Single Sheet Connector Housing With Integrated Keyed Connection Members
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Solution Overview
Problem
Existing connector housings with separate upper, lower, and partition members suffer from poor structural strength, dimensional control issues, and complex assembly processes, leading to manufacturing inefficiencies and potential scratches on rubber shield rings.
Innovation Solution
A connector housing design featuring a single sheet of material with integrated first and second connection members, including dovetail tabs and receiving passageways, which are keyed together to form a robust and efficient structure, allowing for simplified assembly and increased manufacturing automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connector housing is made from separate upper housing, lower housing, and partition member, then the assembly allows for modular manufacturing, but the structural strength is poor and structural cracks may occur
Solution Approach 1:
The patent merges the upper housing, lower housing, and partition member into a single integrated housing structure formed from one piece of metal sheet through stamping and folding processes. This eliminates the separate components and their associated assembly requirements, directly resolving the contradiction by prioritizing structural strength while maintaining manufacturability through forming processes.
2Adaptability or versatility
If the upper housing, lower housing, and partition member are assembled separately, then manufacturing flexibility is improved, but the assembly process becomes complex and manufacturing efficiency decreases
Solution Approach 1:
The housing components are merged into a single stamped and folded metal sheet structure, eliminating multiple assembly steps. The connection members are integrated directly into the housing walls during the forming process, allowing the entire housing to be produced in one manufacturing operation rather than requiring separate assembly of multiple components.
Solution Approach 2:
The patent changes the manufacturing approach from assembly of discrete components to a single forming process. By using stamping and folding operations on metal sheets, the process parameters shift from mechanical assembly to thermal/mechanical forming, significantly improving manufacturing efficiency while maintaining design flexibility.
3Ease of operation
If separate connection members are used to join housing components, then assembly flexibility is improved, but the number of parts increases and assembly complexity increases
Solution Approach 1:
The connection members are merged with the housing walls themselves through integrated forming processes. The first connection members are formed as integral parts of the upper and lower housing walls, while the second connection members are formed as integral parts of the partition member walls. This eliminates separate fasteners and joints, reducing part count while maintaining assembly flexibility through the forming process.
Data Source
AI summary
A connector housing is provide and includes a single sheet of material, a plurality of first connection members, and a plurality of second connection members. The single sheet of material includes a top wall, a pair of side walls, a bottom wall having a first bottom wall portion and a second bottom wall portion connected to the pair of side walls, and a partition member disposed between the top wall and the bottom wall to partition an inner space defined by the top wall, the pair of side walls and the bottom wall. The plurality of first connection members are disposed along one of the pair of longitudinal edge portions, while the plurality of second connection members are disposed along the other of the pair of longitudinal edge portions. The plurality of first connection members are keyed with the plurality of second connection members, respectively.