Connector Housing Latching via Segmented Mold Cores
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for latching electrical contacts in connector housings require additional locking elements, such as snap rings or latching hooks, which are not reliable in the long term due to decreased spring force and require complex mold cores.
Innovation Solution
A method using two partially enclosing mold cores in an injection molding tool to form a through-opening with latching means, including a stop arc and a latching block, allowing direct locking of electrical contacts without additional elements, utilizing a 90° latching block and an 80°-85° angled latching edge for secure retention and easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional locking elements (snap rings, latching hooks) are used to fix electrical contacts, then the latching function is achieved, but the device complexity increases and reliability decreases over time due to spring force degradation
Solution Approach 1:
The patent merges the latching function directly into the insulating body structure by forming latching means (latching block and stop arc) as integral parts of the housing during injection molding. This eliminates the need for separate locking elements like snap rings or latching hooks, thereby reducing device complexity while maintaining reliable latching through the geometric design of the integrated features.
Solution Approach 2:
The patent extracts the spring element from the latching mechanism, eliminating the component subject to spring force degradation over time. The latching function is achieved purely through geometric interlocking features (latching block with 90° angle and stop arc with 80-85° angle) formed in the insulating body, removing the source of reliability degradation while maintaining the latching function.
2Ease of manufacture
If complex shaped mold cores are used to form latching means, then the latching function is integrated into the insulating body, but the manufacturing complexity increases
Solution Approach 1:
The patent segments the mold core into two simpler, separate components: a first mold core forming the latching block and a second mold core forming the stop arc. These segmented cores are easier to manufacture and remove individually compared to a single complex integrated core, while still achieving the integrated latching function in the final insulating body.
Solution Approach 2:
Instead of using a complex positive mold core to directly form the latching means, the patent uses negative mold cores that form cavities in the insulating body. The latching block and stop arc are formed as negative impressions in the molded housing, which are then filled by molten plastic. This inversion approach simplifies the mold core design while achieving the same functional result.
3Reliability
If a single-sided latching design is used, then the manufacturing is simpler, but the latching reliability is insufficient for long-term use
Solution Approach 1:
The patent employs asymmetric geometric angles in the latching features: the latching block has a 90° angle while the stop arc has an 80-85° angle. This asymmetric design creates a mechanical interference fit that prevents the electrical contact from being pulled out axially, providing reliable retention in the insertion direction while maintaining manufacturing simplicity through the use of standard molding techniques.
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
For the locking of an electrical contact within an insulating body (1) for a connector, it is proposed to mold locking elements (10, 13) axially spaced apart within a through-hole (2) on both the mating side (4) and the termination side (5), the locking edges (11, 14) of which allow the electrical contact (20) to be locked. A method is proposed in which two mold cores, forming the through-hole with the locking elements, can be removed from the through-hole in opposite directions after the injection molding process.