High Speed Wire End Connector Insert Molding
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Solution Overview
Problem
Conventional Slim SAS transmission lines experience high attenuation rates due to excessive circuit board length and inconsistent assembly tolerances, limiting transmission rate and quality in high-speed electronic devices.
Innovation Solution
A high-speed wire end connector manufacturing method involving insert molding to form an inner film covering the cable and printed circuit board, with a molded bonding layer and outer casing that includes limit protrusions and adhesive features to secure the components, reducing board length and improving positioning accuracy and waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the circuit board length is increased to accommodate assembly type connectors, then the connector structure can be assembled, but the attenuation rate increases and transmission quality deteriorates
Solution Approach 1:
The connector is divided into two separate components: a wire-end connector and a board-end connector. The wire-end connector is directly soldered to the cable, eliminating the need for a long circuit board assembly. This segmentation allows the transmission line to be much shorter while still achieving proper connector assembly, thereby reducing attenuation and improving transmission quality.
Solution Approach 2:
A molded bonding layer is introduced as an intermediary element to bond the wire-end connector to the board-end connector. This bonding layer includes adhesive grooves and adhesive bumps that provide reliable mechanical and electrical connection without requiring a long circuit board, thus maintaining transmission quality while enabling connector assembly.
2Ease of manufacture
If assembly type connectors are used for Slim SAS Low Profile, then the connector can be assembled, but fit tolerances vary resulting in positioning problems
Solution Approach 1:
The wire-end connector is pre-assembled with the cable and inner film through insert molding before final assembly with the board-end connector. This preliminary assembly ensures precise positioning and consistent fit tolerances are achieved during the initial manufacturing stage, eliminating positioning problems in subsequent assembly operations.
Solution Approach 2:
The inner film and wire-end connector are merged into a single integrated component through insert molding. This combination ensures consistent positioning and fit tolerances by eliminating the need for separate assembly steps that would introduce additional tolerance accumulation, thereby improving manufacturing precision.
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
The method enhances transmission rate and quality by reducing circuit board length, improving positioning accuracy, and increasing waterproofing, resulting in a more reliable high-speed wire end connector.
Implementation Method 1
a cable is soldered on a printed circuit board
Implementation Method 2
an inner film is formed to cover a portion of the cable and a portion of the printed circuit board
Implementation Method 3
a molded bonding layer is formed to bond to the outer casing and the inner film
Data Source
AI summary
A high speed wire end connector manufacturing method includes the following steps. First, a cable is soldered to a printed circuit board, and then an inner film is formed to cover a portion of the cable and a portion of the printed circuit board by an insert molding process. Another portion of the printed circuit board is passed through a guide hole of an outer casing, and a molded bonding layer is formed by an outer molding process to bond to the outer casing and the inner film. In addition, a metal spring latch is fixed on the outer casing. In addition, a high speed wire end connector is also disclosed herein.