Patent Publication Number: US-2023163547-A1

Title: Insert molded connector

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the priority of Taiwanese Patent Application No. 110213771, entitled “INSERT MOLDED CONNECTOR”, filed on Nov. 19, 2021, the disclosure of which is incorporated herein by reference in its entirety. 
     FIELD OF THE DISCLOSURE 
     The present disclosure relates to an insert molded connector, and more particularly, to an insert molded connector with a simple structure and high reliability. 
     BACKGROUND 
     The conventional data transmission conductor cables can be used to connect two electronic devices or two circuit boards for high-frequency data transmission, such as flexible flat cables (FFC) or flexible printed circuit board (Flexible Printed Circuit Cable). Single-sided, double-sided, or multi-layer flexible printed circuit board cables can be manufactured by etching the base material that has been coated with copper. Flexible flat cables could be manufactured by using automated equipments to laminate insulating material layers and extremely thin flat conductors. Flexible flat cables can be mass-produced in an automated production, and the distance between conductors can be precisely adjusted by the settings of the machine and the jig. Therefore, it is very suitable for the control of high-frequency signal transmission, and the flexible flat cable has the characteristics of neatly arranged cores, large transmission capacity, flat structure, small size and better flexibility and can be flexibly applied to various electronic products, as a data transmission conductor cable. 
     In the case that the insulating material is used as a coating insulating layer in a very thin transmission wire, when a flexible flat cable is made by laminating by automated equipments, the wires of the flexible flat cable are arranged in parallel and then the upper and lower layers of the covering insulation layer are glued together by the adhesive layer, so that the upper and lower layers of the covering insulation layer covers the parallel-arranged wires therein and the contact portions of the wires are exposed. 
     However, in the manufacturing process of the flexible flat cable, when the tongue is formed by insert molding, the tongue cannot have any contact with the coating insulating layer because the high temperature of the insert molding process will affect the characteristics of the insulating layer or even damage the insulating layer. Therefore, the conventional flexible flat cable manufacturing process first performs insert molding process on the contact portion (transmission terminal). That is, the tongue portion is completed first. And then, the contact portion (transmission terminal) is welded to the welding portion of the multiple wires with the coated insulating layer. 
     As long as the high-frequency transmission of electronic signals passes through a medium conversion (such as one more solder joint in the connector), the loss of the signal increases. Therefore, the conventional connector structure not only has many components, but also increases the difficulty of realizing high reliability. 
     As the demands for light, thin, short, and affordable connectors increase, it is necessary to improve the high-frequency signal transmission performance. Therefore, the connector design with a simple structure and a high reliability is required. Therefore, this is an issue that the present disclosure creation would like to solve here. 
     SUMMARY 
     One objective of an embodiment of the present disclosure is to provide an insert molded connector with a simple structure and a high reliability, in order to solve the above-mentioned issues. 
     According to an embodiment of the present disclosure, an insert molded connector is disclosed. The insert molded connector comprises a plurality of wires arranged in parallel, a coating insulating layer, and a tongue. The plurality of wires are configured to transmit electrical signals. The coating insulating layer covers main portions of the wires to expose the contact portions of the wires. The tongue is insert molded to cover the contact portion and a portion of the coating insulating layer close to the contact portion to expose a contact surface of the contact portion. 
     According to an embodiment of the present disclosure, the wires are a plurality of flat conductors. 
     According to an embodiment of the present disclosure, a main portion of the wires is a plurality of circular conductors, and the contact portion of the wires is a flat conductor. 
     According to an embodiment of the present disclosure, the wires further comprise an end portion, which is not parallel to the contact portion, so as to be embedded in the tongue portion during insert-molding. 
     According to an embodiment of the present disclosure, the coating insulating layer comprises an upper coating film layer and a lower coating film layer. 
     According to an embodiment of the present disclosure, a portion of the coating insulating layer close to the contact portion comprises at least one fixing through hole, so that the tongue is insert-molded in the at least one fixing through hole. 
     According to an embodiment of the present disclosure, a portion of the coating insulating layer close to the contact portion comprises at least one fixing through notch, so that the tongue is insert-molded in the at least one fixing through notch. 
     According to an embodiment of the present disclosure, the tongue further comprises engaging portions located on both sides. 
     According to an embodiment of the present disclosure, the tongue further comprises a contact opening, configured to expose the contact surface of the contact portion during insert-molding. 
     According to an embodiment of the present disclosure, the coating insulating layer further comprises positioning notches on both sides. 
     According to an embodiment of the present disclosure, the upper coating film layer and the lower coating film layer are formed by thermocompression to cover the main portion of the wires. 
     According to an embodiment of the present disclosure, a withstand temperature of the coating insulating layer is higher than an insert-molding temperature of the tongue. 
     According to an embodiment of the present disclosure, a material of the coating insulating layer is selected from polyester, polyimide, polyethylene, polypropylene, polytetrafluoroethylene, acrylic or liquid crystal polymer plastics. 
     According to an embodiment of the present disclosure, a material of the tongue is selected from polyester, polyimide, polyethylene, polypropylene, polytetrafluoroethylene, acrylic or liquid crystal polymer plastics. 
     In contrast to the conventional art, the insert molded connector of the present disclosure can maintain the original physical, chemical and electrical characteristics by implementing the insert molding process due to the high temperature resistance of the insulating layer. While directly forming the tongue that covers and holds the contact portion and the partial coating insulating layer, there is no need to insert molding the independent contact portion (transmission terminal) first. That is, the tongue is completed first, and then the transmission contact (transmission terminal) is welded to the welding portion of the flexible flat cable with the coating insulating layer, so as to create an insert molding connector with a very simple structure and high reliability. 
     To make the above-mentioned content of this disclosure easier to understand, the following is a detailed description of preferred embodiments in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a diagram of an insert molded connector according to a first embodiment of the present disclosure. 
         FIG.  2 A  is a top view of the insert-molded connector according to the first embodiment of the present disclosure. 
         FIG.  2 B  illustrates a cross-sectional view along the A-A line of  FIG.  2 A . 
         FIG.  2 C  illustrates a cross-sectional view along the B-B line of  FIG.  2 A . 
         FIG.  3    is a cross-sectional view of the insert molded connector along a plane formed by a plurality of conductors arranged in parallel according to the first embodiment of the present disclosure. 
         FIG.  4    is a diagram of an insert molded connector according to a second embodiment of the present disclosure. 
         FIG.  5 A  is a top view of the insert-molded connector according to the second embodiment of the present disclosure. 
         FIG.  5 B  illustrates a cross-sectional view along the A-A line of  FIG.  5 A . 
         FIG.  5 C  illustrates a cross-sectional view along the B-B line of  FIG.  5 A . 
         FIG.  6    is a cross-sectional view of the insert molded connector along a plane formed by a plurality of conductors arranged in parallel according to the second embodiment of the present disclosure. 
         FIG.  7    is a diagram of an insert molded connector according to a third embodiment of the present disclosure. 
         FIG.  8 A  is a top view of the insert-molded connector according to the third embodiment of the present disclosure. 
         FIG.  8 B  illustrates a cross-sectional view along the A-A line of  FIG.  8 A . 
         FIG.  8 C  illustrates a cross-sectional view along the B-B line of  FIG.  8 A . 
         FIG.  9    is a cross-sectional view of the insert molded connector along a plane formed by a plurality of conductors arranged in parallel according to the third embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The realization of the purpose of the present embodiments, the functional characteristics, and advantages will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. 
     Spatially relative terms, such as “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used herein for ease of description to describe one element or feature’s relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. 
     Please refer to  FIG.  1   ,  FIG.  2 A ,  FIG.  2 B ,  FIG.  2 C  and  FIG.  3   .  FIG.  1    is a diagram of an insert molded connector according to a first embodiment of the present disclosure.  FIG.  2 A  is a top view of the insert-molded connector according to the first embodiment of the present disclosure.  FIG.  2 B  illustrates a cross-sectional view along the A-A line of  FIG.  2 A .  FIG.  2 C  illustrates a cross-sectional view along the B-B line of  FIG.  2 A .  FIG.  3    is a cross-sectional view of the insert molded connector along a plane formed by a plurality of conductors arranged in parallel according to the first embodiment of the present disclosure. 
     According to the first embodiment of the present disclosure, the insert molded connector  10  comprises a plurality of wires  100  arranged in parallel, a coating insulating layer  200  and a tongue  300 . Each of the plurality of wires  100  arranged in parallel includes a main portion  101 , a contact portion  102  and an end portion  103 . The coating insulating layer  200  includes a fixing through hole  201 , a fixing notch  202  and a positioning notch  203 . The tongue  300  includes a contact opening  301  and an engaging portion  302 . 
     The wires  100  arranged in parallel are used to transmit electrical signals. For example, the coating insulating layer  200  is used for covering the main portions  101  of the wires  100  and exposing the contact portions  102  of the wires  100 . The tongue  300  is formed by insert molding, while covering the contact portion  102  and a portion of the coating insulating layer  200  close to the contact portion  102 , such that the contact surface of the contact portion  102  is exposed through the contact opening  301 . In addition, the end portions  103  of the wires  100  are not parallel to the contact portion  102 . For example, the end portions  103  are bent downward at a certain angle as shown in the  FIG.  1   , so that the end portions  103  can be embedded into the tongue  300  when the tongue  300  is insert-molded. This structure could strength the fixing strength between the wires  100  and the tongue  300 , but the present disclosure is not limited thereto. 
     As shown in  FIG.  2 A ,  FIG.  2 B ,  FIG.  2 C  and  FIG.  3   , the wires  100  arranged in parallel are a plurality of flat conductors. That is, the main portion  101 , the contact portion  102  and the end portion  103  are an integrated flat conductor. The contact opening  301  of the tongue  300  is used to expose the contact surface of the contact portion  102 , which is the upper surface of the contact portion  102  as shown in the figures. Furthermore, a portion of the insulating covering layer  200  close to the contact portion  102  includes at least one fixing through hole  201 , so that the tongue  300  is insert-molded into the at least one fixing through hole  201 . In the first embodiment, a plurality of circular fixing through holes  201  are provided. A plurality of circular fixing through holes  201  are arranged at equal distances, and the fixing through holes  201  are all arranged between the wires  100  arranged in parallel. When the tongue  300  is insert-molded, the circular fixing through holes  201  are filled to strengthen the fixing strength between the insulating cover layer  200  and the tongue  300 . 
     As shown in  FIG.  1   ,  FIG.  2 A ,  FIG.  2 B ,  FIG.  2 C  and  FIG.  3   , at least one fixing notch  202  of the coating insulating layer  200  is disposed near the contact portion  102 , so that the tongue  300  is insert-molded in the fixing notch  202  for strengthening the fixing strength between the coating insulating layer  200  and the tongue  300 . In the first embodiment, the fixing notch  202  is disposed on both sides of the coating insulating layer  200  near the contact portion  102 , and its shape is a rectangle. The positioning notches  203  of the coating insulating layer  200  are arranged on both sides of the coating insulating layer  200  and are used for the positioning of automatic equipment during the manufacturing process of the insert molding connector  10 . In the first embodiment, as shown in  FIG.  1   ,  FIG.  2 A ,  FIG.  2 B , and  FIG.  2 C , the contact opening  301  of the tongue  300  is disposed correspondingly to the contact portion  102  of the wire  100 . When the tongue  300  is insert-molded, the contact surface of the contact portion  102  is exposed. The engaging portions  302  of the tongue  300  are located on both sides of the contact portion  102 , and are used for snapping and fixing the board end connector (not shown) disposed on the circuit board. 
     In the first embodiment, as shown in  FIGS.  2 A- 2 C , the coating insulating layer  200  includes an upper coating film layer  200 - 1  and a lower coating film layer  200 - 2 . The material of the coating insulating layer  200  is selected from polyester, polyimide, polyethylene, polypropylene, polytetrafluoroethylene (PTFE), acrylic or liquid crystal polymer plastics, and the material of the insert-molded tongue  300  is selected from polyester, polyimide, polyethylene, polypropylene, PTFE, acrylic or liquid crystal polymer plastics. The upper coating film layer  200 - 1  and the lower coating film layer  200 - 2  can be formed by thermocompression. As shown in  FIG.  1   ,  FIG.  2 A ,  FIG.  2 B ,  FIG.  2 C  and  FIG.  3   , the upper coating film layer  200 - 1  and the lower coating film layer  200 - 2  cover the main portions  101  of the wires  100  from the above and below and expose the contact portions  102  of the wires  100 . It should be noted that the temperature resistance of the coating insulating layer  200  is higher than the temperature of the insert molding process of the tongue  300 . That is, the resistance temperature of the upper coating film layer  200 - 1  and the lower coating film layer  200 - 2  is higher than the insert molding process temperature of the tongue  300 . Therefore, the present disclosure can maintain the physical, chemical and electrical characteristics of the coating insulating layer  200  in the subsequent insert molding process of the tongue  300  by virtue of the high temperature resistance of the coating insulating layer  200 . That is, after the tongue  300  is insert-molded, the original physical, chemical and electrical states of the insulating covering layer  200  will not be affected by the high temperature of the insert-molding process. Accordingly, an insert-molded connector with a simple structure and a high reliability is created. 
     Please refer to  FIG.  4   ,  FIG.  5 A ,  FIG.  5 B ,  FIG.  5 C  and  FIG.  6   .  FIG.  4    is a diagram of an insert molded connector according to a second embodiment of the present disclosure.  FIG.  5 A  is a top view of the insert-molded connector according to the second embodiment of the present disclosure.  FIG.  5 B  illustrates a cross-sectional view along the A-A line of  FIG.  5 A .  FIG.  5 C  illustrates a cross-sectional view along the B-B line of  FIG.  5 A .  FIG.  6    is a cross-sectional view of the insert molded connector along a plane formed by a plurality of conductors arranged in parallel according to the second embodiment of the present disclosure. According to the second embodiment of the present disclosure, the insert-molded connector  20  also comprises a plurality of wires  100  arranged in parallel, a coating insulating layer  200  and a tongue  300 . Each of the plurality of wires  100  arranged in parallel includes a main portion  101 , a contact portion  102  and an end portion  103 . The coating insulating layer  200  includes a fixing through hole  201 , a fixing notch  202  and a positioning notch  203 . The tongue  300  includes a contact opening  301  and an engaging portion  302 . 
     Please refer to  FIG.  4   ,  FIG.  5 A ,  FIG.  5 B ,  FIG.  5 C  and  FIG.  6   . The difference between the insert-molded connector  20  of the second embodiment and the insert-molded connector  10  of the first embodiment is: the main portions  101  of the parallel-arranged wires  100  are a plurality of circular conductors, and the contact portions  102  of the parallel-arranged wires  100  are the extension of the main portions  101  and are originally circular but becomes flat conductors by applying an external force to it (for example, knocking it flat). Similarly, each of the end portions  103  is also a flat conductor, which is formed by bending the front end of the contact portion  102 . In the second embodiment, the shape of the positioning notch  203  for automated positioning can be a circle, a semi-circle or other shapes suitable for the automated equipments. However, the shape of the positioning notch  201  is not limited thereto. 
     Please refer to  FIG.  7   ,  FIG.  8 A ,  FIG.  8 B ,  FIG.  8 C  and  FIG.  9   .  FIG.  7    is a diagram of an insert molded connector according to a third embodiment of the present disclosure.  FIG.  8 A  is a top view of the insert-molded connector according to the third embodiment of the present disclosure.  FIG.  8 B  illustrates a cross-sectional view along the A-A line of  FIG.  8 A .  FIG.  8 C  illustrates a cross-sectional view along the B-B line of  FIG.  8 A .  FIG.  9    is a cross-sectional view of the insert molded connector along a plane formed by a plurality of conductors arranged in parallel according to the third embodiment of the present disclosure. According to the second embodiment of the present disclosure, the insert-molded connector  30  comprises a plurality of wires  100  arranged in parallel, a coating insulating layer  200  and a tongue  300 . Each of the plurality of wires  100  arranged in parallel includes a main portion  101 , a contact portion  102  and an end portion  103 . The coating insulating layer  200  includes a fixing through hole  201 , a fixing notch  202  and a positioning notch  203 . The tongue  300  includes a contact opening  301  and an engaging portion  302 . 
     Please refer to  FIG.  7   ,  FIG.  8 A ,  FIG.  8 B ,  FIG.  8 C  and  FIG.  9   . The difference between the insert-molded connector  30  of the third embodiment and the insert-molded connector  10  of the first embodiment is: the insert molding connector  10  of the first embodiment has a plurality of circular fixing through holes  201 . In contrast, the insert molding connector  30  has a plurality of rectangular fixing through holes  201  in the coating insulating layer  200  near the contact portion  102 . Please note, the present disclosure does not limit the number and/or the length of the through holes as long as portions of the main portions  101  of the wires  100  covered by the coating insulating layer can be exposed as shown in  FIG.  7   ,  FIG.  8 A ,  FIG.  8 B ,  FIG.  8 C  and  FIG.  9   . After the tongue  300  is insert-molded, the insert-molding strength of the tongue  300  is further increased. When the tongue  300  is insert-molded, the rectangular through holes  201  are filled to strengthen the fixing strength between the coating insulating layer  200  and the tongue  300 . 
     In contrast to the conventional art, the insert molded connector of the present disclosure can maintain the original physical, chemical and electrical characteristics by implementing the insert molding process due to the high temperature resistance of the coating insulating layer  200 . While directly forming the tongue  300  that covers and holds the contact portion  102  and the partial coating insulating layer  200 , there is no need to insert molding the independent contact portion (transmission terminal) first. That is, the tongue is completed first, and then the transmission contact (transmission terminal) is welded to the welding portion of the flexible flat cable with the coating insulating layer, so as to create an insert molding connector with a very simple structure and high reliability. 
     Above are embodiments of the present disclosure, which does not limit the scope of the present disclosure. Any modifications, equivalent replacements or improvements within the spirit and principles of the embodiment described above should be covered by the protected scope of the disclosure.