1. Connector Project  SummaryThe electrical connector is a connecting system, which can provide a detachable interface between two secondary electrical system, and was used widely in computer, automobile, appliance and industrial area.

Since our founding, we has been an important sub tooling supplier to a wide variety of connectors for some electronics and automobile companies, providing high quality and tight tolerances connector tooling for:

Nano Connector
Housing / Socket Connector
Thermoset / High temperature Application
Multi-Pin Connectors
Insert Molding/Overmolding (metals and plastics)
Sensors
Terminals / Switches

Our success in building precision connector mold was guaranteed by :

Extensive mold making experience;
Our in-house jig-grinding capability;
Experience in Design and molding of connectors

2. Resin used for Connector

We have experience in tooling  virtually every type of engineered connector material, such as PPS, LCP, PA46 and PA6T, as well as classic thermoset materials (phenolics  and epoxies , these resin is still important to certain segments of the electronics industry. Many connector applications require the physical properties that only thermoset materials can provide).

3.Moldbase

A steel with good strength and stability should be used for all the connector mold, especially for the molding of thermoset material ,considering the high production volume required(It’s over 1000K usually),critical dimension and shutoff with a small angle.

In practices, at least DME #2 mold base should be used.

4.Steel for Cavity/Core Block and Sub Insert

Cavity/Core Block:8407 from ASSAB, HRC50-52, it features:

High level of resistance to thermal shock and thermal fatigue

• Good high-temperature strength
• Excellent toughness and ductility in all directions
• Good machinability and Polishability
• Excellent through-hardening properties
• Good dimensional stability during hardening

Sub Insert:V I K I N G from ASSAB, HRC54-56, it features:

• good dimensional stability during heat treatment

• good machinability and grindability

• excellent combination of toughness and wear resistance

• ideal for surface coating (CVD, PVD)

5.Mold Design / Building

Before the project was kick off, the following info should be reviewed and available:

• Is the 2D/3D data complete and updated?
• Is the tolerance and other specification reasonable? Need to be changed?
• Is the resin info available? The shrinkage value?
• Number of cavity, injection machine size, tie bar and shot size?
• Mold type:2 plate or 3 plate?
• Feeding system : cold or hot runner?
• Ejection method? ejector pin, blade or sleeve?
• Cooling method, is the beryllium copper cooling plate needed under the small sub inserts?
• Is the P/L location approved ?
• Reviewed the macinability of all cavity/core block and sub insert?
• The steel condition for small inserts and shut off ?

5.1 Mold Design : sub insert splitting

The following check point  should be always attempted when splitting the sub insert:

• Is machinability and grindability  OK?  It’s very important for all the connector mold, the sub inserts can be made by grinding with little EDM/CNC/Wirecut machining.
• Is there thin steel? Steel condition should be confirmed before cutting.
• Is there a shut off with a angle less than 0.25 degree? If yes, was the insert backed at opposite side?

5.2 Mold Design : sub insert splitting

5.3 Mold Design : Cavity/Core Block Design

The following check point  should be always attempted when splitting the sub insert:

• Is machinability and grindability  OK?  It’s very important for all the connector mold, the sub inserts can be made by grinding with little EDM/CNC/Wirecut machining.
• Can the  cooling lines  be placed  and adequate? is the beryllium copper cooling plate needed under the small sub inserts?
• Is there a shut off with a angle less than 0.25 degree? If yes, is the insert was backed at opposite side?

5.4 Mold Design : Cavity/Core Block Design

all the cavity/core block ,spacers,guide rail and wedge block should be screwed from parting line instead of the back side to easy the maintenance.

5.5 Mold Design : Cooling of Cavity/Core Block

• W/L IN the beryllium copper cooling plate
• the beryllium copper cooling plate is always needed under the cavity/core block and small sub inserts to speed the cycle, dissipate the heating, because there is limited room for placing water lines in the cavity/core block and sub insert.

5.6Mold Design:2D Print dimensioning

5.7 Mold Design:sub insert layout on 2D print

6. Dimension Checking

Every dim of sub insert should be checked and verified before assembly , no hand work should be done to them.  This practice can ensure the interchangeability of sub insert.

7.1 Connector Mold and Part Sample