Plastic Tube-Wire Connector Assembly for Standardized Mass Production

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Solution Overview

Problem

Existing methods for manufacturing assemblies with plastic tube portions and wire inserts lack efficiency and standardization for mass production, particularly in establishing reliable electrical and mechanical connections.

Innovation Solution

A method involving prefabrication of an electrical conducting component group, separation of conducting components, electrical contacting with the tube-wire insert, and connection of a terminal connector to the plastic tube portion, which can be automated and includes options like soldering, welding, or crimping for secure connections, with a lead frame used for robustness and flexibility in assembly configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional manufacturing methods are used for assemblies with plastic tube portions and wire inserts, then manual assembly and connection processes are required, but this results in low production efficiency and lack of standardization for mass production

Engineering Contradiction:

Improveproduction efficiencyVSAvoidstandardization

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The invention divides the assembly into modular components: a plastic tube portion with pre-inserted tube-wire inserts, and a separate terminal connector. This segmentation allows each component to be manufactured independently using standardized processes, enabling mass production while maintaining assembly flexibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The tube-wire inserts are pre-installed into the plastic tube portion during tube manufacturing, before the terminal connector is attached. This preliminary action standardizes the wire insertion process and enables automated production lines, significantly improving productivity and consistency.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If electrical connection is established between tube-wire insert and terminal connector, then reliable electrical contact is achieved, but this requires complex manual assembly processes

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidassembly process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The tube-wire inserts are designed with self-positioning features that automatically align with the terminal connector during assembly. The conducting components within the terminal connector automatically contact the tube-wire inserts when the connector is attached to the tube portion, eliminating the need for complex manual alignment and connection procedures while ensuring reliable electrical contact.

Inventive Principle:

Principle #25Self-service

3Strength

If conducting components are electrically contacted with tube-wire insert, then secure electrical and mechanical connection is provided, but this requires multiple separate operations

Engineering Contradiction:

Improveconnection strengthVSAvoidassembly speed

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The invention combines electrical contacting and mechanical connection into a single integrated operation. When the terminal connector is attached to the plastic tube portion, the conducting components automatically establish both mechanical contact and electrical connection with the tube-wire inserts simultaneously. This merging of functions eliminates multiple separate operations, maintains strong connections, and enables high-speed automated assembly.

Inventive Principle:

Principle #5Merging (Combining)

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 method simplifies and standardizes the electrical contact between the tube-wire insert and terminal connector, enabling robust and reliable assemblies suitable for mass production, with applications in smart sensors, heated tubes, and other mechanical systems, while ensuring mechanical and electrical integrity.

Implementation Method 1

Electrical contacting of the conducting component configuration with the at least one tube-wire insert may be performed by soldering, by stirrup soldering, by welding, by bonding, by gluing or by crimping

Methodology Applied

Scientific EffectSoldering: Soldering

Implementation Method 2

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 3

Methodology Applied

Scientific EffectCrimping: Mechanical Fastener

Data Source

PatentUS20240030661A1Method for manufacturing an assembly consisting of a plastic tube portion having at least one tube-wire insert and a terminal connector

Publication Date: 2024.01.25 RAUMEDIC AG

AI summary

In order to manufacture an assembly consisting of a plastic tube portion having at least one tube-wire insert and a terminal connector, an electrical conducting component group is first prefabricated. Conducting components of the conducting component group provide an electrical connection with the at least one tube-wire insert, in the assembled state. A conducting component configuration is separated from the prefabricated conducting component group. The conducting component configuration is electrically contacted with the at least one tube-wire insert. The terminal connector is connected to the plastic tube portion. This results in an assembly manufacturing method which is suitable for mass production. The conducting component group is part of a multi-lead frame which has a plurality of different, selectable conducting component configurations that can be specified by selecting appropriate conducting components depending on the electrical contacting requirements.