Connector Contact Module Layout That Protects Molded Securing Segments
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Solution Overview
Problem
Existing electrical connectors with insert-molded contacts have securing portions that are prone to damage due to exposed segments, which can lead to manufacturing challenges and reduced tool life during molding processes.
Innovation Solution
The contact module design features a securing portion with specific segments (upper, front upstanding, lower, and rear upstanding segments) that allow for forward-pointing soldering tails, enabling efficient molding and reducing tool wear by providing an access space for the molding tool, thus protecting the segments and extending tool life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the securing portion has an upstanding segment exposing to outside, then the contact structure is simplified, but the segment is prone to damage during molding
Solution Approach 1:
The securing portion is divided into multiple segments (upper level segment, front upstanding segment, lower level segment, rear upstanding segment) arranged in a specific spatial configuration. This segmentation allows the molding tool to access and form each segment separately, preventing damage while maintaining structural simplicity.
Solution Approach 2:
The segments are arranged in different spatial levels and orientations (upper, lower, front, rear) rather than a single exposed configuration. This multi-dimensional arrangement protects segments from molding tool damage while maintaining the necessary electrical and mechanical functions.
2Productivity
If the soldering tail points forward, then the contact layout is optimized, but the exposed securing portion segments are damaged during molding
Solution Approach 1:
The securing portion is segmented into multiple parts arranged in a staggered configuration, allowing the molding tool to access each segment from different directions without interference from the forward-pointing soldering tail, thus preventing damage while maintaining molding efficiency.
Solution Approach 2:
The multi-level segment structure acts as an intermediary between the forward-pointing soldering tail and the molding tool, providing access paths that avoid direct contact between the tool and vulnerable segments, thereby preventing damage during the molding process.
3Ease of manufacture
If the securing portion segments are exposed, then manufacturing is simplified, but molding tool life is reduced due to wear and damage
Solution Approach 1:
The securing portion is divided into multiple segments arranged in a configuration that allows the molding tool to form each segment separately with reduced wear, extending tool life while maintaining manufacturing simplicity.
Solution Approach 2:
Segments are arranged in different spatial dimensions (upper, lower, front, rear levels) creating access pathways that reduce molding tool wear and damage, thereby extending tool life while keeping the manufacturing process simple.
Data Source
AI summary
A contact module for an electrical connector includes: an insulator; and a row of contacts insert-molded with the insulator, each of the row of contacts including a soldering tail and a body having a securing portion and a contacting portion, the soldering tail of each contact pointing toward a forward direction, wherein the securing portion of each contact has an upper level segment, a front upstanding segment continuing the upper level segment, a lower level segment continuing the front upstanding segment, and a rear upstanding segment continuing the lower level segment and connecting to the soldering tail thereof, and the lower level segment of each contact is offset from the soldering tail thereof.