Electrical Connector Sealing via Molded Insulative Frame
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Solution Overview
Problem
Existing electrical connectors with metallic covers and MIM supports suffer from poor sealing due to direct mounting of the metallic cover outside the MIM support, leading to inadequate sealing effectiveness.
Innovation Solution
The electrical connector design includes an insulative frame molded inside the metallic cover, a metal injection molded (MIM) support with a contact module, and an insulator molded outside the MIM support and secured to the insulative frame, enhancing the sealing by integrating the insulative frame within the metallic cover and ultrasonic welding for improved sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the metallic cover is directly mounted outside the MIM support, then the assembly process is simplified, but the sealing effectiveness deteriorates
Solution Approach 1:
The patent introduces an insulator as an intermediary component between the MIM support and the metallic cover. This insulator includes an insulative body that receives the contact module and MIM support, and an insulative frame that is injection molded to the metallic cover. This intermediary structure enables both simplified assembly (through integrated molding) and effective sealing (through the insulator's sealing engagement with the MIM support).
Solution Approach 2:
The patent merges multiple functions into the insulator component: it provides electrical insulation, mechanical support for the contact module, sealing between the MIM support and metallic cover, and structural integration through injection molding. The insulative frame is injection molded directly to the metallic cover, combining two components into one integrated sealing structure.
2Device complexity
If the metallic cover is directly mounted outside the MIM support, then the number of components is reduced, but the vapor-tight connection deteriorates
Solution Approach 1:
The insulator serves as a mediator that provides the necessary vapor-tight sealing between the MIM support and metallic cover. Although this adds a component, it consolidates multiple functions (sealing, insulation, support) into a single integrated piece that is injection molded to the metallic cover, effectively managing the complexity while achieving the vapor-tight connection.
Solution Approach 2:
The patent uses composite construction with the insulator made of insulative material (such as PBT or PA6) that provides both electrical insulation and vapor-tight sealing properties. The combination of the insulative body and insulative frame creates a composite structure that achieves both component reduction and effective sealing.
3Reliability
If the insulator is molded outside the MIM support and contact module, then the sealing effect is improved, but the manufacturing process complexity increases
Solution Approach 1:
The insulator is pre-assembled with the contact module and MIM support before final installation into the connector housing. The insulative frame is injection molded to the metallic cover in advance, creating a pre-integrated sealing structure that simplifies the final assembly while maintaining effective sealing.
Solution Approach 2:
The injection molding process combines the insulative frame and metallic cover into a single integrated component, reducing the number of separate parts while maintaining the sealing effect. This merging of components through molding reduces manufacturing complexity despite the added sealing functionality.
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 significantly improves the sealing effect between the metallic cover and the MIM support, ensuring a better vapor-tight connection and securement of the insulator, thereby enhancing the overall performance of the electrical connector.
Implementation Method 1
an insulative frame molded inside the metallic cover
Implementation Method 2
an insulator molded outside the MIM support and the contact module
Implementation Method 3
securing the insulator to the insulative frame through ultrasonic welding
Data Source
AI summary
An electrical connector includes: a metallic cover; an insulative frame molded inside the metallic cover; a metal injection molded (MIM) support and a contact module received by the MIM support, the contact module having a rear base, a front tongue, and an upper and a lower rows of contacts extending through the base and exposing to two opposite faces of the tongue, the MIM support having a pair of side arms flanking the two rows of contacts; and an insulator molded outside the MIM support and the contact module and secured to the insulative frame.