Cable Connector Cap Structure for Easy Mold Release
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing process of connectors with inwardly concave structures in the cap is complex due to mold release issues, leading to increased production costs and quality challenges.
Innovation Solution
A connector design with staggered opening slots and a retaining hook that avoids undercuts during mold opening, allowing for easier manufacturing through injection molding and improved structural bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cap includes inwardly concave structures (undercuts) for cable accommodation and hooking functions, then the connector achieves functional requirements for cable retention and connection, but the mold release becomes difficult requiring auxiliary sliders and complex manufacturing processes
Solution Approach 1:
The patent inverts the traditional undercut design by making the opening slots outwardly convex rather than inwardly concave. This allows the mold to easily release from the cap without requiring complex slider mechanisms, while still achieving the necessary cable retention and hooking functions through the protruding slot structures
Solution Approach 2:
The patent divides the single opening slot into multiple segmented slots (first opening slot and second opening slot) that are staggered in the first direction. This segmentation allows each slot to be independently formed with simpler mold geometry, eliminating the need for complex undercut structures while maintaining cable retention functionality
2Device complexity
If the cap has a single nearly circular opening slot with hooking portion, then the structure is simple, but the manufacturing process becomes complex due to undercuts preventing mold release
Solution Approach 1:
The patent segments the opening slot structure into multiple slots (first opening slot and second opening slot) that are staggered in the first direction. This segmentation simplifies the mold release process by eliminating undercuts, thereby improving manufacturing efficiency and productivity despite adding some structural elements
Solution Approach 2:
The patent arranges the first and second opening slots to be staggered in the first direction rather than concentric or linearly arranged. This dimensional arrangement allows the slots to interlock and provide retention while maintaining outwardly convex profiles that facilitate easy mold release
3Reliability
If the opening slot has inwardly concave structure, then the cable can be retained within the cap, but the forming quality becomes difficult to ensure due to complex molding requirements
Solution Approach 1:
The patent inverts the concave structure to an outwardly convex opening slot design. This allows the slot to retain cables through its protruding geometry while being easily formable through standard injection molding processes, ensuring consistent forming quality without complex mold mechanisms
Solution Approach 2:
The patent changes the geometric parameters of the opening slots from inwardly concave to outwardly convex profiles. This parameter change fundamentally simplifies the molding process while maintaining the essential cable retention function through the staggered slot arrangement
Data Source
AI summary
A connector includes a cap having a first main body that includes a first opening slot and a second opening slot staggered in a first direction. The first opening slot has a first concave portion and the second opening slot has a second concave portion. The first concave portion and the second concave portion are arranged opposite to each other in a second direction. The first opening slot and the second opening slot are used together to accommodate a cable. An extension direction of the cable within the cap is the first direction; the second direction is perpendicular to the first direction. The connector includes a terminal piercing the cable to form an electrical connection with the cable and a housing accommodating the terminal.