Rear Shielding Shell Welding for Electrical Connector Stability

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Solution Overview

Problem

Existing electrical connectors lack a secure and efficient method for welding the rear shielding shell to the front shielding shell, which can lead to instability and potential disconnection during mating and usage.

Innovation Solution

The electrical connector design includes a rear notch in the insulative outer cover that exposes the rear portion of the front shielding shell, allowing for a secure welding of the rear shielding shell to the front shielding shell, with the rear shielding shell featuring an upper welding piece that is welded to the rear portion of the front shielding shell, ensuring a stable and secure enclosure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the rear shielding shell is removably mounted to the front shielding shell, then the assembly is easier to manufacture and disassemble, but the connection stability and reliability deteriorate due to potential disconnection during usage

Engineering Contradiction:

Improveease of assemblyVSAvoidconnection stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces the mechanical removable mounting system with a welding system. The rear shielding shell is welded to the front shielding shell using welding pieces, transforming the connection method from mechanical (removable) to metallurgical (permanent). This substitution eliminates the risk of disconnection while maintaining manufacturing feasibility through standardized welding procedures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The shielding shell connection is segmented into distinct welding pieces attached to both the rear shielding shell and front shielding shell. This segmentation allows for controlled welding at specific locations rather than requiring complete fusion, making the manufacturing process more manageable while ensuring reliable connection at critical points.

Inventive Principle:

Principle #1Segmentation

2Object-affected harmful factors

If the insulative outer cover completely encloses the front shielding shell, then the insulation and protection are improved, but the welding access for securing the rear shielding shell deteriorates

Engineering Contradiction:

Improveprotection from interferenceVSAvoidwelding accessibility

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The insulative outer cover is designed with a rear notch that exposes the rear portion of the front shielding shell before the final assembly is complete. This preliminary exposure allows welding operations to be performed on the shielding shells while maintaining eventual full enclosure for protection. The notch is strategically positioned to provide welding access without compromising the overall protective function.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The insulative outer cover has different structural qualities at different locations: it is fully enclosed at most areas for maximum protection, but has a localized notch at the rear portion to provide welding access. This local modification allows the cover to simultaneously provide both protection and manufacturing accessibility where needed.

Inventive Principle:

Principle #3Local quality

3Reliability

If the rear shielding shell is securely welded to the front shielding shell, then the connection stability is improved, but the device complexity increases due to additional welding pieces and processes

Engineering Contradiction:

Improveconnection stabilityVSAvoidstructural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The welding pieces are merged with the shielding shells as integral components rather than separate fastening elements. The upper welding piece is attached to the rear shielding shell and the lower welding piece to the front shielding shell, creating a unified welded structure. This merging approach ensures stable connection while minimizing additional structural complexity compared to using separate mechanical fastening systems.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design enhances the stability and security of the electrical connector by preventing backward movement and ensuring proper alignment during mating, while also protecting the engaging fingers from deflection, thus maintaining a reliable connection.

Implementation Method 1

the rear shielding shell has an upper welding piece welded to the rear portion of the front shielding shell

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS10505318B2Electrical connector having separate front and rear shielding shells

Publication Date: 2019.12.10 FOXCONN INTERCONNECT TECHNOLOGY LTD

AI summary

An electrical connector includes: a housing having a base and a tongue; an upper and lower rows of contacts arranged in the housing and exposed respectively to two opposite surfaces of the tongue; a front and rear shielding shells enclosing the housing; and an insulative outer cover enclosing the front shielding shell, wherein the insulative outer cover has a rear notch exposing upwardly a rear portion of the front shielding shell, and the rear shielding shell has an upper welding piece welded to the rear portion of the front shielding shell.