Seamless Metallic Shell for Electrical Connector Retention
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Solution Overview
Problem
Existing electrical connectors face challenges in achieving reliable retention and structural strength, particularly in the upper part of the metallic shell during mating with complementary connectors, and traditional manufacturing methods limit the production of matrix-type connectors.
Innovation Solution
The electrical connector features a seamless metallic shell sleeve formed through metal drawing, with inward bulges and a chamfered edge for secure retention, and an insert-molding process that allows simultaneous formation of multiple connectors in a matrix configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional manufacturing methods are used for metallic shells, then production flexibility is maintained, but structural strength and retention reliability are insufficient
Solution Approach 1:
The patent changes the manufacturing parameters by transitioning from traditional segmented fabrication methods to a seamless metal drawing process. This parameter change enables the metallic shell to achieve superior structural strength and retention reliability while maintaining manufacturing efficiency through a continuous forming operation that can produce matrix-type connector arrays.
2Reliability
If traditional metallic shell structures are used, then manufacturing simplicity is maintained, but retention reliability during mating is insufficient
Solution Approach 1:
The patent applies curvature principles by forming the metallic shell through a drawing process that creates a seamless, curved structure with optimized geometry. The shell features a rounded profile with controlled radii that enhance retention reliability during mating operations while the seamless construction avoids complex joints or seams that would compromise reliability.
3Productivity
If traditional manufacturing processes are used, then production of single connectors is feasible, but matrix-type connector production is limited
Solution Approach 1:
The patent merges multiple manufacturing operations into a single seamless metal drawing process. This combining of operations enables the simultaneous production of matrix-type connector arrays from a single blank material, dramatically improving productivity by producing multiple connectors in one operation rather than requiring separate manufacturing steps for each connector.
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
The seamless metallic shell provides enhanced structural strength and reliable retention, enabling efficient mating with complementary connectors while enabling matrix-type manufacturing of multiple connectors simultaneously.
Implementation Method 1
the insulative housing is insert-molded with the center conductor and the metallic shell
Implementation Method 2
The seamless upper part is sufficiently rigid to not easily deform during mating with a complementary electrical connector
Data Source
AI summary
An electrical connector includes: an insulative housing having a base; a center conductor secured to the insulative housing; and a metallic shell secured to the insulative housing and surrounding the center conductor, the metallic shell including a sleeve having a lower part secured to the base of the insulative housing and an upper part extending upwardly beyond the base of the insulative housing; wherein the insulative housing is insert-molded with the center conductor and the metallic shell; and the sleeve of the metallic shell is formed as a seamless structure.