Over-molding Covers for Electrical Connector Gap Elimination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors with metallic shells and contact modules suffer from gaps that compromise mechanical and electrical performance, and single over-molding covers result in uneven exterior surfaces with poor aesthetics.
Innovation Solution
An electrical connector design featuring a contact module enclosed within a pair of over-molding covers, where the contacts are retained via an insert-molding process, with only one row of contacts exposed vertically on one tongue part, ensuring a gap-free and aesthetically pleasing appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single over-molding cover is used to cover the contact module, then the gap between the shell and contact module is eliminated, but the exterior surface becomes uneven with poor appearance
Solution Approach 1:
The single over-molding cover is divided into two separate covers (first and second over-molding covers). Each cover independently encloses portions of the contact module, allowing the positioning/core pins to be hidden within the structure while maintaining a uniform exterior surface. This segmentation resolves the contradiction by eliminating gaps through multiple covers while preserving aesthetic appearance.
2Stability of the object's composition
If positioning/core pins are used to hold the contact module during over-molding, then the contact module is securely retained, but the exterior surface becomes uneven due to pin exposure
Solution Approach 1:
The positioning/core pins are extracted from the exterior view by enclosing them within the over-molding covers. The pins remain functional for holding the contact module during manufacturing, but their exposure to the exterior is eliminated. This allows secure retention of the contact module while achieving a smooth, uniform exterior surface without visible pins.
3Shape
If all contacts are enclosed within the housing, then the appearance is uniform, but the contacting sections are not accessible for connection
Solution Approach 1:
The over-molding covers are designed with selective exposure: the contacting sections of the contacts are exposed on the exterior surfaces of the covers, while other portions of the contact module remain enclosed. This local differentiation allows the housing to maintain a uniform, enclosed appearance for most components while providing accessible contacting sections for electrical connection operations.
Data Source
AI summary
An electrical connector includes a contact module enclosed within a pair of over-molding covers. The contact module includes one row of contacts retained in an insulator via an insert-molding process. Each cover includes a rear base part and a front tongue part extending forwardly from the base part. Each contact has a front contacting section exposed upon the tongue in a vertical direction, and a rear tail section exposed outside of the base. The contacts are exposed upon only one tongue part in the vertical direction.