Terminal Block Seal Member Segmentation
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Solution Overview
Problem
The existing terminal block designs face challenges in mold complexity and increased production costs due to the need for under-shaped grooves for seal members, which can lead to insufficient waterproofing and excessive protrusions during resin molding.
Innovation Solution
An assembled body with a main body member, an annular seal member, and a cover member, where the seal member attachment region is created by the exposed surface of the main body member and the cover member, eliminating the need for an under-shaped mold and preventing axial displacement of the seal member, thus simplifying molding and assembly while ensuring a smooth surface for sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an under-shaped groove is formed on the resin portion to hold the seal member, then the seal member can be restrained from axial displacement, but the mold structure becomes complicated and manufacturing cost increases
Solution Approach 1:
The terminal block is divided into a resin portion and a separate cover member. The cover member is fitted onto the protruding portion of the resin portion, and the seal member is held between these two segmented parts. This segmentation allows the seal member to be restrained without requiring a complex under-shaped groove in the resin portion, thus simplifying the mold structure while maintaining positioning stability.
2Shape
If an under-shaped groove is directly molded by injection molding, then the groove shape can be formed, but excessive protrusions (burrs) are formed on the groove surfaces
Solution Approach 1:
By segmenting the terminal block into a resin portion and a cover member, the under-shaped groove is formed on the cover member rather than being directly molded into the resin portion. This allows the groove to be formed without excessive burrs, as the cover member can be separately manufactured with higher precision, thus improving groove surface quality.
3Reliability
If an under-shaped groove is formed to hold the seal member, then the seal member can be positioned, but secondary processing such as polishing is required to remove burrs
Solution Approach 1:
The seal member retention function is achieved through the assembly of the cover member fitted on the resin portion, rather than through a complex molded groove requiring secondary processing. This segmentation eliminates the need for polishing and other secondary operations, simplifying the manufacturing process while maintaining reliable seal member retention.
4Ease of manufacture
If a cover member is added to cover the protruding portion, then the seal member attachment region is defined and assembly is simplified, but the number of components increases
Solution Approach 1:
The terminal block is segmented into a resin portion and a cover member, where the cover member serves multiple functions: it covers the protruding portion, defines the seal member attachment region, and simplifies the molding process by eliminating the need for complex under-shaped grooves in the resin portion. This segmentation, while adding a component, overall simplifies manufacturing and assembly.
Data Source
AI summary
An assembled body attachable to an attached body includes: a main body member made of a rigid material; an annular seal member made of a material that is more easily deformed than the main body member, and assembled on the main body member to close a gap between the main body member and the attached body; and a cover member assembled on the main body member. The main body member is formed with an attachment portion to be disposed inside the attached body, and the cover member is installed on the attachment portion. A seal member attachment region is assigned between a part of the main body member and the cover member, and the seal member attachment region is defined at least by an exposed surface of the attachment portion that is not covered by the cover member and one end surface of the cover member.