Connector Spacer and EMC Pad Integration via Insert Molding
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Solution Overview
Problem
The existing connector manufacturing process is complex and requires a large number of molds and manpower, leading to high costs and inefficiencies.
Innovation Solution
A connector design featuring first and second contacts, a middle plate, EMC pads, an insulating body, and a spacer, where the EMC pads are connected to the middle plate via spot welding, and the insulating body is formed through insert molding, reducing the need for molds and assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If insert molding and over molding are performed separately on upper contacts and bottom contacts, then the contacts can be formed with EMC pads and middle plate, but the process becomes complicated and requires large quantity of molds
Solution Approach 1:
The patent combines the formation of upper contacts, bottom contacts, EMC pads, and middle plate into a single integrated insert molding process. The connector housing, contacts, and EMC pads are molded together as one unit, eliminating the need for separate molding operations and reducing the number of molds required.
Solution Approach 2:
The connector housing serves multiple functions simultaneously: it provides structural support, acts as an insulating body, houses the contacts, and integrates the EMC pads. This multi-functional design reduces the number of separate components and assembly steps.
2Manufacturing precision
If multiple separate components are assembled manually, then the connector can be formed with precise components, but the required manpower increases
Solution Approach 1:
The patent merges multiple separate components (housing, contacts, EMC pads) into a single integrated structure through co-molding. This eliminates the need for manual assembly operations while maintaining manufacturing precision, as all components are formed in their final positions during the molding process.
Solution Approach 2:
The contacts and EMC pads are pre-positioned and integrated into the housing during the molding process itself, rather than being assembled later. This preliminary integration eliminates subsequent assembly steps and reduces manpower requirements.
3Reliability
If traditional multi-step molding process is used, then the connector can be manufactured with proper structure, but the manufacturing cost increases
Solution Approach 1:
The patent combines multiple molding operations into a single insert molding process, reducing the number of molds and tooling required. This integration significantly reduces manufacturing costs while maintaining structural reliability, as the contacts and EMC pads are molded in place with proper material properties.
Solution Approach 2:
The connector utilizes composite construction with the housing material and contact materials being molded together. This composite approach allows for optimized material selection for each component while achieving cost savings through process integration and reduced tooling requirements.
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 design reduces mold and manufacturing costs, simplifies the assembly process, and decreases the required manpower, thereby lowering production costs effectively.
Implementation Method 1
forming an insulating body by means of insert molding so that the insulating body is partially embedded with the first contacts, the second contacts, the middle plate, the first EMC pad, and the second EMC pad
Implementation Method 2
forming a spacer by means of over molding so that the spacer is formed between the first contacts and the second contacts and is partially embedded with the first contacts and the second contacts
Implementation Method 3
the first EMC pad and the second EMC pad are connected to the middle plate by means of spot welding respectively, thereby achieving a better grounding effect
Data Source
AI summary
A connector includes first contacts, second contacts, a middle plate, a first electromagnetic compatibility (EMC) pad, a second EMC pad, an insulating body, and a spacer. The middle plate is clamped between the first contacts and the second contacts. The first EMC pad is located above the first contacts. The second EMC pad is located below the second contacts. The first EMC pad and the second EMC pad are connected to the middle plate respectively. The insulating body is partially embedded with the first contacts, the second contacts, the middle plate, the first EMC pad, and the second EMC pad. The spacer is formed between the first contacts and the second contacts, and is partially embedded with the first contacts and the second contacts. A manufacturing method where the connector is assembled as a semi-finished product in advance is further provided to reduce the production cost.