Shielded Connector Single Core Segmentation Calking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing shielded connectors have complex and costly manufacturing processes, leading to unstable calking and high production costs due to the need for split pieces and complicated apparatuses.
Innovation Solution
A shielded connector design featuring a single core with a stepped portion inserted into a shielded shell, where a knitted conductor is calked between a shield ring and the shell, forming a calk-deformed portion within the stepped portion, allowing for stable integration and cost-effective manufacturing without dividing the core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If split pieces are used to form the shielded shell, then the manufacturing process can accommodate complex shapes, but the apparatus becomes complicated and expensive
Solution Approach 1:
The shielded shell is formed from a single core that is divided into multiple segments after calking. The core is inserted as one piece for simplified manufacturing, then split into plurality of pieces subsequent to the calking process, resolving the contradiction between shape complexity and apparatus simplicity
Solution Approach 2:
The core is prepared in advance as a single integrated piece with the shielded shell formed around it before any splitting occurs. This preliminary formation allows the manufacturing apparatus to remain simple while still achieving complex final shapes through subsequent segmentation
2Ease of manufacture
If split pieces are used to form the shielded shell, then the shell can be manufactured, but the calking pressure cannot be concentrated and the calking becomes unstable
Solution Approach 1:
The core is divided into multiple segments after the calking process is complete. During calking, the core remains as a single unified structure that can concentrate pressure, ensuring stable calking. The segmentation occurs subsequently, maintaining both manufacturing ease and calking precision
Solution Approach 2:
The core is inserted as a complete, undivided structure before calking takes place. This preliminary state allows for concentrated pressure application during calking, ensuring manufacturing precision, while the final segmented configuration is achieved after the critical calking operation
3Shape
If a complicated apparatus with spring means is used, then the shielded shell can be manufactured with expanding outline, but the manufacturing cost increases
Solution Approach 1:
The shielded shell is formed around a single core and then divided into segments after calking. This approach allows the shell to achieve complex expanding outlines without requiring complicated apparatus with spring means, as the segmentation is achieved through a simpler subsequent process
Solution Approach 2:
The shielded shell is preliminarily formed around the complete core structure before any segmentation occurs. This preliminary formation can be achieved with simpler apparatus, and the complex expanding outline is realized through subsequent division into multiple pieces rather than through complicated apparatus
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
This design simplifies the manufacturing process, reduces costs, and ensures stable integration by maintaining the shape of the shielded shell without deforming it, eliminating the need for split pieces and complex apparatuses.
Implementation Method 1
a shield ring interposing the knitted conductor between the shield ring and the shielded shell, to be calked so that the knitted conductor is electrically connected to the shielded shell
Implementation Method 2
a contact portion which contacts a peripheral face of the core for maintaining a clearance formed by the stepped portion between the contact portion and the peripheral face of the core
Data Source
AI summary
There is provided a method of manufacturing a shielded connector which includes: a terminal-attached wire; a housing containing the terminal of the terminal-attached wire; a shielded shell integrated to the housing; a knitted conductor mounted to the wire; and a shield ring interposing the knitted conductor between the shield ring and the shielded shell so that the knitted conductor is electrically connected to the shielded shell. The method includes: inserting, into the shielded shell, a single core having a stepped portion formed in a opposed drawing direction; bringing a contact portion formed at the shielded shell into contact with the core; covering the shield ring on the shielded shell via the knitted conductor; and calking the shield ring, the knitted conductor, and the shielded shell from outer side of the shield ring to form, on the shielded shell, a calk-deformed portion contained into the stepped portion of the core.