Insertion-Type Connector Manufacturing via Integrated Stamping and Embedding
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Solution Overview
Problem
The high assembly costs associated with manufacturing insertion-type connectors, which are typically mass-produced and require low unit costs, are not effectively reduced by existing methods.
Innovation Solution
A method where multiple second conductor contacts form a conductor contact plate and are connected to first conductor contacts via a connecting part, which is then embedded in an insulating material to form a housing, eliminating the need for separate assembly and reducing costs by integrating the conductor contacts and connecting part into a single, stamped metal component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conductor contacts are manufactured separately and assembled into the housing, then individual component quality can be controlled, but assembly costs increase significantly
Solution Approach 1:
The patent combines multiple conductor contacts (signal contacts and ground contacts) with the housing into a single integrated component. The conductor contacts are embedded directly into the housing material during formation, eliminating separate assembly steps. This merging of previously separate components (contacts and housing) resolves the contradiction by maintaining manufacturing precision through integrated formation while dramatically reducing assembly costs through elimination of separate assembly operations.
2Reliability
If conductor contacts are embedded in insulating material to form housing, then electrical insulation is improved, but manufacturing complexity increases
Solution Approach 1:
The housing and insulating material are formed as a single integrated component with the conductor contacts embedded within. The housing material itself serves as the insulating medium, eliminating the need for separate insulating components. This merging approach improves electrical insulation reliability by ensuring direct integration while reducing manufacturing complexity by consolidating multiple formation steps into a single integrated process.
Solution Approach 2:
The housing material serves multiple functions simultaneously: it provides structural support, electrical insulation, and mechanical fixation for the conductor contacts. By making the housing material multi-functional, the patent improves electrical insulation reliability without adding manufacturing complexity, as the same material and process accomplish multiple objectives that would otherwise require separate components and assembly steps.
3Reliability
If connecting part is separated off after embedding, then conductor contacts are electrically insulated from each other, but production time increases
Solution Approach 1:
The connecting part is designed to be separated off after the embedding process, but before final assembly. This preliminary separation action allows the conductor contacts to be electrically insulated from each other in advance, ensuring reliable electrical insulation is established before the contacts are fully assembled and connected to external circuits. The separation timing is optimized to maintain insulation reliability while minimizing impact on overall production time.
Data Source
AI summary
A method of manufacturing an insertion-type connector having at least two mutually electrically insulated conductor contacts with the conductor contacts cut from a metal sheet in such a way that they are connected together via a connecting part of the metal sheet, the conductor contacts being partly embedded in an electrically insulating material to form an electrically insulating housing which fixes the conductor contacts relative to one another, and the connecting part then separated off.