Electrical Connector Dual-Gate Molding for Stable Terminal Bonding
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Solution Overview
Problem
Existing electrical connectors face challenges in molding the front end of the tongue, resulting in thin plastic coverage over terminal head portions, leading to unstable bonding and tilting, which affects electrical transmission.
Innovation Solution
The introduction of a first gate at the front end surface of the tongue and a second gate in the middle or rear portion of the insulation body ensures reliable plastic flow, stabilizing the bonding of terminal head portions and preventing tilting by embedding them securely within the tongue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastics feed from the rear end of the insulation body to form point gates at the base, then the molding process is simple, but the plastics cannot flow adequately to the front end, resulting in thin plastic coverage and unstable bonding of terminal head portions
Solution Approach 1:
The gate system is segmented into two parts: a first gate at the front end surface of the tongue and a second gate in the middle or rear portion of the insulation body. This segmentation allows plastics to flow from multiple directions, ensuring adequate coverage at the front end while maintaining manufacturing simplicity through a structured two-gate approach.
Solution Approach 2:
The gating system transitions from a single-point gate at the base to a multi-point distribution system by adding a first gate at the front end surface. This dimensional change in gate placement enables plastics to flow from both rear and front directions, resolving the thickness issue without complicating the overall molding process.
2Ease of manufacture
If plastics flow from the rear end in a molten state, then the feeding process is straightforward, but the front end of the tongue is difficult to mold or forms a relatively thin structure, causing unstable terminal bonding
Solution Approach 1:
The feeding process is segmented into two feeding paths: one through the first gate at the front end and another through the second gate at the middle or rear portion. This segmentation ensures reliable plastic flow to the front end for stable terminal bonding while keeping the overall feeding process straightforward through a organized two-path system.
Solution Approach 2:
The first gate at the front end surface performs a preliminary action of introducing plastics directly to the front end region before the main molding cycle completes. This preliminary plastic introduction ensures adequate coverage and bonding stability at the critical front end area where terminal head portions are embedded.
3Productivity
If the plastic coverage at the front end is very thin, then the molding cycle is short, but the bonding of terminals and plastics is unstable, causing head portions to tilt and affect electrical transmission
Solution Approach 1:
The gating system is segmented to provide dual plastic flow paths, ensuring adequate plastic coverage at the front end for reliable electrical transmission. The segmentation allows sufficient material flow without significantly extending the molding cycle, maintaining productivity while improving bonding stability.
Solution Approach 2:
By adding a first gate at the front end surface, the plastic flow transitions from a single rear-direction flow to a multi-directional flow pattern. This dimensional change in flow architecture ensures adequate coverage thickness for reliable electrical transmission without substantially increasing the molding cycle time.
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 solution ensures stable bonding of terminals with plastics, prevents head portion tilting, and maintains reliable electrical contact and transmission functions in the electrical connector.
Implementation Method 1
As plastics flow into a die cavity from the rear end in a molten state
Data Source
AI summary
An electrical connector includes multiple terminals and an insulation body integrally formed with the terminals. Each terminal has a contacting portion and a head portion extending forward from the contacting portion. The insulation body includes a tongue extending along a front-back direction. Each contacting portion is partially insert-molded to the tongue and partially exposed to a surface of the tongue. Each head portion is embedded into a front end of the tongue. The insulation body has a first gate and a second gate. The first gate is located on a front end surface of the tongue, and the second gate is located in a middle portion or a rear portion of the insulation body.