Connector Insert-Molding Using Exposed Holding Sections
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Solution Overview
Problem
Existing connectors with integrated connecting members become large in size due to the need for external gripping by the mold during insert-molding, leading to increased size and material costs.
Innovation Solution
A connector design where the connecting member's portions are used as connection member holding sections, exposed outside the housing, allowing the mold to grip these sections during molding, reducing the size of the connecting member and the overall connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the connecting member is gripped by the mold on the outside of the molding area for insert-molding, then the connecting member can be held at a predetermined position, but the connector becomes large in size
Solution Approach 1:
The invention moves the gripping location from the external space (outside the molding area) to the internal space (within the molding area) by utilizing the opening section. This dimensional repositioning allows the mold to grip the connecting member at a location that does not increase the external dimensions of the connector, thereby resolving the contradiction between positioning accuracy and connector size.
Solution Approach 2:
The invention embeds the gripping function within the existing structure of the connector by utilizing the opening section as both a functional gripping point and an integrated part of the housing design. The connecting member is nested within the housing such that its exposed portion serves dual purposes: electrical connection and mold gripping, eliminating the need for additional external gripping structures.
2Ease of manufacture
If the connecting member is made large for external gripping, then the mold can grip the connecting member effectively, but the material cost increases
Solution Approach 1:
The opening section of the connecting member serves multiple functions: it provides the gripping point for the mold during insert-molding, maintains the electrical connection function through the tab sections, and integrates with the housing structure. This multi-functionality eliminates the need for additional dedicated gripping structures, reducing material usage while ensuring effective manufacturing.
3Volume of moving object
If the connecting member is exposed at the opening section, then the mold can grip it during molding, but the connecting member size is reduced
Solution Approach 1:
The connecting member is pre-positioned within the mold cavity before the injection molding process begins. The opening section is specifically designed to be accessible to the mold's gripping mechanism during this preliminary positioning stage, ensuring that the connecting member is securely held at the correct location before resin injection, thereby maintaining high molding precision despite the reduced size.
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
The connector is downsized, reducing material usage and costs, while maintaining effective connectivity through the use of exposed connection member holding sections for mold gripping during the molding process.
Implementation Method 1
portions of the connecting member are gripped by the mold on the outside of the molding area of the housing
Implementation Method 2
injected into a mold in a state in which the connecting member is set inside the mold so that the connecting member is integrally molded with the resin
Data Source
AI summary
A connector includes: a connecting member including a plurality of tab sections and made of a conductive metal material; and a housing which is made of resin and in which the connecting member is insert-molded. Terminals of a counterpart connector are connectable to the tab sections by a connection of the counterpart connector. A part of the connecting member is used as a connection member holding section gripped by a mold. The connection member holding section is exposed to an outside at an opening section formed in the housing.