Reinforced Connector Receptacles with Metallic Frames
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Solution Overview
Problem
Connector receptacles in electronic devices are prone to damage from insertion and extraction forces, leading to premature wear and reliability issues, and current manufacturing methods are not optimized for high volume production.
Innovation Solution
The use of reinforced connector receptacles with metallic frames and internal center pieces, along with molded non-conductive materials, to provide structural support and protection against forces during insertion, extraction, and positional stress, while also enabling easy manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional connector receptacles are used without reinforcement, then manufacturing is simpler and cost is lower, but the receptacles are prone to damage from insertion and extraction forces
Solution Approach 1:
The connector receptacle combines a non-conductive molded body with a metallic frame assembly, creating a composite structure that leverages the advantages of both materials: the molded body provides insulation and basic structure, while the metallic frame provides reinforcement and conductivity. This composite approach resolves the contradiction by achieving high strength through material combination rather than relying solely on complex geometry.
Solution Approach 2:
The receptacle is divided into distinct functional components: a molded non-conductive body, a metallic frame, and separate ground contacts. This segmentation allows each component to be optimized independently for its specific function while being manufactured separately and assembled together, reducing overall complexity while achieving the required strength through the metallic frame reinforcement.
2Ease of manufacture
If the tongue is made thin to reduce material usage, then manufacturing cost decreases, but the tongue becomes prone to damage during insertion
Solution Approach 1:
The tongue is constructed as a composite structure with a thin non-conductive molded portion providing insulation and a metallic frame portion providing structural strength. This allows the tongue to be made thin for ease of manufacture and cost reduction while the metallic frame ensures durability during insertion and extraction operations.
Solution Approach 2:
The tongue is segmented into a non-conductive molded portion and a metallic frame portion that are separately manufactured and then assembled. This segmentation enables the molded portion to be produced simply and economically while the metallic frame provides the necessary mechanical strength, resolving the contradiction between manufacturing ease and reliability.
3Reliability
If reinforcement structures are added to the receptacle, then durability against insertion forces improves, but manufacturing complexity increases
Solution Approach 1:
The reinforcement function is separated into a distinct metallic frame assembly that is manufactured independently and then attached to the molded body. This segmentation allows the reinforcement structure to be optimized for strength without complicating the molding process, as the frame is a separate component that provides durability while maintaining manufacturing efficiency through modular assembly.
Solution Approach 2:
The metallic frame serves multiple functions simultaneously: it reinforces the receptacle against insertion forces, provides electrical conductivity for ground contacts, and offers structural support for the tongue. This multi-functionality reduces the need for additional separate reinforcement components, thereby improving reliability without proportionally increasing manufacturing complexity.
4Productivity
If high volume manufacturing is pursued, then productivity increases, but any reduction or simplification in manufacturing becomes significant
Solution Approach 1:
The receptacle is segmented into components that can be manufactured using different optimized processes: the molded body through injection molding and the metallic frame through stamping or extrusion. This segmentation enables parallel manufacturing of components and simplifies the overall manufacturing process, making high volume production more efficient and scalable.
Solution Approach 2:
The composite construction with standardized metallic frame and molded body components enables modular assembly that can be rapidly produced at high volumes. The standardized interfaces and separate manufacturing processes for each material type facilitate automation and scaling, allowing productivity to increase while keeping the manufacturing process manageable through repetition and standardization.
Data Source
AI summary
Connector receptacles that are able to withstand insertion and other forces, are reliable, and are easy to manufacture. In various examples, the connector receptacle tongue or other portions may be reinforced such that they may withstand the insertion forces exerted through a connector insert.