Plastic Plug-In Connector Molding for Axial Straightness
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Solution Overview
Problem
Existing plastic plug-in connectors face challenges in maintaining axial straightness during injection molding, leading to potential distortion and leakage issues in fluidic connections, particularly in quick-action connectors used in motor vehicle brake systems.
Innovation Solution
The solution involves injecting the polymer compound through a single side using a needle closure nozzle and employing filling control elements within the molding tool to create a radially asymmetrical mass distribution, which inhibits axial flow and promotes circumferential flow, thereby minimizing distortion and ensuring optimal straightness of the plug-in connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the polymer compound is injected through a single side, then material waste is eliminated and productivity is improved, but axial distortion occurs leading to poor straightness
Solution Approach 1:
The patent applies asymmetry by creating a radially asymmetrical mass distribution of the plastic in the molded part. This is achieved by positioning the gate point exclusively at one side on the outer circumference, causing the polymer compound to flow asymmetrically during injection molding. The asymmetrical mass distribution compensates for the inherent distortion caused by single-side injection, thereby maintaining axial straightness while eliminating sprues and improving productivity.
2Manufacturing precision
If conventional injection molding is used with multiple injection openings, then axial straightness is maintained, but material waste occurs due to sprue formation and productivity is reduced
Solution Approach 1:
The patent extracts and eliminates the sprue system from the injection molding process by using a single injection opening. The gate point is positioned exclusively at one side on the outer circumference of the molded part, allowing the polymer compound to be injected directly into the cavity without forming a separate sprue. This extraction of the sprue system eliminates material waste and improves productivity while the asymmetrical mass distribution compensates for the resulting axial distortion.
3Shape
If the polymer compound flows radially inward into the cavity, then the inner channel is formed, but axial curvature develops during cooling and solidification
Solution Approach 1:
The patent applies local quality by creating a radially asymmetrical mass distribution specifically in certain regions of the molded part. The gate point is positioned exclusively at one side, causing non-uniform plastic flow and mass distribution during injection. This localized asymmetry compensates for the axial curvature that would otherwise develop during cooling and solidification, while still allowing the polymer compound to flow radially inward and form the inner channel correctly.
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 results in a plug-in connector with reduced axial deviation, improved sealing, and enhanced assembly reliability, while also eliminating the need for sprues and reducing material waste, thus improving productivity and material economy.
Implementation Method 1
the polymer compound flows in a circumferential and in an axial direction until the cavity has been completely filled
Implementation Method 2
the polymer compound cools, possibly with application of a holding pressure, until it solidifies
Implementation Method 3
the polymer compound cools, possibly with application of a holding pressure, until it solidifies
Data Source
AI summary
A plug-in connector produced by injection molding a plastic material and having an internal channel for a fluid and having three main sections situated axially one behind the other. The plug-in connector has a gate point on its outer circumference solely on one side and a mass distribution of the plastic material that is radially asymmetrical with respect to the circumference and which is present in at least one of the main sections of the shaped part. A method for the production of the plug-in connector is likewise disclosed.