Shielded Electrical Connector with Integrated Sheet Metal Terminal
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Solution Overview
Problem
Existing coaxial connector assemblies lack effective shielding and efficient manufacturing processes, leading to increased part counts and complex manufacturing steps.
Innovation Solution
A method involving cutting a shield terminal preform from sheet metal, forming it into specific shapes with integral shields and semicircular channels, inserting an inner insulator, and placing it within an outer housing to create a shielded electrical connector with reduced parts and simpler assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional coaxial connector assemblies are manufactured with separate shield components, then shielding effectiveness is maintained, but part count increases and manufacturing complexity increases
Solution Approach 1:
The patent combines multiple shield components (first shield and second shield) into a single integrated shield terminal formed from one piece of sheet metal. This merging eliminates the need for separate shield parts while maintaining the shielding effectiveness through the integral construction that provides continuous electromagnetic shielding.
Solution Approach 2:
The shield terminal serves multiple functions simultaneously: it provides electromagnetic shielding, structural support for the connector assembly, and integration points for other components. The single-piece construction performs what previously required multiple separate components, reducing part count while maintaining all necessary functions.
2Reliability
If traditional coaxial connector assemblies use multiple separate shield components, then shielding coverage is maintained, but manufacturing steps increase
Solution Approach 1:
The manufacturing process benefits from combining multiple shield components into a single integrated shield terminal. This eliminates the need for separate manufacturing steps for producing and assembling multiple shield parts, while the integral construction ensures complete shielding coverage through continuous metal formation.
Solution Approach 2:
The shield terminal is pre-formed as a single integrated component with all necessary shield features built in during the initial sheet metal forming process. This preliminary action of creating the complete shield structure in one piece eliminates subsequent assembly steps required for multiple separate shield components.
3Adaptability or versatility
If traditional coaxial connector assemblies are assembled with multiple separate components, then component functionality is maintained, but assembly efficiency decreases
Solution Approach 1:
The integration of multiple shield components into a single shield terminal reduces the number of parts that need to be handled and assembled, directly improving assembly efficiency. The merged component maintains all necessary functionalities through its integrated design that incorporates multiple features into one piece.
4Strength
If sheet metal is formed into complex three-dimensional shapes with multiple seams, then structural integrity is improved, but manufacturing complexity increases
Solution Approach 1:
The shield terminal employs an asymmetric formation strategy where the first shield forms a generally tubular shape with a single seam, while the second shield forms two semicircular channels. This asymmetric approach optimizes structural integrity for each functional requirement while minimizing the total number of seams and forming operations compared to symmetric multi-seam designs.
Data Source
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AI summary
A method (100) of forming a shield terminal (10) from sheet metal having a tubular first portion (42) having a single seam (16) and aligned with a first axis (X) and a second tubular portion (44) having two seams radially (18) opposed to one another and aligned with a second axis (Y) that is oriented at a right angle to the first axis (X), an inner insulator (28) disposed within the shield terminal (10), and an outer housing (38) defining a cylindrical cavity (40) in which the tubular first portion (42) of the shield terminal (10) is disposed. Edges (20) of the single seam (16) and edges (20) of the two seams (18) are joined solely by the disposition of the tubular first portion (42) in the cylindrical cavity (40). The shield terminal (10) formed by this method (100) is also presented.