Reversible Dual-Position Electric Connector Shielding
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Solution Overview
Problem
Conventional electric connectors face challenges in manufacturing precision, high costs, and inconvenient assembly due to embedded terminals, separate ground shielding sheets, and complex shielding structures, which affect their shielding properties and structural strength.
Innovation Solution
A reversible dual-position electric connector design featuring a metal housing with integrated ground shielding members, a gapless connection surface, and a metal shell formed by bending metal plate sheets, providing excellent shielding and structural support while allowing easy manufacturing and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two rows of terminals are integrally embedded into the plastic seat, then the electrical connection is achieved, but the manufacturing precision requirement becomes extremely high and manufacturing becomes difficult
Solution Approach 1:
The connector is divided into separate components: the plastic seat and the terminal assembly. The terminal assembly can be manufactured separately and then assembled to the plastic seat, avoiding the need for high-precision integral embedding of terminals into the seat. This segmentation allows each component to be manufactured with relaxed tolerances and then joined together.
Solution Approach 2:
The terminal assembly combines multiple terminals and the plastic holder into a single pre-assembled unit. This merging allows the terminals to be positioned and fixed relative to each other in a controlled manufacturing process, and then the entire assembly is attached to the plastic seat, reducing the overall manufacturing precision requirements compared to integral embedding.
2Object-affected harmful factors
If the metal housing is bent from a metal plate sheet to form a four-sided housing, then the shielding effect is provided, but a seam is created that affects the shielding performance
Solution Approach 1:
The metal housing is designed as a nested structure where multiple metal sheets or panels are layered and interlocked. The seams between panels are positioned such that they are shielded by overlapping edges or conductive gaskets, effectively blocking electromagnetic interference while maintaining the segmented construction for ease of manufacturing.
Solution Approach 2:
Conductive gaskets or shielding sheets are introduced as intermediary elements between the metal housing panels. These intermediaries bridge the gaps and seams between panels, providing continuous electromagnetic shielding while allowing the housing to be constructed from separate bent metal sheets for manufacturing convenience.
3Object-affected harmful factors
If the rear shielding shell is formed by metal pulling and extending to create front and rear shells fitting together, then the shielding structure is completed, but the manufacturing cost becomes very high
Solution Approach 1:
The shielding shell is divided into front and rear sections that can be manufactured separately using simpler, lower-cost processes. These segmented sections are then assembled together, avoiding the need for complex and expensive metal pulling and extending operations required for monolithic shielding shells. The segmentation enables the use of standard stamping or bending processes for each section.
Solution Approach 2:
The front and rear shielding shells are merged through a simplified assembly process such as welding, riveting, or interlocking joints. This merging creates the complete shielding structure at a lower cost than forming a single complex piece through metal pulling and extending, while maintaining the necessary shielding effectiveness.
4Reliability
If two separate ground shielding sheets are provided in the socket and plug, then the grounding function is achieved, but the assembling becomes inconvenient and the overall structure strength cannot be strengthened
Solution Approach 1:
Two separate ground shielding sheets are merged into a single integrated ground shielding component. This integrated component performs the grounding function for both the socket and plug while reducing the number of parts to be assembled. The unified structure also provides enhanced mechanical strength and structural rigidity compared to two separate sheets.
5Reliability
If the connection slot is made asymmetrical in the top-to-bottom direction to provide mistake-proof effect, then single-position electrical connection is achieved, but reversible dual-position connection is prevented
Solution Approach 1:
The connection slot employs asymmetric features in specific regions to guide proper alignment and provide mistake-proof connection at the correct position. However, the overall structure maintains symmetry or complementary features that allow the connector to be inserted in either orientation, enabling reversible dual-position connection. The asymmetric elements act as alignment guides rather than absolute constraints.
Data Source
AI summary
A reversible dual-position electric connector comprises: an insulated seat provided with a base seat and one docking part, wherein the docking part is provided with two connection surfaces facing opposite directions; two terminal sets disposed on the insulated seat, wherein each of the terminal sets is provided with at least one row of terminals, and the contacts of the two terminal sets are exposed from the two connection surfaces of the docking part, respectively; and a metal housing, which covers the insulated seat and is provided with a four-sided primary housing; characterized in that a metal shell is further provided to rest against the metal housing, the metal shell is provided with a four-sided housing, the four-sided housing is fitted with and rests against the four-sided primary housing.