Receptacle Connector Simultaneous Insert-Molding Efficiency
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Solution Overview
Problem
The existing insert-molding process for manufacturing receptacle electrical connectors is inefficient for batch production, as each insulative housing must be formed sequentially on a metal plate, limiting productivity and increasing production time.
Innovation Solution
The use of metallic beltings to connect multiple shielding plates allows for simultaneous formation and assembly of multiple insulative housings and terminal sets during the insert-molding process, enhancing manufacturing efficiency by forming multiple components at once.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sequential insert-molding processes are used to attach each insulative housing to each metal plate, then manufacturing precision is maintained, but productivity is reduced
Solution Approach 1:
The patent merges multiple sequential insert-molding operations into a single simultaneous molding process. Multiple insulative housings are formed and assembled onto multiple metal plates in one injection molding cycle, rather than processing each housing-plate pair sequentially. This consolidation dramatically increases productivity while maintaining manufacturing precision through unified process control.
Solution Approach 2:
The patent segments the molding process by using multiple separate metal plates and insulative housing cavities within a single molding setup. Each plate-housing pair is independently formed simultaneously, allowing parallel processing while maintaining the precision of individual components. The segmented approach enables batch production without compromising quality.
2Productivity
If multiple sequential insert-molding processes are required for batch production, then manufacturing precision is ensured, but device complexity increases
Solution Approach 1:
The patent combines multiple insert-molding processes into a single integrated molding operation. The mold setup includes multiple cavities or positioning areas that accommodate several metal plates simultaneously, allowing all insulative housings to be formed and assembled in one process cycle. This reduces process complexity by eliminating the need for repeated setup, loading, and molding operations.
3Productivity
If metallic beltings are used to connect multiple shielding plates, then productivity is enhanced through simultaneous molding, but manufacturing precision requirements increase
Solution Approach 1:
The patent employs metallic beltings to pre-connect and position multiple metal plates in the correct spatial arrangement before the insert-molding process begins. This preliminary positioning ensures that when the insulative housing material is injected, multiple housings are formed with precise relative positioning simultaneously. The beltings act as temporary fixtures that maintain geometric accuracy throughout the molding cycle.
Data Source
AI summary
A receptacle electrical connector has an insulated housing, a first terminal set, a second terminal set, a shielding plate and a metallic shell. The shielding plate has two connection portions formed respectively on two opposite sides of the shielding plate and each connection portion has a cutting surface. The cutting surface is formed on the connection portion, and the two cutting surfaces of the connection portions are exposed out of two opposite sides of the insulated housing. During the insert-molding processes of insulated housings, the connection beltings of metallic beltings are connected to the cutting surfaces of multiple shielding plates for simultaneously forming multiple insulated housings. Therefore, production efficiency and yield rate of the receptacle electrical connectors are enhanced.