Insert-Molded Connector Structure for Accurate Through-Nut Positioning
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Solution Overview
Problem
Existing connector manufacturing methods face challenges in maintaining the accurate position and posture of through nuts during insert molding, leading to potential inclination and increased mold complexity due to the lack of support from both the upper and lower molds.
Innovation Solution
A connector design utilizing a core resin portion with connector terminals and through nuts, where the core resin portion holds the through nuts in a specified posture, preventing resin penetration into the screw holes by using injection marks and pressure during molding, and a simple mold structure is maintained by avoiding movable parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the through nut is supported only by the lower mold during insert molding, then the mold structure remains simple, but the position and posture of the through nut cannot be accurately maintained, causing inclination
Solution Approach 1:
The through nut is preliminarily positioned and fixed to the lower mold before injection molding begins. Positioning protrusions on the lower mold fit into positioning recesses on the through nut, establishing accurate initial positioning. This preliminary action ensures the through nut maintains its specified position and posture throughout the molding process without requiring complex support structures.
Solution Approach 2:
Positioning protrusions and positioning recesses serve as intermediary elements that mediate between the lower mold and the through nut. These intermediaries transmit and maintain the positional relationship, ensuring accurate positioning without direct complex mechanical constraints on the through nut itself.
2Manufacturing precision
If a stopper is provided in the lower mold to fix the nut, then the position of the nut is maintained, but the structure of the lower mold becomes complicated with movable parts
Solution Approach 1:
Instead of providing a stopper in the lower mold that actively engages with the through nut, the positioning features are inverted: positioning recesses are provided on the through nut itself, which passively receive positioning protrusions from the lower mold. This inversion eliminates the need for complex movable stoppers while achieving the same positioning function.
Solution Approach 2:
The through nut is designed with integrated positioning recesses that enable it to self-position on the lower mold through the positioning protrusions. The through nut essentially positions itself without requiring external active positioning mechanisms, simplifying the mold structure while maintaining positioning accuracy.
3Ease of manufacture
If the gate is positioned to allow resin flow, then the outer resin portion is successfully molded, but resin may penetrate into the screw hole of the through nut
Solution Approach 1:
The opening of the screw hole is preliminarily closed by the nut facing surface before resin injection occurs. This preliminary closure prevents resin from entering the screw hole during the molding process. The gate is strategically positioned and the nut facing surface is designed to close the screw hole opening, creating preliminary protection against resin penetration while allowing successful molding of the outer resin portion.
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 connector is successfully molded with the through nuts accurately positioned and postured, preventing resin penetration into screw holes, and the mold structure remains uncomplicated, ensuring precise manufacturing.
Implementation Method 1
receiving a pressure during injection of the resin material when the resin material is injected toward the opposite side surface from the gate
Data Source
AI summary
A connector (1) is provided with a plurality of connector terminals (3), core resin portions (2A, 2B), through nuts (4) and an outer resin portion (5). An opening (402) of a screw hole (40) located in an inner end surface (42) of the through nut (4) is closed by a nut facing surface (21A) of the core resin portion (2A). The outer resin portion (5) covers the core resin portions (2A), (2B) and the through nuts (4) with exposed surfaces (25) of the core resin portions (2A, 2B) and outer end surfaces (41) of the through nuts (4) exposed. Injection marks (51) at the time of molding the outer resin portion (5) are formed on a surface of a part of the outer resin portion (5) covering an opposite side surface (22B) of the core resin portion (2B).