Connector Housing Latch Arm with Variable Material Transition
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional connector housings face challenges in achieving high rigidity for the housing main body while allowing the latch arm to elastically deform, as forming them from the same material results in excessive operating force, and multi-material injection molding is costly and prone to reliability issues due to separation at the juncture.
Innovation Solution
A connector housing is designed with a housing main body made from a high-rigidity material and a latch arm made from a lower-rigidity material, featuring a transition region with a continuously variable mixing ratio between the two materials, which allows for elastic deformation and integration without separation, using a mold with separate inlets for each material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the latch arm is formed from the same material as the housing main body, then the housing main body has high rigidity, but the operating force for the latch arm becomes too large
Solution Approach 1:
The patent applies local quality by creating a transition region with a continuously variable mixing ratio of first and second materials. The housing main body portion has a higher proportion of the first material for rigidity, while the latch arm portion has a higher proportion of the second material for elasticity, with a gradual transition between them to prevent stress concentration and separation.
Solution Approach 2:
The patent uses composite materials by combining a first material (for rigidity) and a second material (for elasticity) in different proportions within different regions of the same component. This allows the housing main body to have high rigidity while the latch arm has appropriate elasticity for easy operation.
2Force
If multi-material injection molding is used to form the housing main body and latch arm from different materials, then the operating force is reduced, but the manufacturing cost increases and separation at the juncture may occur
Solution Approach 1:
The patent uses composite materials formed in a single injection molding process, combining a first material and a second material in different proportions within the same component. This achieves the mechanical property benefits of multi-material construction without the separation issues and doubled manufacturing costs of traditional multi-material injection molding.
Solution Approach 2:
The patent merges the housing main body and latch arm into a single integrated component formed by one injection molding process. The transition region with continuously variable material composition ensures strong bonding between regions of different material proportions, eliminating the need for separate molding and assembly steps while preventing separation at material boundaries.
3Reliability
If a transition region with continuously variable mixing ratio is created, then separation between housing main body and latch arm is prevented, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies parameter changes by varying the mixing ratio of first and second materials continuously through the transition region. This gradual parameter change prevents abrupt material property transitions that would cause stress concentration and separation, while the single-shot injection molding process manages the manufacturing complexity.
Solution Approach 2:
The patent ensures continuity of useful action by creating a continuous transition region with continuously variable material composition. This continuous material gradient eliminates discontinuities at material boundaries, preventing separation while maintaining structural integrity throughout the component.
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 design ensures high reliability by preventing separation between the housing main body and latch arm, reducing the operating force required for the latch arm while maintaining the necessary rigidity for the housing, and allows for easy material confirmation through color differentiation.
Implementation Method 1
A transition region having a continuously variable mixing ratio between the first material and the second material is present within an expanded boundary region including the boundary portion
Implementation Method 2
the latch arm is configured to elastically deform in relation to the housing main body to latch a latched member
Data Source
AI summary
A connector housing includes a housing main body formed from a first material and a latch arm formed from a second material having a lower rigidity than the first material. The latch arm extends in a cantilever form, forms a boundary portion at a connection between the latch arm and the housing main body, and is configured to elastically deform in relation to the housing main body to latch a latched member. A transition region having a continuously variable mixing ratio between the first material and the second material is present within an expanded boundary region including the boundary portion and expanding into the housing main body and into the latch arm.