Electrical Connector Manufacturing via Integrated Electroplating and Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods of manufacturing electrical connectors are cumbersome and costly due to the need for a separate fixing fixture, which increases manufacturing time and expenses, and prevents direct electroplating of terminals and clamping elements after the insulating housing is molded.
Innovation Solution
The method involves stamping terminals with clamping portions and a clamping element, inserting them into a material carrier with limiting slots, electroplating, and then molding an insulating housing, eliminating the need for a fixing fixture and allowing direct electroplating and injection molding in a single automatic process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixing fixture is used to mount terminals and clamping element, then the terminals can be positioned and molded with insulating housing, but the manufacturing process becomes complex and time-consuming with additional steps
Solution Approach 1:
The patent removes the fixing fixture from the manufacturing process entirely. Instead of mounting terminals and clamping element on a separate fixing fixture and then transferring them to the material carrier, the invention directly places these components onto the material carrier which has pre-formed positioning structures (limiting slots and limiting grooves). This extraction of the fixing fixture eliminates the transfer step and reduces process complexity while maintaining positioning accuracy through the integrated positioning features on the material carrier.
2Ease of manufacture
If a fixing fixture is used to hold terminals and clamping element, then assembly is possible, but electroplating cannot be performed directly on terminals after molding
Solution Approach 1:
The patent performs the electroplating operation at an earlier stage in the manufacturing process, before the insulating housing is molded. The terminals and clamping element are electroplated while they are still accessible on the material carrier, and only after this electroplating step are they enclosed by the molded insulating housing. This preliminary action of electroplating before molding eliminates the need for subsequent disassembly or specialized post-molding electroplating operations, thereby improving manufacturing efficiency while maintaining ease of assembly.
3Manufacturing precision
If multiple separate steps are used for stamping, mounting, electroplating, and molding, then each operation can be performed carefully, but the overall manufacturing time increases
Solution Approach 1:
The patent merges multiple manufacturing operations into a more integrated sequence. The terminals and clamping element are stamped with positioning features (clamping portions) that are directly compatible with the material carrier's positioning structures. This merging of design features allows the components to be directly mounted on the material carrier without transfer fixtures, and the subsequent electroplating and molding operations follow in a streamlined sequence, reducing total manufacturing time while maintaining the quality of each individual step through proper process sequencing.
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 approach reduces manufacturing time and costs by eliminating the need for a fixing fixture, enabling faster and more efficient production of electrical connectors with improved dimensional stability and streamlined processes.
Implementation Method 1
electroplate the plurality of the terminals and the clamping element
Implementation Method 2
the insulating housing is molded to the plurality of the terminals and the clamping element by an injection molding technology
Data Source
AI summary
A method of manufacturing an electrical connector includes specific steps described hereinafter. Stamp a plurality of terminals together with a plurality of clamping portions and a clamping element having a material belt. Insert and fix the plurality of the terminals together with the plurality of the clamping portions to a material carrier, and place the material belt above the material carrier. Electroplate the plurality of the terminals and the clamping element. Mold an insulating housing to the plurality of the terminals and the clamping element. Separate the material carrier, the plurality of the clamping portions and the material belt from the plurality of the terminals and the clamping element respectively, thereby completing manufacturing the electrical connector which has the insulating housing, the plurality of the terminals and the clamping element.