Wire Terminal Sealing Mold for UV Resin Flow Restriction
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Solution Overview
Problem
The existing method of manufacturing coated wires with terminals faces challenges in controlling the flow and curing of anti-corrosive materials with high fluidity, leading to difficulties in forming a sealing member with a specific shape, especially in complex wire configurations, which can result in unintended material flow into non-required areas.
Innovation Solution
A method using a transparent mold with a cavity and a protruding portion to restrict the flow of an ultraviolet curable resin, ensuring the sealing member is formed only in the required parts by irradiating the anti-corrosive material with ultraviolet light, which includes a combination of photopolymerizable (meth)acrylate monomers and oligomers to achieve the desired shape and properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If anti-corrosive material with high fluidity is applied to the joint part, then the material can easily fill the joint space, but the material flows into non-required areas such as contact portions of the terminal
Solution Approach 1:
The mold cavity is segmented into different regions using a partition wall. The partition wall divides the cavity into a first cavity portion for receiving the conductor and terminal, and a second cavity portion for receiving the anti-corrosive material. This segmentation prevents the material from flowing into non-required areas while maintaining the benefits of high fluidity material.
Solution Approach 2:
The mold structure is designed with local quality variations - the partition wall is positioned specifically to restrict material flow only in certain areas (contact portions of terminal) while allowing material to fill the joint space. This localized structural modification enables precise control of material distribution without affecting the overall filling capability.
2Productivity
If ultraviolet curable resin is used, then the curing time is shortened and production speed increases, but the fluidity control during filling becomes more difficult
Solution Approach 1:
The partition wall is installed in the mold before the anti-corrosive material is introduced. This preliminary action establishes the flow restrictions in advance, ensuring that when the ultraviolet curable resin (which cures quickly) is injected, the material flow is immediately constrained to the correct areas without requiring post-filling adjustments.
Solution Approach 2:
The partition wall acts as an intermediary structure between the injected material and the mold cavity. It mediates the material flow by allowing the ultraviolet curable resin to fill the joint space efficiently while preventing it from entering non-required areas, thus enabling both fast curing and precise shape control.
3Shape
If a mold is used to form the sealing member, then the shape can be controlled, but the complex wire configuration causes material to flow into contact portions where sealing is not required
Solution Approach 1:
The mold cavity is divided into functional zones using the partition wall. The first cavity portion accommodates the conductor and terminal contact portions, while the second cavity portion receives the anti-corrosive material. This segmentation enables precise shape control of the sealing member while preventing material intrusion into contact portions through the partition barrier.
Solution Approach 2:
The partition wall creates local structural differentiation within the mold - it is positioned to restrict material flow specifically at contact portions where sealing is not needed, while allowing material to form the sealing member in the joint area. This localized control achieves the desired sealing member geometry without unwanted material flow.
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 allows for the precise formation of a sealing member with improved strength, hardness, and elongation, effectively preventing corrosion at the joint between the conductor and metal terminal while maintaining a high production speed and avoiding defects in the sealing member.
Implementation Method 1
The ultraviolet curable resin is cured instantaneously through irradiation with ultraviolet light
Implementation Method 2
a protruding portion that protrudes from the transparent mold into the cavity portion and restricts flowing of the anti-corrosive material
Data Source
AI summary
Provided is a method of manufacturing a wire with a terminal, the wire with a terminal including a wire, a metal terminal, and a sealing member obtained by curing an anti-corrosive material, the method using a manufacturing apparatus for the wire with a terminal including a transparent mold including a cavity portion, and a protruding portion that protrudes into the cavity portion, the method including an introducing step of placing, in the cavity portion, a non-sealed wire with a terminal before including the sealing member including the wire and the metal terminal, and introducing the anti-corrosive material into the cavity portion; and an irradiating step of irradiating the anti-corrosive material in the cavity portion with ultraviolet light through the transparent mold.