Fine-Pitch Connector Contact Assembly for Stable Insert Molding
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Solution Overview
Problem
The challenge of achieving compatibility between insert molding and fine pitch disposition of signal contacts in connectors, where the gap between adjacent contacts is not sufficiently filled with molten resin, leading to potential misalignment or detachment of contacts.
Innovation Solution
A connector design featuring a housing made of insulating resin with a contact assembly integrally formed by insert molding, comprising metal bases with projecting parts and conductive patterns on an insulating layer, where the fixed parts of contact units are linked together in an unbroken manner in the pitch direction, ensuring stable positioning during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If signal contacts are disposed in fine pitch, then the connector achieves higher integration density, but the gap between adjacent contacts is not sufficiently filled with molten resin during insert molding
Solution Approach 1:
The contact assembly is divided into multiple contact units, each with its own base and conductive pattern. This segmentation allows the resin to be injected around each individual contact unit, ensuring complete filling even in fine pitch configurations where gaps between contacts are narrow.
Solution Approach 2:
The bases of the contact units are pre-positioned and fixed to the housing before the insert molding process. This preliminary action creates defined spaces around each contact unit, guiding the molten resin flow to ensure complete filling of gaps between adjacent fine pitch contacts during the subsequent molding process.
2Quantity of substance
If signal contacts are disposed in fine pitch, then the connector achieves higher integration density, but the contacts may fall or come out of the housing
Solution Approach 1:
The base of each contact unit is integrally formed with the housing through insert molding, merging the contact structure with the housing into a single unified component. This integration ensures that contacts cannot fall or come out of the housing, maintaining positioning stability even in fine pitch configurations.
Solution Approach 2:
The bases are pre-fixed to the housing before molding, establishing stable anchor points that prevent contact displacement during the molding process and ensure long-term positioning stability in the final assembled connector.
3Productivity
If insert molding is used to integrate housing and contacts, then manufacturing efficiency is improved, but compatibility with fine pitch disposition is difficult to achieve
Solution Approach 1:
The contact assembly is segmented into multiple contact units with individual bases and conductive patterns. This segmentation enables the insert molding process to effectively accommodate fine pitch dispositions by allowing resin to be injected around each contact unit, maintaining both manufacturing efficiency and fine pitch compatibility.
Solution Approach 2:
Each contact unit has a localized base structure that is fixed to the housing, creating local quality variations that facilitate resin flow and filling in fine pitch areas. This local structural optimization maintains manufacturing efficiency while enabling fine pitch compatibility.
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 allows for the achievement of fine pitch contact disposition without misalignment, enhancing the compatibility of housing and contacts, improving signal characteristics and reducing the risk of contact detachment, while maintaining high productivity and cost-effectiveness.
Implementation Method 1
a contact assembly integrally formed with the housing by insert molding
Data Source
AI summary
A receptacle includes a housing made of insulating resin and a first receptacle contact assembly integrally formed with the housing by insert molding. The first receptacle contact assembly includes a plurality of contact units arranged in a pitch direction. Each contact unit includes a base made of metal including a fixed part in a flat-plate shape fixed to the housing and four projecting parts projecting upward from the fixed part, an insulating layer that covers the base, and four conductive patterns that are formed on the insulating layer, extend from the fixed part to the four projecting parts, and function as contacts. The fixed parts of the plurality of contact units link together in an unbroken manner in the pitch direction.