Unipolar Terminal Block Molding With Interchangeable Cores
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Solution Overview
Problem
The manufacturing of terminal blocks of various shapes requires constructing a separate mold for each product, leading to increased development time and cost.
Innovation Solution
A manufacturing method for unipolar terminal blocks using a mold unit with multiple molds and cores, allowing for the sharing of molds by selecting different terminals and cores to produce various types of terminal blocks with the same mold unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate mold is constructed for each terminal block shape, then manufacturing precision and product quality are improved, but device complexity and development cost increase
Solution Approach 1:
The patent applies universality by designing a single mold unit that can produce multiple types of terminal blocks through interchangeable cores. The mold unit includes a cavity and multiple cores that can be swapped to create different terminal block shapes, eliminating the need for separate molds for each product variant while maintaining manufacturing precision.
Solution Approach 2:
The patent segments the molding system into a reusable mold unit and interchangeable cores. The mold unit contains the cavity and core mounting structure, while specific terminal block shapes are defined by separate cores that can be independently selected and replaced, allowing flexible production of various terminal block types.
2Adaptability or versatility
If a separate mold is constructed for each terminal block shape, then product design flexibility is improved, but loss of time and development duration increase
Solution Approach 1:
The patent applies preliminary action by pre-manufacturing multiple cores with different terminal block shapes and storing them for use. When a specific terminal block type is needed, the appropriate core is already prepared and can be quickly installed in the mold unit, eliminating the time-consuming process of designing and constructing new molds for each product variant.
Solution Approach 2:
The universal mold unit can accommodate different cores to produce various terminal block shapes, providing design flexibility without requiring separate development cycles for each product type. The same mold unit serves multiple functions by simply changing the core component.
3Adaptability or versatility
If a separate mold is constructed for each terminal block shape, then product customization capability is improved, but manufacturing cost increases
Solution Approach 1:
The patent reduces manufacturing cost by creating a universal mold unit that can produce multiple terminal block types. Instead of investing in separate expensive molds for each product variant, the company can use one mold unit with interchangeable cores, significantly reducing tooling costs while maintaining the ability to produce various terminal block shapes.
Solution Approach 2:
The patent enables cost-effective production by allowing the recovery and reuse of the mold unit across different product lines. The expensive mold unit is retained and reused indefinitely by simply swapping the relatively inexpensive cores, eliminating the need to discard and recreate entire mold systems for each new terminal block design.
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
Enables the efficient production of multiple terminal block types using a single mold unit, reducing development time and cost while maintaining flexibility in design configurations.
Implementation Method 1
The housing 504 is formed by filling a mold cavity with molten resin and solidifying the molten resin
Implementation Method 2
the busbar 502 and the collar 503 are set in the mold cavity when the housing 504 is molded, and are insert-molded into the housing 504
Data Source
AI summary
A manufacturing method for a unipolar terminal block including a terminal having a first connection portion and a second connection portion at both end sides thereof, and a resin portion holding the terminal includes using a mold unit including a plurality of molds forming a cavity for molding the resin portion, and a core configured to hold the terminal that is molded in advance and incorporated in one of the plurality of molds; preparing various types of terminals and various types of cores for holding the terminals respectively; and selecting one terminal from the various types of terminals and one core from the various types of cores, and filling molten resin into the cavity in a state in which the selected one core is incorporated in the mold and the one terminal is set in the cavity to manufacture the unipolar terminal block.