Connector Flat Portion Resin Flow Barrier
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Solution Overview
Problem
Existing connectors face issues where resin pushed by a molding-die can cover the end part of the contact portion, leading to interrupted electrical connections due to improper alignment and resin flow during the molding process.
Innovation Solution
A connector design featuring a housing with a plate-like mating portion, where each contact has a contact portion exposed at the upper surface, an end portion embedded within, and a flat portion forming a boundary between them, preventing resin from being pushed onto the contact area during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a molding-die is inserted between neighboring contacts to arrange them appropriately in the pitch direction, then the contacts are arranged accurately, but resin may be pushed aside by the molding-die and cover the end part of the contact portion, interrupting electrical connection
Solution Approach 1:
The contact structure is segmented into three distinct parts: contact portion, flat portion, and end portion. This segmentation allows the flat portion to serve as a dedicated barrier element that prevents resin from reaching the contact portion, while still allowing the molding-die to access the flat portion for positioning purposes.
Solution Approach 2:
The flat portion acts as an intermediary element between the contact portion and end portion. It serves as a buffer zone that the molding-die can interact with for alignment, while simultaneously blocking resin flow toward the contact portion, thus protecting the electrical connection without compromising positioning accuracy.
2Ease of manufacture
If the contact structure allows free resin flow during molding, then the molding process is simpler, but resin can cover the contact portion and cause short-circuits or connection interruptions
Solution Approach 1:
The flat portion is designed with specific local properties: it has a width that is sufficient to block resin flow but not so wide as to interfere with molding-die access. Its position at the boundary between contact and end portions creates a localized barrier exactly where needed, without affecting overall molding simplicity.
Solution Approach 2:
The flat portion, which could be seen as an additional structural complexity, actually simplifies the molding process by providing a dedicated target area for the molding-die to position against. This eliminates the need for complex positioning mechanisms while simultaneously protecting the contact portion from resin contamination.
Data Source
AI summary
A connector according to the present invention comprises a housing and a plurality of contacts. The housing includes a mating portion having a plate shape. The mating portion projects forward and has an upper surface and a bottom surface. The plurality of contacts is held by the housing. Each of the contacts comprises a contact portion, an end portion and a flat portion. The contact portion extends in a connection direction and is exposed at the upper surface of the mating portion. The end portion is embedded in the mating portion. The flat portion forms a boundary between the contact portion and the end portion and does not projects from the upper surface. The flat portion is able to be viewed from above the upper surface of the mating portion.