Bent Terminal Connector Structure for Molding Accuracy
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Solution Overview
Problem
Existing connectors face challenges in maintaining the accuracy of terminal position and orientation due to deformation during the molding process, particularly with resin shrinkage affecting the bent parts.
Innovation Solution
A connector design featuring a terminal with a bent part, a first resin portion that holds the terminal, and a second resin portion molded with the first as an insert, along with a reinforcing portion in the inner corner of the bent part to suppress deformation, ensuring the accuracy of terminal positioning and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a terminal with a bent part is molded using a single resin portion, then the manufacturing process is simple, but the position and orientation accuracy of the terminal deteriorates due to deformation from resin shrinkage
Solution Approach 1:
The resin portion is divided into a first resin portion and a second resin portion that are molded separately and then integrated. The first resin portion holds the terminal with the bent part exposed, while the second resin portion is molded with the first as an insert part. This segmentation allows the terminal to be positioned and fixed accurately before the second molding, preventing deformation from resin shrinkage and maintaining position and orientation accuracy.
2Object-affected harmful factors
If the bent part is fully covered by resin, then the terminal is protected, but deformation occurs due to resin shrinkage affecting the bent part
Solution Approach 1:
The first resin portion covers only a specific region of the terminal, holding it securely while leaving the bent part exposed. This localized coverage protects the terminal body from harmful factors during molding without subjecting the bent part to resin shrinkage stress, thereby preventing deformation while maintaining protection where needed.
3Manufacturing precision
If a reinforcing portion is added to suppress deformation, then terminal accuracy improves, but device complexity increases
Solution Approach 1:
The first resin portion is molded in advance with the terminal inserted, establishing precise position and orientation before the second resin portion is molded. This preliminary action secures the terminal in the correct position, and the subsequent second molding process does not cause deformation because the terminal is already fixed. This eliminates the need for additional reinforcing structures, maintaining simplicity while achieving high accuracy.
Data Source
AI summary
The purpose of the present invention is to further improve the accuracy of the orientation and position of a terminal of this connector. The connector comprises: a terminal including a bending section; a first resin part that holds a portion of the terminal in a state in which the bending section is exposed to the outside; a second resin part that is die-molded with the first resin part used as an insert section; and a reinforcing part that is disposed inside an inner corner of the bending section in a state in which an outer corner of the bending section is exposed. The bending section and the reinforcing part are covered with the second resin part.