Connector Production Method Reducing Misalignment
Solution Overview
Problem
Conventional connector production methods face challenges with misalignment of components due to production tolerance, leading to increased complexity and costs, especially when using adhesives to address these issues.
Innovation Solution
A method involving a first insulator that holds a flat plate conductor and contacts, with a metal shell covering the contacts, and a second insulator formed through insert molding to align and secure the components without adhesives, using welding for electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive bonding is used to fix components, then assembly flexibility is improved, but production cost increases
Solution Approach 1:
The patent removes the adhesive bonding step from the manufacturing process. Instead of using adhesives to fix the shell to the insulator or contacts to the insulator, the design uses mechanical fitting and integrated molding where components are directly assembled without additional bonding materials, thereby reducing production cost while maintaining assembly capability
Solution Approach 2:
The patent combines multiple functions into fewer steps. The insulator is molded with integrated contact holders and positioning features that simultaneously achieve contact fixation, alignment, and structural support, eliminating the need for separate adhesive bonding operations
2Manufacturing precision
If multiple components are assembled with tolerance compensation, then alignment accuracy is improved, but device complexity increases
Solution Approach 1:
The patent incorporates alignment features and tolerance compensation mechanisms directly into the molded insulator structure before assembly. The insulator includes pre-formed positioning protrusions, recesses, and guide features that automatically align components during assembly, eliminating the need for complex post-assembly adjustment procedures
Solution Approach 2:
The patent uses a nested structure where the insulator is molded with integrated contact holders and shell mounting features. The contacts are held within recesses in the insulator, which itself contains the positioning features for the shell, creating a hierarchical nested assembly that simplifies the overall structure while maintaining precision
3Stability of the object's composition
If shell and contacts are fixed with insulator through resin molding, then integration is improved, but positional variability causes misalignment
Solution Approach 1:
The patent applies different local qualities to different regions of the insulator. Specific areas of the insulator are molded with enhanced precision features, tighter tolerances, and specialized geometric configurations that locally compensate for general resin molding variability, ensuring accurate alignment at critical interfaces between the shell, contacts, and insulator
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 approach results in a highly accurate connector with reduced misalignment and production costs, achieving reliable electromagnetic shielding without the need for adhesives.
Implementation Method 1
forming a second insulator by insert molding such that the second insulator covers the rear part of the first insulator and a rear part of the shell and adheres to surfaces of a pair of arm sections
Implementation Method 2
the shell is fixed to and electrically connected to the flat plate conductor through welding
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The connector production method comprises: the step of causing a first insulator to hold a flat plate conductor; the step of joining onto the first insulator the middle portion of one or more contacts in such a manner that the front extremity portion thereof is exposed in the first insulator front portion while the rear extremity portion thereof protrudes from the first insulator rear portion; the step of covering the first insulator with a metal shell in such a manner as to cover the outer periphery of the one or more contacts; the step of fixing and connecting electrically the shell to the flat plate conductor; and the step of forming a second insulator in such a manner that the shell rear portion and the first insulator rear portion are covered while the rear extremity portion of the one or more contacts protrudes therefrom.