Insert Molded Connector Case with Pre-Assembled Wire
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Solution Overview
Problem
The manufacturing efficiency of cases with connectors is hindered by the complexity of assembling conductive members, such as electrical wires, after the integration of the connector and case, leading to decreased assembly efficiency and increased costs.
Innovation Solution
A case with connector and a method of manufacturing that involves insert molding, where the connector is integrated with the case body, and a conductive member is accommodated within the case body, allowing the electrical wire to be connected to the connector before integration, thereby simplifying the assembly process and reducing man-hours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the connector and case body are integrated through insert molding, then the manufacturing precision and structural integrity are improved, but the complexity of assembling conductive members increases and manufacturing efficiency decreases
Solution Approach 1:
The conductive member is preliminarily connected to the connector before the insert molding process. The connector and conductive member are assembled in advance, then integrated with the case body in one molding operation, eliminating post-molding assembly steps and improving manufacturing efficiency
Solution Approach 2:
The connector, conductive member, and case body are combined into a single integrated structure through insert molding. The mold retains both the connector and conductive member, then injects resin to form the case body that integrates all components in one operation
2Stability of the object's composition
If the conductive member is assembled after integration of connector and case, then the structural integrity is maintained, but the assembly operation becomes more complex and time-consuming
Solution Approach 1:
The conductive member is pre-assembled to the connector before integration with the case body. This preliminary assembly ensures proper positioning and connection, while the subsequent insert molding process maintains structural integrity by encapsulating all components in one operation
Solution Approach 2:
The insert molding process acts as an intermediary that integrates the pre-assembled connector and conductive member with the case body. The injected resin serves as the bonding medium that secures all components together while maintaining their relative positions and structural integrity
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 approach enhances manufacturing efficiency by reducing the complexity of connecting electrical wires to the connector, minimizing interconnection harnesses, and lowering costs by using a ready-made connector, while ensuring the connector is securely fixed to the case body.
Implementation Method 1
a connector retention process of causing a mold retain a connector, the mold having a hollow portion into which resin is injected and a conductive member accommodation portion partitioned from the hollow portion
Implementation Method 2
a case formation process of forming a case body by integrating the case body with the connector and accommodating the conductive member in an inside room of the case body with insert molding in which resin is injected into the mold
Data Source
AI summary
A case with connector includes a connector; a case body that has a cylindrical side wall portion and an end wall portion closing one end side of the side wall portion and forming an accommodation portion along with the side wall portion, the case body being formed by insert molding and integrated with the connector at the side wall portion; and an electrical wire that has an end connected to the connector and the other end projecting to the accommodation portion.