One-Piece Die-Cast Duplex Connector Body
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Solution Overview
Problem
Conventional duplex electrical connectors require multiple manufacturing steps and materials, leading to increased costs, flash formation, and potential electrical discontinuity due to their two-piece construction.
Innovation Solution
A one-piece die-cast duplex electrical connector body is produced using a coring system that eliminates secondary manufacturing steps and flash, ensuring better electrical continuity and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a two-piece connector body is used, then the manufacturing process is simpler for each piece, but the overall production time increases and flash formation occurs
Solution Approach 1:
The patent combines two separate connector pieces into a single integrated connector body that is die-cast as one piece. This eliminates the need for secondary operations to join separate parts, reduces production time, and prevents flash formation at joining interfaces while maintaining manufacturing simplicity through single-step die-casting.
2Ease of manufacture
If a two-piece connector body is used, then each piece can be manufactured independently, but material cost increases and electrical continuity is compromised
Solution Approach 1:
The patent integrates two separate connector pieces into one unified die-cast body, eliminating the need for additional materials for joining operations and reducing overall material consumption by approximately 50% while ensuring continuous electrical pathways throughout the connector structure.
3Ease of manufacture
If a two-piece connector body is used, then manufacturing flexibility is maintained, but flash formation occurs and electrical continuity is disrupted
Solution Approach 1:
The patent creates a single-piece die-cast connector body that eliminates interfaces between separate parts, ensuring uninterrupted electrical continuity and eliminating flash formation at joining surfaces while maintaining manufacturing simplicity through conventional die-casting processes.
4Productivity
If a one-piece connector body is used, then production cost and time are reduced, but manufacturing complexity increases
Solution Approach 1:
The patent employs a single-piece die-casting process that consolidates multiple manufacturing operations into one step, reducing production time and secondary operations while the resulting integrated structure actually simplifies the overall manufacturing complexity by eliminating joining operations and flash removal steps.
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 one-piece construction significantly reduces production costs, time, and flash formation, while ensuring excellent electrical continuity and a 50% savings in raw material costs, simplifying the manufacturing process and tooling requirements.
Implementation Method 1
When the cores 6 and 7 of the coring system 5 are joined together by the connecting arrangement 8 and placed in a mold 13 formed by dies 10 and 11, molten metal may be introduced to the mold at the joined area of the two core pieces 6 and 7 to form a one-piece flash-free connector body 22 according to the present invention.
Data Source
AI summary
A duplex electrical connector having a one-piece connector body for securing electrical cables to a panel or junction box. The one-piece connector body includes a leading end with a nose portion having a bore therein and a trailing end with two bores therein. One or two tubular cable retainers secured in the trailing end enable snap in connection of electrical cables to the trailing end of the connector body. A fastening arrangement is included on the nose portion at the leading end of the connector body for securing the connector body to a knockout hole in a panel or an electrical box.