Stacked Electrical Connector Shielding for Receptacle Stability
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Solution Overview
Problem
Conventional electrical connectors with multiple receptacle assemblies suffer from instability and reduced connection reliability due to the inability to prevent the shift of upper receptacle assemblies within the shell, especially when molded using traditional methods that restrict the formation of engagement protrusions on upper inner surfaces.
Innovation Solution
Incorporating a shield member between the lower and upper receptacle assemblies, which is press-fitted into the shell to engage with the cylindrical portion of the upper receptacle assembly, thereby stabilizing the position of the upper receptacle assembly and enhancing the holding force, thus preventing shifts and improving contact reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional molding methods are used for the shell, then manufacturing simplicity is maintained, but engagement protrusions cannot be formed on upper inner surfaces, causing upper receptacle assemblies to shift
Solution Approach 1:
The shell is divided into multiple parts: a main shell body and separate engagement protrusions that can be formed independently. This segmentation allows the engagement protrusions to be created using simple post-molding operations rather than requiring complex multi-directional molding, thus improving position stability without significantly increasing manufacturing complexity
Solution Approach 2:
The engagement protrusions are formed on the inner surfaces of the shell before the upper receptacle assemblies are installed. This preliminary formation of engagement features ensures that the positioning structure is ready in advance, preventing any shift during assembly and operation while using straightforward molding or post-processing techniques
2Strength
If engagement protrusions are formed on upper inner surfaces of the shell, then holding force for upper receptacle assembly is improved, but molding process becomes more complex
Solution Approach 1:
The engagement protrusions are designed as separate structural elements that can be formed independently from the main shell body. This allows them to be created using simple post-molding operations such as punching, embossing, or separate injection molding, rather than requiring complex multi-cavity or multi-directional molding tools, thus increasing holding force without significantly complicating the manufacturing process
Solution Approach 2:
The engagement protrusions act as intermediary elements between the shell and the upper receptacle assembly. These protrusions provide the necessary mechanical interlocking without requiring the shell itself to be molded with complex internal geometries, thereby enhancing holding force while keeping the molding process relatively simple
3Reliability
If upper receptacle assembly is allowed to shift, then device complexity is reduced, but contact reliability deteriorates
Solution Approach 1:
The positioning function is segmented from the main shell structure and implemented through discrete engagement protrusions. This segmentation allows the shell to maintain a relatively simple overall structure while incorporating specific localized features for positioning, thus improving contact reliability without significantly increasing device complexity
Solution Approach 2:
Instead of making the entire shell structure complex to prevent shifting, engagement protrusions are added only at specific local positions where positioning is needed. This localized approach provides the necessary constraint on upper receptacle assemblies while keeping the rest of the shell structure simple, thereby improving reliability without proportionally increasing complexity
Data Source
AI summary
An electrical connector includes at least one lower receptacle assembly, at least one upper receptacle assembly located on the upper side of the at least one lower receptacle assembly, at least one shield member located between the at least one lower receptacle assembly and the at least one upper receptacle assembly, and a metal shell for holding the at least one lower receptacle assembly, the at least one upper receptacle assembly, and the at least one shield member. The at least one shield member engages with a cylindrical portion of an upper housing of the at least one upper receptacle assembly.