Cured Plastic Connector Cap Without Custom Molding Dies
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Solution Overview
Problem
The existing manufacturing process for connectors with caps requires separate molding dies for each type of connector, leading to increased time, effort, and cost due to the need for different sizes and shapes of caps.
Innovation Solution
A connector with cap design that uses a plastic material with plasticity before curing, which is applied and pressed over the connector opening with a protective member in between, eliminating the need for molding dies and allowing for a more efficient manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate molding dies are prepared for each type of connector, then caps can be manufactured with precise fit and shape, but manufacturing time, effort, and cost increase
Solution Approach 1:
The invention changes the state of the plastic material from cured to uncured (moldable) form, allowing the same material to adapt to different connector shapes and sizes without requiring different molding dies. The uncured material can be molded into various configurations and then cured to achieve the final cap structure, eliminating the need for multiple specialized dies.
Solution Approach 2:
The invention creates a universal manufacturing process using a single type of plastic material that can serve multiple functions across different connector types. The same uncured plastic material can be used to create caps for various connector configurations, making the manufacturing process universally applicable rather than requiring type-specific molding dies.
2Manufacturing precision
If separate molding dies are prepared for each type of connector, then caps can be manufactured with precise fit and shape, but manufacturing cost increases
Solution Approach 1:
The invention changes the state of the plastic material from cured to uncured (moldable) form, allowing the same material to adapt to different connector shapes and sizes without requiring different molding dies. The uncured material can be molded into various configurations and then cured to achieve the final cap structure, eliminating the need for multiple specialized dies.
Solution Approach 2:
The invention creates a universal manufacturing process using a single type of plastic material that can serve multiple functions across different connector types. The same uncured plastic material can be used to create caps for various connector configurations, making the manufacturing process universally applicable rather than requiring type-specific molding dies.
3Device complexity
If a plastic material is applied and pressed over the connector opening without a protective member, then the manufacturing process is simplified, but the connector terminal may contact the plastic material causing electrical issues
Solution Approach 1:
The invention introduces a protective member as an intermediary element between the plastic material and the connector terminal. This protective member prevents direct contact between the plastic material and the electrical terminal, ensuring electrical reliability while allowing the manufacturing process to remain simple and efficient.
4Manufacturing precision
If custom molding dies are used for each connector type, then caps can be precisely formed, but the preparation time and effort increase
Solution Approach 1:
The invention changes the state of the plastic material from cured to uncured (moldable) form, allowing the same material to adapt to different connector shapes and sizes without requiring different molding dies. The uncured material can be molded into various configurations and then cured to achieve the final cap structure, eliminating the need for multiple specialized dies.
Solution Approach 2:
The invention creates a universal manufacturing process using a single type of plastic material that can serve multiple functions across different connector types. The same uncured plastic material can be used to create caps for various connector configurations, making the manufacturing process universally applicable rather than requiring type-specific molding dies.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces the time, effort, and cost associated with manufacturing connectors with caps by eliminating the need for custom molding dies and allowing for a simpler, more efficient production method.
Implementation Method 1
a cap formed of a plastic material that has plasticity before being cured and that cures under a predetermined condition
Implementation Method 2
the protective member being formed of an insulating material and arranged inside the connector body on a side of the opening such that the protective member is positioned between the cap and the connector terminal
Data Source
AI summary
A connector with cap includes a connector body and a cap formed of a plastic material that has plasticity before being cured and that cures under a predetermined condition, the cap being cured in a state where the cap is removably closing an opening of the connector body located on a side on which a mating connector is fitted. The connector with cap further includes a protective member formed of an insulating material and arranged inside the connector body on a side of the opening such that the protective member is positioned between the cap and the connector terminal, the protective member being configured to protect the connector terminal from contacting the plastic material.