Electrical Plug-in Connector Group Insertion and Remolding
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Solution Overview
Problem
Existing methods for manufacturing electrical connectors face challenges such as complex assembly processes, imprecise positioning of contact pins, and difficulty in achieving a watertight connection, particularly in the low-voltage range where numerous small contacts are required.
Innovation Solution
The method involves keeping contact pins connected until they are secured in the front housing section through injection molding, allowing for easier assembly and precise positioning by grouping contacts together, and using sealing rings for a watertight connection without requiring the front housing material to be melted again.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If contacts are inserted individually into the mold and overmolded separately, then each contact can be positioned precisely, but the assembly process becomes complex and time-consuming
Solution Approach 1:
Multiple contact pins are connected to each other via connecting pieces (webs) that extend between them, allowing the contacts to be inserted and overmolded as a single group rather than individually. This merging of multiple contacts into a connected assembly simplifies the assembly process while maintaining positioning precision through the group insertion method.
2Ease of manufacture
If the housing is molded in separate sections and assembled, then manufacturing flexibility is improved, but achieving a watertight connection becomes difficult
Solution Approach 1:
The housing sections are connected through a remolding process where the first housing section is heated to melt its material, allowing the second housing section to be joined. The heating and melting of the plastic material creates a watertight bond between the two housing sections, eliminating gaps that would otherwise compromise the seal.
3Manufacturing precision
If contact pins are inserted individually, then positioning accuracy can be maintained, but the number of assembly steps increases
Solution Approach 1:
Multiple contact pins are connected via connecting pieces that extend between adjacent contacts, enabling them to be inserted into the mold as a single group. This group insertion method maintains positioning accuracy while significantly reducing the number of assembly steps and increasing production speed compared to individual insertion.
4Device complexity
If separate housing sections are assembled without melting, then manufacturing complexity is reduced, but gaps remain that compromise moisture sealing
Solution Approach 1:
The first housing section is heated to melt its material, allowing the second housing section to be joined in a remolding process. This phase transition from solid to melted state and back creates a watertight bond, eliminating gaps that would otherwise allow moisture penetration while maintaining relatively simple manufacturing procedures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the assembly process, ensures high precision in contact pin positioning, and achieves a reliable watertight termination of cable connections, suitable for applications in the low-voltage range like automotive engineering.
Implementation Method 1
the contacts (1) are secured in a front housing section (10) by means of an injection mold
Implementation Method 2
at least one sealing ring (14) is formed on the housing sections (10, 25), which engage in one another in a tooth-like manner
Data Source
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AI summary
The invention relates to a method for manufacturing an electrical plug-in connector having a plurality of contacts (1). In this case, first the contacts (1) are produced from an electrically conductive contact material, wherein a plurality of or all of the contacts (1) belonging to the plug-in connector remain connected to one another at connection points (5). Then, the connected contacts (1) are inserted into an injection-moulding die, whereupon a plastic is injected around them in a central holding region (4) so as to form a front housing section (10). Then, the separation of the contacts (1) at the connection point (5) and the fixing of electrical lines (20) to the cable connection ends (3) of the contacts take place, wherein these two substeps can be carried out in any desired sequence. Finally, a plastic is injected around the cable connection ends (3) and the lines (20) so as to form a rear housing section (25). The invention also relates to a plug-in connector which can be manufactured in accordance with this method.