Coring system and method for manufacturing a one-piece die cast electrical connector body
A coring system for producing a flash-free one-piece die-cast body for an electrical connector. The electrical connector of produced by the coring system of the present invention may be used for securing two electrical cables to an electrical panel or electrical box through a single knockout hole. The coring system includes a first core, a second core, and a connecting arrangement for connecting the first and second cores in such a manner that there are no gaps between the joined portions of the two cores. When the cores of the coring system are joined together by the connecting arrangement and placed in a mold, molten metal may be introduced to the mold at the joined area of the two core pieces to form a one-piece flash-free connector body according to the present invention.
1. A coring system for producing a flash free one-piece connector body for securing electrical cables to a panel comprising:
a first core including a base portion with a tubular nose portion extending therefrom, said nose portion including an end thereon;
two grooves on opposing sides of said tubular nose portion of said first core, said grooves forming a narrow end portion, each of said grooves extending from said end toward said base portion and terminating in a shoulder;
a second core including a base portion and two parallel and generally tubular fingers extending from said base portion to an end;
an open channel between said fingers; and
said first core and said second core engaged together in such a manner that said narrow end portion of said first core is fully extended into said channel on said second core and said end of said fingers of said second core engage said shoulders on said first core,
whereby said engaged cores are capable of being inserted in the cavity of a mold that is capable of being closed and having molten metal or plastic admitted therein into said cavity thereby producing said flash free one-piece connector body.
2. The coring system of claim 1 wherein said grooves on said nose portion of said first core include an arcuate bottom surface.
3. The coring system of claim 2 wherein
said fingers include a radius of curvature;
said arcuate bottom surface of said grooves includes a radius of curvature; and
said radius of curvature of said fingers matches said radius of curvature of said arcuate bottom surface of said grooves.
4. The coring system of claim 1 wherein said first core and said second core include smooth and bun-free outer surfaces.
5. The coring system of claim 1 wherein said first core and said second core are constructed of hardened tool steel.
6. The coring system of claim 5 wherein said first core and said second core are constructed of grade AISI H-13 tool steel.
7. The coring system of claim 6 wherein said tool steel includes a Rockwell hardness of between 46 and 48.
8. A method of producing a die cast flash free one-piece connector body for securing electrical cables to a panel including the steps of:
providing a first core including a base portion, a tubular nose portion extending from said base portion, an end on said nose portion, a narrow end portion formed by two grooves on opposing sides of said tubular nose portion, and a shoulder at the end of each of said grooves;
providing a second core including a base portion, two parallel and generally tubular fingers extending from said base portion to an end, and an open channel between said fingers;
joining first core and said second core into joined cores by extending said narrow end portion of said first core into said channel on said second core until said end of said fingers of said second core engage said shoulders on said first core;
providing a mold including an elongated mold cavity having opposing ends therein;
placing said joined cores into said elongated mold cavity in such a manner that said joined cores are longitudinally aligned in said cavity and said base portions are at said opposing ends of said elongated cavity;
closing said mold; and
admitting molding material into said cavity of said mold to form said one-piece connector body.
9. The method of claim 8 wherein said molding material for forming said one-piece connector body is selected from the group including die cast metal alloy and plastic.
10. The method of claim 8 wherein said connector body is constructed of Zamak-7.
11. The method of claim 8 wherein said first core and said second core are constructed of hardened tool steel.
12. The method of claim 11 wherein said first core and said second core are constructed of grade AISI H-13 tool steel.
13. The method of claim 12 wherein said tool steel includes a Rockwell hardness of between 46 and 48.