Electrical Connector Metallic Sliding Block Overmolding

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Solution Overview

Problem

Existing electrical connectors with metallic shells and contact modules suffer from gaps that compromise mechanical and electrical performance, and single overmolding covers result in uneven exterior surfaces, affecting appearance.

Innovation Solution

An electrical connector design featuring an insulative housing with a tongue and internal cavity, where the contact module is integrally formed with a first insulator and covered by a second insulator via overmolding, ensuring no gaps and a smooth exterior, with the internal cavity hidden from view.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a single overmolding cover is used to circumferentially cover the contact module, then the gap between the shell and contact module is eliminated, but the exterior surface becomes uneven and appearance is compromised

Engineering Contradiction:

Improvegap-free connectionVSAvoidexterior surface uniformity

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The invention divides the overmolding cover into two distinct parts: a first insulator formed via insert-molding that provides structural support and contact retention, and a second insulator formed via overmolding that provides aesthetic coverage. This segmentation allows each part to fulfill its specific function without compromising the other, eliminating the gap issue while maintaining smooth exterior surfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first insulator is pre-formed through insert-molding before the overmolding process. This preliminary action creates a prepared substrate with precise geometric features that guide the subsequent overmolding process, ensuring that the second insulator can be applied uniformly without creating surface irregularities.

Inventive Principle:

Principle #10Preliminary action

2Stability of the object's composition

If positioning/core pins are used to hold the contact module during overmolding, then the contact module is secured in position, but the exterior surface becomes uneven

Engineering Contradiction:

Improvecontact module positioningVSAvoidexterior surface smoothness

Core Design Contradiction:

Stability of the object's compositionVSShape

Solution Approach 1:

The invention removes the problematic positioning/core pins from the final product design. Instead, it uses the first insulator with integrated geometric features (such as recesses and protrusions) to securely hold the contact module in position. This extraction eliminates the source of exterior surface irregularities while maintaining stable contact module positioning.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The first insulator serves as an intermediary component between the contact module and the second insulator. It provides the necessary positioning and support functions that were previously achieved by positioning pins, while its smooth exterior surface allows the second insulator to form a uniform outer layer without irregularities.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If an insulative over-molding cover is applied upon the contact module, then mechanical and electrical performance is improved, but the appearance is compromised due to uneven surfaces

Engineering Contradiction:

Improvemechanical and electrical performanceVSAvoidappearance quality

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The protective cover is segmented into two functional parts: the first insulator that provides mechanical support and electrical insulation with a smooth surface, and the second insulator that provides additional aesthetic coverage. This segmentation ensures both performance and appearance requirements are met simultaneously.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The housing is formed as a composite structure combining two insulator materials through different molding processes. The first insulator (insert-molded) and second insulator (overmolded) work together as a composite system, where each material is optimized for its specific function, resulting in both improved performance and enhanced appearance.

Inventive Principle:

Principle #40Composite materials

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

The solution provides a gap-free, aesthetically pleasing electrical connector with improved mechanical and electrical performance by enclosing the contact module within a single overmolded cover, enhancing retention and appearance while maintaining contact exposure only on one mating surface.

Implementation Method 1

The housing includes a first insulator integrally formed with the contacts via an insert-molding process

Methodology Applied

Scientific EffectInsert-molding:

Implementation Method 2

a second insulator, i.e., the cover, overmolded upon the first insulator

Methodology Applied

Scientific EffectOvermolding:

Data Source

PatentUS11081819B2Electrical connector using a metallic sliding block to hold an inner insulator during the overmolding of an outer insulator onto the inner insulator

Publication Date: 2021.08.03 FOXCONN (KUNSHAN) COMPUTER CONNECTOR CO LTD

AI summary

An electrical connector includes an insulative housing having a first insulator integrally formed with the contacts via an insert-molding process, and a second insulator, i.e., the cover, overmolded upon the first insulator wherein an internal cavity is formed within the housing and between the first insulator and the second insulator in the transverse direction, through which a sliding block presses the first insulator in position in the transverse direction during overmolding the second insulator.