Insert-Molded Terminal Structure for Single-Step Positional Accuracy
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Solution Overview
Problem
The existing method of molding resin for terminals requires two separate molding processes, which is time-consuming, labor-intensive, and costly, and struggles to maintain high positional accuracy of terminals after molding.
Innovation Solution
An insert-molded article design where the terminal has higher rigidity at specific portions adjacent to the resin portion, supported by a molding die, with a resin supplied between these portions to improve positional accuracy, and a method involving supporting these rigid portions during molding to reduce deformation and enhance accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If molding is performed only once, then productivity is improved, but manufacturing precision deteriorates
Solution Approach 1:
The terminal is designed with non-uniform rigidity distribution, where specific portions adjacent to the resin portion have higher rigidity than other portions. This local quality enhancement allows the terminal to maintain positional accuracy during single-step molding while improving overall productivity.
Solution Approach 2:
The molding die supports specific high-rigidity portions of the terminal before resin injection occurs. This preliminary support action prevents deformation during the molding process, enabling single-step molding to achieve the same positional accuracy as multi-step molding.
2Manufacturing precision
If the terminal is supported by the molding die during molding, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The molding die is designed to support only specific high-rigidity portions of the terminal rather than the entire terminal structure. This localized support approach improves positional accuracy while minimizing the complexity increase of the molding die structure.
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 improves the positional accuracy of terminals after resin molding, reducing the need for multiple molding processes and associated costs while minimizing deformation due to injection pressure.
Implementation Method 1
supplying a resin to the terminal between the first portion and the second portion in a state where the first portion and the second portion are supported by the molding die, and curing the resin
Data Source
AI summary
An insert-molded article includes a resin portion, and a terminal having a first portion extending in a first direction from the resin portion to be adjacent to the resin portion at a first side of the resin portion, a second portion extending in a second direction different from the first direction from the resin portion to be adjacent to the resin portion at a second side of the resin portion that is different from the first side, and a tip portion connected to one of the first and second portions. The first and second portions have rigidities that are higher than a rigidity of the tip portion.