Electrical Connector One-Shot Insert-Molding Carrier Strip Removal
Solution Overview
Problem
Existing electrical connectors face challenges in integrating multiple components, such as upper and lower contacts, and a metallic shielding sheet, within an insulator via a single insert-molding process, due to the need for precise positioning and removal of cutoff bridges and carrier strips, which is difficult under high pressure and requires efficient space management.
Innovation Solution
The electrical connector employs a one-shot initial insert-molding process integrating upper and lower rows of contacts and a metallic shielding sheet within an insulator, utilizing carrier strips, cutoff bridges, and sidewardly protruding ears to maintain positions and facilitate the removal of bridges, ensuring proper alignment and spacing for efficient molding and intermateability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple components (upper contacts, lower contacts, metallic shielding sheet) are integrated via a single insert-molding process, then manufacturing efficiency and component alignment are improved, but the complexity of positioning and removing carrier strips and cutoff bridges increases
Solution Approach 1:
The contacts are divided into separate carrier strips (first carrier strip for upper contacts, second carrier strip for lower contacts) that can be independently positioned and removed. The cutoff bridges connecting adjacent contacts are also segmented, allowing selective removal between specific contact groups while maintaining connections where needed.
Solution Approach 2:
The carrier strips and cutoff bridges are pre-positioned and pre-connected before the insert-molding process. The ears protruding from the insulator are formed in advance to provide predetermined removal paths for the carrier strips and cutoff bridges, eliminating the need for complex real-time positioning during molding.
2Manufacturing precision
If carrier strips and cutoff bridges are used to maintain contact positions, then alignment precision is improved, but the difficulty of removing bridges and strips under high pressure increases
Solution Approach 1:
The ears protruding from the insulator act as intermediary elements between the cutoff bridges/carrier strips and the removal mechanism. These ears provide dedicated pathways and leverage points that facilitate the removal of bridges and strips under molding pressure without requiring direct manipulation of the tightly constrained contact components.
Solution Approach 2:
The removal mechanism utilizes the vertical dimension (protruding ears extending upward from the insulator base) to access and remove the horizontally positioned carrier strips and cutoff bridges. This dimensional approach allows removal operations to occur from a different spatial direction, avoiding interference with the high-pressure molding environment.
3Area of stationary object
If all contacts are arranged in a compact layout, then space utilization is improved, but the difficulty of managing and removing carrier strips and bridges increases
Solution Approach 1:
The carrier strips are nested within or alongside the insulator structure, with ears protruding from the insulator base to provide access. The cutoff bridges connect contacts in a compact arrangement while the carrier strips run parallel to the contact rows, creating a nested configuration that maximizes space utilization while maintaining removal accessibility.
Data Source
AI summary
An electrical connector includes: an insulative housing having a base and a tongue; an upper and lower rows of contacts mounted in the insulative housing and exposed to an upper and lower surfaces of the tongue, the upper row of contacts and the lower row of contacts being equal in number; and an auxiliary contact disposed among the upper row of contacts. The upper rows of contacts and the lower row of contacts and a metallic shielding sheet are integrally formed within an insulator via a one shot initial insert-molding process to form an initial module. Some of the contacts are equipped with ears viewable upon the corresponding surface of the tongue.