Co-Molded Conductive and Magnetic Assembly for Stable Current Sensing
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Solution Overview
Problem
Existing electrical assemblies face challenges due to complex designs and manufacturing tolerances that lead to inconsistent operation and sensing, necessitating solutions to minimize or eliminate these issues.
Innovation Solution
An electrical assembly comprising an electrically conductive first member, a magnetic second member, and a housing molded onto both, assembled by disposing the members in molds and injecting housing material to form a cohesive structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex designs and multiple components are used in electrical assemblies, then functionality can be enhanced, but manufacturing precision and operational consistency deteriorate due to significant tolerances between components
Solution Approach 1:
The patent combines multiple components (conductive member, magnetic member, housing) into a single integrated structure through co-molding. The conductive member and magnetic member are positioned within a mold cavity, and housing material is injected to form all components and their interconnections in one manufacturing process, eliminating tolerance accumulation between separate parts
Solution Approach 2:
The housing material serves multiple functions simultaneously: it forms the structural housing, provides positioning features for the conductive and magnetic members, creates electrical connections, and establishes magnetic pathways. This multi-functionality reduces the number of separate components needed while maintaining operational consistency
2Ease of manufacture
If traditional assembly methods with separate components are used, then ease of manufacture is improved, but reliability deteriorates due to inconsistent operation and sensing
Solution Approach 1:
The patent merges the housing and internal components (conductive member, magnetic member) into a single co-molded unit. The conductive and magnetic members are positioned in the mold before housing material is injected, creating an integrated assembly that eliminates variability from separate component assembly while maintaining manufacturing efficiency
Solution Approach 2:
The conductive member and magnetic member are pre-positioned within the mold cavity before the housing material is injected. This preliminary positioning ensures precise spatial relationships and consistent tolerances between components are achieved during the molding process itself, rather than through subsequent assembly operations
Data Source
AI summary
An electrical assembly may include an electrically conductive first member, a magnetic second member, and/or a housing molded on the first member and the second member. A method of assembling an electrical assembly may include disposing the first member in contact with a first mold, disposing the second member in contact with the first mold, moving a second mold into contact with the first mold, and/or inserting a housing material (e.g., liquid plastic) into the first mold and the second mold to form the housing.