One-Piece Die-Cast Connector Body via Gapless Core Joining
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Solution Overview
Problem
Existing electrical connectors for connecting two cables to a panel or electrical box are complex and costly due to their multi-piece construction, requiring multiple secondary operations and die-casting processes that result in flash, which can damage cables and necessitate additional chamfering operations.
Innovation Solution
A coring system that uses a first and second core, connected without gaps, to form a one-piece die-cast connector body, eliminating secondary operations and flash by allowing molten metal to fill the joined area, thereby simplifying production and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multiple separate body portions are die-cast and assembled, then the connector body can be formed with complex internal structures, but the manufacturing complexity and secondary operations increase significantly
Solution Approach 1:
The patent merges multiple separate body portions into a single integrated connector body that is die-cast as one piece. This eliminates the need for separate die-casting operations and secondary assembly operations, reducing manufacturing complexity while maintaining the complex internal structures needed for cable management and electrical connectivity.
Solution Approach 2:
The connector body is designed with integrated segmentation for different functional zones (cable entry areas, electrical contact regions, mounting sections) all formed within a single die-cast piece. This allows complex internal structures to be created through core design rather than assembly of separate parts.
2Adaptability or versatility
If multiple separate body portions are assembled with fasteners, then the connector can accommodate complex cable routing, but the number of secondary operations and production time increase
Solution Approach 1:
The patent combines multiple body portions into a single integrated structure that provides all necessary cable routing capabilities internally. The connector body includes integrated features such as internal channels, mounting provisions, and electrical contact arrangements that eliminate the need for separate assembly operations while maintaining versatility for different cable configurations.
Solution Approach 2:
The single-piece connector body is designed to perform multiple functions simultaneously: cable securing, electrical connectivity, panel mounting, and strain relief. This multi-functionality is achieved through integrated design elements within the die-cast structure, eliminating the need for separate components and assembly steps.
3Manufacturing precision
If traditional die-casting is used for separate body portions, then each part can be optimized independently, but flash is produced in interior areas requiring additional chamfering operations
Solution Approach 1:
The patent uses a single die-casting operation to produce the entire connector body as one piece, eliminating interior flash problems that occur when multiple parts are assembled. The single-piece construction removes the interfaces between parts where flash would accumulate, eliminating the need for chamfering operations while maintaining precise geometric control through optimized core design.
4Device complexity
If separate body portions are die-cast and assembled, then complex internal features can be formed in each part, but material usage and production cost increase
Solution Approach 1:
The patent integrates all internal features into a single die-cast connector body, eliminating the need for separate parts and their associated material consumption. The single-piece construction reduces total material usage by removing redundant features, fasteners, and assembly materials, while maintaining all necessary internal complexities for cable management and electrical connectivity through optimized core design.
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
The coring system simplifies manufacturing, eliminates flash, reduces material consumption, and enhances electrical continuity by producing a one-piece connector body with thinner walls, minimizing tooling needs and secondary operations, while ensuring better cable security and reduced production costs.
Implementation Method 1
When the cores of the coring system are joined together by the connecting arrangement and placed in a mold, molten metal may be introduced to the mold at the joined area of the two core pieces to form a one-piece flash-free connector body
Data Source
AI summary
A coring system for producing a flash-free one-piece die-cast body for an electrical connector. The electrical connector of produced by the coring system of the present invention may be used for securing two electrical cables to an electrical panel or electrical box through a single knockout hole. The coring system includes a first core, a second core, and a connecting arrangement for connecting the first and second cores in such a manner that there are no gaps between the joined portions of the two cores. When the cores of the coring system are joined together by the connecting arrangement and placed in a mold, molten metal may be introduced to the mold at the joined area of the two core pieces to form a one-piece flash-free connector body according to the present invention.