Connector Housing Flexible Wall Resin Molding Deformation
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Solution Overview
Problem
Existing circuit device manufacturing methods face challenges in preventing deformation of the connector housing during the molding process due to strong pressure from the mold, which can lead to leakage and structural issues.
Innovation Solution
Incorporating a cut-off receiving portion with a flexible wall that deflects inwardly to receive the pressing force from the mold, preventing direct contact and deformation of the housing body, and ensuring the cut-off portion is continuous over the entire periphery to maintain structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the mold is pressed strongly against the connector housing to reliably cut off the resin, then the resin leakage is prevented, but the connector housing may be deformed
Solution Approach 1:
The connector housing is segmented into a rigid main body and a flexible receiving portion. The receiving portion is designed with flexibility to locally deform and absorb the pressing force from the cut-off portion, while the main body remains rigid and maintains its shape. This segmentation allows the pressing force to be isolated to a specific flexible region rather than being distributed throughout the entire housing structure.
Solution Approach 2:
The receiving portion of the connector housing is designed with flexible material properties, allowing it to elastically deform under the pressing force from the mold's cut-off portion. This flexible receiving portion acts as a cushion that absorbs the molding pressure, preventing it from being transmitted to the rigid main body of the housing where it could cause deformation.
2Ease of manufacture
If the receptacle is made hollow for design convenience, then the connector structure is simplified, but the receptacle is highly susceptible to deformation under pressing force
Solution Approach 1:
The receptacle structure is segmented into a rigid main body and a flexible receiving portion. The receiving portion is specifically designed to be flexible so that it can locally deform to absorb pressing forces, protecting the hollow receptacle structure from deformation. This allows the receptacle to maintain its simplified hollow design while gaining deformation resistance through the flexible receiving portion.
Solution Approach 2:
The flexible receiving portion acts as a pre-designed cushioning element that is built into the connector housing structure. This receiving portion is positioned to intercept and absorb pressing forces from the mold's cut-off portion before these forces can reach and deform the hollow receptacle. The cushioning effect is built into the structure itself, allowing the receptacle to maintain its hollow form without compromising strength.
3Stability of the object's composition
If the cut-off receiving portion is arranged over the entire periphery of the housing body, then the deformation of the housing body is avoided reliably, but the device complexity increases
Solution Approach 1:
The flexible receiving portion is strategically positioned at specific locations where pressing forces are most likely to occur during molding, rather than uniformly distributing the flexible structure throughout the entire periphery. This localized approach provides adequate deformation protection at critical points while minimizing the overall complexity of the connector structure.
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 configuration effectively suppresses deformation of the housing body during resin molding, ensuring a reliable and waterproof circuit device with reduced risk of resin leakage and improved structural stability.
Implementation Method 1
a flexible wall extending from the projection and deflectable toward the housing body
Implementation Method 2
forming a resin portion covering the circuit board and the connector by pouring molten resin into the mold and curing the molten resin
Data Source
AI summary
An ECU 1 includes a circuit board 10, a connector 20 fixed to the circuit board 10 and a resin portion 50 covering the circuit board 10 and the connector 20. The connector 20 includes a housing body 22 and a cut-off receiving portion 27 projecting from the housing body 22. The cut-off receiving portion 27 includes a flange portion 28 projecting outward from the housing body 22 and a flexible wall 29 extending from the flange portion 28 and inclined to be closer to the housing body 22 toward a tip, and a part of the flexible wall 29 is embedded in the resin portion 50.