Three-Stage Insert Molding for Circuit Board Connectors
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Solution Overview
Problem
Conventional methods face difficulties in molding circuit board connectors using small molding apparatuses due to the complexity of insert molding with terminal fittings and connector configurations, which requires further ingenuity to enable efficient manufacturing.
Innovation Solution
The circuit board connector is molded in three stages: first, core resin portions with connector terminals are molded; second, an outer resin portion covers these core resin portions; and third, a case resin portion is molded around the connector resin portion, allowing for enhanced freedom in terminal arrangement and simplifying the molding apparatus structure, enabling molding by a small molding apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If insert molding is performed in two stages (housing first, then case body) as in conventional methods, then the connector structure can be formed, but the molding apparatus size becomes large and complex
Solution Approach 1:
The patent divides the connector into three separately moldable parts: housing, terminal fittings, and case body. This segmentation allows each component to be molded independently in sequential stages using a small molding apparatus, avoiding the need for a large complex apparatus required by conventional two-stage insert molding.
Solution Approach 2:
The housing is molded first as a preliminary action, then the terminal fittings are inserted and molded in the second stage, and finally the case body is molded in the third stage. This preliminary action approach enables sequential manufacturing with a small apparatus while maintaining structural integrity.
2Ease of manufacture
If terminal fittings are arranged to form an undercut shape, then the connector structure is achieved, but conventional insert molding methods become difficult to perform with small molding apparatus
Solution Approach 1:
The terminal fittings are separated from the housing and molded as a distinct component in the second stage. This segmentation allows the undercut-shaped terminal fittings to be formed independently without requiring complex slide molds or large apparatus, solving the manufacturability issue with small molding equipment.
Solution Approach 2:
The housing acts as an intermediary structure that receives the terminal fittings in the second molding stage. This intermediary approach allows the terminal fittings with undercut shapes to be inserted and molded separately, avoiding the need for complex simultaneous molding of housing and terminal fittings.
3Strength
If the housing and case body are molded integrally, then the structural integrity is improved, but the molding apparatus size must be enlarged
Solution Approach 1:
The connector is segmented into housing, terminal fittings, and case body that can be molded separately. This segmentation enables the use of a small molding apparatus with a stroke corresponding only to the largest single component, rather than requiring a large apparatus needed for integral molding of the entire assembly.
Solution Approach 2:
The terminal fittings are nested within the housing in the second stage, and the case body is nested around these components in the third stage. This nesting approach allows sequential molding with a small apparatus while achieving the final integrated structure through resin joining.
4Volume of stationary object
If three-stage insert molding is performed, then the molding apparatus size is reduced, but the number of molding stages increases
Solution Approach 1:
The three-stage segmentation (housing, then terminal fittings, then case body) allows each stage to use a small molding apparatus, reducing the apparatus size requirement. While this increases the number of stages, it enables manufacturing flexibility and reduces equipment investment costs.
Data Source
AI summary
It is aimed to provide a circuit board connector and a circuit board connector manufacturing method capable of enabling molding by a small-size molding apparatus by performing insert molding in three stages. A circuit board connector (1) includes a case resin portion 2, a connector resin portion 3 having a base (31) and a tower (32) and connector terminals (6A, 6B and 6C). The connector resin portion (3) includes core resin portions (4A, 4B and 4C) for covering intermediate parts (63) of the connector terminals (6A, 6B and 6C) and an outer resin portion (5) for covering the core resin portions (4A, 4B and 4C). A resin material constituting the case resin portion (2) is joined to a resin material constituting the outer resin portion (5) by resin molding.