Shielded Electrical Connector With Segmented Inserts
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Solution Overview
Problem
Existing electrical connectors face issues with conductor damage during installation, improper positioning leading to damage, and challenging electrical continuity of shields, requiring costly rework and specific skills.
Innovation Solution
A shielded electrical connector design featuring a terminal subassembly with inserts and shells providing electrical shielding, where the back shell is terminated to the overbraid of the cable, and the front shell is mated to a mating connector, with contacts engaging to ensure electrical connection and reduce damage risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If removable inserts are used to hold conductors, then the connector allows flexible assembly, but the conductors may be damaged during installation and mating processes
Solution Approach 1:
The connector body includes pre-formed guide features (ridges and grooves) that direct conductor placement before the insert is installed. This preliminary positioning structure ensures conductors are properly supported and aligned during the assembly process, preventing damage while maintaining flexible insert installation
2Adaptability or versatility
If multiple inserts are installed into a connector body, then the connector can accommodate multiple terminals, but control of inserts during installation becomes problematic
Solution Approach 1:
The connector is divided into modular components: a connector body with guide features, multiple separable inserts, and a shield assembly. Each insert can be independently positioned and installed, with the segmented structure providing natural alignment references that simplify the installation process for multiple inserts
3Object-affected harmful factors
If shielding is used extensively, then electrical interference is reduced, but installation and rework require specific knowledge, tools and skills
Solution Approach 1:
The shield assembly is merged with the connector body as an integrated unit, with the shield already positioned and secured within the connector housing. This combination eliminates the need for separate shield installation steps, reducing the required knowledge and tools while maintaining comprehensive electrical shielding
4Ease of repair
If reworking of shielded connectors is performed, then repairs can be made, but destructive means are required to the retention component
Solution Approach 1:
The shield assembly is designed as a recoverable component that can be removed and reinstalled multiple times without destructive damage. The retention features are engineered to allow non-destructive removal and reattachment, enabling repair and rework while preserving the integrity of the retention components
Data Source
AI summary
An electrical connector includes a terminal subassembly having inserts holding terminals. The terminals extend between a mating end and a cable end. The cable end is configured to be terminated to corresponding wires of a cable. A front shell surrounds a front portion of the terminal subassembly. The front shell provides electrical shielding around the mating ends of the terminals. The front shell is configured to be mated to a mating connector. A back shell surrounds a rear portion of the terminal subassembly. The back shell provides electrical shielding around the cable ends of the terminals. The back shell is configured to be terminated to an overbraid of the cable. The back shell includes a plurality of contacts that extend from a front of the back shell. The contacts engage, and are electrically connected to, the front shell.