Coated Connection Element Injection Molding Adhesion
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Solution Overview
Problem
Connection contacts in electronic modules experience mobility issues due to shrinkage and thermal expansion differences between the housing and the contact, leading to gaps and unstable fixation during ultrasonic welding.
Innovation Solution
An electrically conductive connection element with a non-metallic coating is injected into the module housing during injection molding, providing a fixed position and acting as an adhesion promoter to minimize mobility and gap formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connection contacts are injected into the housing without coating, then the injection process is simple, but gaps form due to shrinkage and thermal expansion differences causing mobility issues
Solution Approach 1:
The connection contact is provided with a non-metallic coating (such as polymer or plastic coating) that creates a composite structure combining metal conductivity with polymer adhesion properties. This composite material approach allows the coated connection contact to bond more effectively with the plastic housing, preventing gaps and mobility issues while maintaining electrical conductivity.
Solution Approach 2:
The non-metallic coating acts as an intermediary layer between the metal connection contact and the plastic housing. This intermediate layer facilitates better adhesion and bonding between the two dissimilar materials, compensating for shrinkage and thermal expansion differences, thereby improving fixation stability without complicating the injection process.
2Reliability
If connection contacts are strongly fixed in the housing, then mobility is reduced for welding, but higher ultrasonic power is required
Solution Approach 1:
The non-metallic coating changes the physical and chemical parameters of the connection contact surface, improving adhesion to the housing and reducing mobility. This parameter change allows for stronger fixation with reduced play, which in turn reduces the ultrasonic power required during welding compared to strongly fixed uncoated contacts.
Solution Approach 2:
The composite structure of coated connection contact provides optimal balance between fixation strength and weldability. The coating ensures sufficient adhesion to reduce mobility while maintaining characteristics that facilitate ultrasonic welding with lower power requirements.
3Ease of manufacture
If connection contacts have mobility during injection, then the injection process is easier, but gaps form leading to unstable fixation
Solution Approach 1:
The non-metallic coating on the connection contact creates a composite material that bonds well with the plastic housing during injection. This coating ensures that even if some mobility occurs during injection, the final fixation is precise and stable without gap formation, maintaining manufacturing precision.
Solution Approach 2:
The coating serves as an intermediary that improves bonding between the connection contact and housing during injection. This intermediate layer ensures precise fixation is achieved even with moderate injection mobility, preventing gap formation and ensuring stable final positioning.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The non-metallic coating enhances adhesion between the connection element and the housing, reducing relative mobility and ensuring a stronger, more reproducible fixation, thereby improving the ultrasonic welding process.
Implementation Method 1
The shaft is provided with a non-metallic coating. The connection element is injected together with the coating in the region of the shaft into the module housing, such that the connection element is fixed in the module housing
Implementation Method 2
the connection element provided with the coating is encapsulated by injection molding with a material which forms the module housing
Implementation Method 3
If, during the production of the electronic module, the connection contact injected into the housing is to be connected by ultrasonic welding to another conductor element of the electronic module to be produced, a relative movement is required between the connection contact and the conductor element during the welding operation
Data Source
AI summary
One aspect of the invention relates to an electronic module comprising a module housing and an electrically conductive connection element. The connection element has a first portion and a second portion, and also a shaft between the first portion and the second portion. The connection element, which is provided with a non-metallic coating in the region of the shaft, is injected together with the coating in the region of the shaft into the module housing, such that the connection element is fixed in the module housing.