Mini Plug Connector Recesses Prevent Molding Deformation
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Solution Overview
Problem
Conventional Mini-HDMI connectors experience deformation and defective production due to insufficient mold filling and deformation during the injection molding process, resulting in an unsatisfactory production rate.
Innovation Solution
A Mini-HDMI plug connector design featuring an insulative housing with a base, tongue, and top and bottom elongated recesses, along with a metal shell that includes pressing members to prevent deformation, ensuring proper filling and maintaining structural integrity during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the mold size is reduced to create Mini-HDMI connectors, then the size of the connector is reduced, but the mold cannot be filled completely causing defective production
Solution Approach 1:
The insulative housing is segmented into multiple sections with recesses that divide the mold cavity into separate regions. This segmentation allows the injection molding process to fill each region independently, ensuring complete filling even in reduced-size connectors while preventing defects caused by insufficient material flow in compact geometries.
Solution Approach 2:
Resses are strategically positioned at specific locations on the insulative housing to create localized expansion spaces within the mold cavity. These local modifications enable better material distribution and filling control in critical areas without increasing the overall connector size, addressing the manufacturing precision issue while maintaining compact dimensions.
2Volume of moving object
If the mold size is reduced to create Mini-HDMI connectors, then the size of the connector is reduced, but the production rate becomes unsatisfactory
Solution Approach 1:
The segmented design with recesses enables more efficient mold filling patterns that reduce cycle time. By creating separate fill zones, the injection molding process can proceed more smoothly without delays caused by air traps or incomplete filling, thereby improving production rate despite the reduced connector size.
Solution Approach 2:
The recesses modify the cavity volume parameters at strategic locations, creating optimal flow paths for the injection molding material. This parameter modification ensures complete filling and reduces defects, leading to higher yield rates and improved productivity in miniaturized connector production.
3Volume of moving object
If the mold size is reduced to create Mini-HDMI connectors, then the size of the connector is reduced, but deformation occurs during the injection molding process
Solution Approach 1:
The recesses segment the insulative housing structure, creating internal support zones that resist deformation during injection molding. These segmented regions distribute the molding pressure more evenly, preventing the housing from deforming while maintaining the reduced overall size of the Mini-HDMI connector.
Solution Approach 2:
The recesses create localized structural features that reinforce specific areas of the insulative housing prone to deformation. By modifying the local geometry at strategic positions, the design provides internal support that maintains shape integrity during the molding process without increasing the overall connector dimensions.
Data Source
AI summary
A mini plug connector has an insulative housing, a plurality of terminals and a metal shell. The insulative housing has a base, a tongue and a plurality of mounting holes. The tongue protrudes from the base and has a top, a space and at least one top elongated recess. The space and the at least one top elongated recess are defined in the top of the tongue. The terminals are mounted respectively through the mounting holes. The metal shell covers the insulative housing. The at least one top elongated recess prevents the insulative housing from being defective and deforming when the insulative housing is manufactured by an injection molding process.