Method and injection mold for manufacturing a plug

Abstract

The present invention relates to a method and an injection mold for manufacturing a plug (20), the plug (20) comprising at least two plug contacts (24) and a housing (28), wherein the at least two plug contacts (24) are at least partially arranged inside a cavity (28.1) of the housing (28) with a first end (24.1), the method having the following steps: placing and positioning a blanking grid (22) into a chamber of the injection mold, wherein the blanking grid (22) comprises at least two plug contacts (24) which are connected to each other by a blanking strip (26); extruding and encapsulating the at least two plug contacts (24) with a liquid plastic material so as to produce a contour of the housing (28) and the at least two plug contacts (24) are respectively at least partially arranged in a cavity (28.1) of the manufactured housing (28) with a first end (24.1); aging and hardening the plastic material and demolding and taking out the plug (20). Herein, before demolding, at least two plug contacts (24) of the blanking grid (22) are blanked freely by a blanking device integrated into the injection mold (1) by cutting off the blanking strip (26).

Description

Field of the Invention

[0001] The present invention relates to a method for manufacturing a plug of the type according to independent claim 1. An injection mold is also the subject of the present invention, which is configured to implement a method for manufacturing a plug. Background Art

[0002] Different methods for manufacturing plugs are known from the prior art, the plugs comprising at least two plug contacts and a housing. Here, the at least two plug contacts are arranged at least partially with a first end inside a cavity of the housing. Such methods generally have the following steps: placing and positioning a punching grid into a chamber of an injection mold, wherein the punching grid comprises the at least two plug contacts, which are connected to one another by a punching strip; extruding and encapsulating the at least two plug contacts with a liquid plastic material, thereby producing a contour of the housing and arranging the at least two plug contacts at least partially with a first end inside a cavity of the produced housing; aging and hardening the plastic material and demolding and removing the plug. After removing the plug from the injection mold, the plug is placed into a punching device, which is configured to freely punch the at least two plug contacts of the punching grid.

[0003] DE 10 2008 064 046 A1 discloses a method for manufacturing an electrical component group, in which interconnected lead frames or carrier strips are punched as a punching grid and equipped with electronic components. After the lead frame or carrier strip is completely equipped, an additional plasma treatment process is performed before at least partially extruding and encapsulating the equipped lead frame or carrier strip with a liquid plastic material or molding compound in an injection mold. Here, a plurality of electrical component groups are connected by connecting tabs substantially in the form of a chain or strip. After the extrusion and encapsulation process, the individual electrical component groups are placed into a punching tool and separated by a punching process.

[0004] An electrical module unit having a lead frame and a method for manufacturing such an electrical module unit of this type are known from DE 10 2006 030 133 A1. The module unit includes a wire bundle connected by tabs and a wire grid of at least one surface area, and a die of an integrated sensor circuit is applied to the surface area. The housing for insulation is formed such that a plurality of wire bundles and the integrated circuit are embedded. The starting point in manufacturing the electrical module unit is a thin strip of sheet material having side conveying strips, and the strip of sheet material is conveyed between different workstations on the side conveying strips. This means that electrical structural units are formed on the strip of sheet material in different workstations and the electrical structural units are further processed in such a way that a finished electrical module unit exists after the final processing step. Thus, in the first workstation, the wire grid is blanked out from the strip of sheet material. In the second workstation, the wire grid is equipped with dies. In the third workstation, a first injection molding process is performed, in which the dies are compression-molded. In the fourth workstation, the wire grid is equipped with additional structural elements and in the fifth workstation, the additional structural elements are compression-molded in a second injection molding process. In the sixth workstation, the wire grid is freely blanked, so that a finished module unit exists after the free blanking. Summary of the Invention

[0005] The method having the features of independent claim 1 is used for manufacturing a plug and the injection mold having the features of independent claim 4 is configured to implement the method for manufacturing a plug, and the method and the injection mold accordingly have the following advantages, namely: Each plug contact in the blanking grid can be placed as a component into the injection mold. Thereby, the troublesome manipulation of small individual plug contacts is eliminated. In addition, the precise positioning of the plug contacts can be significantly simplified by a special centering mechanism in the blanking grid. The plug contacts can be accurately held in position and sealed against the plastic melt by the blanking grid and the clamping force in the closed injection mold. The free blanking of the plug contacts is performed by a blanking device integrated in the injection mold after the actual filling process and before the now completed plug is demolded from the injection mold. Thereby, a separate blanking station can be saved and the manufacturing cost can be reduced.

[0006] Embodiments of the present invention provide a method for manufacturing a plug, the plug including at least two plug contacts and a housing, wherein the at least two plug contacts are at least partially arranged inside a cavity of the housing with a first end. The method includes the following steps: placing a blanking grid into and positioning it in a cavity of an injection mold, wherein the blanking grid includes the at least two plug contacts, and the plug contacts are connected to each other through a blanking strip; extruding and encapsulating the at least two plug contacts with a liquid plastic material to generate a contour of the housing and the at least two plug contacts are at least partially arranged inside the cavity of the manufactured housing with a first end respectively; aging and hardening the plastic material and demolding and taking out the plug. Herein, before demolding, at least two plug contacts of the blanking grid are freely blanked by a blanking device integrated into the injection mold, and the method is to cut off the blanking strip.

[0007] Furthermore, an injection mold is provided, which is configured to implement the method for manufacturing a plug according to the present invention. The injection mold includes a hot runner system and a cavity. The plug to be manufactured has at least two plug contacts and a housing, wherein the at least two plug contacts are at least partially arranged inside a cavity of the housing with a first end. Herein, the injection mold includes an integrated blanking device as follows, and the integrated blanking device is configured to freely blank at least two plug contacts of the blanking grid.

[0008] The core of the present invention lies in the combination of an injection mold and a blanking tool. The injection mold is geometrically configured such that there is sufficient space position for a driving device with a punch and a die even though there is a casting system. For a simple equipment of the injection mold, an inner region of the plug is configured as a movable core, and the movable core then also allows easy demolding. An implementation of a mold with a feasible solution for independently controlling an injection process and a blanking process enables setting an optimal blanking moment without depending on an injection process control. Thereby, a very stable manufacturing process is generated. A favorable implementation of the combined injection mold and blanking tool allows automating the placement of the plug contacts and increasing productivity.

[0009] Through the measures and expansion schemes listed in the dependent claims, favorable improvements of the method for manufacturing a plug described in independent claim 1 and the injection mold described in independent claim 4 can be achieved.

[0010] Particularly advantageously, a blanking grid having at least two plug contacts and a blanking strip can be continuously blanked out before being placed into the cavity of the injection mold. Thereby, the blanking grid can be obtained inexpensively in large quantities as a supply part in an advantageous manner. Here, the blanking strip connecting at least two plug contacts can be constructed in the region of the second end of the at least two plug contacts, and the second end is arranged outside the cavity of the housing to be manufactured in the manufactured plug. Thereby, the manipulation and clamping of the blanking grid can be simplified during the extrusion encapsulation process.

[0011] In an advantageous design of the injection mold, the blanking device can have a punch, a blanking matrix, a drive device, and a positioning device, which can be easily integrated into the injection mold.

[0012] In another advantageous design of the injection mold, the drive device can be configured as a hydraulic drive device, which is configured to move the punch in the direction of the blanking matrix. For this purpose, the hydraulic drive device can include, for example, a drive cylinder, which can act directly on the punch.

[0013] In another advantageous design of the injection mold, the positioning device can be configured to center the blanking grid and clamp and / or support it during the extrusion encapsulation process. The positioning device can include, for example, a movable plug core, which is configured to be pushed onto the first end of the at least two plug contacts, and the first end is arranged in the cavity of the housing to be manufactured in the manufactured plug. This means that the outer contour of the plug core can predefine the shape of the cavity inside the plug housing.

[0014] In another advantageous design of the injection mold, the positioning device can include a positioning fork-shaped member, which is configured to position and support the second end of the at least two plug contacts, which is arranged outside the cavity of the housing to be manufactured in the manufactured plug. Description of the Drawings

[0015] Embodiments of the present invention are shown in the drawings and are explained in detail in the following description. In the drawings, the same reference numerals denote components or elements that perform the same or similar functions.

[0016] Figure 1 A schematic flow chart of an embodiment of a method for manufacturing a plug according to the present invention is shown.

[0017] Figure 2Shows a schematic half-sectional view of an embodiment of an injection mold according to the present invention, the injection mold being configured to implement a method for manufacturing Figure 1 a plug according to the present invention.

[0018] Figures 3 to 8 Shows different schematic perspective views of the plug during the implementation of the method for manufacturing Figure 2 a plug according to the present invention using an Figure 1 injection mold. Detailed Description

[0019] As can be seen from Figure 1 the illustrated embodiment of the method 100 for manufacturing a plug 20 according to the present invention includes steps S100 to S150.

[0020] As can be seen from Figure 8 the manufactured plug 20 has at least two plug contacts 24 and a housing 28, wherein at least two plug contacts 24 are at least partially arranged inside a cavity 28.1 of the housing 28 with a first end 24.1. In the illustrated embodiment, the plug 20 includes four plug contacts 24.

[0021] As can also be seen from Figure 1 the punching grid 22 is placed into a cavity 5 of the injection mold 1 shown in Figure 2 and positioned in step S100. As can be seen especially from Figure 3 the punching grid 22 includes at least two plug contacts 24 which are connected to each other by a punching strip 26. In step S120, the at least two plug contacts 26 are extrusion-coated with a liquid plastic material to produce the contour of the housing 28 and the at least two plug contacts 24 are at least partially arranged in a cavity 28.1 of the manufactured housing 28 with a first end 24.1 respectively. In step S130, the plastic material is age-hardened. In step S140, the at least two plug contacts 24 of the punching grid 22 are freely punched by a punching device 10 integrated into the injection mold 1 before the demolding process, by cutting off the punching strip 26. In the final step S150, the plug 20 is demolded and removed.

[0022] In the illustrated embodiment, the punching grid 22 having at least two plug contacts 24 and a punching strip 26 is continuously punched out before being placed into the cavity 5 of the injection mold 1. As can be seen from Figures 3 to 7As can be seen, the blanking strip 26 connecting at least two plug contacts 24 is constructed in the region of the second end 24.2 of the at least two plug contacts 24, and the second end is arranged outside the cavity 28.1 of the housing 28 to be manufactured in the manufactured plug 20.

[0023] As can be seen from Figure 2 As can be seen from the illustrated embodiment of the injection mold 1 according to the invention, it includes a hot runner system 3 and a cavity 5, wherein the injection mold is configured to implement the method according to the invention for manufacturing Figure 1 the plug 20. Here, the hot runner system 3 is configured to fill the cavity 5 with liquid plastic material during the overmolding process. Here, a blanking device 10 is integrated into the injection mold 1, and the blanking device blank punches at least two plug contacts 24 of the blanking grid 22.

[0024] As can also be seen from Figure 2 As can be seen from the illustrated embodiment, the blanking device 10 includes a die 12, a blanking substrate 14, a drive device 16, and a positioning device 7, and the positioning device centers the blanking grid 22 and clamps and / or supports it during the overmolding process. As can also be seen from Figure 2 As can be seen from the illustrated embodiment, the drive device 16 is configured as a hydraulic drive device 16A, and the drive cylinder of the hydraulic drive device can directly act on the die 12 and move it in the direction of the blanking substrate 14. The positioning device 7 includes a movable plug core 7A and a positioning fork 7B.

[0025] As can also be seen from Figure 4 and 5 As can be seen from and, the movable plug core 7A is pushed onto the first end 24.1 of the at least two plug contacts 24, and the first end is arranged in the cavity 28.1 of the housing 28 to be manufactured in the manufactured plug 20. Here, the outer contour of the plug core 7A corresponds to the inner contour or profile of the cavity 28.1 of the housing 28. As can also be seen from Figure 4 and 5As can be seen, the second ends of the at least two plug contacts 24 are placed on the positioning fork 7B, and in the manufactured plug 20, the second ends are arranged outside the cavity 28.1 of the housing 28 to be manufactured. For this purpose, the positioning fork 7B includes corresponding cutouts which are separated from each other by the tabs or "teeth" of the positioning fork 7B. The cutouts at least partially receive the second ends 24.2 of the plug contacts 24 respectively. Thereby, the punching grid 22 is centered and supported during further manufacturing by the movable plug core 7A in combination with the positioning fork 7B. After positioning the punching grid 22, the injection mold 1 is closed and the injection molding process is started, in which the liquid plastic material is guided through the hot runner system 3 into the closed chamber 5, so that the contour of the housing 28 is produced in combination with the movable plug core 7A and the at least two plug contacts 24 are each arranged at least partially with the first ends 24.1 in the cavity 28.1 of the manufactured housing 28, as can be seen from Figures 6 to 8 As can also be seen from Figure 7 As can be seen, before demolding, the die 12 of the punching device 10 integrated into the injection mold 1 freely punches at least two plug contacts 24 of the punching grid 22 by cutting off the punching strip 26. Subsequently, the manufactured plug 20 shown in Figure 8 can be removed from the injection mold 1.

[0026] The embodiment of the present invention combines the injection molding process of the punching grid 22 with plastic and the punching process of freely punching at least two plug contacts 24 of the punching grid 22 in a common mold.

Claims

1. A method (100) for manufacturing a plug (20), the plug (20) comprising at least two plug contacts (24) and a housing (28), wherein the at least two plug contacts (24) are at least partially arranged with a first end portion (24.1) inside a cavity (28.1) of the housing (28), the method (100) having the following steps: placing and positioning a blanking grid (22) into a chamber (5) of an injection mold (1), wherein the blanking grid (22) comprises at least two plug contacts (24) which are connected to each other by a blanking strip (26); extruding and encapsulating the at least two plug contacts (24) with a liquid plastic material so as to produce a contour of the housing (28) and the at least two plug contacts (24) are respectively at least partially arranged with the first end portion (24.1) inside a cavity (28.1) of the manufactured housing (28); aging and hardening the plastic material and demolding and removing the plug (20), characterized in that, Before demolding, at least two plug contacts (24) of the punching grid (22) are thereby freely punched by a punching device (10) integrated into the injection mold (1) by cutting off the punching strip (26), wherein the punching strip (26) connecting at least two plug contacts (24) is configured in the region of the second end (24.2) of the at least two plug contacts (24), and the second end is arranged outside the cavity (28.1) of the housing (28) to be manufactured in the manufactured plug (20).

2. The method (100) according to claim 1, characterized in that, Before being placed into the cavity (5) of the injection mold (1), a punching grid (22) having at least two plug contacts (24) and a punching strip (26) is continuously punched out.

3. An injection mold (1) configured to implement the method (100) for manufacturing a plug (20) according to any one of claims 1 to 2 and comprising a hot runner system (3) and a cavity (5), wherein the plug (20) has at least two plug contacts (24) and a housing (28), wherein the at least two plug contacts (24) are at least partially arranged with a first end portion (24.1) inside a cavity (28.1) of the housing (28), characterized in that, An integrated punching device (10) is provided, which is configured to freely punch at least two plug contacts (24) of the punching grid (22).

4. The injection mold (1) according to claim 3, characterized in that, The punching device (10) includes a punch (12), a punching base (14), a drive device (16), and a positioning device (7).

5. The injection mold (1) according to claim 4, characterized in that, The drive device (16) is configured as a hydraulic drive device (16A), which is configured to move the punch (12) in the direction of the punching base (14).

6. The injection mold (1) according to claim 4 or 5, characterized in that, The positioning device (7) is configured to center the punching grid (22) and hold and / or support it during the extrusion encapsulation process.

7. The injection mold (1) according to claim 6, characterized in that, The positioning device (7) includes a movable plug core (7A), which is configured to be pushed onto the first end (24.1) of at least two plug contacts (24), and the first end is arranged in the cavity (28.1) of the housing (28) to be manufactured in the manufactured plug (20).

8. The injection mold (1) according to claim 7, wherein The positioning device (7) includes a positioning fork (7B), which is configured to position and support the second end of the at least two plug contacts (24) that is arranged outside the cavity (28.1) of the housing (28) to be manufactured in the manufactured plug (20).

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