Wedge-Shaped Outer Shell for Plug Connector Cable Adaptation

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Solution Overview

Problem

Existing plug connector assemblies have a uniform thickness, which does not accommodate cables of varying diameters efficiently, leading to a bulkier structure when a larger diameter cable is used.

Innovation Solution

A plug connector assembly with a wedge-shaped outer shell, where the thickness gradually increases from the front to the rear, allowing for a thinner structure that can accommodate larger diameter cables while maintaining structural strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the outer shell has a constant thickness, then the structure is simple to manufacture, but the overall thickness increases when accommodating larger diameter cables

Engineering Contradiction:

Improveease of manufactureVSAvoidthickness of outer shell

Core Design Contradiction:

Ease of manufactureVSLength of stationary object

Solution Approach 1:

The outer shell transitions from uniform thickness to variable thickness, with the front portion having a first thickness and the rear portion having a second thickness greater than the first. This local variation in thickness allows the shell to accommodate larger diameter cables at the rear while maintaining a thinner profile at the front where the mating member is located, thereby reducing the overall thickness of the plug connector assembly.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If the outer shell thickness is increased to accommodate larger cables, then cable accommodation is improved, but the overall structure becomes bulkier

Engineering Contradiction:

Improvecable accommodation capabilityVSAvoidoverall thickness of assembly

Core Design Contradiction:

Adaptability or versatilityVSLength of stationary object

Solution Approach 1:

The outer shell is designed with different thicknesses at different locations: the front portion has a first thickness suitable for enclosing the mating member, while the rear portion has a second thickness (greater than the first) for accommodating larger diameter cables. This localized thickness variation allows the assembly to adapt to larger cables without increasing the overall thickness of the entire plug connector assembly.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent introduces a vertical dimension variation in the outer shell thickness, creating a wedge-shaped profile where thickness changes from front to rear. This dimensional change allows the shell to provide increased cable accommodation capacity at the rear while maintaining a thinner overall profile, effectively solving the contradiction between cable adaptability and overall thickness.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS9698544B2Electrical connector having a sloping outer shell and a light emitting member

Publication Date: 2017.07.04 FOXCONN INTERCONNECT TECHNOLOGY LTD

AI summary

A plug connector assembly (1) adapted to plug into a receptacle in two reversed directions, includes a mating member (10), a cable (30) electrically connected with the mating member, and an outer shell (50) including a main body (51), and a strain relief member (52) disposed at a rear end of the main body and enclosing the cable. The main body includes a front portion (510) enclosing a rear end (102) of the mating member, and a rear portion (511) opposite to the front portion and connected with the strain relief member. A thickness of the front portion is smaller than a thickness of the rear portion measured along a vertical direction. A thickness of the outer shell measured along the vertical direction is gradually increased in a constant slope along a front to rear direction