Plug Prong Recessed Groove for Injection Molding Overflow Control

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Solution Overview

Problem

Existing plug prong manufacturing processes face challenges with excessive material overflow due to high injection pressure and lack of material due to insufficient pressure, leading to inefficiencies and potential safety issues.

Innovation Solution

A plug prong design featuring a to-be-clamped section with a recessed groove that can absorb excessive material and provide fluidic supply in case of material deficiency, thereby stabilizing the injection molding process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the injecting pressure of the injection molding machine is increased to ensure adequate material filling, then material distribution is improved, but excessive material overflow occurs

Engineering Contradiction:

Improvematerial distributionVSAvoidexcessive material overflow

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The recessed groove is designed to receive and contain the excessive material that would otherwise overflow harmfully. By providing a designated space within the to-be-clamped section, the harmful overflow is converted into a beneficial feature that ensures adequate material filling while preventing defects

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Object-generated harmful factors

If the injecting pressure of the injection molding machine is decreased to prevent excessive material overflow, then material control is improved, but lack of material occurs in other portions

Engineering Contradiction:

Improvematerial overflow controlVSAvoidmaterial sufficiency

Core Design Contradiction:

Object-generated harmful factorsVSManufacturing precision

Solution Approach 1:

The recessed groove creates a localized region with different material requirements. This local feature allows the mold to accommodate varying material pressures - accepting excess material in the groove area while ensuring adequate filling in other critical portions of the inner frame

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If manual scraping is performed to remove excessive material, then material precision is improved, but manufacturing efficiency deteriorates

Engineering Contradiction:

Improvematerial precisionVSAvoidmanufacturing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The recessed groove is designed into the prong structure itself to automatically contain and manage excessive material during injection molding. This self-service feature eliminates the need for subsequent manual scraping operations, maintaining material precision while significantly improving manufacturing efficiency

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20250192462A1Plug prong

Publication Date: 2025.06.12 SU TUN LI

AI summary

A plug prong comprises a contact section configured to be inserted into a socket, a riveting section configured for wire connection via riveting, and a to-be-clamped section located between the contact section and the riveting section and configured to be clamped by an inner frame. The to-be-clamped section includes a neck having a notch which is open in a lateral side. The notch includes a recessed groove formed on a lower edge of the notch. The recessed groove includes a bottom edge located outside of an outermost face of the inner frame facing the contact section. After injection molding to form a plug product, the recessed groove will extend from an inner side to an outer side of an engagement face of the plug product.