Angular Connector Injection Molding Positioning
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Solution Overview
Problem
Conventional cable connectors face issues with displacement and overturning during the injection molding process when forming corners, leading to reduced production yield.
Innovation Solution
The angular connector design includes a plug, transmission cable, inner molding body, positioning case, and outer molding body, where the positioning case is fastened to the plug to maintain the insertion portion exposed, and the outer molding body is connected to the inner molding body and positioning case to form a corner structure with an angle greater than 90 degrees, allowing for precise electrical coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the molding compound is formed in an injection molding manner to create a corner of a specific angle, then the corner structure can be formed, but the plug easily experiences displacement or overturning during the forming process
Solution Approach 1:
The patent applies preliminary action by pre-positioning the plug at a specific angle (45 degrees) relative to the injection molding direction before the molding process begins. The plug is fixed in this preliminary position using positioning structures, ensuring that when the molding compound is injected, the plug maintains its correct orientation and does not experience displacement or overturning. This pre-positioning resolves the contradiction by establishing the corner structure angle while preserving plug position accuracy throughout the forming process.
2Strength
If the plug is fully covered by the molding compound, then the connection strength is improved, but the insertion portion cannot be properly exposed for electrical coupling
Solution Approach 1:
The patent applies local quality by differentiating the coverage of the molding compound across different regions of the plug. The molding compound fully covers the body portion of the plug to provide strong connection strength and protection, while deliberately leaving the insertion portion exposed at a precise distance (0.5mm to 1.5mm) from the end of the molding compound. This localized differentiation resolves the contradiction by maintaining both strong overall connection and precise insertion portion exposure for electrical coupling.
3Volume of moving object
If the insertion length is too short, then the plug fits compactly, but the electrical coupling with the mating connector is insufficient
Solution Approach 1:
The patent applies parameter changes by precisely controlling the insertion length parameter within an optimal range (0.5mm to 1.5mm exposure distance). This specific parameter range ensures that the insertion portion is sufficiently exposed to achieve reliable electrical coupling with the mating connector, while maintaining compact overall dimensions. The defined parameter range resolves the contradiction by balancing electrical coupling reliability with connector compactness.
Data Source
AI summary
An angular connector and a manufacturing method thereof are provided. The angular connector includes a plug, a transmission cable connected to the plug, an inner molding body covering part of the plug and part of the transmission cable, a positioning case fastened to the plug, and an outer molding body that is connected to the inner molding body and the positioning case. The plug has an insertion slot recessed in an end of the insertion portion. An insertion portion of the plug is maintained to be exposed from the positioning case by an insertion length along the insertion direction, and the insertion length is within a range of 6.5 mm to 6.8 mm. The outer molding body and the positioning case jointly define a corner structure having an angle that is greater than or equal to 90 degrees and that is less than 180 degrees.