Over-molded IS4/DF4 Plug with Integrated Monolithic Connector
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Solution Overview
Problem
Existing medical plugs, such as IS4/DF4 plugs, have complex designs that complicate electrical attachment and require multiple components, leading to increased manufacturing costs and potential for assembly errors.
Innovation Solution
A method for producing a plug with a simplified design using a casting mold to integrate a plug connector and three contact rings, where the connector forms a monolithic body with a contact and fastening portion, and conductors are electrically connected before casting, resulting in a plug with only four components and a cohesive structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex multi-component design is used for the plug connector and contact rings, then the electrical attachment and connection reliability are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the plug connector and contact rings into a single integrated component formed by casting. The connector body and multiple contact rings are created as one monolithic structure, eliminating the need for separate assembly of multiple components. This merging maintains connection reliability through the integrated design while significantly reducing device complexity and the number of parts.
Solution Approach 2:
The integrated plug connector serves multiple functions simultaneously: it provides the structural housing, contains multiple electrical contact rings, and ensures proper alignment and connection. This multi-functional design eliminates the need for separate anti-twist mechanisms and additional assembly steps, reducing complexity while maintaining reliability.
2Reliability
If multiple separate components are used for the plug connector and contact rings, then the electrical connection reliability is improved, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
The casting process creates the plug connector and all contact rings as a single integrated component. This merging of previously separate manufactured parts into one casting operation significantly simplifies manufacturing while maintaining electrical connection reliability through the precise, consistent geometry achieved by the casting process.
Solution Approach 2:
The invention changes the manufacturing parameter from multiple separate fabrication and assembly operations to a single casting process. This parameter change in the manufacturing method reduces complexity and cost while maintaining the reliability of electrical connections through the precision of the casting process.
3Stability of the object's composition
If separate anti-twist mechanisms are added to prevent rotation, then the connection stability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The anti-twist functionality is merged into the integrated connector design itself. The monolithic structure formed by casting inherently prevents rotation and maintains stable connections without requiring separate anti-twist mechanisms. This integration maintains connection stability while eliminating the complexity of additional anti-twist components.
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 simplifies the manufacturing process, reduces costs, ensures identical contactability of all conductors, and eliminates the need for additional anti-twist mechanisms and separate assembly, while maintaining a secure and sealed connection.
Implementation Method 1
a plug housing is formed by introducing a casting material into the casting mold so that the fastening portion is surrounded form-fittingly by the casting material
Data Source
AI summary
A method for producing a plug, and to a plug. It is provided, in particular, that a plug connector and three plug contact rings are arranged in a casting mold, wherein the plug connector extends along a longitudinal axis and has a contact portion and a fastening portion connected integrally to the contact portion, and wherein a plug housing is formed by introducing a casting material into the casting mold so that the fastening portion is surrounded form-fittingly by the casting material and the contact portion protrudes out from the plug housing at a first end of the plug housing in the direction of the longitudinal axis.