Receptacle Connector Shell Structure for Stable Mating Alignment
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Solution Overview
Problem
Existing receptacle connectors face challenges in reliability due to movements among components during insertion and removal of mating components, leading to unreliable connections and inefficient shielding.
Innovation Solution
The proposed receptacle connector design includes a terminal assembly with conductive elements held by a housing, an inner shell engaged with the housing, a main shell attached to the inner shell, and an outer shell with a sealing member. This configuration provides a secure connection and efficient shielding by distributing forces and reducing component movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional receptacle connector design is used, then the structure is simple, but the reliability is poor due to component movements during insertion and removal
Solution Approach 1:
The connector is divided into multiple independent shells (first shell, second shell, third shell, fourth shell) that each perform specific functions. This segmentation allows each component to be optimized independently while working together to provide stable support and reliable connection, resolving the contradiction between reliability and complexity.
Solution Approach 2:
The connector employs a nested structure where the first shell contains the second shell, and the third shell contains the fourth shell. This nested arrangement provides multiple layers of support and protection, enhancing connection reliability while maintaining a compact overall structure that does not excessively increase complexity.
2Object-generated harmful factors
If traditional connector structures are used, then manufacturing is easier, but shielding efficiency is poor
Solution Approach 1:
The shielding structure is segmented into multiple shells (second shell and fourth shell) that can be manufactured separately and then assembled. This segmentation enables each shell to be optimized for shielding performance while maintaining manufacturability through standardized production processes for individual components.
Solution Approach 2:
The shells serve multiple functions: structural support, electrical shielding, and mechanical guidance. By designing each shell to perform multiple functions, the connector achieves high shielding efficiency without requiring additional separate components, thus maintaining ease of manufacture.
3Stability of the object's composition
If a simple connector design is used, then assembly is easier, but component misalignment occurs during insertion and removal
Solution Approach 1:
The connector is segmented into multiple shells with progressively smaller contours, where each shell provides specific positional support. This segmentation creates a staged guidance system that maintains component alignment throughout the insertion and removal process, achieving stability without excessive complexity.
Solution Approach 2:
The shells feature asymmetric contour designs with progressively smaller dimensions, creating a tapered guidance path. This asymmetric geometry naturally guides components into proper alignment during insertion and maintains stability during removal, preventing misalignment without requiring complex alignment mechanisms.
Data Source
AI summary
A reliable receptacle connector and method of manufacturing thereof. The connector includes a terminal assembly having conductive elements held by a housing. Each conductive element has a mating end held by a housing tongue, a tail end extending outside the housing, and an intermediate portion partially held by portions of the housing that have different contours. The terminal assembly can be formed by assembling terminal subassemblies on opposite sides of a shield and molding over the assembly to form the housing. An inner shell is sleeved on the housing and engages with both portions of the housing that have different contours. A main shell is sleeved on the inner shell. An outer shell is sleeved on the main shell and shaped such that a seal can be formed between the shells. Such a configuration enables distributing forces to mate/unmate the connector from the shells to the housing and therefore reduces relevant movements between the components of the connector.