Waterproofing Connector Terminal with Adhesive Coating
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Solution Overview
Problem
Existing methods for waterproofing coated electric wire connector terminals face challenges in ensuring strong adhesion to both metal and resin materials, leading to potential damage during molding and compromised waterproofing due to strong resin adhesion to metal molds.
Innovation Solution
A method involving a connecting plate with adhesive material applied to its surfaces, allowing for the use of resin with weak adhesion to metal, ensuring secure adhesion to the connector terminal and preventing water invasion, while avoiding adhesion to metal molds during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin with strong adhesion to metal materials is used to ensure waterproofing, then the adhesive performance on metal connector terminal is improved, but the resin adheres to the metal mold during molding causing damage and complicating the molding process
Solution Approach 1:
The patent introduces a releasing agent as an intermediary substance between the resin and the metal mold. The releasing agent prevents the resin from adhering to the metal mold surface during injection molding, allowing for easy demolding while maintaining the resin's strong adhesion to the connector terminal. This resolves the contradiction by mediating the interaction between resin and mold without compromising waterproofing performance.
Solution Approach 2:
The patent changes the surface properties of the metal mold by applying a releasing agent coating, which alters the surface energy and adhesion characteristics. This parameter change allows the resin to maintain strong bonding to the connector terminal while preventing unwanted adhesion to the mold, thus simplifying the molding process and enabling easy demolding.
2Reliability
If resin with strong adhesion to metal is used, then the adhesive performance on connector terminal is improved, but the molded part may be damaged when taken out of the metal mold
Solution Approach 1:
The releasing agent acts as a protective intermediary layer between the resin and the metal mold during the molding process. This intermediary prevents the resin from bonding to the mold surface, ensuring that when the molded part is removed, its structural integrity is maintained and no damage occurs at the mold-part interface.
Solution Approach 2:
The patent applies the releasing agent to the metal mold surface before the injection molding process begins. This beforehand cushioning prevents potential adhesion-related damage to the molded part by creating a non-stick barrier in advance, thus protecting the molded part's strength and integrity during demolding.
3Ease of manufacture
If resin with weak adhesion to metal is used, then the resin can be easily removed from the metal mold, but the resin does not adhere well to the metal connector terminal compromising waterproofing
Solution Approach 1:
The releasing agent serves as a temporary intermediary during molding that prevents adhesion to the mold, enabling easy demolding. After the molded part is removed, the releasing agent can be washed away, allowing the resin to maintain its inherent strong adhesion to the metal connector terminal, thus ensuring waterproofing performance without compromising ease of manufacture.
Solution Approach 2:
The patent applies the releasing agent to the mold surface as a preliminary action before injection molding. This preliminary action temporarily modifies the mold surface properties to prevent adhesion during the critical molding phase. After demolding, the releasing agent is removed, restoring the metal surface's natural adhesion properties for subsequent waterproofing functionality.
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
Enables easy molding and achieves high waterproofing effectiveness by ensuring the resin molded part adheres to the connector terminal through an adhesive material, preventing water ingress and reducing the risk of resin adhesion to metal molds.
Implementation Method 1
adhesive material which is applied to the connecting plate... the resin molded part can be surely adhered to the connecting plate of the coated electric wire attached connector terminal through the adhesive material
Implementation Method 2
a resin molded part which is formed to cover the connecting plate, the barrel part and the sheath... the resin molded part can be surely adhered to the connecting plate... and the waterproofness can be enhanced
Data Source
AI summary
A method of waterproofing a coated electric wire attached connector terminal which is formed of metal material and which includes a barrel part which is crimped to a conductor which is exposed from a sheath, a terminal part, a connecting plate which is formed between the barrel part and the terminal part, and connects the barrel part and the terminal part. The method includes an adhesive material applying step in which adhesive material is applied to the connecting plate, and a molded part molding step in which the coated electric wire attached connector terminal is placed in a metal mold to form an injection space around the connecting plate, the barrel part and the sheath and resin is injected into the injection space to cover the connecting plate, the barrel part and the sheath with a resin molded part.