Male Terminal Connector Insert Molding for Heat-Resistant Locking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connector manufacturing processes are inefficient due to the need for separate operations to insert and thermally weld insulating members, resulting in longer manufacturing times and reduced holding force and heat resistance, especially when using lower melting temperature resins.
Innovation Solution
The integration of a resin molded portion with a hollow tubular terminal contact portion, featuring a shaft with an insulating portion and a flange, allows for insert molding of high heat resistance resin, simplifying the manufacturing process and enhancing the holding force, while eliminating the need for thermal welding and expensive cutting techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermal welding is used to attach the insulating member to the terminal contact portion, then the manufacturing time can be reduced, but the holding force and heat resistance are reduced due to easier deformation at lower temperatures
Solution Approach 1:
The insulating member is integrally molded with the terminal contact portion through insert molding, combining two previously separate components into a single integrated structure. This eliminates the need for separate attachment operations while enabling the use of high heat resistance resin that provides both strong holding force and thermal stability.
Solution Approach 2:
The thermal welding process is replaced with insert molding, substituting a thermal-chemical bonding method with a mechanical-molding process. This allows the insulating member to be formed directly on the terminal contact portion without requiring the resin to be melted, thereby maintaining high heat resistance while reducing manufacturing complexity.
2Reliability
If separate operations are used to insert and thermally weld the insulating member, then the holding force can be maintained, but the manufacturing time becomes longer
Solution Approach 1:
The insertion and attachment operations are merged into a single insert molding process. The insulating member is molded directly onto the terminal contact portion in one operation, simultaneously achieving both the mechanical attachment (holding force) and the positioning function without requiring separate steps.
Solution Approach 2:
The insulating member is pre-formed and then directly molded onto the terminal contact portion during the insert molding process. This preliminary preparation of the insulating member structure allows it to be attached in a single operation, eliminating subsequent welding or fastening steps.
3Productivity
If lower melting temperature resin is used to reduce manufacturing time, then the thermal welding can be completed faster, but the retaining portion deforms more easily and heat resistance is reduced
Solution Approach 1:
The resin selection parameter is changed from low melting temperature to high heat resistance resin. By using high melting temperature resin in the insert molding process, the retaining portion maintains its shape and mechanical properties at elevated temperatures while the manufacturing time is reduced through the elimination of thermal welding operations.
Solution Approach 2:
The thermal welding process using low melting temperature resin is replaced with insert molding using high heat resistance resin. This substitution eliminates the need to melt the resin for attachment, allowing the use of thermally stable materials that maintain their mechanical strength and dimensional stability at high temperatures.
4Reliability
If the male terminal is provided with a flange and locking portions, then the sleeve can be securely mounted, but the manufacturing complexity increases requiring expensive cutting techniques
Solution Approach 1:
The flange and locking portions are integrated into the resin molded portion as a single molded structure. This combining of features that would traditionally require separate machining operations allows the male terminal to be manufactured using inexpensive press working techniques while maintaining secure mounting capability through the locking portions engaging with the sleeve.
Solution Approach 2:
The resin molded portion combines the structural functions of the flange and locking portions in a single composite component. This integrated design allows the use of molding techniques instead of expensive cutting or machining operations, reducing manufacturing cost and complexity while maintaining the mechanical functionality of secure sleeve mounting.
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 configuration reduces manufacturing time, improves the holding force and heat resistance of the resin molded portion, and allows for mass production of resin molded portions, while simplifying the male terminal design and enabling cost-effective press working.
Implementation Method 1
the resin molded portion is molded integrally to the terminal contact portion and is provided with the insulating portion. Thus, the insulating portion can be formed by insert molding
Implementation Method 2
Two locking portions are provided on a peripheral edge of the flange. The sleeve includes a concave portion into which the flange enters from one side. Two locked portions are provided on an inner wall of the concave portion and are to be locked by the locking portions from the other side.
Data Source
AI summary
A connector includes a male terminal (10) having a tubular terminal contact (20) open in a front-rear direction. A resin molded portion (50) is molded to the terminal contact (20). A wire (W) is pulled out rearward from the male terminal (10), and a sleeve (60) covers a core (W1) exposed in front of the wire (W). The resin molded portion (50) includes a shaft (51) inside the terminal contact (20), an insulating portion (52) projecting forward from a front of the shaft (51), a flange (53) protruding radially outward from a rear end of the shaft (51), and two locking portions (57) on a periphery of the flange (53). The flange (53) enters a concavity (64) of the sleeve (60) from one side, and two locked portions (65) provided on an inner wall of the concavity (64) lock the locking portions (57) from the other side.