Unitary Overmolded Backshell for Cable Connector Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cable connector assemblies with backshells face manufacturing complexities and assembly issues due to discrete shell members, remnant portions, and the need for precise assembly to prevent electromagnetic interference (EMI).
Innovation Solution
A cable connector assembly featuring a unitary, overmolded backshell with a latch assembly that includes a deflectable spring beam for secure engagement with panels or mating connectors, providing efficient shielding and simplified installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If discrete shell members are used to form the backshell, then the backshell can be assembled around the electrical connector, but the assembly process becomes complex and time-consuming due to multiple guide pins and fasteners
Solution Approach 1:
The patent combines multiple discrete shell members and fasteners into a single integrated backshell component. This unification eliminates the need for multiple guide pins, screws, and bolts, thereby simplifying the assembly process and reducing the number of parts required while maintaining the protective and shielding functions of the backshell.
2Productivity
If die casting process is used to form shell members, then the shell members can be produced efficiently, but remnant portions remain that require post-processing grinding
Solution Approach 1:
The patent modifies the die casting process parameters and mold design to produce shell members with optimized geometry that eliminates remnant portions. By adjusting casting parameters and mold features, the process directly produces ready-to-assemble components without requiring subsequent grinding or post-processing operations.
3Reliability
If multiple shell members are fastened together, then the backshell can be assembled around the connector, but the seals may fail if not precisely assembled, allowing EMI interference
Solution Approach 1:
The patent integrates multiple sealing features into a single backshell component, eliminating the interfaces between separate shell members. This integration removes the risk of seal failure at joints while maintaining the protective sealing function, thereby improving reliability without demanding high assembly precision.
Solution Approach 2:
The patent incorporates pre-formed gaskets and sealing features directly into the single backshell component during manufacturing. These sealing elements are positioned and configured in advance to ensure proper sealing contact, compensating for any dimensional variations and preventing EMI interference without requiring precise assembly operations.
4Reliability
If gaskets are integrated at interfaces between shell members, then sealing can be provided, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The patent combines the backshell structure and gasket sealing features into a single integrated component. By forming the gaskets as integral parts of the backshell during manufacturing, the design eliminates the need for separate gasket installation steps, thereby maintaining the sealing function while simplifying the overall assembly process.
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
The solution enhances the manufacturing process by eliminating remnant portions and complex assembly, ensuring precise sealing and effective EMI shielding, thereby improving the performance and reliability of the cable connector assembly.
Implementation Method 1
The latch member includes a deflectable spring beam configured to engage the panel or the mating connector
Data Source
AI summary
A cable connector assembly includes an electrical connector and a backshell. The electrical connector includes a housing and electrical conductors held in the housing. The electrical conductors are terminated to a cable that extends from a cable end of the electrical connector. The backshell has an overmolded body and a latch assembly for removably coupling the cable connector assembly to one or more of a panel or a mating connector. The overmolded body is a unitary, one-piece body that surrounds the electrical connector around a full perimeter of the electrical connector. The latch assembly includes a latch frame and a latch member. The latch frame is embedded in the overmolded body. The latch member is held by the latch frame. The latch member includes a deflectable spring beam configured to engage the panel or the mating connector.