Microphone Unit Insert Molding Pressfit Contacts
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Solution Overview
Problem
Existing methods for producing microphone units with plug connectors are costly and complex, requiring multi-part housings and soldering processes, which increase costs and reduce quality.
Innovation Solution
A method involving insert injection molding of contacts with a bridge to form pressfit ends and pins, allowing for a one-part housing assembly without soldering, where contacts are bent to create a 90° angle and inserted into a housing with a retaining plate, enabling a pressfit connection to a circuit board for reliable and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-part housing and soldering processes are used to produce microphone units, then reliable electrical connections are achieved, but production costs increase and manufacturing complexity increases
Solution Approach 1:
The patent replaces the soldering process (thermal/mechanical system) with a press-fit connection system. The contacts are insert-molded into the housing with pre-formed contact pins that mechanically engage with the circuit board through friction and elastic deformation, eliminating the need for soldering while maintaining reliable electrical connections.
Solution Approach 2:
The patent combines the housing and contacts into a single integrated component through insert injection molding. The contacts are molded directly into the housing material, creating a unified structure that reduces the number of separate parts and assembly steps while ensuring reliable electrical connections through the integrated design.
2Stability of the object's composition
If multi-part housing is used for microphone unit assembly, then reliable component fixation is achieved, but production costs increase and assembly complexity increases
Solution Approach 1:
The patent merges the housing and contacts into a single insert-molded component, reducing multi-part assembly to a single molding operation. This integration maintains component fixation stability while dramatically simplifying the manufacturing process by eliminating separate housing assembly steps.
Solution Approach 2:
The patent performs preliminary formation of the contact fixation structure during the insert molding process itself. The contact pins are pre-configured with appropriate elasticity and geometry during molding, enabling self-fixing capability when the circuit board is inserted, thereby eliminating subsequent fixation operations.
3Strength
If contacts are bent to create 90° angles for pressfit connections, then reliable mechanical fixation is achieved, but contact pin deformation risk increases during handling
Solution Approach 1:
The patent provides beforehand cushioning by embedding the bent contacts within the rigid housing material through insert molding. The housing material acts as a protective matrix that cushions and supports the bent contact pins, preventing deformation during handling while maintaining the 90° angle geometry for effective press-fit connections.
Solution Approach 2:
The patent introduces the housing material as an intermediary that protects the vulnerable bent contact pins. The housing serves as a protective medium that maintains the geometric precision of the bent contacts while shielding them from mechanical damage during assembly and operation.
4Productivity
If insert injection molding is used to integrate contacts with housing, then production efficiency increases and costs decrease, but process complexity increases
Solution Approach 1:
The patent replaces multiple separate manufacturing processes (contact fabrication, housing production, assembly operations) with a single insert injection molding process. This substitution integrates multiple functions into one operation, improving productivity despite the specialized nature of the molding process.
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 method reduces costs and improves quality by eliminating the need for multi-part housings and soldering, allowing for efficient assembly and protection of the microphone component with a dust protector and pressfit connections for reliable electrical and mechanical fixation.
Implementation Method 1
insert injection molding a first assembly, which comprises the contacts, with a housing
Implementation Method 2
producing a pressfit connection between the pressfit ends of the contacts and the circuit board that is populated with the microphone unit as the circuit board is inserted into the first hollow chamber
Data Source
AI summary
The present invention relates to a method for producing a microphone unit, which can be contacted by a plug connector, and a microphone unit, wherein this comprises a housing, a circuit board having a microphone component and contacts, wherein the contacts are embodied on second contact ends as contact pins and wherein the contacts are connected at the first contact ends to the circuit board, wherein a multi-pole plug connector can be connected to the contact pins. The housing is embodied as a one-part injection molded part and the first contact ends are embodied as pressfit contacts.