Stamped Threads on Non-Circular Tubes for Electrical Connectors
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Solution Overview
Problem
Existing methods for fabricating threaded connection members in electrical connectors, such as screw machining and die casting, are costly and time-consuming, generating significant scrap material and limiting production capacity.
Innovation Solution
The use of stamped threads formed on a non-circular cross-sectional tube using a stamping process, which reduces material waste and fabrication costs by creating a threadable connection member with discontinuous threads along a portion of the perimeter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If screw machining or die casting processes are used to fabricate threaded connection members, then the connection members can be produced with continuous threads, but the fabrication cost increases and production time is extended
Solution Approach 1:
The thread structure is segmented from continuous to discontinuous, with gaps introduced between thread segments. This segmentation allows the use of faster stamping processes instead of slower screw machining or die casting, while the discontinuous threads still provide sufficient mechanical engagement for the connector application.
Solution Approach 2:
Instead of forming complete continuous threads around the entire perimeter, the patent applies threads only to partial segments of the connector body. This partial action reduces fabrication complexity and time while maintaining the functional requirement for threadable engagement with mating connectors.
2Manufacturing precision
If screw machining process is used to fabricate threaded connection members, then accurate thread dimensions can be achieved, but a relatively large amount of scrap material is generated
Solution Approach 1:
The connector body is first formed as a complete non-circular tube using a forming process, and then threads are stamped onto the exterior surface. This preliminary formation of the base structure allows material to be retained and reused, rather than being removed as scrap during thread formation as in traditional screw machining.
Solution Approach 2:
The patent changes the manufacturing parameter from subtractive machining (screw machining) to formative stamping. This parameter change transforms the process from one that removes material (creating scrap) to one that forms threads by displacing material, thereby eliminating scrap generation while maintaining dimensional accuracy.
3Productivity
If die casting process is used to fabricate threaded connection members, then production speed can be increased, but fabrication cost increases and production time is extended
Solution Approach 1:
The patent merges two operations into one: the connector body is formed and threads are stamped in a single manufacturing step using a stamping die. This combination eliminates the need for separate die casting and thread formation operations, reducing total production time and fabrication cost while maintaining production speed.
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 cost-effective and efficient method for producing threaded connection members with reduced material waste, enabling higher production volumes and lower fabrication costs compared to traditional methods.
Implementation Method 1
Stamped threads are formed on the exterior side of the tube along at least a portion of the length of the tube
Data Source
AI summary
A connection member includes a tube extending a length along a central longitudinal axis. The tube includes a central passageway that extends through the length of the tube. The tube has a non-circular cross-sectional shape along the length of the tube. The tube includes an exterior side that defines a perimeter of the non-circular cross-sectional shape of the tube. Stamped threads are formed on the exterior side of the tube along at least a portion of the length of the tube. The stamped threads are discontinuous along the perimeter of the non-circular cross-sectional shape of the tube such that the stamped threads only extend along at least one portion of the perimeter of the non-circular cross-sectional shape of the tube.