Connector Insert Molding with Separated Contacts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connector manufacturing methods fail to efficiently integrate contact arrays and housings through insert molding, leading to suboptimal structural integrity and increased production complexity.
Innovation Solution
A novel manufacturing method involving assembly, insert molding, and separation steps to form connectors with integrally molded contact arrays and housings, utilizing supporting parts and coupling beams to ensure precise alignment and structural integrity, with the housing featuring penetrating holes and pitch extension grooves for enhanced mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If contacts are held by a carrier that is cut off after insert molding, then the contacts can be positioned during molding, but the structural integrity and production efficiency are reduced
Solution Approach 1:
The patent removes the carrier component entirely from the molding process. Instead of using a separate carrier to hold contacts during insert molding, the contacts are directly positioned and molded into the housing, eliminating the need for carrier assembly and subsequent cutting operations.
Solution Approach 2:
The patent combines the contact positioning function and the housing structure into a single integrated molding process. The contacts are directly embedded in the housing during insert molding, merging what were previously separate components (carrier + housing) into a unified structure.
2Quantity of substance
If contacts are held by a carrier that requires cutting after molding, then the contacts can be arranged in arrays, but the production complexity and time increase
Solution Approach 1:
The patent performs preliminary positioning of contacts directly in their final positions within the housing during the insert molding step itself, eliminating subsequent cutting and separation operations. The contact arrays are configured and fixed in place before the housing material is molded around them.
Solution Approach 2:
The patent skips the intermediate carrier removal and cutting steps by directly molding the housing around the positioned contacts. This rushes through the manufacturing process by eliminating unnecessary intermediate operations, improving overall productivity.
3Stability of the object's composition
If the coupling beam is positioned between width side surfaces and separated from them, then the contact assembly is stable during molding, but the structural integrity may be compromised
Solution Approach 1:
The patent applies different positioning strategies to different parts of the contact assembly. The coupling beam is positioned between the width side surfaces to provide lateral stability, while supporting parts extend to engage with the housing to ensure overall structural integrity. Each component is positioned optimally for its specific function.
Solution Approach 2:
The housing acts as an intermediary that bonds the contact assembly components together. The supporting parts extend from the coupling beam to engage with the housing, allowing the housing material to serve as the bonding medium that maintains both stability and structural integrity of the assembled components.
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
The method enables the production of connectors with improved structural integrity and reduced production complexity, allowing for efficient integration of contact arrays and housings while maintaining mechanical stability and ease of assembly.
Implementation Method 1
an insert molding step of molding the housing integrally with the at least one contact assembly by insert molding
Data Source
AI summary
An accommodating step accommodates a plug contact assembly into an injection mold in such a way that the plug contact assembly is supported at both ends in the injection mold by using two supporting parts. An insert molding step molds a plug housing integrally with the plug contact assembly by insert molding in such a way that a coupling beam of the plug contact assembly is between two width side surfaces and separated from the two width side surfaces in the width direction. A separation step removes at least part of the plug contact assembly to as to disjoin the plurality of plug contacts.