Insert-Molded Connector Terminals for Overlap-Free Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connectors with insert molded terminals face challenges in manufacturing due to contact overlapping issues, leading to increased complexity, reduced productivity, and higher costs, particularly when the mating direction is parallel or vertical to the board surface, regardless of the number of contacts.
Innovation Solution
The connector design includes a housing with terminals where at least one terminal portion is positioned closer to the mating side than the other, with a surface extending across the mating direction that does not overlap the other terminal portion, allowing for partial exposure outside the housing and easier molding without displacement during resin injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If contacts are arranged with overlapping positions as viewed in the mating direction, then the connector achieves compact design and proper contact alignment, but it becomes impossible to place molds for each contact and perform simultaneous insert molding, requiring complicated manufacturing processes
Solution Approach 1:
The terminal is divided into multiple portions (first terminal portion and second terminal portion) with different functions. The first terminal portion has a first surface that does not overlap with the second terminal portion when viewed in the mating direction, allowing mold placement, while the second terminal portion maintains the overlapping contact configuration for proper alignment. This segmentation enables both compact design and feasible manufacturing.
Solution Approach 2:
The first surface of the first terminal portion extends along a plane crossing the mating direction, creating a non-overlapping region in a different dimensional orientation. This allows the mold to access and secure the terminal at a position that does not interfere with the overlapping contact arrangement when viewed from the mating direction, resolving the contradiction between compact configuration and manufacturability.
2Manufacturing precision
If contacts are insert molded with molded portions to prevent displacement during resin injection, then manufacturing precision is improved, but the number of molds required increases and productivity decreases when contacts overlap
Solution Approach 1:
The terminal structure is segmented into first and second terminal portions, where the first terminal portion provides a non-overlapping first surface for mold placement. This allows a single mold to securely fix the terminal at the predetermined position during insert molding, eliminating the need for multiple molds while maintaining manufacturing precision and improving productivity.
3Manufacturing precision
If multiple molds are used to manufacture connectors with overlapping contact configurations, then proper contact alignment is achieved, but manufacturing costs increase
Solution Approach 1:
The terminal is segmented to provide a first surface on the first terminal portion that does not overlap with the second terminal portion when viewed in the mating direction. This non-overlapping surface allows a single mold to properly align and secure the contact during insert molding, achieving proper contact alignment while reducing manufacturing costs by eliminating the need for multiple molds.
Solution Approach 2:
By extending the first surface along a plane crossing the mating direction, the invention creates a mold-accessible region in a different dimensional orientation. This allows proper contact alignment to be achieved with a single mold, reducing manufacturing complexity and cost while maintaining the overlapping contact configuration for proper alignment.
Data Source
AI summary
Provided a connector including a plurality of terminals insert molded with a housing. At least one of terminals includes a first terminal portion and a second terminal portion spaced apart from the first terminal portion in a direction along a direction of mating to a counterpart connector. The first terminal portion includes a first surface extending along a plane crossing the mating direction on a side opposite to the side that mates to the counterpart connector. The first surface includes a portion that does not overlap the second terminal portion as the first and second terminal portions are viewed in the direction from the side opposite to the side that mates to the counterpart connector. At least a partial region of the portion, which does not overlap the second terminal portion, of the first surface is exposed to an outside of the housing through an opening of the housing.