SMT Electrical Plug with Sheet Metal Strain Relief
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Solution Overview
Problem
Existing connectors face limitations in achieving maximum plugging security and optimal strain relief due to the thickness of plastic webs, which compromise stability and over-mating safety.
Innovation Solution
The strain relief elements are designed as sheet metal parts angled to form a bearing surface directly attached to the plastic webs, eliminating the need for additional fastening devices and allowing for thinner, more stable attachments that enhance nesting and reverse polarity protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plastic webs are made thinner to enable maximum plugging depth, then over-mating security is improved, but strain relief stability deteriorates
Solution Approach 1:
The connector combines plastic housing material with metal strain relief elements to achieve both thin-web depth and high stability. The metal elements provide the necessary strength and rigidity that plastic alone cannot deliver at reduced thickness, while allowing the plastic web to be made thinner for maximum plugging depth.
Solution Approach 2:
The strain relief function is segmented from the plastic web structure and implemented as separate metal elements. This allows the plastic web to be optimized for thickness (thin for depth) while the metal elements provide the strain relief stability independently, resolving the contradiction between the two requirements.
2Length of moving object
If plastic webs are made thinner to increase plugging depth, then nesting is improved, but structural stability deteriorates
Solution Approach 1:
The connector uses a composite structure where thin plastic webs provide the necessary plugging depth while attached metal strain relief elements provide the structural stability that thin plastic alone cannot achieve.
Solution Approach 2:
The web structure is segmented into thin plastic portions for depth and separate metal reinforcement elements for stability, allowing each component to be optimized for its specific function without compromise.
3Strength
If additional fastening devices are added to attach strain relief elements, then attachment stability is improved, but device complexity increases
Solution Approach 1:
The strain relief elements are integrated directly into the plastic web structure through attachment projections formed on the webs themselves, eliminating the need for separate fastening devices. The web and strain relief element function as a unified assembly, reducing overall complexity while maintaining attachment stability.
Solution Approach 2:
The plastic webs serve multiple functions: providing structural support, enabling plugging depth, and directly attaching strain relief elements through integrated projections. This multi-functionality eliminates the need for dedicated fastening components, simplifying the overall device structure.
Data Source
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AI summary
The invention relates to a plug comprising a plurality of contact elements located in a plug housing and strain relief elements (200, 200') arranged on the housing (110, 310), wherein both contact elements and strain relief elements can be fixed to a printed circuit board (10) using SMT technology. The invention is characterized in that the strain relief elements (200, 200') are sheet metal elements that can be fixed to parts of the plug housing and are bent essentially at a right angle on the side facing the printed circuit board (10), thereby forming a bearing surface (220, 220') for SMT attach.