Header Connector Interior Undercut Over-Molding
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Solution Overview
Problem
Existing methods for producing header connectors in the automotive industry require additional materials, specialized equipment, and separate assembly steps, which are time-consuming and inefficient.
Innovation Solution
A header connector design featuring a frame with recesses for over-molded interface portions, eliminating the need for separate assembly by integrating the interface portions into the frame through over-molding, which provides robust mechanical properties and sealing capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If gluing, ultrasonic welding or laser welding is used to assemble interface portions to the frame, then the header connector can be produced in a modular way, but additional materials, equipment and assembly steps are required
Solution Approach 1:
The patent merges the frame and interface portions into a single integrated component by injecting frame material directly into the interface portions during the molding process. This eliminates the need for separate assembly steps (gluing, ultrasonic welding, or laser welding) and additional equipment, while maintaining modular design benefits. The interface portions are formed with recesses that receive the frame material, creating a unified structure.
2Productivity
If separate assembly steps are used to connect the frame to interface portions, then modular production is enabled, but production time increases
Solution Approach 1:
The interface portions are pre-formed with specific recess geometries during their initial molding process. These recesses are designed to receive the frame material in a controlled manner during the subsequent injection step. This preliminary preparation enables the frame material to automatically lock into the interface portions without requiring additional assembly time or equipment.
3Ease of manufacture
If the frame material flows into recesses without control, then the interface portions can be integrated, but the mechanical properties may be compromised
Solution Approach 1:
The recesses in the interface portions are designed with specific geometric characteristics (undercut features) that create controlled flow patterns for the frame material. The recesses have wider openings that gradually narrow towards the bottom, ensuring that the frame material fills the recesses completely while maintaining consistent mechanical properties. This local geometric optimization ensures both integration capability and structural integrity.
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 approach reduces production time and enhances efficiency by eliminating the need for additional assembly steps and specialized equipment, while ensuring robust mechanical locking and sealing of the interface portions.
Implementation Method 1
The interior undercut space is occupied by a portion of the frame by means of over molding. In other words, the interior undercut space is filled by means of over molding and forms an integral part of the frame.
Data Source
Figure 1a~1c
Figure 2a~2b
Figure 3
AI summary
The invention relates to a header connector comprising a frame for receiving an interface portion. The header connector comprises at least two interface portions. Each interface portion comprises a side wall portion that protrudes inwards into the frame opposite to the mating direction, the side wall portion having an outer side wall surface and an opposing inner side wall surface, wherein a lock protrusion transversely protrudes away from the outer side wall surface into the frame perpendicular to the mating direction. The frame comprises an interior undercut space at least partly defined by the bottom wall and the inner side wall surface, wherein the interior undercut space is occupied by a portion of the frame by means of over molding.