Receptacle Contact Assembly Insert Molding for Compact Connectors
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Solution Overview
Problem
Existing connector manufacturing methods require an accommodation case, leading to increased size.
Innovation Solution
A manufacturing method involving insert molding of contact assemblies with a base made of metal, including a coupling base and conductive patterns separated by an insulating layer, where the assemblies are supported at both ends in an injection mold during molding, allowing for integration with a housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an accommodation case is used to accommodate multiple supporting bodies, then the connector can house multiple contact assemblies, but the size of the connector increases
Solution Approach 1:
The housing is designed to directly accommodate multiple contact assemblies without requiring a separate accommodation case. The contact assemblies are arranged side-by-side within the housing structure itself, merging the accommodation function into the housing rather than requiring an additional component layer.
Solution Approach 2:
The accommodation case is completely removed from the connector structure. Instead of using supporting bodies that require an accommodation case, the invention uses contact assemblies that can be directly housed in the housing, extracting the unnecessary intermediate component that was causing size increase.
2Adaptability or versatility
If multiple supporting bodies are joined together, then multiple contact assemblies can be accommodated, but the manufacturing process becomes more complex
Solution Approach 1:
The connector is segmented into independent contact assemblies, each consisting of a contact base and contact terminal. This segmentation allows each assembly to be manufactured separately and then integrated into the housing, simplifying the overall manufacturing process compared to joining multiple supporting bodies together.
Solution Approach 2:
The contact assemblies are prepared in advance as pre-fabricated units with their conductive patterns and insulating layers already in place. This preliminary preparation allows for streamlined manufacturing where the assemblies are simply positioned and fixed into the housing, rather than requiring complex joining operations during assembly.
3Reliability
If supporting bodies are used to support contact assemblies, then the contact assemblies can be held in place, but an additional accommodation case is required
Solution Approach 1:
The housing serves multiple functions: it provides structural support, accommodates the contact assemblies, and eliminates the need for a separate accommodation case. The contact bases themselves provide the support function, making the housing a multi-functional component that reduces overall structural complexity.
Solution Approach 2:
The accommodation case is extracted from the connector structure, and its support function is transferred to the contact bases and housing combination. This eliminates the redundant accommodation case while maintaining the necessary support functionality through a simpler structure.
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 method achieves a reduction in connector size and facilitates efficient manufacturing.
Implementation Method 1
the at least one contact assembly and the housing being integrally formed by insert molding
Data Source
AI summary
A method of manufacturing a receptacle includes an assembly manufacturing step, an accommodating step, and an insert molding step. The assembly manufacturing step manufactures each receptacle contact assembly in such a way that a base includes two supporting bases with a coupling base interposed therebetween in a pitch direction. The accommodating step accommodates a plurality of receptacle contact assemblies into an injection mold in such a way that each receptacle contact assembly is supported at both ends in the injection mold by using the two supporting bases. The insert molding step molds a receptacle housing integrally with the plurality of receptacle contact assemblies by insert molding.