Connector Terminal Displacement Suppression via Segmented Mold Projections
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Solution Overview
Problem
Existing connector manufacturing processes face challenges in maintaining the fluidity of plastic material during insert-molding, leading to potential terminal displacement and inefficient electromagnetic wave equalization.
Innovation Solution
The connector design features a body with strategically positioned recesses and protrusions in the mold, creating flow paths for plastic material and ensuring proper alignment of terminals, which enhances fluidity and reduces displacement, while also allowing for electromagnetic wave equalization through specific terminal exposure configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an elongated projection is used to press terminals during insert-molding, then terminal displacement is suppressed, but fluidity of plastic material deteriorates
Solution Approach 1:
The mold projection is divided into multiple segments corresponding to different terminal groups. Each segment independently presses specific terminals, allowing localized control without requiring a single large elongated projection that would block plastic material flow paths.
Solution Approach 2:
Different regions of the mold have different projection characteristics tailored to local requirements. High-pressure regions are provided where terminal displacement needs suppression, while low-pressure regions maintain open flow paths for plastic material injection.
2Ease of manufacture
If plastic material flows freely during insert-molding, then fluidity is maintained, but terminal displacement increases
Solution Approach 1:
The mold projections are designed to apply preliminary counter-pressure to terminals in anticipated high-displacement zones before plastic material injection completes, preventing terminal displacement while maintaining overall fluidity.
Solution Approach 2:
Pressure is applied partially to specific terminal regions rather than uniformly across all terminals. This selective partial action suppresses displacement where needed while leaving other regions free for adequate plastic material flow.
3Reliability
If terminals are fully exposed through recesses, then electromagnetic wave equalization is achieved, but terminal displacement increases during molding
Solution Approach 1:
Terminals are pre-positioned and partially secured by mold projections before complete plastic material injection, allowing subsequent full exposure through recesses for electromagnetic wave equalization without experiencing excessive displacement during molding.
Data Source
AI summary
A connector including a body, an adjacent pair of first terminals, a second terminal next to one of the first terminals, a third terminal next to the other first terminal, and a fourth terminal. The body holds the terminals at least partially and includes a first recess, a second recess, and a first separating portion therebetween. The first and third terminals each have a portion exposed through the first recess. The fourth terminal has a portion exposed through the second recess. The second terminal includes an exposed portion and an unexposed portion. The unexposed portion includes an area on one side in the first direction of a part in the second direction of the second terminal and is covered with the body. The exposed portion includes an area on the other side in the first direction of the part of the second terminal and is exposed through the first recess.