Foamed Connector Cladding via Blowing Agent Injection
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Solution Overview
Problem
Existing injection molding processes for producing casings are inefficient and costly, requiring high pressures and temperatures, and result in casings that are not cost-effective or durable under mechanical stress.
Innovation Solution
Incorporating a chemical blowing agent into the thermoplastic material during injection molding to create gas inclusions, reducing cooling time and allowing for lower injection pressures and temperatures, resulting in a faster, cheaper, and more durable product with controlled porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional injection molding processes are used to produce casings, then the casings can be manufactured with standard material properties, but the process requires high injection pressures and temperatures, resulting in longer cooling times and higher production costs
Solution Approach 1:
The patent applies porous materials by incorporating gas inclusions within the casing structure during injection molding. The blowing agent creates a cellular foam structure that reduces material density and thermal mass, enabling faster cooling while maintaining structural integrity. This porous structure allows heat to be dissipated more efficiently through the reduced thermal mass, directly addressing the contradiction between production speed and energy consumption.
Solution Approach 2:
The patent changes the physical and chemical parameters of the molding process by introducing a blowing agent that decomposes at specific temperatures to generate gas. This chemical transformation occurs at lower temperatures than conventional molding, and the resulting gas inclusions fundamentally alter the thermal and mechanical properties of the casing. The parameter change from solid homogeneous material to cellular foam structure enables the process to operate at lower pressures and temperatures while achieving faster cycle times.
2Strength
If conventional injection molding is used, then sufficient material strength can be achieved, but the cooling time is extended and production cost increases
Solution Approach 1:
The cellular foam structure created by gas inclusions provides sufficient strength through the cell wall network and bubble structure. The porous architecture distributes mechanical stresses across multiple cell walls, maintaining structural integrity despite reduced material volume. This allows the casing to achieve adequate strength with faster cooling rates, resolving the contradiction between strength requirements and cooling time.
Solution Approach 2:
The blowing agent is incorporated into the polymer matrix before injection, so that gas inclusions form during the molding process itself rather than requiring post-processing. The chemical decomposition of the blowing agent occurs at controlled temperatures during molding, pre-establishing the cellular structure that will provide both strength and rapid cooling characteristics, eliminating the need for extended cooling periods.
3Reliability
If more thermoplastic material is used to ensure durability, then the casing can withstand mechanical stress, but the production cost and weight increase
Solution Approach 1:
The foam structure provides durability through its cellular architecture that absorbs and distributes mechanical energy. The cell walls and bubble structures create a lightweight composite material that maintains structural integrity under stress while weighing significantly less than solid plastic. This porous configuration achieves the required reliability with reduced material quantity, directly addressing the weight-durability contradiction.
4Manufacturing precision
If high injection pressures are used to ensure proper filling, then the mold can be completely filled, but the production cost and energy consumption increase
Solution Approach 1:
The introduction of gas inclusions fundamentally changes the rheological properties of the molding material. The cellular structure formed during injection reduces material viscosity and improves flow characteristics, allowing complete mold filling at lower pressures. The blowing agent's decomposition temperature and gas generation rate are carefully controlled to ensure proper filling without requiring high injection pressures, thereby reducing production costs while maintaining manufacturing precision.
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 method shortens the injection molding process, reduces material usage, and enhances the casing's elasticity and durability, making it lighter, cheaper, and more resistant to mechanical stress.
Implementation Method 1
the addition of blowing agent and the resulting gas inclusions in the coating allow for precise adjustment of the elasticity of the final product
Implementation Method 2
Gas inclusions form in the coating due to the blowing agent's outgassing. This causes the coating to cool more quickly
Data Source
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AI summary
Method for producing a covering (1) of a connector part (2) for an electrical and/or optical connector and/or a cable (3), wherein the covering (1) is produced by injection molding from a thermoplastic material (4) in an injection mold (5), wherein in addition to the thermoplastic material (4) at least one outgassing blowing agent (6) and/or at least one gas is injected into the injection mold (5) and gas inclusions (7) are formed in the covering (1).