Preformed Metallic Tubular Bracket for Electrical Connector Assembly
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Solution Overview
Problem
The existing methods for assembling electrical connectors with metallic tubular brackets are labor-intensive and prone to damaging the housing due to the need for bending the rear wall of the bracket, which complicates the process and increases the risk of injury.
Innovation Solution
A preformed metallic tubular bracket with an L-shaped fixing section is used, which is assembled forwardly onto a sub-assembly with a securing section, allowing for easy engagement and welding without the need for additional deformation, thereby simplifying the assembly process and reducing the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the rear wall of the bracket is bent to shield the rear side of the sub-assembly, then the shielding function is improved, but the assembly process becomes more complex and labor-intensive, and there is a risk of damaging the housing
Solution Approach 1:
The rear wall of the bracket is pre-bent during the bracket forming process to achieve the desired shielding angle (e.g., 45 degrees). This preliminary action eliminates the need for post-assembly bending operations, simplifying the assembly process while maintaining the shielding function. The bracket is delivered in its final configured state, ready for direct installation onto the sub-assembly.
Solution Approach 2:
The bracket is divided into distinct functional sections: the main tubular body for structural support, the pre-formed rear wall for shielding, and the front opening for sub-assembly insertion. This segmentation allows each part to be manufactured and configured independently with optimal properties, then assembled together without complex deformation operations.
2Reliability
If the rear wall of the bracket is bent after assembly to achieve shielding, then the shielding position is adjusted, but the process costs labor and may damage the housing
Solution Approach 1:
The rear wall is pre-configured to the correct shielding angle and position during bracket manufacturing. This ensures the shielding function is achieved without requiring post-assembly bending operations that could damage the housing or require additional labor. The pre-formed angle (e.g., 45 degrees) is optimized for the specific application requirements.
3Ease of manufacture
If the bracket is assembled with a preformed fixing section, then the assembly process is simplified and labor is reduced, but additional manufacturing steps are required for the bracket
Solution Approach 1:
The fixing section (e.g., L-shaped structure) is pre-formed as an integral part of the bracket during the bracket forming process. This preliminary configuration of the fixing section allows for straightforward assembly onto the corresponding securing section of the sub-assembly, eliminating the need for post-assembly deformation operations. The additional manufacturing step in bracket production is offset by the significant simplification of the assembly process.
Data Source
AI summary
An electrical connector includes an terminal module and a metallic tubular shield fixedly enclosing the terminal module to form a sub-assembly, and a metallic tubular bracket enclosing the sub-assembly. The terminal module includes an insulator having a base and a tongue portion forwardly extending from the base, and a plurality of terminals disposed in the insulator. The base includes a rear end having a securing section, and the bracket has a fixing section correspondingly, wherein the bracket is adapted to be forwardly assembled from a rear side of the sub-assembly to have the fixing section engaged with the securing section.