity while lowering labor and overhead costs, resolving the contradiction between manufacturing efficiency and cost.
4Reliability
If the connector uses separate front shell and rear shell with inner mold, then the cable protection is improved, but the device complexity increases
Solution Approach 1:
The integrated housing combines the protective functions previously distributed across multiple separate components (front shell, rear shell, inner mold) into a single unified structure. This merger maintains cable protection capabilities while eliminating the complexity of coordinating multiple separate parts, their assemblies, and interconnections.
Data Source
AI summary
A plug connector for mating with a receptacle connector in a mating direction, includes: an insulative housing; a connecting member accommodated in the insulative housing, the connecting member having a mating portion to be mated with the receptacle connector; and a cable connected to the connecting member, wherein the insulative housing includes a first housing and a second housing integrally formed on the first housing, and the second housing is further integrally formed at a junction between the connecting member and the cable so as to fix the first housing, the cable, and the connecting member together as a whole.