Circulation Pump Control Housing Overmolding Precision
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Solution Overview
Problem
Existing methods for manufacturing control boxes for circulation pumps lack precision in positioning electrical contacts, which complicates the fixing of electronic control cards and affects the overall assembly process.
Innovation Solution
A method involving the production of an envelope part with a first set of electrical contacts, followed by precise positioning and overmolding of a second set of contacts, and optionally additional sets, to ensure accurate alignment and fixation, allowing for reduced volume overmolding operations that minimize positioning defects and deformations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple successive overmolding operations are used to manufacture the control box, then the manufacturing speed is increased, but the positioning precision of electrical contacts deteriorates
Solution Approach 1:
The patent segments the electrical contacts into two distinct sets: a first set that is overmolded directly into the control box housing, and a second set that is pre-positioned on a support structure and then overmolded as a unit. This segmentation allows each set to be positioned and fixed independently, ensuring high positioning precision for both sets while maintaining manufacturing efficiency through the modular approach.
2Manufacturing precision
If electrical contacts are pre-positioned on a support and then overmolded, then the positioning precision is improved, but the device complexity increases
Solution Approach 1:
The patent merges the second set of electrical contacts with a support structure by overmolding them together as a single unit. This merging simplifies the overall device by eliminating the need for separate positioning mechanisms for each contact in the second set, while still achieving high positioning precision. The support structure acts as a unified base that holds multiple contacts in their correct positions simultaneously.
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 enhances the precision of contact positioning, facilitating the assembly of electronic control cards and improving the overall manufacturing process by reducing errors and deformations, enabling more precise and efficient assembly of control boxes for circulation pumps.
Implementation Method 1
Fixing the second set of electrical contacts with respect to the envelope part by overmolding
Data Source
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AI summary
The method involves producing an envelope part (12) on which a set of electrical contacts (10) is fixed and another set of electrical contacts (18) is prepositioned. The latter set of electrical contacts is fixed relative to the envelope part by molding. A support part comprising housings (16) adapted to receive the latter set of electrical contacts is formed in the envelope part by molding. The latter set of electrical contacts is overmolded to form a cap (22), which immobilizes the latter set of contacts relative to the envelope part. Independent claims are also included for the following: (1) a method for manufacturing a circulation pump (2) a circulation pump.