Additive Printed Insulator Socket Housing for High-Density Connectors
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Solution Overview
Problem
Traditional methods for manufacturing connector and socket housings, such as injection molding and precision machining, are inadequate for high-density connectors with fine pitches and complex features, leading to dimensional instability and high production costs.
Innovation Solution
The development of a high-performance insulator socket housing using additive printing technology, which allows for digital production without tooling, enabling the creation of complex structures like undercuts and hollows, and integration of multiple materials and circuit-like features, such as embedded components and conductive paths, to enhance electrical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding or precision machining is used to manufacture connector housings, then production efficiency and structural strength are improved, but manufacturing flexibility and adaptability to complex features deteriorate
Solution Approach 1:
The patent transitions from subtractive machining or injection molding to additive manufacturing, fundamentally changing the manufacturing parameter space. This enables complex features like undercuts and hollows that are difficult or impossible to achieve with traditional methods, while maintaining production efficiency through digital fabrication processes.
Solution Approach 2:
The invention moves from 2.5D manufacturing (molding and machining) to true 3D additive manufacturing. This dimensional transition allows for complex geometries, internal hollow structures, and undercut features that cannot be produced by conventional subtractive or formative processes, significantly enhancing manufacturing adaptability.
2Strength
If glass fibers or particles are loaded into the base material to provide strength, then mechanical strength is improved, but dimensional stability under thermal cycling deteriorates
Solution Approach 1:
The patent employs composite materials consisting of dielectric polymer matrix combined with reinforcing fillers such as glass fibers, glass particles, or other inorganic materials. This composite structure provides both the necessary mechanical strength and dimensional stability, as the inorganic fillers maintain structural integrity during thermal cycling while the polymer matrix provides flexibility and manufacturability.
3Ease of manufacture
If traditional molding methods are used for high density connectors with fine pitches, then production cost is reduced, but manufacturing precision and feature complexity deteriorate
Solution Approach 1:
The patent replaces traditional mechanical molding and machining systems with additive manufacturing technology. This substitution eliminates the need for expensive molds and tooling, reducing upfront costs for low-volume production while simultaneously enabling fine pitch features and complex geometries that are difficult to achieve with conventional mechanical processes.
4Adaptability or versatility
If additive printing technology is used to manufacture insulator socket housing, then manufacturing flexibility and feature complexity are improved, but production cost and process complexity deteriorate
Solution Approach 1:
The additive manufacturing process is divided into discrete layers that are built sequentially. This segmentation allows for precise control of each layer's geometry and material composition, simplifying the overall process by breaking down complex 3D structures into manageable 2D cross-sections that can be manufactured with high precision and flexibility.
Data Source
AI summary
A socket housing and method of making the socket housing. A plurality of dielectric layers are printed with a plurality of recesses on a substrate. The dielectric layers include at least two different dielectric materials. A sacrificial material is printed in the recesses. The assembly is removed from the substrate and the sacrificial material is removed from the recesses. At least one contact member is located in a plurality of the recesses. Distal ends of the contact members are adapted to electrically couple with circuit members.