Injection Molded Sensor Connectors With Stiffening Elements
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
During the plastic injection molding process for manufacturing housings, metallic inserts used in electrical components can bend or twist, affecting the alignment and accuracy of sensors, such as acceleration and magnetic field sensors, due to mechanical stresses, which compromises the longevity and sealing integrity of the connecting elements.
Innovation Solution
The integration of stiffening elements, either as bent areas of the line part or separate plastic parts, provides reinforcement to the line part, preventing bending or torsion during injection molding, thus maintaining the precise alignment and position of electrical components and enhancing the structural integrity and sealing of the connecting elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the metallic insert is extrusion-coated with plastic during injection molding, then the housing protects the insert and electrical components, but the metallic insert may bend or twist due to plastic flow, altering sensor position
Solution Approach 1:
The patent applies preliminary action by pre-bending the line part to a predetermined shape before the injection molding process. This pre-formed geometry provides structural rigidity that resists deformation during the molding process, ensuring the line part maintains its shape despite the plastic flow forces, thereby preventing sensor misalignment while still allowing the housing to provide protection
2Manufacturing precision
If the line part is reinforced with a stiffening element, then bending or torsion during injection molding is suppressed, but the device complexity increases
Solution Approach 1:
The patent merges the stiffening function with the line part itself by forming an integrated structure where the line part's geometry provides both electrical connection and structural reinforcement. The bent configuration of the line part creates inherent stiffness without requiring separate stiffening elements, thus maintaining manufacturing precision while avoiding increased device complexity
Solution Approach 2:
The line part serves multiple functions simultaneously: it provides electrical connection, structural reinforcement through its bent geometry, and positioning for the sensor. This multi-functionality eliminates the need for separate stiffening components, resolving the contradiction between stability and complexity
Data Source
AI summary
A connecting element for electrical contacting of an electrical component having at least one electrically conductive line part, embedded at least partially in an injection-molded housing, is provided, the connecting element having at least one stiffening element reinforcing the line part.