Nano-coating reinforced M12 connector waterproof full-wrapping integrated forming system

Abstract

The invention belongs to the technical field of connectors, and particularly relates to a nano-coating reinforced M12 connector waterproof full-wrapping integrated forming system which comprises a base material pretreatment module, a nano-coating embedded coating module, a waterproof full-wrapping integrated forming module, a precision detection module and a finished product packaging module which are sequentially linked and connected. The linkage control module is used for cooperatively controlling all the modules; each module adopts a standardized interface design, and can be independently debugged and flexibly combined; the nano coating is applied and embedded in a waterproof full-wrapping integrated forming process, and a synergistic structure of plasma activation pretreatment, a two-component nano composite coating and one-time injection molding seamless forming is adopted, so that the problems of incomplete coating coverage, poor adhesive force, easiness in falling and unreliable waterproof sealing caused by the fact that the coating is formed first and then formed in the prior art are solved; meanwhile, seam gaps caused by mold splitting forming are eliminated, and the waterproof grade and the structural stability of the connector are remarkably improved.

Description

Technical Field

[0001] This invention belongs to the field of connector technology, specifically a nano-coating reinforced M12 connector waterproof all-enclosed integrated molding system. Background Technology

[0002] M12 connectors are widely used circular connectors in industrial automation, sensing and control, and signal transmission, primarily for electrical connections and signal transmission between devices. As industrial environments become increasingly complex, higher demands are placed on connectors' waterproof performance, mechanical strength, corrosion resistance, and service life. Nano-coating reinforcement and fully enclosed integrated molding have become mainstream technologies for improving connector protection levels and reliability.

[0003] This technical solution is mainly applicable to industrial automation control, rail transit, engineering machinery, smart agriculture, underwater equipment, and harsh working environments such as high humidity, high salt spray, and strong vibration. It can be widely used in the production and manufacturing of M12 connectors with various structural forms such as wired, non-wired, straight, and bent connectors, meeting the long-term stable operation requirements of high-end equipment.

[0004] Existing M12 connector manufacturing processes often employ a segmented workflow, which commonly suffers from the following technical defects: Coating and molding processes are separated, with molding typically preceding coating. This means the nano-coating cannot cover delicate areas such as pins and inner walls, leading to issues like incomplete coating, poor adhesion, and peeling during use, resulting in waterproofing failure. Injection molding often uses a split-mold structure, creating gaps that hinder true full-coverage waterproofing. Protection levels generally only reach IP67, failing to meet IP68 and higher requirements for long-term underwater and high-salt-spray environments. Pre-treatment, coating, molding, and testing are independent processes, lacking unified intelligent collaborative control. Process parameters cannot be synchronized, easily leading to molding defects, uneven coating thickness, and poor product consistency. Traditional systems have low modularity and poor mold versatility, resulting in high modification costs and low efficiency when changing specifications. Furthermore, limited testing methods prevent simultaneous testing and closed-loop control of dimensions, waterproofing, coating, and electrical performance, leading to low product yield and high production costs.

[0005] Therefore, the present invention provides a nano-coating reinforced waterproof all-in-one molding system for M12 connectors. Summary of the Invention

[0006] In order to overcome the shortcomings of the prior art, at least one technical problem raised in the background art is solved.

[0007] The technical solution adopted by the present invention to solve its technical problem is as follows: The present invention provides a nano-coating reinforced M12 connector waterproof full-coverage integrated molding system, which includes a substrate pretreatment module, a nano-coating embedded application module, a waterproof full-coverage integrated molding module, a precision detection module, a finished product packaging module, and a linkage control module for coordinated control of all the above modules; each module adopts a standardized interface design and can be independently debugged and flexibly combined.

[0008] Preferably, the substrate pretreatment module adopts a pretreatment structure that combines plasma activation and degreasing, including a plasma activation unit, a degreasing unit, a substrate positioning fixture, and a drying unit connected in sequence; the plasma activation unit uses low-temperature plasma technology; the degreasing unit uses an environmentally friendly, VOC-free degreasing agent to remove oil and dust from the substrate surface; the drying unit uses hot air circulation drying, the temperature can be precisely adjusted as needed, and the drying time is automatically matched with the substrate size.

[0009] Preferably, the nano-coating embedded application module is an embedded structure, embedded in the front end of the waterproof all-in-one molding process, including a nano-coating storage unit, a precise application unit, a coating curing unit, and an online thickness detection unit; the nano-coating is a two-component composite structure, with a hydrophobic nano-coating as the bottom layer and a wear-resistant and corrosion-resistant nano-coating as the surface layer; the precise application unit adopts high-precision spraying technology; the coating curing unit adopts room temperature rapid curing technology; and the online thickness detection unit can monitor the coating thickness in real time.

[0010] Preferably, the waterproof, fully enclosed, integrated molding module adopts a one-time injection molding, fully enclosed, seamless molding structure, including a customized integrated mold, an intelligent injection molding unit, a stress dispersion unit, and a seamless bonding unit. The customized integrated mold has high positioning accuracy, eliminating traditional mold seams. The intelligent injection molding unit uses engineering plastics compatible with M12 connectors, and the injection parameters can be automatically adjusted according to the M12 connector specifications. The stress dispersion unit is located at the transition between the connector and the wire harness. The seamless bonding unit achieves a gapless and tight bond between the molding layer and the nano-coating through precise control of injection parameters, forming a double waterproof barrier.

[0011] Preferably, the linkage control module adopts intelligent control technology as the core of the system control, including a parameter coordination and adjustment unit, a real-time data acquisition unit, a fault early warning unit, and a remote debugging and maintenance unit. The parameter coordination and adjustment unit can realize the linkage and matching of process parameters of each module, automatically adjust the nano-coating parameters according to the substrate pretreatment status, and adjust the injection molding parameters according to the coating effect. The real-time data acquisition unit can record the operating parameters of each module and the product qualification rate, forming a traceable production ledger. The fault early warning unit monitors the operating status of the module through sensors, automatically warns of abnormal situations, and provides solutions. The remote debugging and maintenance unit can realize remote debugging and fault diagnosis.

[0012] Preferably, the precision testing module adopts a multi-dimensional synchronous testing structure, including a dimensional precision testing unit, a coating performance testing unit, a waterproof performance testing unit, an electrical performance testing unit, and an automatic sorting unit. The dimensional precision testing unit uses high-precision visual inspection technology, achieving high testing accuracy. The coating performance testing unit can test the wear resistance and corrosion resistance of the nano-coating. The waterproof performance testing unit uses an IP68+ waterproof rating test to monitor for water leakage in real time and test insulation performance. The electrical performance testing unit tests the connector contact resistance and signal transmission performance. The automatic sorting unit grades and sorts the products according to the test results and feeds back unqualified products to the corresponding module for rework.

[0013] Preferably, the finished product packaging module adopts a modular design, allowing for flexible selection of packaging methods according to needs. This includes a customized packaging unit, a secondary waterproof reinforcement unit, a label printing unit, and a modular packaging unit. The customized packaging unit employs a dual waterproof packaging structure to adapt to the packaging requirements of different types of M12 connectors. The secondary waterproof reinforcement unit provides secondary waterproofing to the packaging interface, forming multiple waterproof barriers with the nano-coating and molding layer. The label printing unit can print relevant product traceability information. The modular packaging unit allows for selection of appropriate packaging methods based on production batch size, and the packaging materials possess moisture-proof properties.

[0014] Preferably, the customized integrated mold adopts a modular design, which allows for quick cavity replacement and adapts to the production of M12 connectors of different specifications without the need to replace the entire mold.

[0015] Preferably, the system can achieve IP68+ waterproof protection for M12 connectors, and has excellent wear resistance, corrosion resistance, vibration resistance and stable electrical performance, making it suitable for harsh industrial environments.

[0016] The beneficial effects of this invention are as follows: 1. The present invention discloses a nano-coating reinforced M12 connector waterproof all-enclosed integrated molding system. By embedding the nano-coating application into the waterproof all-enclosed integrated molding process, and adopting a synergistic structure of plasma activation pretreatment, two-component nano-composite coating, and one-time injection molding seamless molding, it solves the problems of incomplete coating coverage, poor adhesion, easy peeling, and unreliable waterproof sealing caused by molding before coating in the prior art. At the same time, it eliminates the seam gap caused by mold splitting, significantly improving the waterproof level and structural stability of the connector.

[0017] 2. The nano-coating reinforced M12 connector waterproof all-enclosed integrated molding system of the present invention, through modular integrated design and intelligent linkage control, and by realizing multi-dimensional synchronous detection and closed-loop production control, solves the problems of independent processes, mismatched parameters, poor versatility, single detection, low product consistency and low pass rate of the existing production system, greatly improves production efficiency, reduces transformation costs, and makes the system adaptable to the mass production of high-quality M12 connectors in harsh industrial scenarios. Attached Figure Description

[0018] The invention will now be further described with reference to the accompanying drawings.

[0019] Figure 1 This is a flowchart of the overall closed-loop production process of the system in this invention; Figure 2 This is a detailed flowchart of the substrate pretreatment module in this invention; Figure 3 This is a detailed flowchart of the nano-coating embedded application module in this invention; Figure 4 This is a flowchart of the waterproof, fully-enclosed, integrated molding module of the present invention; Figure 5 This is a flowchart of the multi-dimensional precision detection module in this invention; Figure 6 This is a flowchart of the closed-loop process for finished product packaging and linkage control in this invention. Detailed Implementation

[0020] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0021] like Figures 1 to 6As shown in the embodiment of the present invention, a nano-coating reinforced M12 connector waterproof all-encapsulation integrated molding system includes a substrate pretreatment module, a nano-coating embedded application module, a waterproof all-encapsulation integrated molding module, a precision testing module, and a finished product packaging module, which are sequentially linked and connected, as well as a linkage control module for coordinated control of all the above modules. Each module adopts a standardized interface design, which can be independently debugged and flexibly combined. Through the coordinated linkage of each module, a closed-loop production of M12 connectors is achieved from "substrate pretreatment - nano-coating reinforcement - waterproof all-encapsulation molding - precision testing - finished product packaging", breaking the traditional technical mode of "molding first, coating later" and "multiple modules operating independently", and adapting to the production needs of M12 connectors of different specifications (including but not limited to straight, bent, wired, and non-wired). The "embedded" in the nano-coating embedded application module refers to embedding the nano-coating application process into the front end of the waterproof all-encapsulation integrated molding process, realizing a seamless connection between nano-coating application and waterproof all-encapsulation molding.

[0022] like Figures 1 to 6 As shown, the substrate pretreatment module adopts a pretreatment structure that combines plasma activation and degreasing, including a plasma activation unit, a degreasing unit, a substrate positioning fixture, and a drying unit connected in sequence. The plasma activation unit uses low-temperature plasma technology, with an operating temperature not exceeding 100℃, and can perform all-round activation on fine parts such as M12 connector pins and inner walls, improving the surface roughness of the substrate to 0.3-0.5. This enhances the adhesion of subsequent nano-coatings. The degreasing unit uses an environmentally friendly, VOC-free degreasing agent to remove oil and dust from the substrate surface through spraying or immersion, leaving no residue and causing no secondary pollution. The drying unit uses hot air circulation drying, and the temperature can be precisely adjusted as needed within the range of 40-100℃. The drying time is automatically matched with the substrate size to ensure that the substrate surface is dry and free of moisture.

[0023] like Figures 1 to 6 As shown, the embedded application module for the nano-coating is an embedded structure, integrated into the front end of the waterproof all-encompassing integrated molding process, achieving seamless connection between "coating-molding". It includes a nano-coating storage unit, a precise application unit, a coating curing unit, and an online thickness detection unit. The nano-coating is a two-component composite structure, with a hydrophobic nano-coating as the bottom layer and a wear-resistant and corrosion-resistant nano-coating as the surface layer, with a total thickness of 0.2-4 mm. The precision coating unit employs high-precision spraying technology, achieving a coating accuracy of no less than ±0.1. It can perform all-round, no-dead-angle coating on connector pins, inner walls, and outer shell connections; the coating curing unit adopts room temperature rapid curing technology, with a curing temperature of 20-35℃ and a curing time of no more than 10 minutes, without the need for high-temperature baking, avoiding coating aging and substrate deformation; the online thickness detection unit monitors the coating thickness in real time through optical detection, and when the coating thickness is detected to exceed the preset range, the unqualified signal is fed back to the substrate pretreatment module to form a closed-loop control.

[0024] like Figures 1 to 6 As shown, the waterproof, fully enclosed integrated molding module adopts a one-time injection molding seamless structure, breaking the traditional "separate molding and secondary assembly" process. It includes a customized integrated mold, an intelligent injection molding unit, a stress dispersion unit, and a seamless bonding unit. The customized integrated mold has a positioning accuracy of no less than ±0.1mm, eliminating traditional mold seams and preventing water seepage at the seams. The intelligent injection molding unit uses engineering plastics (including but not limited to PA66+glass fiber modified material and PPS material) adapted to M12 connectors. The injection parameters can be automatically adjusted according to the M12 connector specifications to ensure that there are no defects such as bubbles, shrinkage cavities, and cracks after injection molding. The stress dispersion unit adopts a gradient buffer structure and is set at the transition between the connector and the wire harness to reduce stress concentration during vibration and extend the bending life of the connector. The seamless bonding unit achieves a gapless and tight bonding between the molding layer and the nano-coating by precisely controlling the injection speed and injection pressure, forming a double waterproof barrier of "nano-coating + molding layer".

[0025] like Figures 1 to 6 As shown, the linkage control module adopts intelligent control technology (including but not limited to PLC + IoT control technology) as the core of the system control, including a parameter coordination and adjustment unit, a real-time data acquisition unit, a fault early warning unit, and a remote debugging and maintenance unit. The parameter coordination and adjustment unit realizes the linkage matching of process parameters of each module through a preset control algorithm, automatically adjusts the nano-coating parameters according to the substrate pretreatment status, and adjusts the injection molding parameters according to the coating effect, avoiding human operation errors. The real-time data acquisition unit collects the operating parameters of each module and the product qualification rate through sensors, forming a traceable production ledger with a data storage time of no less than one year. The fault early warning unit monitors the module operating status in real time through sensors. When abnormal parameters or equipment failures occur, it automatically issues audible and visual warnings and displays the fault location and solution on the control interface. The remote debugging and maintenance unit realizes remote parameter debugging and fault diagnosis through network communication, without the need for on-site operation.

[0026] like Figures 1 to 6As shown, the precision testing module adopts a multi-dimensional synchronous testing structure, including a dimensional accuracy testing unit, a coating performance testing unit, a waterproof performance testing unit, an electrical performance testing unit, and an automatic sorting unit. The dimensional accuracy testing unit uses high-precision visual inspection technology, with a testing accuracy of no less than ±0.02mm, and can detect key parameters such as connector pin spacing and shell dimensions. The coating performance testing unit can test the wear resistance and corrosion resistance of the nano-coating through friction testing, adhesion testing, and salt spray testing. The waterproof performance testing unit adopts an IP68+ waterproof rating test, simulating scenarios such as immersion in 1.5 meters of water and high-pressure spraying, monitoring for water leakage in real time, and testing that the connector insulation resistance is no less than 100 Ω. The electrical performance testing unit detects the connector contact resistance and signal transmission attenuation rate to ensure stable contact resistance and no significant signal attenuation. The automatic sorting unit automatically sorts qualified and unqualified products (classified by fault type) according to the test results, and unqualified products are fed back to the corresponding module for rework.

[0027] like Figures 1 to 6 As shown, the finished product packaging module adopts a modular design, allowing for flexible selection of packaging methods according to customer needs. It includes a customized packaging unit, a secondary waterproof reinforcement unit, a label printing unit, and a modular packaging unit. The customized packaging unit employs a dual waterproof packaging structure of a waterproof sealing sleeve and sealant, adapting to the packaging requirements of different types (with and without wires) of M12 connectors. The secondary waterproof reinforcement unit uses nano-waterproof spray or waterproof sealant to provide secondary waterproofing to the packaging interface, forming a triple or higher waterproof barrier with the nano-coating and molding layer. The label printing unit can print product specifications, production batches, protection levels, and other relevant traceability information, facilitating product lifecycle traceability. The modular packaging unit can be selected for individual packaging or batch packaging based on production volume. The packaging materials are environmentally friendly and moisture-proof, effectively preventing product moisture and damage during transportation.

[0028] like Figures 1 to 6 As shown, the customized integrated mold adopts a modular design, with the cavity and the mold body being detachably connected. Different cavities of different specifications can be quickly replaced to adapt to the production of M12 connectors of different specifications. There is no need to replace the entire mold, reducing production modification costs and mold change time.

[0029] like Figures 1 to 6As shown, the system can achieve IP68+ waterproof protection for M12 connectors (no water leakage after immersion in 1.5 meters of water for 24 hours), and has excellent wear resistance, corrosion resistance, and vibration resistance. The product has a mating life of no less than 50,000 cycles, a bending life of no less than 1 million cycles, and can withstand high and low temperatures from -50℃ to 150℃. It can be adapted to harsh industrial scenarios such as underwater, high humidity, and high salt spray. The M12 connectors produced by the system have stable electrical performance, low contact resistance, and low signal transmission attenuation rate.

[0030] Example 1 Compatible with M12 straight connectors with wires, suitable for typical industrial applications. System Configuration This embodiment employs the nano-coating-reinforced, fully enclosed, integrated molding system for the M12 connector waterproofing with a complete enclosure, as described in claims 1-9. The configuration of each module is as follows: Substrate pretreatment module: The plasma activation unit operates at 80℃, the degreasing unit uses environmentally friendly VOC-free degreasing agent and removes oil through high-pressure micro-mist spraying, and the drying unit operates at 60℃ for 5 minutes. Nanocoating embedded application module: The bottom layer of the nanocoating is a silicon-based hydrophobic nanocoating (0.5 mm thick). The surface layer is a DLC nano-coating (thickness 2). The precision coating unit employs piezoelectric valve spraying technology, achieving a coating accuracy of ±0.08. The curing unit has a curing temperature of 25℃ and a curing time of 5 minutes. The online thickness detection unit uses an optical detection method. Waterproof all-in-one molding module: Customized integrated mold positioning accuracy ±0.08mm, intelligent injection unit uses PA66+30% glass fiber modified material, injection inlet temperature 230℃, injection pressure 6MPa, holding pressure time 45 seconds, stress dispersion unit is a gradient arc buffer structure; Linkage control module: adopts PLC + IoT control technology, data storage time is 1.5 years, and the fault early warning method is audible and visual warning; Precision testing module: Dimensional accuracy testing unit with a detection accuracy of ±0.01mm; coating performance testing including a 500-hour salt spray test; waterproof performance testing simulating immersion in 1.5 meters of water for 24 hours; insulation resistance testing ≥100Ω. ; Finished product packaging module: It adopts double sealing with waterproof sealing sleeve + sealant, and secondary waterproof reinforcement uses nano waterproof spray. The packaging method is individual moisture-proof packaging.

[0031] Implementation process The substrate material (PA66 + 30% glass fiber) of the M12 straight connector with wire was placed in the substrate pretreatment module and sequentially underwent plasma activation (activation time 30s), high-pressure micro-mist spray degreasing (time 15s), and hot air circulation drying (temperature 60℃, time 5min). After pretreatment, the surface roughness of the substrate was 0.4. Subsequently, the nano-coating embedded application module was used to apply the two-component nano-coating from all directions via a 360° rotating nozzle. After coating, it was cured at room temperature (25°C) for 5 minutes, and online thickness detection confirmed a total coating thickness of 2.5 mm. After passing the initial inspection, the product enters the waterproof all-in-one molding module, where it is injection molded in one go using a customized integrated mold. The injection parameters are adjusted according to the above configuration. After molding, the stress is reduced at the transition point by a stress dispersion unit. The molded product then enters the precision testing module, where dimensional accuracy, coating performance, waterproof performance, and electrical performance are tested simultaneously. Qualified products enter the finished product packaging module, where they undergo double packaging, secondary waterproof spraying, and label printing. Each product is then individually packaged with moisture-proof packaging. Unqualified products are fed back to the corresponding module for rework. The entire process achieves closed-loop production.

[0032] Implementation effect The manufactured M12 straight connector with wire has a waterproof rating of IP68+ (no water leakage after immersion in 1.5 meters of water for 24 hours) and an insulation resistance of 120Ω. The nano-coating exhibits excellent adhesion, showing no peeling after 1000 friction tests and no corrosion after 500 hours of salt spray testing; it has a plug-in life of 60,000 cycles, a bending life of 1.2 million cycles, and can withstand high and low temperatures ranging from -50℃ to 150℃; the product qualification rate is 99.7%, production efficiency is increased by 45% compared to traditional segmented production, and there are no pollutant emissions, meeting environmental protection standards.

[0033] Example 2 Compatible with M12 elbow connectors without cables, suitable for high salt spray industrial environments. System Configuration This embodiment is based on the system described in claims 1-9, with optimized configuration for high salt spray scenarios, as follows: Substrate pretreatment module: The plasma activation unit operates at a temperature of 90℃ and an activation time of 40s. The degreasing unit uses an environmentally friendly, VOC-free degreasing agent and performs immersion degreasing (time 20s). The drying unit operates at a temperature of 70℃ and a drying time of 6 minutes to ensure that there are no residual impurities on the substrate surface. Nanocoating embedded application module: The bottom layer of the nanocoating is a fluorine-based hydrophobic nanocoating (thickness 0.8 mm). The surface layer is a DLC nano-coating (thickness 3). Coating accuracy ±0.05 The curing time is 8 minutes, and the online thickness detection unit provides real-time feedback on the coating thickness to ensure no missed coating. Waterproof all-in-one molding module: Customized integrated mold positioning accuracy ±0.05mm, intelligent injection unit uses PPS high temperature resistant material, injection inlet temperature 240℃, injection pressure 8MPa, holding pressure time 60 seconds, stress dispersion unit is a gradual stepped buffer structure; Precision testing module: Coating performance testing adds 1000 hours of salt spray test, waterproof performance testing simulates immersion in 2 meters of water for 24 hours, and insulation resistance testing ≥150 Ω. ; Finished product packaging module: It adopts double packaging of waterproof sealing sleeve + high temperature resistant sealant, and secondary waterproof reinforcement is achieved by applying waterproof sealant. The packaging material is salt spray resistant and moisture resistant packaging.

[0034] Implementation process The substrate material (PPS) of the M12 non-wire elbow connector is placed in the substrate pretreatment module and sequentially undergoes plasma activation, immersion degreasing, and hot air drying. After pretreatment, the surface roughness of the substrate is 0.5. The nano-coating is applied via an embedded coating module, completing the all-around application of the two-component nano-coating. After curing at room temperature for 8 minutes, the total coating thickness is measured online to be 3.8 mm. After passing the test, the product enters the waterproof all-in-one molding module, where it is seamlessly molded in one injection. After molding, it undergoes multi-dimensional testing by the precision testing module, with a focus on passing the 1000-hour salt spray test and the 2-meter water depth waterproof test. Qualified products enter the finished product packaging module, where they undergo double packaging, secondary waterproof coating, and label printing. They are then packaged in salt spray and moisture-proof packaging to achieve closed-loop production.

[0035] Implementation effect The manufactured M12 non-wired elbow connector has a waterproof rating of IP68+ (no water leakage after immersion in 2 meters of water for 24 hours) and an insulation resistance of 160 ohms. No corrosion or rust was observed during a 1000-hour salt spray test, and the nano-coating did not peel off. The insertion and removal life is 55,000 cycles, the bending life is 1.1 million cycles, and the high and low temperature range is -50℃ to 150℃, making it suitable for high salt spray industrial scenarios. The product qualification rate is 99.6%, and the production efficiency is 40% higher than that of traditional processes, meeting the needs of harsh environments.

[0036] Example 3 Compatible with small M12 connectors with wires, for underwater equipment applications. System Configuration This embodiment is based on the system described in claims 1-9, with optimized configuration for underwater equipment scenarios (high waterproofing requirements), as follows: Substrate pretreatment module: The plasma activation unit operates at a temperature of 70℃ and an activation time of 25s; the degreasing unit uses high-pressure micro-mist spraying to remove oil; and the drying unit operates at a temperature of 50℃ and a drying time of 4 minutes to ensure that the substrate surface is dry and free of moisture. Nanocoating Embedded Application Module: The bottom layer of the nanocoating is a silicon-based hydrophobic nanocoating (thickness 1). The surface layer is a DLC nano-coating (thickness 2). Coating accuracy ±0.06 Curing time is 4 minutes, with special emphasis on coating fine areas such as pins and inner walls; Waterproof all-in-one molding module: Customized integrated mold positioning accuracy ±0.07mm, intelligent injection unit uses PA66+40% glass fiber modified material, injection inlet temperature 220℃, injection pressure 5MPa, holding pressure time 30 seconds, seamless bonding unit optimizes injection speed to ensure no gap between molding layer and nano coating; Precision testing module: Waterproof performance testing simulates immersion in 3 meters of water for 24 hours; insulation resistance testing ≥200 Ω. Electrical performance testing focuses on underwater signal transmission attenuation rate; Finished product packaging module: It adopts double packaging of waterproof sealing sleeve + waterproof potting compound, and secondary waterproof reinforcement is achieved by spraying nano waterproof spray twice to form a four-fold waterproof barrier. It is packaged in a waterproof sealed box.

[0037] Implementation process The substrate material (PA66 + 40% glass fiber) for small M12 wire connectors is placed in the substrate pretreatment module, where plasma activation, high-pressure spray degreasing, and hot air drying are performed. After pretreatment, the surface roughness of the substrate is 0.3. The nano-coating is applied into the embedded coating module, using a 360° rotating nozzle to apply the coating to delicate areas such as pins and inner walls. After curing at room temperature for 4 minutes, the total coating thickness is measured online. After passing the test, the product enters the waterproof all-in-one molding module for seamless one-time injection molding. After molding, it passes through the precision testing module to complete the waterproof test at a depth of 3 meters, the insulation resistance test, and the underwater signal transmission test. Qualified products enter the finished product packaging module, where they undergo double packaging, secondary waterproof spraying (2 times), and label printing before being packaged in a waterproof sealed box, thus achieving closed-loop production.

[0038] Implementation effect The manufactured miniature M12 connectors with wires have a waterproof rating of IP68+ (no water leakage after immersion in 3 meters of water for 24 hours) and an insulation resistance of 220 ohms. Underwater signal transmission attenuation rate ≤0.5%, stable electrical performance; strong nano-coating adhesion, showing no peeling after 1500 friction tests; 58,000 insertion / extraction cycles, 1.3 million bending cycles, high and low temperature resistance range -50℃ to 150℃, fully suitable for underwater equipment scenarios; 99.8% product qualification rate, production efficiency increased by 50% compared to traditional processes. Comparative Example 1 Traditional segmented production systems involve molding first and then coating. System Configuration The existing traditional production system is divided into segmented operations: "substrate cleaning - injection molding - nano-coating - testing - packaging". There is no linkage control module, and each module operates independently. Substrate cleaning is carried out using chemical cleaning (with VOC emissions). Injection molding uses a split molding process, which results in seams. Nano-coating is applied separately after molding, using a single silicon-based nano-coating. Testing is carried out in segments (first size testing, then waterproof testing). There is no secondary waterproof reinforcement.

[0039] Implementation process The M12 straight connector substrate (PA66 + 30% glass fiber) is chemically cleaned and naturally dried before being molded in a parting injection mold. After molding, it is manually transferred to a nano-coating equipment to be coated with a single silicon-based nano-coating (thickness 2). UV curing (80℃, 30min), followed by dimensional inspection, waterproofing inspection, and electrical performance inspection. Qualified products are simply packaged, while unqualified products are manually sorted, without closed-loop control.

[0040] Implementation effect The manufactured M12 connectors have a waterproof rating of only IP67 (slight water leakage occurs after immersion in 1 meter of water for 24 hours) and an insulation resistance of 80 ohms. The nano-coating coverage is incomplete, with some missed areas at the pins. The coating peeled off after 500 friction tests, and slight corrosion was observed after 500 hours of salt spray testing. The insertion and extraction life is 30,000 cycles, and the bending life is 600,000 cycles. The product qualification rate is 95.2%, but the production efficiency is low (45% lower than in Example 1). Chemical cleaning produces VOC emissions, which does not meet environmental standards. There are seams in the molded parts, which can easily lead to water leakage.

[0041] Comparative Example 2 No embedded coating, only a single molded waterproofing system System Configuration Using existing waterproof molding systems, without an embedded nano-coating module, it only has the functions of simple substrate cleaning, injection molding, testing, and packaging; substrate cleaning adopts sandblasting pretreatment; injection molding is a split mold forming, without a stress dispersion unit; testing is a single waterproof test; packaging is ordinary packaging, without secondary waterproof reinforcement.

[0042] Implementation process The M12 non-wire elbow connector substrate (PPS material) is pre-treated by sandblasting and then molded in a split injection mold. After molding, it undergoes a simple waterproof test (IP67 level). Qualified products are packaged normally, while unqualified products are reworked manually. There is no linkage control or closed-loop regulation.

[0043] Implementation effect The manufactured M12 connectors have an IP67 waterproof rating (no water leakage after immersion in 1 meter of water for 24 hours, water leakage occurs after immersion in 2 meters of water), and an insulation resistance of 60 ohms. Without nano-coating protection, the surface is easily worn and corroded, and obvious rust appeared after 500 hours of salt spray testing; the insertion and removal life is 25,000 times, the bending life is 500,000 times, and the shell is prone to cracking due to vibration; the product qualification rate is 94.8%, the production efficiency is low (40% lower than Example 2), the applicable scenarios are limited, and it cannot meet the needs of harsh scenarios such as high salt spray and underwater.

[0044] Embodiments 1-3 of this invention employ the integrated molding system described in the claims. Through the innovative design of "embedded coating + seamless molding + modular linkage," compared with Comparative Example 1 (traditional segmented system) and Comparative Example 2 (system without embedded coating), it shows significant improvements in waterproof protection level, nano-coating performance, product lifespan, production efficiency, environmental friendliness, and scene adaptability. The specific advantages are as follows: Waterproof performance: The waterproof rating of the examples all reaches IP68+, which is much higher than the IP67 of the comparative example, and can be used in harsh environments such as underwater and high humidity. Coating performance: The example uses a two-component nano-coating, which has comprehensive coverage, strong adhesion, and excellent wear and corrosion resistance. In contrast, the coating of Comparative Example 1 is incomplete and easy to peel off, while Comparative Example 2 has no coating protection. Product lifespan: The example shows a insertion / removal lifespan of ≥50,000 cycles and a bending lifespan of ≥1 million cycles, which is significantly higher than the comparative examples (≤30,000 cycles and ≤600,000 cycles). Production efficiency and pass rate: The pass rate of the product in the example is ≥99.6%, and the production efficiency is 40%-50% higher than that of the traditional process, while the pass rate of the comparative example is ≤95.2%, which is inefficient; Environmental friendliness: The example uses VOC-free degreasing and room temperature curing, with no pollutant emissions, which meets environmental standards, while Comparative Example 1 uses chemical cleaning, which emits VOCs. Scene adaptability: The example can be adapted to different specifications of connectors such as straight / bent, wired / unwired, as well as harsh scenes such as high salt spray and underwater, while the comparative example has limited scene adaptability.

[0045] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention.

Claims

1. A nano-coating-reinforced, waterproof, fully enclosed, integrated molding system for M12 connectors, characterized in that: It includes a substrate pretreatment module, a nano-coating embedded application module, a waterproof all-in-one molding module, a precision detection module, a finished product packaging module, and a linkage control module that coordinates the control of all the above modules; each module adopts a standardized interface design, which can be independently debugged and flexibly combined; The substrate pretreatment module adopts a pretreatment structure that combines plasma activation and degreasing. The nano-coating embedded application module is an embedded structure, embedded in the front end of the waterproof full-coverage integrated molding process; The waterproof, fully enclosed, integrated molding module adopts a one-time injection molding, fully enclosed, seamless molding structure. The linkage control module adopts intelligent control technology as the core of the system control; The accuracy detection module adopts a multi-dimensional synchronous detection structure, including a dimensional accuracy detection unit, a coating performance detection unit, a waterproof performance detection unit, an electrical performance detection unit, and an automatic sorting unit; The finished product packaging module adopts a modular design, and the packaging method can be flexibly selected according to the needs, including customized packaging unit, secondary waterproof reinforcement unit, marking printing unit and modular packaging unit.

2. The nano-coating reinforced waterproof all-enclosed integrated molding system for M12 connectors according to claim 1, characterized in that: The substrate pretreatment module includes a plasma activation unit, an oil removal unit, a substrate positioning fixture, and a drying unit connected in sequence. The plasma activation unit uses low-temperature plasma technology. The oil removal unit uses an environmentally friendly, VOC-free oil remover to remove oil and dust from the substrate surface. The drying unit uses hot air circulation drying, and the temperature can be precisely adjusted as needed. The drying time is automatically matched with the substrate size.

3. The nano-coating reinforced waterproof all-enclosed integrated molding system for an M12 connector according to claim 1, characterized in that: The nano-coating embedded application module includes a nano-coating storage unit, a precise application unit, a coating curing unit, and an online thickness detection unit; the nano-coating is a two-component composite structure, with a hydrophobic nano-coating as the bottom layer and a wear-resistant and corrosion-resistant nano-coating as the surface layer. The precision coating unit employs high-precision spraying technology; the coating curing unit employs room-temperature rapid curing technology; and the online thickness detection unit can monitor the coating thickness in real time.

4. The nano-coating reinforced waterproof all-enclosed integrated molding system for M12 connectors according to claim 1, characterized in that: The waterproof, fully enclosed integrated molding module includes a customized integrated mold, an intelligent injection molding unit, a stress dispersion unit, and a seamless bonding unit. The customized integrated mold has high positioning accuracy and eliminates traditional mold seams. The intelligent injection molding unit uses engineering plastics compatible with M12 connectors, and the injection parameters can be automatically adjusted according to the M12 connector specifications. The stress dispersion unit is located at the transition between the connector and the wire harness. The seamless bonding unit achieves a gapless and tight bond between the molding layer and the nano-coating by precisely controlling the injection molding parameters, forming a double waterproof barrier.

5. The nano-coating reinforced waterproof all-enclosed integrated molding system for an M12 connector according to claim 1, characterized in that: The linkage control module includes a parameter coordination and adjustment unit, a real-time data acquisition unit, a fault early warning unit, and a remote debugging and maintenance unit; The parameter coordination and control unit can realize the linkage and matching of process parameters of each module, automatically adjust the nano-coating parameters according to the substrate pretreatment state, and adjust the injection molding parameters according to the coating effect; the real-time data acquisition unit can record the operating parameters of each module and the product qualification rate, forming a traceable production ledger. The fault early warning unit monitors the operating status of the module through sensors, automatically issues early warnings for abnormal situations, and provides solutions; the remote debugging and maintenance unit can realize remote debugging and fault diagnosis in different locations.

6. The nano-coating reinforced waterproof all-enclosed integrated molding system for an M12 connector according to claim 1, characterized in that: The dimensional accuracy detection unit adopts high-precision visual inspection technology, ensuring high detection accuracy; the coating performance detection unit can detect the wear resistance and corrosion resistance of the nano-coating; the waterproof performance detection unit adopts IP68+ waterproof testing, monitors for water leakage in real time, and detects insulation performance; the electrical performance detection unit detects the contact resistance and signal transmission performance of the connector; the automatic sorting unit grades and sorts the products according to the detection results, and feeds back unqualified products to the corresponding module for rework.

7. The nano-coating reinforced waterproof all-enclosed integrated molding system for M12 connectors according to claim 1, characterized in that: The customized packaging unit adopts a dual waterproof packaging structure to adapt to the packaging requirements of different types of M12 connectors; the secondary waterproof reinforcement unit performs secondary waterproofing treatment on the packaging interface, forming multiple waterproof barriers with the nano-coating and molding layer; the marking and printing unit can print relevant product traceability information; the modular packaging unit can select the appropriate packaging method according to the production batch, and the packaging material has moisture-proof properties.

8. The nano-coating reinforced waterproof all-enclosed integrated molding system for an M12 connector according to claim 4, characterized in that: The customized integrated mold adopts a modular design, which allows for quick cavity replacement and adapts to the production of M12 connectors of different specifications without the need to replace the entire mold.

9. The nano-coating reinforced waterproof all-enclosed integrated molding system for an M12 connector according to claim 1, characterized in that: The system provides IP68+ waterproof protection for M12 connectors, and features excellent wear resistance, corrosion resistance, vibration resistance, and stable electrical performance, making it suitable for harsh industrial environments.

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