Electric Connector Terminal Positioning via Intermediary Protrusion
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Solution Overview
Problem
Conventional methods for manufacturing electric connectors with shield plates struggle to accurately position second terminals with respect to primary molded portions due to terminal downsizing, leading to potential misalignment and increased noise interference.
Innovation Solution
A manufacturing method involving the formation of primary and secondary molded portions with integral engaging portions, followed by a tertiary molded portion that integrates both, using resin to securely fix and position the terminals and shield plate, ensuring accurate alignment and secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If terminals are downsized to accommodate device miniaturization, then device size is reduced, but terminal positioning accuracy deteriorates
Solution Approach 1:
A positioning protrusion is introduced as an intermediary element between the mold and the terminal. This protrusion engages with a corresponding positioning recess on the terminal, providing a reliable positioning mechanism that works effectively even with downsized terminals. The intermediary structure enables accurate positioning without requiring direct mold-terminal contact, thus resolving the contradiction between device miniaturization and positioning accuracy.
Solution Approach 2:
The terminal is pre-positioned on the carrier board before the injection molding process. The positioning protrusion and recess are designed to engage in advance, establishing the terminal's correct position before resin is injected. This preliminary positioning action ensures that even small terminals maintain their intended positions throughout the molding process, preventing misalignment while allowing device downsizing.
2Object-affected harmful factors
If shield plate is provided to reduce noise, then noise reduction is improved, but terminal positioning accuracy deteriorates
Solution Approach 1:
The positioning protrusion acts as an intermediary that establishes terminal position independently of the shield plate. By providing this dedicated positioning feature, the system can include the shield plate for noise reduction without compromising terminal positioning accuracy. The protrusion-shield plate interaction ensures the shield plate does not interfere with terminal placement.
3Ease of manufacture
If second terminals are left exposed during insert molding, then manufacturing simplicity is improved, but positioning accuracy deteriorates
Solution Approach 1:
The positioning protrusion serves as a simple yet effective intermediary that provides accurate positioning without complicating the manufacturing process. This single structural feature enables both exposed terminal molding and precise alignment, resolving the contradiction between manufacturing simplicity and positioning accuracy.
Solution Approach 2:
The positioning protrusion and recess are designed to engage before injection molding begins, establishing terminal position in advance. This preliminary action allows terminals to be left exposed during molding while maintaining alignment accuracy, as the positioning mechanism is already in place before resin injection starts.
Data Source
AI summary
Provided is a method for manufacturing an electric connector. The electric connector is an electric connector having contact portions on both one surface and the other surface opposite to the one surface of a plate-shaped fitting portion that fits with a mating connector, and can accurately position a plurality of first terminals forming the contact portion on the one surface of the fitting portion and a plurality of second terminals forming a contact portion on the other surface of the fitting portion through a shield plate. The method for manufacturing the electric connector includes: a step of forming a primary molded portion in which a plurality of first contact portions is integrally provided by insert molding; a step of forming a secondary molded portion in which a plurality of second contact portions is integrally provided by insert molding; and a step of producing a housing by forming a tertiary molded portion in which the primary molded portion and the secondary molded portion are integrally provided by insert molding.