Connector Nut Positioning via Core Resin Insert Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connector manufacturing methods face challenges in maintaining the position and posture of nuts with high accuracy using a simple mold structure, as they often rely on complex mold designs and movable parts to support the nut during insert molding.
Innovation Solution
A connector design and manufacturing method where a core resin portion with embedded connector terminals and nuts is used, allowing the nut to be positioned and maintained in a specified posture through a simple mold structure by injecting resin material from a gate that faces the opposite side surface of the core resin portion, with the core resin portion holding the nut in place and forming an injection mark on the outer resin portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the through nut is supported only by the lower mold, then the mold structure remains simple, but the position and posture of the nut cannot be maintained with high accuracy when resin collides with the lid
Solution Approach 1:
The nut is preliminarily positioned and fixed in the mold before injection molding begins. The mold includes a fixing structure that secures the nut in a predetermined position and orientation, preventing displacement when resin is injected and collides with the lid during the molding process.
Solution Approach 2:
The mold design incorporates a counteracting structure that prevents the harmful effect of resin collision on the nut. By providing a fixing mechanism that opposes and neutralizes the disruptive force of resin impact, the nut's position and posture are maintained with high accuracy throughout the injection process.
2Manufacturing precision
If a fastener is provided in the lower mold to fix the nut, then the nut position is maintained accurately, but the mold structure becomes complicated with movable parts
Solution Approach 1:
The fixing function for the nut is merged into the mold structure itself rather than being a separate movable component. The mold includes integrated fixing features such as positioning protrusions, clamping structures, or embedded fixtures that are part of the stationary mold body, eliminating the need for separate movable fastening mechanisms.
Solution Approach 2:
The mold structure provides self-fixing capabilities through its design, where the mold itself contains and secures the nut without requiring external movable fasteners. The fixing function is inherent in the mold's structure, reducing the need for additional components and simplifying the overall system.
3Ease of manufacture
If the lid and through nut are covered by insert molding, then the connector terminals can be arranged, but the nut posture may incline when resin collides with the lid
Solution Approach 1:
The mold design applies different local characteristics to different regions: the area around the nut includes enhanced fixing and positioning features to maintain posture accuracy, while other areas allow for the insert molding of connector terminals. This localized differentiation ensures both ease of manufacture and high precision where needed.
Data Source
AI summary
A connector (1) includes a plurality of connector terminals (3), core resin portions (2A), (2B), nuts (4) and an outer resin portion (5). A plurality of the nuts (4) are arranged to face a nut facing surface (21A) of the core resin portion (2A). The outer resin portion (5) covers the core resin portions (2A), (2B) and the nuts (4) with exposed surfaces (25) of the core resin portions (2A), (2B) and outer end surfaces (41) of the nuts (4) exposed. Injection marks (51) during molding of the outer resin portion (5) are formed on a surface of a part of the outer resin portion (5) covering an opposite side surface (22B) located on a side opposite to the nut facing surface (21A).