Plug Recess Design for Injection Molding Heat Dissipation
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Solution Overview
Problem
Existing plug connections for motor vehicle engine compartments face challenges with material accumulation and distortion due to low heat dissipation and mechanical stress during injection molding, leading to increased cooling times and potential breakage during handling.
Innovation Solution
A plug design featuring a cuboid outer circumference with rounded edges and recesses integrated into the mold for improved heat dissipation and reduced material accumulation, allowing for more precise molding and increased stability, while maintaining compatibility with existing connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pins are inserted into the mold for material removal, then material accumulation is prevented, but cooling time increases due to limited heat dissipation
Solution Approach 1:
The invention transitions from one-dimensional pin-based material removal to a surface-based approach where the recess is formed directly on the mold surface. This dimensional change allows the recess to be created as an integral part of the mold cavity, enabling simultaneous cooling and material removal without requiring separate pin structures that extend into the molded part.
Solution Approach 2:
The invention merges the material removal function with the mold cooling system. The recess is integrated into the mold's inner circumference, combining the functions of material accumulation prevention and heat dissipation into a single structural feature, thereby eliminating the need for separate pins that would otherwise be required.
2Manufacturing precision
If pins are used for material removal, then material buildup is prevented, but mechanical and thermal stress on pins increases
Solution Approach 1:
The invention extracts the pins from the system entirely. Instead of using removable pins that are inserted and withdrawn, the recess is formed directly in the mold's inner circumference. This eliminates the pins as separate components, removing them from the stress cycle and preventing the mechanical and thermal degradation that would occur with repeated insertion and withdrawal.
3Stability of the object's composition
If material is removed from the straight section, then warpage is reduced, but the aspect ratio of recess becomes unfavorable for demolding
Solution Approach 1:
The invention applies local quality by positioning the recess specifically on the curved outer circumference rather than the straight section. This localized approach allows material removal where it most effectively prevents warpage while maintaining favorable demolding characteristics. The recess is strategically placed to address the specific warpage issue without creating the aspect ratio problems associated with deep recesses in straight sections.
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 solution enhances dimensional accuracy, reduces material usage by 3%, and improves handling stability, minimizing the risk of breakage and simplifying quality control, while ensuring interoperability with prior art connectors.
Implementation Method 1
The negative mold of the recess provided according to the invention can be directly integrated into the inner circumference of the mold used for injection molding. This inner circumference can be cooled, thus improving heat dissipation from the recess area.
Implementation Method 2
This molded part is manufactured by injection molding. In this process, liquid plastic is injected at high temperature and a pressure of several hundred bar into a multi-part mold
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
Plug (1) for producing an electrical connection protected against polarity reversal, comprising a moulded part (2) made of a plastic, the outer circumference of which is formed at least in one sub-region by a cuboid (3) having rounded edges (4a, 4b), which is continued into a semi-circular cylinder (5), wherein the moulded part (2) comprises a cavity (7) open towards the end face (6) thereof for receiving the electrical contacts (8a, 8b, 8c) and wherein said end face (6) contains the bottom surface (3a) of the cuboid (3), wherein at least one lateral face (9, 10, 11) of the cuboid (3) comprises at least one recess (12, 13, 4, 15) extending along the rounded edge (4a, 4b).