Electrical Connector Contact Module With Insert-Molded Grounding Bars
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Solution Overview
Problem
Existing electrical connectors with integral grounding bars waste materials during manufacturing due to their design.
Innovation Solution
The electrical connector features a contact module with an upper and lower contact unit, where contacts and plastic tie bars are formed through insert-molding, with differential pair signal contacts and grounding contacts alternately arranged, and conductive secondary parts are added to grounding contacts via a secondary insert-molding process to enhance material efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If grounding bar and grounding pin are made as integral structure, then manufacturing is simplified, but material waste increases
Solution Approach 1:
The patent divides the grounding structure into separate components: grounding pins, grounding bars, and plastic tie bars are manufactured independently and then assembled. This segmentation allows each component to be optimized separately and reduces material waste compared to integral structures.
Solution Approach 2:
The patent changes the manufacturing parameters by using insert-molding process to create plastic tie bars with integrated conductive pathways. This allows precise control over material usage and eliminates excess material that would be present in traditional integral manufacturing methods.
2Ease of operation
If multiple contacts are integrally formed with plastic tie bars via insert-molding, then assembly is simplified, but manufacturing complexity increases
Solution Approach 1:
The contact assembly is segmented into modular units where each plastic tie bar holds a specific group of contacts. These modular units can be manufactured separately and then assembled into the final connector, simplifying the overall assembly process while managing manufacturing complexity through standardization.
Solution Approach 2:
The insert-molding process creates self-contained contact assemblies where the plastic tie bar and contacts are permanently bonded in the correct configuration. This self-service feature eliminates the need for separate assembly steps for these components, simplifying the overall assembly process despite the complex molding operation.
3Reliability
If differential pair signal contacts and grounding contacts are alternately arranged, then signal integrity is improved, but device complexity increases
Solution Approach 1:
The patent merges the signal contacts and grounding contacts into a single integrated contact assembly held together by the plastic tie bar. The alternating arrangement is built into the mold, combining multiple functions (signal transmission and grounding) into one unified structure, which improves signal integrity while managing complexity through integration.
Solution Approach 2:
The plastic tie bar provides localized structural support and electrical connection at specific positions where contacts are arranged. This local quality approach allows the alternating pattern of signal and grounding contacts to be maintained precisely without requiring complex overall structural design.
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 reduces material waste and ensures reliable mechanical and electrical connections between contacts, improving the overall efficiency and stability of the electrical connector.
Implementation Method 1
Each of the upper contact unit and the lower contact unit includes a front/outer contact part and a rear/inner contact part each including a plurality of side by side arranged contacts integrally formed with a plurality of plastic tie bars at different positions via insert-molding
Data Source
AI summary
The electrical connector includes a contact module received within an insulative housing. The contact module includes an upper contact unit and a lower contacts unit stacked with each other. Each of the upper contact unit and the lower contact unit includes a front/outer contact part and a rear/inner contact part each including a plurality of side by side arranged contacts integrally formed with a plurality of plastic tie bars at different positions via insert-molding. The contacts include a plurality of differential pair signal contacts and a plurality of grounding contacts alternately arranged with each other along a transverse direction. Each plastic tie bar includes an insulative primary part integrally formed with all contacts via a first insert-molding process, and a conductive secondary part integrally formed with the primary part and the grounding contacts via a second insert-molding process after the first insert-molding process.