Overmolded Plug Retainer for Wire Positioning

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Solution Overview

Problem

Existing methods for overmolding electrical circuits fail to maintain components, such as wires and cables, in precise and fixed positions within a die mold cavity, leading to potential visibility and integrity issues in the molded item, especially when components are not rigid and have limited clearance for positioning.

Innovation Solution

A retainer device with built-in bushings and securing members, like wire ties, is used to hold the electric circuit firmly in place during the overmolding process, ensuring it remains fixed and integrated within the molded item, with the retainer being permanently molded and providing mounting holes for secure attachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If retractable holding devices are used to avoid visibility at the surface, then the aesthetic appearance is improved, but the component cannot be held sufficiently taut and in a precisely defined position

Engineering Contradiction:

Improvevisibility of holding devicesVSAvoidpositioning precision

Core Design Contradiction:

Illumination intensityVSManufacturing precision

Solution Approach 1:

The holding device is segmented into multiple functional elements: locator pins for positioning, retainer arms for holding, and integration with the mold structure. This segmentation allows each element to perform its specific function optimally without compromising overall precision or aesthetics.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The retainer device is nested within the mold cavity structure, with retainer arms that can be positioned within the mold and integrated into the molding process. This nesting allows the holding mechanism to be concealed within the mold structure rather than visible on the final product surface.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Manufacturing precision

If locator pins are used to hold wires in fixed positions, then the positioning is improved, but holes are left in the molded item reducing its integrity

Engineering Contradiction:

Improvepositioning precisionVSAvoidintegrity of molded item

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The harmful effect of holes in the molded item is extracted and eliminated by replacing traditional locator pins with a retainer arm system that holds components without penetrating the mold cavity or leaving holes in the final product.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The retainer arms serve as an intermediary mechanism between the mold structure and the components being held. Instead of direct pin penetration, the retainer arms provide indirect holding through contact surfaces, maintaining component position without compromising product integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Area of stationary object

If components are positioned close to the interior surfaces of the die mold to maximize clearance, then the available positioning space is improved, but components may become visible at or extend through the exterior surfaces

Engineering Contradiction:

Improveclearance spaceVSAvoidcomponent positioning

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The retainer arms are designed with dynamic positioning capability, allowing them to be adjusted to precisely locate components at optimal positions within the mold cavity. This dynamic adjustment ensures components are held firmly without extending through the exterior surfaces.

Inventive Principle:

Principle #15Dynamics

4Ease of manufacture

If traditional molding processes are used without mounting mechanisms, then the manufacturing simplicity is maintained, but the molded items become difficult to mount

Engineering Contradiction:

Improvemolding process simplicityVSAvoidmounting ease

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The mounting function is merged with the molding process itself. The retainer device with integrated bushings is molded together with the product, creating built-in mounting features as an integral part of the molding operation rather than a separate post-processing step.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Mounting features (bushings) are prepared in advance during the molding process itself. The retainer arms and bushings are positioned and molded into the product while it is being manufactured, so mounting preparation is completed before the product leaves the mold cavity.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS8272896B2Retainer for overmolded electrical circuit

Publication Date: 2012.09.25 GROTE IND INC

AI summary

A plug assembly comprises a molded plug first and second ends, front and back surfaces, and extending along a longitudinal axis. The plug includes a socket extending from the front surface at least partially through the plug along a width axis. The socket defines at least one hole extending at least partially therethrough. The plug assembly also includes a retainer at least partially molded within the plug, with a first end adjacent the first end of the plug and a second end adjacent the second end of the plug. Additionally, the plug assembly includes a first wire set connected to the socket within the plug. The plug assembly further includes a first securing member securing the first wire set to the retainer within the plug, adjacent the first end of the retainer, to hold the first wire set in a fixed position within the plug during the overmolding process.