Split Metal Shell Connector Assembly Without Soldering
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Solution Overview
Problem
Existing electrical connectors have low assembly efficiency due to the one-piece outer metal shell assembly method, which is time-consuming and prone to errors, and the use of soldering or welding that can cause short circuits from slag accumulation.
Innovation Solution
The electrical connector features a split outer metal shell composed of a first and second metal shell that are assembled together via buckle and engaging portions, eliminating the need for soldering or welding and improving assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a one-piece outer metal shell is used and fixed to the inner metal shell by soldering or welding, then better shielding effect is achieved, but assembly efficiency is reduced and production time increases
Solution Approach 1:
The outer metal shell is divided into a first metal shell and a second metal shell that can be assembled separately. The first metal shell is assembled on the inner metal shell along the mating direction, and the second metal shell is assembled on the first metal shell along the width direction, eliminating the need for soldering or welding while maintaining shielding effectiveness.
2Strength
If soldering or welding is used to fix the outer metal shell to the inner metal shell, then strong bonding is achieved, but production efficiency is reduced and slag may cause short circuits
Solution Approach 1:
The outer metal shell is segmented into multiple parts that are assembled through mechanical buckling and engaging structures rather than thermal bonding processes. This eliminates slag generation while maintaining strong mechanical bonding through the buckle portions and engaging portions.
Solution Approach 2:
The patent replaces the thermal bonding system (soldering or welding) with a mechanical bonding system using buckle portions and engaging portions. The first buckle portion and second buckle portion interlock mechanically, and the engaging portions provide additional mechanical retention, eliminating the need for heat-based processes.
3Device complexity
If a one-piece outer metal shell is assembled along the mating direction, then simple assembly is achieved, but assembly efficiency is low due to time-consuming processes
Solution Approach 1:
The outer metal shell is divided into multiple segments that can be assembled in different directions (mating direction and width direction) simultaneously or in parallel, distributing the assembly workload and reducing the time required for complete assembly while maintaining structural simplicity.
Data Source
AI summary
An electrical connector includes a connector body and an outer metal shell. The connector body includes an insulating body, a conductive terminal fixed to the insulating body, and an inner metal shell at least partly covering the insulating body. The outer metal shell at least partially covers the inner metal shell. The outer metal shell includes a first metal shell and a second metal shell assembled together. The first metal shell includes a first buckle portion. The second metal shell includes a second buckle portion buckled with the first buckle portion. As a result, assembly efficiency of the electrical connector is improved.