Shielded Connector Assembly via Integrated Fastening Element
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Solution Overview
Problem
Existing shielded connectors, such as D-Sub connectors, are complex and costly to produce due to their numerous components, making them inefficient in terms of assembly and component production.
Innovation Solution
A D-Sub connector design that utilizes a base body with recesses for uninterrupted insertion of fastening elements, which are stamped and bent parts with a U-shaped holding device, and a shielding element with peripheral tabs for non-positive connection, reducing the number of components to three and simplifying assembly, while maintaining effective shielding and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional shielded connectors are assembled using multiple separate components (mounting elements, side elements, contact springs, lugs), then the connector achieves adequate shielding and electrical contact, but the assembly process becomes complex and expensive
Solution Approach 1:
The patent combines multiple separate components (mounting element, side element, contact spring, and lug) into a single integrated fastening element. This fastening element includes a mounting portion, a side portion with contact spring, and a lug portion, all formed as one piece through stamping and bending operations. This merging reduces the component count from four or more separate parts to a single component, simplifying assembly while maintaining the shielding and electrical contact functions through the integrated structure's geometric design and material properties
2Object-affected harmful factors
If traditional shielded connectors use multiple separate components for mounting and shielding, then the shielding function is achieved, but the manufacturing effort and production cost increase
Solution Approach 1:
The patent integrates the mounting function, shielding function, and electrical contact function into a single fastening element. The element is manufactured through stamping and bending operations that create the mounting portion, side portion with contact spring, and lug portion as one integrated component. This reduces assembly effort from multiple separate assembly operations to a single installation step, while the geometric design of the integrated structure maintains effective shielding against interfering electrical fields
Solution Approach 2:
The fastening element serves multiple functions simultaneously: it provides mechanical mounting through its mounting portion, electrical contact through its contact spring, and shielding through its conductive body and lug portion. This multi-functionality eliminates the need for separate components for each function, simplifying manufacturing while maintaining all required protective and functional properties
3Productivity
If the connector uses a simplified design with fewer components, then the assembly process is simplified, but the mechanical stability against tensile, compressive and torsional forces may be compromised
Solution Approach 1:
The fastening element is designed with distinct functional portions (mounting portion, side portion with contact spring, and lug portion) that are integrated into a single component. Each portion is optimized for its specific function while being structurally connected to provide overall mechanical stability. The segmented design within the integrated structure allows efficient assembly while maintaining strength against tensile, compressive, and torsional forces through the interconnection of these portions
4Ease of operation
If the fastening element is inserted uninterrupted into the additional recess, then the assembly is simplified, but the precision of electrical contact alignment may be affected
Solution Approach 1:
The fastening element is designed to automatically align itself during the uninterrupted insertion process. The geometric design of the element, including the U-shaped holding device and the contact spring positioning, ensures that as the element is inserted into the additional recess, it self-aligns to the correct position without requiring external alignment tools or complex positioning mechanisms. This self-alignment maintains manufacturing precision while allowing simple insertion operations
Data Source
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AI summary
For a shielded connector, it is proposed that, to simplify its assembly, an electrically insulating base body, intended as a carrier for electrical contacts, has a mounting surface with two openings. Around each of these openings is a recess, on the inner side of each recess a collar is formed. Furthermore, lateral mounting elements are provided on the base body, each with a window formed by a frame. By bending the mounting elements, the frame can be positively inserted into the corresponding recesses, thereby fixing the mounting element to the base body in a form-fit and force-fit manner. An electrically conductive shielding element, largely surrounding the base body, contacts the mounting elements, which in turn contact ground traces on a printed circuit board, thus shielding the connector against external voltages.