Electrical connectors with thin interior walls
AssigneeYazaki Corporation
InventorTroy Dean Robinson
Life of this patent
Estimating the term…
Abstract
An electrical connector with thin interior walls is made by extruding a polymer or polymer composite into a sheet of approximately 0.25 mm to 0.5 mm thickness. The sheet is then calendered to a thickness of about 0.05 mm to 0.3 mm. The calendered sheet is cut into notched sections. The notched sections are assembled and placed into an injection molded housing of a connector. The sections are secured in place by using an adhesive, force fit, snap fit, or welding process to form the thin interior walls of the connector.
Claims13
A method for manufacturing an electrical connector, the method comprising:
- extruding a polymer or polymer composite into a first sheet having a thickness of about 0.25 mm to 0.5 mm;
- calendering the first sheet into a second sheet having a thickness of about 0.05 mm to 0.3 mm;
- cutting the second sheet into notched sections;
- positioning the notched sections to form a grid of thin walls configured for an interior of a housing of the electrical connector;
- assembling a structure including the grid of thin walls;
- inserting the structure into the interior of the housing to form the electrical connector;
- and
- securing the grid of thin walls to the interior of the housing.
A method for making a structure of thin interior walls for an electrical connector, the method comprising:
- extruding a polymer or polymer composite into a first sheet having a thickness equal to or less than 0.5 mm;
- calendering the first sheet into a second sheet having a thickness equal to or less than 0.3 mm;
- cutting the second sheet into notched sections;
- and
- positioning the notched sections to form the a grid of thin interior walls;
- and
- assembling the structure including the grid of thin interior walls,
- wherein the structure is configured to secure to an interior of a housing to form the electrical connector.
Dependencies are inferred from the claim text.