Electrical Connector Metallic Bracket Insert Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing dual orientation electrical connectors face challenges in securely and efficiently aligning and integrating terminal modules with a metallic plate and bracket, particularly under high pressure, while maintaining structural strength and waterproofing.
Innovation Solution
The electrical connector design involves securing upper and lower terminal modules to a metallic plate, accommodating the plate within a metallic bracket, and then insert-molding the assembly to form a tongue that exposes the terminals, ensuring secure contact and alignment, with the metallic bracket bordering the tongue and providing structural reinforcement through metal die-casting or injection molding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If terminal modules are securely fastened to the metallic plate under high pressure, then structural strength and alignment are improved, but the molding process becomes more difficult and device complexity increases
Solution Approach 1:
The connector is divided into separate components: terminal modules, metallic plate, metallic bracket, and insulative body. Each component is manufactured independently and then assembled through insert molding, allowing for simplified individual manufacturing while achieving strong integrated structure.
Solution Approach 2:
The terminal modules are first secured to the metallic plate, then the entire assembly is nested within the metallic bracket, and finally the insulative body is molded over the entire structure. This nested assembly approach enables progressive integration while maintaining manufacturing simplicity.
2Manufacturing precision
If terminal modules are securely fastened to the metallic plate under high pressure, then alignment precision is improved, but manufacturing difficulty increases
Solution Approach 1:
The terminal modules are pre-secured to the metallic plate before the final insert molding process. This preliminary assembly ensures proper alignment is established early, and the subsequent molding process locks this alignment in place without requiring complex real-time adjustment mechanisms.
3Strength
If the metallic bracket accommodates the metallic plate and terminal modules, then structural strength is improved, but device complexity increases
Solution Approach 1:
The metallic bracket and insulative body are combined into a single integrated component through the insert molding process. The molten insulative material is injected around the metallic bracket, plate, and terminal modules, creating a unified structure that provides both mechanical support and electrical insulation without requiring separate assembly steps.
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
This design enhances the structural strength and securement of the connector, effectively resisting high pressure during the molding process and ensuring waterproofing, while maintaining exposed terminals for efficient electrical connectivity.
Implementation Method 1
an insulative body insert-molding the metallic bracket with the secured metallic plate and upper and lower terminal modules to form a tongue exposing the terminals
Data Source
AI summary
An electrical connector includes: an upper and lower terminal modules each including plural terminals; a metallic plate secured between the upper and lower modules; a metallic bracket accommodating the secured metallic plate and upper and lower terminal modules; and an insulative body insert-molding the metallic bracket with the secured metallic plate and upper and lower terminal modules to form a tongue exposing the terminals of each of the upper and lower terminal modules. The metallic bracket contacts the metallic plate and borders the tongue.