Overmolded Automotive Connector Contacts for Precise Signal Alignment
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Solution Overview
Problem
Current high-speed modular twisted-pair-data connectors for automotive applications face challenges in manufacturing tolerances, particularly for male and female signal contacts, which affect data transmission precision and mass production feasibility.
Innovation Solution
The use of overmolding with a non-conducting molded part to precisely position elongated male and female signal contacts, combined with twisted and non-circular cross-sections, allows for precise alignment and secure connectivity, enabling mass production and improved data transmission capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods are used for signal contacts, then production cost is reduced, but manufacturing precision and positioning accuracy deteriorate
Solution Approach 1:
The patent combines the signal contact and insulation body into a single integrated component. The signal contact is embedded within the insulation body, merging two previously separate manufacturing steps into one injection molding process. This integration achieves precise positioning (±0.05mm) while maintaining manufacturing efficiency, as the entire assembly is produced in a single step rather than requiring separate assembly operations.
Solution Approach 2:
The insulation body serves multiple functions simultaneously: it provides electrical insulation, positions the signal contacts with high precision, and acts as a structural support element. The non-conducting material of the insulation body creates natural positioning features for the signal contacts, eliminating the need for separate positioning mechanisms and achieving multi-functionality in a single component.
2Productivity
If manufacturing tolerances are loosened for mass production, then productivity increases, but connectivity precision between male and female connectors deteriorates
Solution Approach 1:
The signal contacts are pre-positioned within the insulation body during the injection molding process itself. The molding cavity is designed with built-in positioning features that automatically locate the signal contacts at precise positions (±0.05mm) before the final connector assembly. This preliminary positioning action ensures high connectivity precision is achieved during mass production without requiring additional post-processing or assembly steps.
Solution Approach 2:
The insulation body's geometry itself provides the positioning function for the signal contacts. The non-conducting material forms natural定位 features (such as recesses, ribs, or geometric constraints) that automatically locate the signal contacts during molding. This self-positioning mechanism eliminates the need for external fixtures or complex tooling, enabling high-precision mass production through the part design alone.
3Stability of the object's composition
If signal contacts are completely covered by molded part, then positioning stability improves, but manufacturing complexity increases
Solution Approach 1:
The molded part is segmented into functional zones: a first molded part covers the signal contact for positioning and insulation, while a second molded part (or separate housing) provides overall connector structure. This segmentation allows the signal contact embedding to be achieved through a focused injection molding process without requiring the entire connector to be molded as one complex piece, thus maintaining positioning stability while managing manufacturing complexity.
Solution Approach 2:
The insulation body acts as an intermediary element between the signal contact and the external environment. It completely covers the signal contact to provide stable positioning and electrical insulation, while its modular design allows it to be manufactured separately and then integrated with other connector components. This intermediary structure simplifies the overall manufacturing process by decoupling the signal contact positioning function from the external connector housing.
Data Source
AI summary
The application deals with a male or female connector for automotive applications with at least one signal contact having an elongated male pin or a female signal contact portion; wherein a section of the signal contact is covered by a molded part that is manufactured by overmolding the section of the signal contact. The application further deals with a method for producing a male or female connector for automotive applications; including the steps of providing at least one signal contact having an elongated pin or a female signal contact portion; and overmolding a section of the at least one signal contact.