Power Connector Housing With Breakable-Bridge Insert Assembly
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Solution Overview
Problem
The manufacturing of electrical connector housings is labor-intensive and time-consuming due to the need for separate molds and lengthy cooling times, especially for large parts with thick sections, which increases costs.
Innovation Solution
The terminal carrier and insert of the power connector are molded as a single piece with a breakable bridge, allowing for simplified assembly by breaking the bridge to load the insert into the terminal carrier, reducing cooling time and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrical connectors are manufactured from two separate housings molded in separate molds, then the housing can be assembled to secure terminals, but the assembly becomes labor intensive and time consuming while doubling manufacturing time
Solution Approach 1:
The patent merges two separate housing components into a single integrally molded housing structure. The first and second housing portions are combined into one piece that is molded as a single unit, eliminating the need for separate molding operations and manual assembly of housing parts. This reduces manufacturing complexity and increases productivity by removing assembly steps.
2Strength
If large plastic molded parts with thick sections are used, then the housing provides sufficient structural support, but the cooling time before ejection increases
Solution Approach 1:
The housing is segmented into multiple wall sections with varying thicknesses. Instead of using uniform thick walls throughout, the design incorporates thinner wall sections where sufficient structural support is not critical, allowing those areas to cool faster. This segmentation enables the housing to maintain adequate strength while reducing overall cooling time for mold ejection.
3Ease of manufacture
If small and/or long cores through the part are used, then the housing features can be molded with complicated features, but heat builds up and lengthens cooling time
Solution Approach 1:
The patent extracts or removes certain core features from the molded housing design. By eliminating small and/or long cores that would extend through the housing, the design avoids the heat buildup problems associated with these features. The housing is molded without these problematic cores, thereby reducing cooling time while still achieving the necessary structural features through alternative design approaches.
Data Source
AI summary
A power connector includes a housing including a terminal carrier and an insert matable to the terminal carrier. The terminal carrier includes terminal channels holding power terminals. The terminal carrier includes a pocket aligned with carrier openings. The insert is coupled to the terminal carrier at the pocket and configured to be received in the pocket. The insert includes insert openings therethrough configured to be aligned with the carrier openings when the insert is received in the pocket. The terminal carrier and the insert are molded as a single piece with a bridge connecting the terminal carrier and the insert. The bridge is breakable prior to or during assembly to allow loading of the insert into the pocket and coupling of the insert to the terminal carrier.