Direct-Mount Shield Connector Bolt Retention via Metal Shell Integration
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Solution Overview
Problem
Conventional device direct-mounting shield connectors face issues with upsizing due to permanent set in fatigue of resin-made flanges and the need for metal collars to prevent bolt loss, leading to increased size and thickness requirements.
Innovation Solution
A device direct-mounting shield connector design featuring a nonconductive connector housing with a metal shield shell that is integrated by embedding or press-fitting, eliminating the need for metal collars and allowing for downsizing by positioning the fastening section outside a waterproofing member, which reduces the overall size and eliminates the need for additional locking structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal collars are fixed to the resin-made flange by insert-molding or press-fitting to prevent bolt loss, then reliability is improved, but the flange must be made larger in thickness and size, causing the device to upsize
Solution Approach 1:
The invention extracts the metal collar from the resin flange assembly and attaches it directly to the shield shell instead. This separates the bolt retention function from the resin component, eliminating the need for insert-molding or press-fitting metal collars into the flange, and thus avoids the size increase that would be required to accommodate these fastening features in the resin structure.
Solution Approach 2:
Instead of attaching the metal collar to the resin flange (conventional approach), the invention inverts the attachment relationship by fixing the metal collar to the shield shell. This reversal allows the resin flange to remain thin and compact while still achieving reliable bolt retention through the shield shell-mounted collar.
2Reliability
If the flange is made larger to hold metal collars and prevent cracking from thermal shock, then reliability is improved, but the device direct-mounting shield connector upsizes
Solution Approach 1:
The invention extracts the thermal shock resistance function from the resin flange and transfers it to the metal shield shell. Since metal has superior thermal shock resistance compared to resin, the shield shell assumes this protective role, allowing the resin flange to be made thinner and smaller without compromising overall reliability.
Solution Approach 2:
The invention employs a composite structure combining resin flange and metal shield shell, each material performing the functions it is best suited for. The metal shield shell provides thermal shock resistance and structural strength, while the resin flange provides insulation and electrical isolation, allowing optimal performance without excessive size.
3Ease of manufacture
If bolts are used to fasten the flange to the casing, then ease of assembly is improved, but the resin flange is subject to permanent set in fatigue causing bolts to fall off
Solution Approach 1:
The invention extracts the bolt fastening function from the resin flange and relocates it to the metal shield shell. By mounting the metal collar on the shield shell rather than the flange, the bolts are supported by the rigid metal structure which does not suffer from permanent set, thereby maintaining reliable bolt retention while preserving simple assembly.
Solution Approach 2:
Instead of fastening the flange directly to the casing (conventional approach), the invention inverts the fastening hierarchy by attaching the metal collar to the shield shell and then fastening through that. This inversion transfers the mechanical stress from the resin flange to the metal shield shell, eliminating fatigue-induced permanent set while maintaining bolted assembly simplicity.
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 design achieves a downsized connector with enhanced shielding effectiveness and reduced risk of bolt loss, maintaining stable electrical connections while preventing water intrusion and deformation.
Implementation Method 1
the shield shell is fastened to the casing by passing a bolt into the through hole provided in the fastening section and a bolt hole formed in the casing and by tightening the bolt
Implementation Method 2
a waterproofing member configured to prevent water from intruding from the opening section via a clearance between the connector housing and the casing
Implementation Method 3
a metal shield shell installed in the connector housing and covering the circumference of the terminal housing section
Implementation Method 4
the shield shell has an elastic contact piece. In the case that the flange section of the connector housing is bolted to the casing, the elastic contact piece of the shield shell is pressed against the casing
Data Source
AI summary
A device direct-mounting shield connector configured to be installed in an opening section in a metal casing, includes a nonconductive connector housing and a metal shield shell. The connector housing has a cylindrical hood section which includes a terminal housing section. The metal shield shell is installed in the connector housing and covers a circumference of the terminal housing section. The shield shell integrally has an exposed section and a fastening section. The exposed section is configured to contact to a shield shell of the mating connector when the mating connector is fitted with the connector housing. The fastening section has a through hole at a rear end side of the connector housing. The shield shell is fastened to the casing by passing a bolt into the through hole and a bolt hole in the casing and by tightening the bolt.