EP0959538A2 - Procédé de fabrication d'un connecteur électrique - Google Patents

Procédé de fabrication d'un connecteur électrique Download PDF

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Publication number
EP0959538A2
EP0959538A2 EP99109801A EP99109801A EP0959538A2 EP 0959538 A2 EP0959538 A2 EP 0959538A2 EP 99109801 A EP99109801 A EP 99109801A EP 99109801 A EP99109801 A EP 99109801A EP 0959538 A2 EP0959538 A2 EP 0959538A2
Authority
EP
European Patent Office
Prior art keywords
circuits
molding die
blank
web
housing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP99109801A
Other languages
German (de)
English (en)
Other versions
EP0959538A3 (fr
Inventor
Jose H. Chavez Jr.
Yew Teck Yap
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Molex LLC
Original Assignee
Molex LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Molex LLC filed Critical Molex LLC
Publication of EP0959538A2 publication Critical patent/EP0959538A2/fr
Publication of EP0959538A3 publication Critical patent/EP0959538A3/fr
Withdrawn legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/20—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for assembling or disassembling contact members with insulating base, case or sleeve
    • H01R43/24—Assembling by moulding on contact members

Definitions

  • This invention generally relates to the art of electrical connectors and, particularly, to a method of manufacturing an electrical connector, such as a small motor mounting connector.
  • a basic electrical connector includes some form of dielectric housing which mounts a plurality of conductive circuits, contacts and/or terminals.
  • the dielectric housing typically is a molded plastic housing.
  • the circuits or terminals often are stamped and formed from sheet metal material.
  • the circuits or terminals are mounted in the housing.
  • the plastic housing may be overmolded about portions of the circuits or terminals.
  • the stamped and formed circuits or terminals often are very small and delicate. If they are stamped as discrete elements, it is very difficult to insert these tiny elements into a dielectric housing. It also is extremely difficult to hold the tiny and intricate circuits or terminals during an overmolding process and maintaining proper positions of the circuits.
  • the present invention is directed to providing a method of manufacture which solves these various problems.
  • An object, therefore, of the invention is to provide a new and improved method of manufacturing an electrical connector module, such as a small motor mounting connector.
  • the method includes the steps of stamping from conductive sheet metal material a blank including a plurality of circuits. At least two of the circuits are joined by a web of the sheet metal material.
  • the stamped blank is placed into a first molding die.
  • a second molding die is closed onto the first molding die and the web is concurrently sheared and bent creating a gap between the sheared edges.
  • a dielectric housing is molded about portions of the sheared circuits to form the connector module.
  • shearing and bending of the web that joins the circuits is carried out by a shear portion of the second molding die. Terminals for the circuits may be formed from the blank prior to positioning the blank into the first molding die.
  • the blank may be stamped with a carrier strip joined to at least one of the circuits by a bridge section.
  • the molded module then can be moved on the carrier strip to another fabricating station whereat the bridge sections can be subsequently severed.
  • Another feature of the invention contemplates coining edges of at least one of the circuits during the stamping step.
  • the dielectric housing then is molded about the coined edges to anchor the circuit on the housing.
  • the invention involves a method of manufacturing an electrical connector module, such as a small motor mounting connector, generally designated 12.
  • the connector module is mounted on top of a printed circuit board 14.
  • the module includes a one-piece dielectric housing, generally designated 16, unitarily molded of plastic material or the like.
  • the housing mounts four circuits 18.
  • the circuits have tail portions 18a for connection, such as by soldering, to appropriate circuit pads 20 on printed circuit board 14, along with circuit pads 18b.
  • One of the circuits includes a side contact arm 22.
  • a separate terminal, generally designated 24, also is mounted on housing 16 and includes an end contact arm 26, along with a tail portion 28 for engaging a circuit pad 30 on the printed circuit board.
  • Figure 2 shows connector module 12 of Figure 1 mounting a small motor 32.
  • the motor has a side contact (not visible) for engaging side contact arm 22 of one of the circuits 18.
  • the motor also has an end contact 34 for engaging end contact arm 26 of terminal 24.
  • Motor 32 may be a small vibratory motor, such as is used in a mobile telephone system.
  • FIG. 3 The first step of the method of manufacture according to the invention is shown in Figures 3 and 4. Specifically, a blank, generally designated 36, is stamped and formed from conductive sheet metal material. It can be seen that the blank includes circuits 18, tail portions 20 of the circuits and side contact arm 22 of one of the circuits. It should be noted that the circuits are joined by five web portions 38. In addition, the two outside circuits are joined to a rectangular carrier strip 40 by a pair of bridge sections 42. Finally, locating holes 44 are stamped through the four corners of carrier strip 40.
  • Figure 5 shows a first or bottom molding die, generally designated 46, for carrying out the method of manufacture according to the invention.
  • bottom molding die 46 will have mold cavities for receiving molten plastic material conforming to the desired configuration of the connector housing.
  • bottom molding die 46 has a plurality of upstanding locating posts 48.
  • Bottom molding die 46 also has four platforms 50 on top of which blank 36 will be placed as described hereinafter.
  • Each platform 50 has a shear-form receiving notch or slot 52.
  • This notch 52 provides not only a shear surface allowing one edge of web portion 38 to be cut but also allowing the web portion to bend about its opposite edge creating a gap between the sheared edges.
  • one of the platforms defines an additional shear surface 54.
  • bottom molding die 46 has cavity means, generally designated 56, for receiving plastic material during an injection molding process.
  • the bottom molding die has angled side surfaces 57.
  • Figure 6 shows blank 36 placed onto bottom molding die 46, with locating posts 48 of the die projecting through locating holes 44 of the blank. It can be seen that the four circuits are still joined by webs 38, and the network of circuits are still joined to carrier strip 40 by bridge sections 42.
  • top molding die is closed onto the top of the bottom molding die.
  • Figure 7 shows the underside of top molding die 58.
  • the top molding die includes a planar area 60 which will engage the combined planar area of circuits 18.
  • the top molding die also includes a block 62 which forms a side planar surface 64 for engaging circuit pads 18b. Therefore, when the molding dies are closed and molten plastic material is injected into cavity means 56, the plastic material will flow around the side edges of circuits 18 and the side edges of circuit pads 18b but not onto the outside planar surfaces of the circuits and circuit pads because planar portions 60 and 64 of the top molding die engage the outer surfaces of the circuits and circuit pads.
  • top molding die 58 includes five knife or shearing portions 66 which, when the molding dies are closed, are aligned with shear-form receiving slots 52 and 54 in platforms 50 of the bottom molding die as shown in Figure 5 and described above.
  • shearing portions 66 are effective to shear or sever and bend the five web portions 38 which join the four circuits 18.
  • This shearing and bending action takes place substantially concurrently with the final closing action of the molding dies which is effective to sandwich circuits 18 between planar area 60 of the top molding die and platforms 50 of the bottom molding die, as well as sandwiching contact pads 18b between planar surface 64 of the top molding die and side surfaces 57 of the bottom molding die.
  • the circuits are severed substantially simultaneously with the circuits being gripped between the molding dies, so that the precise relative positioning of the stamped circuits are maintained.
  • Figure 8 shows blank 36 on bottom molding die 46, with the webs between the circuits having been severed and bent. This depiction is shown simply for providing a better understanding of the invention. It should be understood that this condition cannot occur in actual practice unless the top molding die is removed from the bottom molding die before the plastic material is injected into the assembled dies. This would not normally occur in actual practice, but the depiction is shown herein to facilitate a complete understanding of the invention.
  • the next step in the method according to the invention is to injection mold the motor housing 16 (Fig. 1) within cavity means 56 (Fig. 5) between bottom and top molding dies 46 and 58, respectively, when the dies are closed and circuits 18 have been separated by severing web portions 38.
  • Figure 9 shows the motor housing having been fully molded about the circuits and their related components, with top molding die 58 removed.
  • the circuits and their related components now are electrically isolated from each other except for bridge sections 42 still joining the outermost circuits to carrier strip 40.
  • the connector module is fully completed except that it is still attached to the carrier strip by bridge sections 42. Therefore, the overmolded module can be moved, manipulated or otherwise shipped to subsequent fabricating stations. For instance, the overmolded module can be moved to a station where it is connected to printed circuit board 14 as shown in Figure 1. Either before or at the subsequent fabricating station, bridge sections 42 (Fig. 10) are severed, as at 70 (Fig. 1), to leave connector module 12 as a complete finished product. For instance, the module can be soldered to printed circuit board 14 as shown in Figure 1 for receiving motor 32 as shown in Figure 2 and, thereby, interconnect the motor to appropriate circuit traces on the printed circuit board.
  • Figure 11 shows an aspect of the invention wherein circuits 18 and/or circuit pads 18b can be coined, as at 72, to facilitate anchoring the circuits or circuit pads in the plastic material of motor housing 16.
  • the coining of the edges can take place during the stamping and forming process of blank 36.
  • plastic material can flow over the coined edges, as at 74 in Figure 11, to anchor the circuits and/or circuit pads on the motor housing.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
EP99109801A 1998-05-22 1999-05-19 Procédé de fabrication d'un connecteur électrique Withdrawn EP0959538A3 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US8322298A 1998-05-22 1998-05-22
US83222 1998-05-22

Publications (2)

Publication Number Publication Date
EP0959538A2 true EP0959538A2 (fr) 1999-11-24
EP0959538A3 EP0959538A3 (fr) 2001-04-11

Family

ID=22176967

Family Applications (1)

Application Number Title Priority Date Filing Date
EP99109801A Withdrawn EP0959538A3 (fr) 1998-05-22 1999-05-19 Procédé de fabrication d'un connecteur électrique

Country Status (4)

Country Link
EP (1) EP0959538A3 (fr)
JP (1) JP3092067B2 (fr)
CN (1) CN1237019A (fr)
TW (1) TW451534B (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2803113A1 (fr) * 1999-12-22 2001-06-29 Valeo Securite Habitacle Module electrique de serrure de vehicule automobile, et procede pour sa fabrication
WO2004001908A1 (fr) * 2002-06-25 2003-12-31 Matsushita Electric Works, Ltd. Boitier de capteur infrarouge
EP1458078A1 (fr) * 2003-02-15 2004-09-15 ebm-papst St. Georgen GmbH & Co. KG Arrangement avec un moteur éléctrique et un méthode de fabrication de cet arrangement
WO2006133989A1 (fr) * 2005-06-16 2006-12-21 Robert Bosch Gmbh Sirene et procede de realisation
CN104283051A (zh) * 2014-09-05 2015-01-14 东莞中探探针有限公司 一种超薄防水连接器及其制造方法

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9461416B2 (en) * 2013-03-13 2016-10-04 Roche Diabetes Care, Inc. Low force electrical contact on metalized deformable substrates

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4965933A (en) * 1989-05-22 1990-10-30 The Cherry Corporation Process for making insert molded circuit

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4965933A (en) * 1989-05-22 1990-10-30 The Cherry Corporation Process for making insert molded circuit

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2803113A1 (fr) * 1999-12-22 2001-06-29 Valeo Securite Habitacle Module electrique de serrure de vehicule automobile, et procede pour sa fabrication
WO2004001908A1 (fr) * 2002-06-25 2003-12-31 Matsushita Electric Works, Ltd. Boitier de capteur infrarouge
US7157709B2 (en) 2002-06-25 2007-01-02 Matsushita Electric Works, Ltd. Infrared sensor package
EP1458078A1 (fr) * 2003-02-15 2004-09-15 ebm-papst St. Georgen GmbH & Co. KG Arrangement avec un moteur éléctrique et un méthode de fabrication de cet arrangement
WO2006133989A1 (fr) * 2005-06-16 2006-12-21 Robert Bosch Gmbh Sirene et procede de realisation
CN104283051A (zh) * 2014-09-05 2015-01-14 东莞中探探针有限公司 一种超薄防水连接器及其制造方法

Also Published As

Publication number Publication date
CN1237019A (zh) 1999-12-01
JPH11345675A (ja) 1999-12-14
EP0959538A3 (fr) 2001-04-11
TW451534B (en) 2001-08-21
JP3092067B2 (ja) 2000-09-25

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