Plug Connector Assembly Recessed PCB Edge Overmolding
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Solution Overview
Problem
Existing plug connector assemblies face difficulties in completely enclosing the side edges of a printed circuit board with an outer case due to size mismatches during over molding.
Innovation Solution
Incorporating recessing portions on the side edges of the printed circuit board's intermediate portion, which allows the outer case to be over molded and fill these recesses, effectively covering the side edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the intermediate portion of the printed circuit board has the same size as the mating end, then the conductive pads can be properly arranged for electrical connection, but the outer case cannot completely cover the side edges of the intermediate portion during over molding
Solution Approach 1:
The intermediate portion of the printed circuit board is segmented by adding recessing portions on its side edges. This segmentation allows different regions to serve different functions: the main body maintains the same size as the mating end for proper conductive pad arrangement, while the recessing portions provide space for the outer case to completely cover the side edges during over molding.
Solution Approach 2:
The solution introduces a dimensional change by adding recessing portions that extend in the lateral direction from the side edges of the intermediate portion. This creates an L-shaped profile in cross-section, allowing the outer case to extend further laterally and completely cover the side edges while the main body dimension remains unchanged for electrical connection requirements.
2Strength
If the outer case is formed by over molding to completely enclose the printed circuit board, then structural integrity is improved, but the side wall cannot cover the side edges of the intermediate portion when sizes match
Solution Approach 1:
The recessing portions are pre-formed on the intermediate portion before the over molding process. This preliminary action creates predetermined spaces that guide the outer case material to completely cover the side edges during molding, ensuring both structural integrity and complete edge coverage without requiring post-processing or complex tooling.
Data Source
AI summary
A plug connector assembly includes: a cable; a printed circuit board including a mating end for inserting into a mating connector, a connecting end electrically connected with the cable, and an intermediate portion between the mating end and the connecting end, the mating end defining plural conductive pads extending along a longitudinal direction of the printed circuit board for electrically connecting with the mating connector and arranged in a horizontal direction perpendicular to the longitudinal direction; and an outer case enclosing the intermediate portion of the printed circuit board and a part of the cable; wherein the intermediate portion defines on each of two side edges thereof a recessing portion filled by the outer case.