Molded Module Press-In Contact Collar Design
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Solution Overview
Problem
Existing methods for producing electrical contacts between mold modules using press-fit technology are costly and prone to mechanical deformation, often requiring additional tools and inserts, which can lead to delamination and increased manufacturing complexity.
Innovation Solution
The integration of a mold collar and embossing zones in the mold module, which absorbs press-in forces and allows for cost-effective, high-accuracy electrical contacting without additional tools, enabling press-in contacts to be inserted from above or below and supported by the molding compound, thus avoiding deformation and delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If press-fit technology is used to produce electrical contacts between mold modules, then electrical connection is achieved, but mechanical deformation of contacts occurs and additional tools and inserts are required
Solution Approach 1:
The patent merges the support function previously performed by separate inserts and tools into the molding compound itself. The molding compound is integrated directly into the contact region, providing structural support and positioning for the electrical contacts without requiring additional components. This eliminates the complexity of multiple inserts and tools while maintaining reliable electrical connections.
Solution Approach 2:
The molding compound serves multiple functions simultaneously: it provides electrical insulation, mechanical support, precise positioning, and protection for the electrical contacts. The material essentially serves itself by being molded directly into the contact region, eliminating the need for separate support structures or alignment tools that would otherwise be required.
2Manufacturing precision
If inserts with very low mechanical tolerances are used to support external contacts, then contact deformation is avoided, but additional costs increase
Solution Approach 1:
The patent replaces expensive, precision-machined inserts with a cost-effective molding compound that achieves the same positioning accuracy. The molding compound is formed through a standard injection molding process, which is significantly cheaper than machining precision inserts, while still providing the necessary mechanical tolerance control for contact alignment.
Solution Approach 2:
The invention changes the approach from mechanical tolerance control through precision-machined inserts to tolerance control through molding process parameters. By optimizing the injection molding parameters (temperature, pressure, timing), the patent achieves consistent contact positioning without the need for expensive precision inserts, thereby reducing manufacturing costs while maintaining precision.
3Stability of the object's composition
If additional tools are used to support external contacts, then contact stability is improved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent combines the stabilizing function of additional tool supports into the single integrated structure of the molding compound. The molded material forms a unified support structure that holds the electrical contacts in place, eliminating the need for separate tool supports while maintaining contact stability throughout the assembly process.
4Reliability
If press-in force is applied to external contacts, then electrical connection is established, but mechanical deformation and delamination occur
Solution Approach 1:
The patent provides beforehand cushioning by having the molding compound already in place to absorb and distribute the press-in forces. The molded material acts as a cushioning layer that prevents direct transmission of high press-in forces to the contact interfaces, thereby avoiding mechanical deformation and delamination while still establishing reliable electrical connections.
Solution Approach 2:
The invention changes the mechanical properties of the support structure through the molding process. The molding compound can be formulated with specific durometer values and cross-linking characteristics that allow it to be soft enough to cushion press-in forces yet rigid enough to maintain structural integrity, thus preventing both deformation and delamination.
Data Source
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AI summary
The invention relates to a molded module (1), having at least one electronic and/or electrical component (3), which is enclosed by a molding mass (30), and having at least one press-in contact (20), which is arranged on the module edge and which has a contacting region (22) having a press-in opening (24) accessible from both surfaces, and to a method for producing such a molded module (1), and to a molding tool for the overmolding of such a molded module (1). The molding mass (30) is deposited in the region of the at least one press-in contact (20) and forms a molded collar (32) on both surfaces of the press-in contact (20), which molded collar extends around the corresponding press-in contact (20) in some areas and absorbs press-in forces occurring in the event of contacting and leaves a space (34) open above and below the corresponding press-in opening (24), wherein the press-in contact (20) has a stamping zone (26) on both surfaces around the press-in opening (24), which stamping zone separates the contacting region (22) from the molding mass (30).