Signal Module Shielding via Injection Molding
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Solution Overview
Problem
Existing high-speed electrical connectors suffer from signal module deformation during assembly due to unstable shield module structures, which affects production efficiency and stability.
Innovation Solution
The signal module is enhanced by forming an insulator on both the contact and shield piece through injection moulding, ensuring accurate positioning and stability, with bulge structures on ground connection contacts for secure electrical contact, and a simplified injection moulding process that encapsulates the shield piece on the contact insulator part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If shield pieces are clamped on the insulator in a clamping manner, then the assembly process is simplified, but the degree of stability is low and the structure is easily deformed
Solution Approach 1:
The patent combines the shield piece and insulator into a single integrated structure through injection molding. The insulator encapsulates the shield piece, creating a unified component that eliminates the need for separate clamping operations while significantly enhancing structural stability and preventing deformation during assembly.
Solution Approach 2:
The shield piece is nested within the insulator structure. The insulator is molded to encapsulate the shield piece, with the shield piece positioned inside the insulator's cavity. This nesting arrangement provides inherent stability and eliminates the need for external clamping mechanisms.
2Productivity
If all contacts are located and put in the same injection mould in a matching manner, then the production efficiency of contact modules is greatly increased, but the support fixture in the injection mould becomes complex
Solution Approach 1:
The contacts are pre-assembled on the front base plate in the desired configuration before the injection molding process. This preliminary arrangement eliminates the need for complex support fixtures during molding, as the contacts are already positioned correctly and can be encapsulated directly.
Solution Approach 2:
The front base plate serves as a self-positioning structure that holds the contacts in their correct locations. The base plate's design inherently provides the necessary positioning, eliminating the need for additional complex support fixtures in the injection mold.
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 stabilizes the signal module, prevents deformation, ensures accurate positioning, and maintains good electrical connections, thereby improving the assembly efficiency and reliability of high-speed electrical connectors.
Implementation Method 1
The insulator is formed on the contact and the shield piece by means of injection moulding, and thus, the degree of stability of the signal module is enhanced
Implementation Method 2
the ground connection contacts are electrically contacted with the shield piece by the corresponding bulge structures
Data Source
Figure 1
Figure 2~3
AI summary
A high-speed electrical connector, comprising a signal module (1). The signal module comprises a contact (11). At least one side of the contact is provided with a shield piece (12). The signal module further comprises an insulator (13). The insulator is formed on the contact and the shield piece by means of injection moulding so as to combine the contact and the shield piece together. The insulator of the signal module of the electrical connector is encapsulated on the contact and the shield piece by means of injection moulding. Thus, the degree of stability of the signal module is enhanced, and the problem that a signal module of an existing high-speed electrical connector is easily deformed is solved.