Thin Electrical Connector Shell With Exposed Mating Face
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Solution Overview
Problem
The increasing miniaturization of portable devices makes traditional metallic electrical connectors with a certain thickness unsuitable, necessitating a reduction in the overall thickness of electrical connectors.
Innovation Solution
An electrical connector design featuring an insulative housing with a mating tongue and a shell that includes two short-walls and at most one long-wall, allowing at least one mating face to be exposed vertically, thereby reducing the connector's thickness. The shell is formed by metal-injection-molding, and the terminals are retained in the housing via insert molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a traditional metallic shell with certain thickness is used, then the connector has sufficient strength and protection, but the overall thickness of the connector increases
Solution Approach 1:
The shell is divided into multiple walls (first wall, second wall, third wall, fourth wall) with different functions. The first and second walls provide structural support, while the third and fourth walls are designed to be as short as possible to reduce thickness. This segmentation allows the connector to maintain strength where needed while minimizing thickness in other areas.
Solution Approach 2:
The patent exposes at least one mating face of the mating tongue to the exterior in a vertical direction by making the third and fourth walls short. This dimensional change allows the connector to maintain its protective enclosure while reducing the overall thickness in the horizontal direction, enabling miniaturization of portable devices.
2Length of stationary object
If the shell is made thinner to reduce connector thickness, then the overall size is reduced, but the protection and structural integrity may be compromised
Solution Approach 1:
The shell's segmented wall structure allows different portions to serve different protective functions. The first and second walls maintain adequate thickness for structural integrity and protection, while the third and fourth walls are minimized for thickness reduction. This selective segmentation protects against external factors while achieving miniaturization.
Solution Approach 2:
Different walls of the shell have different thickness characteristics tailored to their specific functions. The first and second walls retain sufficient thickness for structural support and protection, while the third and fourth walls are made as short as possible. This local differentiation of quality allows the connector to be thin where protection is less critical while maintaining strength where needed.
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
This design effectively reduces the thickness of the electrical connector while maintaining functionality, allowing for compatible mating with plug connectors and ensuring reliable electrical connections.
Implementation Method 1
The shell is formed by metal-injection-molding
Implementation Method 2
the terminals are retained in the housing via insert molding
Data Source
AI summary
An electrical connector includes an insulative housing, a number of terminals retained in the insulative housing and a shell surrounding around the insulative housing. The insulative housing includes a base and a mating tongue extending forwardly therefrom. The mating tongue includes two opposite mating faces and two opposite side faces. The shell includes a holding portion and a mating portion. The mating portion of the shell includes two short-walls facing to the two side faces of the mating tongue and at most a long-wall facing to one of the mating faces of the mating tongue so that at least one of the mating faces of the mating tongue could be exposed to exterior in a vertical direction.