Shielded Sub-Miniature Connector Assembly for Weight Reduction
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Solution Overview
Problem
Existing shielded sub-miniature connectors are difficult to assemble and disassemble, making repairs and component replacements impossible, and they do not offer the necessary level of miniaturization, weight reduction, or ease of maintenance required for advanced data processing and audio-visual applications.
Innovation Solution
A shielded sub-miniature connection assembly using molded thermoplastic half-shells with nickel protection, a high contact density sub-assembly, and a method involving surface treatment, wiring, and assembly with screws and catches to create a movable and easily maintainable connector system with a shielded ferrule for earth continuity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If duplicate thermoplastic molding is used to assemble the shielded housing, then the housing is securely formed and sealed, but disassembly and repair operations become impossible
Solution Approach 1:
The connector is divided into separate modular components: a reusable housing, a reusable shielded sub-assembly, and a replaceable contact-wire-cable sub-assembly. This segmentation allows the housing to be disassembled and reused while enabling replacement of only the defective contact sub-assembly, resolving the contradiction between secure assembly and repairability.
Solution Approach 2:
The invention enables recovery and reuse of valuable components (housing and shielded sub-assembly) while discarding only the defective contact-wire-cable sub-assembly. This selective replacement approach maintains reliability of reusable parts while enabling easy repair through replacement of consumable components.
2Reliability
If traditional assembly methods are used, then components are securely retained, but the assembly process is complex and time-consuming
Solution Approach 1:
The contact-wire-cable sub-assembly is pre-assembled and pre-positioned with alignment features before insertion into the housing. The shielded sub-assembly is also pre-prepared with integrated shielding and contact retention structures. This preliminary preparation eliminates complex assembly steps during final assembly, improving productivity while maintaining secure component retention through pre-engineered retention features.
3Weight of moving object
If miniaturization is pursued to reduce weight and space, then the connector size is reduced, but assembly and maintenance become more difficult
Solution Approach 1:
The miniaturized connector is segmented into modular sub-assemblies that can be independently handled and replaced. The contact-wire-cable sub-assembly is designed as a separate replaceable unit, allowing maintenance operations on miniaturized components without requiring manipulation of the entire compact assembly, thus maintaining ease of operation despite size reduction.
Solution Approach 2:
The invention employs nested structures where the contact-wire-cable sub-assembly is inserted into the shielded sub-assembly, which in turn is positioned within the housing. This nesting approach achieves miniaturization by efficiently utilizing internal space while maintaining modular replaceability, allowing easy access and replacement of inner components without disassembling the entire compact structure.
4Reliability
If shielded housing is used for electromagnetic protection, then electrical performance is improved, but the structure becomes more complex
Solution Approach 1:
The shielding function is merged with the contact retention structure in the shielded sub-assembly. The metallic shield serves dual purposes: providing electromagnetic shielding and acting as the contact retention clip holder. This merging reduces structural complexity by eliminating separate shielding and retention components while maintaining improved electrical performance through integrated electromagnetic protection.
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 solution achieves significant weight reduction (45% weight reduction and 32% space savings) while enabling easy assembly and disassembly, high electrical performance, and easy maintenance of the connectors, suitable for miniaturized applications like large civil aviation aircraft.
Implementation Method 1
thermoplastic of the two half-shells is covered with nickel protection
Implementation Method 2
nickel protection
Implementation Method 3
metallic shield which makes it possible to provide the continuity of earth
Data Source
Figure 1~3
Figure 4a~5b
Figure 6~8b
AI summary
A shielded sub-miniature connection assembly consisting of two sub-miniature connectors 2 comprising housings provided with means of locking, consisting of two molded thermoplastic half-shells comprising a high contact density miniature sub-assembly 8 comprising a molded thermoplastic insulating body 9 provided with contact cavities 10 for the positioning and retention of contacts, a back plate provided with a contact-retaining clip and whose sidewalls comprise projecting dimples, a molded thermoplastic receptacle shell 12 comprising a flange 13 provided with oblong apertures 14 into which the projecting dimples of the back plate are locked. The present invention likewise concerns the process of forming the connection assembly.