Connector Cap Mold With Interdigitating Core for Small Snap-Fit Parts
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Solution Overview
Problem
Existing methods for molding connectors with cap angles are complex, require compatible materials, and often result in unsightly openings or size limitations, particularly when using collapsing cores or snap-fit mechanisms.
Innovation Solution
A mold design featuring a rotatable and axially movable outer sleeve and inner pin, which simplifies the removal of the core and allows for the production of connectors with annular recesses and cap angles without the need for complex collapsing mechanisms, enabling smaller component production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a collapsing core is used to mold the cap angle into the body wall, then the cap angle can be integrated into the body, but the molding tool becomes complex and cannot be used for small components
Solution Approach 1:
The core is divided into an outer sleeve and an inner pin that can move independently relative to each other. The inner pin carries the cap angle forming features, while the outer sleeve provides structural support. This segmentation allows the core to be withdrawn without collapsing, simplifying the molding tool while maintaining the ability to form integrated cap angles.
Solution Approach 2:
The inner pin is made movable relative to the outer sleeve, allowing it to be withdrawn independently after molding. This dynamic configuration enables the cap angle to be formed while integrated into the body, without requiring a complex collapsing mechanism. The inner pin can be pulled out through the molded part after cooling, leaving no openings.
2Reliability
If blades are used to form the cap angle surface in a radial plane, then the snap fit problem is solved, but openings are created in the distal end which are unsightly and allow dirt ingress
Solution Approach 1:
The cap angle forming features are extracted from the stationary mold and placed on the movable inner pin. This allows the cap angle to be formed by the withdrawing action of the inner pin itself, rather than by blades cutting into the molded part. The result is a smooth surface without openings, while still providing the necessary snap fit connection through the intermediate lip.
3Reliability
If sonoc welding is used to attach the cap to the body, then a reliable connection is achieved, but complex equipment is required and material compatibility is constrained
Solution Approach 1:
The cap and body are merged into a single molded component with the cap angle formed directly in the body wall. The intermediate lip with its radial plane face provides the snap fit connection, eliminating the need for separate cap attachment processes. This integration removes the need for welding equipment and material compatibility constraints while maintaining reliable connection.
Data Source
AI summary
A mold for molding a body or cap for a connector. The mold comprises a mold body (1) and an axial core (2) which together define a mold cavity in the shape of the body or cap. The core has a sleeve (3) and an inner pin (4) each having complementary castellations (8, 10) which interdigitate in a first configuration. In the first configuration, the castellations (8, 10) are arranged such that respective recesses (11) are formed each bound by the proximal end of a first castellation (8) and the side walls of adjacent second castellations (10). Each recess has a shape to form a respective first portion of the body or cap. The sleeve (3) and inner pin (4) are axially movable to a second configuration in which the castellations (8, 10) are disengaged from one another. The inner pin (4) is rotatable to a third configuration in which the first castellations (8) can be axially withdrawn following a path occupied by the second castellations (10) in the first configuration.