Guided Punching Tool for Clean Through-Hole Beam Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing punching tools and conductor receiving elements for injection molded plastic components, particularly those with conductor receiving elements for electrical connectors, face issues such as residue formation, damage to through holes, and high punching forces due to the removal of blocking elements, which are often connected to sealing pins.
Innovation Solution
A punching tool with an elongated shape and a punching end featuring a cutting edge spaced apart from the front surface, allowing for guided insertion and shearing operations, and a conductor receiving element with beam elements and sealing pins that facilitate the removal of blocking elements without damaging the through holes, using a punching system that includes a receptacle for precise guidance and compensation of positional inaccuracies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional punching tool is used to remove blocking elements, then the blocking elements can be removed, but residues remain in the through holes and damage occurs to the through holes
Solution Approach 1:
The patent introduces a receptacle as an intermediary component that receives and guides the punching tool during the punching operation. This receptacle compensates for positional inaccuracies and ensures the cutting edge properly engages the beam element without damaging the through hole, thus mediating between the punching tool and the through hole to prevent damage while maintaining productivity
Solution Approach 2:
The patent replaces the conventional direct punching mechanism with a guided punching system where the cutting edge is spaced from the front surface and guided by the receptacle. This substitution changes the mechanical interaction from direct contact to guided contact, eliminating damage to the through hole while maintaining effective beam element removal
2Productivity
If a conventional punching tool is used to remove blocking elements, then the blocking elements can be removed, but high punching force is required
Solution Approach 1:
The receptacle acts as a mediator that guides the punching tool and ensures proper alignment of the cutting edge with the beam element. This guidance reduces misalignment and friction, thereby reducing the punching force required while maintaining effective beam element removal
Solution Approach 2:
The patent changes the geometric parameters of the punching tool by spacing the cutting edge from the front surface and configuring it to extend transverse to the longitudinal axis. This parameter change allows the cutting edge to engage the beam element more efficiently, reducing the force required for punching while maintaining productivity
3Ease of operation
If the cutting edge is positioned at the front surface of the punching tool, then punching can be performed, but damage to the through hole occurs
Solution Approach 1:
The receptacle serves as an intermediary that guides the punching tool and ensures the cutting edge is properly positioned relative to the beam element. This guidance allows the cutting edge to be spaced from the front surface without compromising the punching operation, while preventing damage to the through hole
Solution Approach 2:
The patent moves the cutting edge from the front surface (one dimension) to a position spaced along the longitudinal axis (another dimension), where it extends transverse to the longitudinal axis. This dimensional change allows the cutting edge to engage the beam element effectively without contacting and damaging the through hole
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 solution effectively removes blocking elements from through holes while minimizing damage and residue formation, ensuring reliable adaptation of electrical connectors to different conductor configurations with reduced force requirements.
Implementation Method 1
at least one cutting edge which is spaced apart from the front surface along the longitudinal axis of the punching tool and extends substantially transverse to the longitudinal axis
Data Source
Figure 1~2
Figure 3~6
Figure 7~8
AI summary
The present disclosure is directed to a punching tool (10) for punching out at least one beam element (22) with both ends (23, 24) attached to the inside surface of an elongated through hole (21c). The punching tool (10) has an elongated shape with a punching end (11) and a holding end (12). The punching end (11) comprises a front surface (13) for being inserted into the elongated through hole first, and at least one cutting edge (14a, 14b, 14c, 14b) which is spaced apart from the front surface (13) along the longitudinal axis (17) of the punching tool (10) and extends substantially transverse to the longitudinal axis (17). Further, the present disclosure is directed to a conductor receiving element (20) for an electrical connector with and a fusible sealing pin and a punching system (30) comprising said punching tool (10) and said conductor receiving element (20).