Coated Plug Connector Component for Burr-Free Deformation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing metallic plug connector components with coatings face issues such as coating flow during deformation, leading to sharp edges, chips, and increased production costs due to secondary processing, which are undesirable in mass production.
Innovation Solution
A metallic plug connector component with a defined surface structure on the coating in processing portions, allowing for precise and cost-effective production by preventing coating flow during deformation, using tools with complementary surface structures to establish a form-fitting connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a coated metallic part is deformed in a processing portion adjacent to an edge, then the desired shape is imparted to the part, but the coating flows and projects beyond the edge forming sharp edges and chips
Solution Approach 1:
A deformation allowance is introduced into the part before the deformation process. This allowance provides extra material in the processing portion that compensates for the coating flow during deformation, preventing the coating from projecting beyond the edge and forming sharp edges or chips.
Solution Approach 2:
The geometry of the part is modified by adding a deformation allowance, which changes the initial shape parameters. This allows the deformation process to proceed without causing coating projection, as the extra material absorbs the coating flow.
2Manufacturing precision
If secondary processing steps are performed to remove coating projections and chips, then manufacturing precision is improved, but production time and costs increase
Solution Approach 1:
The deformation allowance is introduced in advance into the part design, preventing coating projection issues before they occur. This eliminates the need for secondary processing steps to remove chips and projections, thereby reducing production time and costs while maintaining high manufacturing precision.
3Manufacturing precision
If the coating is made thicker to prevent flow during deformation, then coating projection is reduced, but the part becomes more prone to cracking and the coating quality deteriorates
Solution Approach 1:
Instead of increasing coating thickness, a deformation allowance is introduced into the part geometry before deformation. This allows the coating to flow into the allowance during deformation without projecting beyond the edge, preventing coating projection issues while maintaining optimal coating thickness for strength and quality.
Solution Approach 2:
The solution changes the geometric parameters of the part by adding a deformation allowance, rather than changing the coating thickness parameter. This maintains the optimal coating thickness for strength and quality while preventing coating projection through geometric compensation.
Data Source
AI summary
The invention relates to a metallic plug connector component (1), in particular an electrical contact element, or a support sleeve, of an electrical plug connector, having a main body (3) which has been coated with a coating (2) and which has been mechanically deformed in a processing portion (4). It is provided that a surface (6, 7) of the coating (2) in the processing portion (4) has a defined surface structure (8) at least in certain portions.