Device Module Holder Prevents Plastic Ingress During Molding
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Solution Overview
Problem
Conventional device modules face difficulties in preventing plastic material from entering the housing recess of a die during molding, making it challenging to insert the transmission cable effectively due to the need for a precise shape match between the housing recess and the cable, which complicates the insertion process.
Innovation Solution
The device module incorporates a holder embedded in the plastic part with an exposed portion that fits into the housing recess of the die, allowing the external connection to be partially fixed to the holder, enabling easy insertion and preventing plastic material ingress by closing the recess, while the holder's design ensures secure placement and alignment during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the housing recess shape conforms to the outer shape of the transmission cable to prevent plastic material ingress, then plastic material is prevented from entering the housing recess, but the insertion of the transmission cable becomes very difficult
Solution Approach 1:
A holder is introduced as an intermediary component between the transmission cable and the housing recess. The holder has an insertion portion that fits into the housing recess and an exposed portion that protrudes from the plastic part. This mediator allows the housing recess to have a simple shape while still preventing plastic material ingress, as the holder's insertion portion seals the recess without requiring the recess itself to conform to the cable's complex outer shape.
Solution Approach 2:
The functional components are segmented into separate parts: the holder and the transmission cable. The holder's insertion portion prevents plastic material from entering the housing recess, while the transmission cable's outer shape is not constrained to match the recess. This segmentation allows each component to be optimized independently - the holder for sealing and the cable for its electrical function.
2Reliability
If the housing recess is designed to precisely match the transmission cable shape to prevent plastic ingress, then plastic material ingress is prevented, but the device complexity increases
Solution Approach 1:
The holder serves as a mediator that simplifies the housing recess design. Instead of designing a complex recess that precisely matches the transmission cable's outer shape, the recess is designed to simply receive the holder's insertion portion. The holder then provides the sealing function, reducing the overall device complexity while maintaining reliability.
Solution Approach 2:
The sealing function is extracted from the housing recess design and transferred to the holder's insertion portion. This allows the housing recess to have a simple, standardized shape that is easier to manufacture, while the holder's insertion portion provides the precise fit needed to prevent plastic material ingress.
3Ease of operation
If the holder's exposed portion fits into the housing recess to close it, then plastic material ingress is prevented and insertion is easier, but the holder must be precisely positioned to ensure proper closing
Solution Approach 1:
The holder is positioned and fixed to the transmission cable before the molding process. The insertion portion is already in place in the housing recess, and the exposed portion is positioned to close the recess. This preliminary positioning ensures that when plastic material is injected, the holder is already correctly positioned to prevent ingress, eliminating the need for high precision during the molding process itself.
Solution Approach 2:
The holder's exposed portion protrudes from the plastic part beforehand to close the housing recess. This prior positioning acts as a cushioning measure that prevents plastic material from entering the recess during molding, even if there are slight variations in positioning precision. The holder is already in place to absorb any potential ingress issues.
Data Source
AI summary
The invention provides a device module that can be manufactured with a die. The device module includes a plastic part, a device, a holder, and an external connection. The device is embedded in the plastic part. The holder is embedded in the plastic part and includes an exposed portion exposed from the plastic part in a thickness direction of the plastic part in such a manner as to close a housing recess of the die. The external connection is connected to the device and partially fixed to the holder. The external connection includes a lead-out portion insertable in the housing recess of the die. The lead-out portion is embedded in the plastic part and being led out of the plastic part in the thickness direction. Alternatively, the lead-out portion is led through and out of the holder in the thickness direction.