Hon Hai Precision Industry Co., Ltd.

Ming-Wu Lee

Kun-Tsan Wu

Song-Rong Chiou

Jen-Jou Chang

Chao-Hsu Chen

A method of manufacturing a high density connector comprises five steps. The first step is to prepare essential elements of the connector, such as a dielectric cover, a metallic shell, a pair of guiding members and a plurality of contacts. Each contact is L-shaped and comprises a horizontal soldering portion. The second step is to first insert mold a pair of dielectric bases around the contacts to produce a contact subassembly. The three step is to second insert mold a dielectric housing around the contact subassembly to form a contact module. The forth step is to adjust the horizontal soldering portions of the contacts for ensuring a good coplanarity thereof. The fifth step is to assemble the contact module with the cover, the shell and the guiding members, thereby completing the connector. The method of the present invention can produce connection with high density contacts having good insert-molding qualities by double insert molding to form the contact module, resulting in the horizontal soldering sections of the contacts having good coplanarity and having good electrical communication quality.

Method for manufacturing a high density connector

A high-density electrical connector comprises two sets of SMT contacts and two sets of DIP contacts, a dielectric housing formed by insert molding and a shield covering the housing, the dielectric housing comprises a pair of first housing members and a second housing member around the pair of first housing members, each first housing member is insert molded to a set of SMT contacts on one side thereof and a set of DIP contacts on an opposite side thereof in a first insert molding step, the second housing member is insert molded to and combines the pair of first housing members having the SMT contacts and the DIP contacts, thus, proper alignment, engagement, and coplanarity of the contacts assembled in the housing are easily obtained without interference from an insertion force.

High-density electrical connector

A high-density electrical connector comprises a housing, two sets of SMT contacts insert molded in opposite sides of the housing, and a shield covering the housing. The housing comprises a first housing member and a second housing member surroundingly incorporating the first housing member. A recess is defined between the first and second housing members. A method of manufacturing the high-density connector comprises the steps of: 1) insert molding a pair of SMT contact carriers to opposite sides of the first housing member; 2) insert molding the first housing member having the two SMT contact carriers to the second housing member; 3) severing carrier plates from the two SMT contact carriers; 4) assembling the shield to the housing. The first insert molding forms a base and a crossbeam retaining mounting and mating portions of the SMT contacts with a gap defined therebetween. The base defines a plurality of openings. The second insert molding fills the openings and the gap to incorporate the base and the crossbeam to form the housing.

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Tu-Chen, Taiwan

Ming-Wu Lee