Cable assembly end for injection protection and injection mold thereof

Abstract

The utility model provides an injection molding protection cable assembly end and an injection mold thereof. The cable assembly end comprises a cable, an electric connector, an injection molding inner mold and an injection molding outer mold. Wherein the cable is connected with the electric connector in a crimping or welding manner; the injection molding inner mold is used for realizing at least wrapping and fixed protection of the connecting part of the cable and the electric connector through injection molding; and the injection molding outer mold further realizes wrapping and fixed protection on the cable extending out of the injection molding inner mold, a part of tail covers of the electric connectors and the whole injection molding inner mold through injection molding. According to the cable assembly end head provided by the utility model, the fixation and protection of the cable and the shielding layer of the cable assembly end head are enhanced, the cable assembly is buffered in the bending and swinging process, the quality and the reliability of a product are improved, and the service life of the product is prolonged.

Description

Technical Field

[0001] The utility model relates to the technical field of cable assembly terminal protection, and in particular to an injection-molded protection of a terminal of a cable assembly used for connecting a cable with an electric connector and an injection mold of the terminal. Background Art

[0002] Cable assemblies consist of electrical connectors, cables, shielding layers, sheaths, etc. The electrical connectors are usually connected to the cables by crimping or welding and then protected to form cables to achieve signal transmission, control and electrical connection between electrical equipment.

[0003] At present, with the development of electrical equipment towards high integration and miniaturization, the cable assemblies supporting the equipment are also constantly developing towards miniaturization, modularization, high reliability and long life. However, since the tail cover of the electrical connector used in the cable assembly has no tail clip, the existing heat shrink tubing protection method is difficult to effectively fix and protect the cables and shielding layers at the end of the cable assembly, so it is necessary to adopt additional protection methods to strengthen the protection. At the same time, in actual applications, the cable assemblies supporting the equipment have a high installation density and a small installation space. In addition, during the installation and use process, the electrical connector needs to frequently plug and unplug and drag the tail cable, which can easily cause stress on the solder joints, resulting in quality problems such as broken wires and short circuits, which also puts forward higher protection requirements for the protection of the cable assembly ends. In addition, the bending radius of the cable at the end of the electrical connector in a specific cable assembly is too large, making it difficult to install in the narrow space of the electrical equipment. The cables at the end of the cable assembly need to be bent and tied and strengthened according to the actual use situation. Utility Model Content

[0004] In view of the above-mentioned status and problems existing in the prior art, the utility model provides an injection-molded protective cable assembly end, which strengthens the fixation and protection of the cable and shielding layer at the end of the cable assembly, and at the same time provides a buffering effect for the cable assembly during bending and swinging, thereby improving the quality and reliability of the product and extending the service life of the product. In addition, by performing bending binding and bending injection molding protection on the cables at the electrical connector end of the cable assembly, the problem of the large bending radius of the cables at the electrical connector end of the cable assembly, which makes it difficult to assemble in a small space, is solved.

[0005] To this end, the terminal of the cable assembly of the utility model is preferably protected by injection molding, and a suitable injection molding shape is designed according to the external dimensions, installation space, plug-in and unplugging operation comfort and injection molding processability of the cable assembly terminal, and an injection mold is made for injection molding. Among them, the injection molding adopts the molding method of inner and outer two-layer molds to strengthen the fixation and protection of the cable and shielding layer of the cable assembly terminal; and a draft groove is added to the inner mold so that the outer mold can bite with the inner mold after molding, and the combination of the injection inner mold and the injection outer mold is strengthened; in addition, a mesh tail is added to the outer mold to increase the transition between the injection molded body and the cable, which can enhance the bending life of the cable assembly, reduce the risk of damage caused by frequent plugging and unplugging of the plug, and enable the injection mold to effectively protect the cable assembly terminal and extend the service life of the cable assembly.

[0006] Specifically, the utility model provides an injection-molded protective cable assembly terminal, which includes a cable, an electrical connector, an injection-molded inner mold, and an injection-molded outer mold. The cable is connected to the electrical connector by crimping or welding; the injection-molded inner mold is used to wrap and fix at least the connection between the cable and the electrical connector by injection molding; and the injection-molded outer mold is used to further wrap and fix the cable extending out of the injection-molded inner mold, part of the rear cover of the electrical connector, and the entire injection-molded inner mold by injection molding.

[0007] Preferably, the outer surface of the inner injection mold is provided with a draft groove, so that the outer injection mold can engage with the inner injection mold after molding. More preferably, the draft groove is perpendicular to the extension direction of the inner cavity of the inner injection mold.

[0008] Preferably, the injection mold has a mesh tail at one end extending from the cable, so as to increase the transition between the injection molded colloid and the cable. Preferably, the outer surface of the injection mold is also provided with friction lines.

[0009] Furthermore, in order to solve the problem that there are too many and too dense cables used to transmit signals at the electrical connector end of the cable assembly, the bending radius is too large, and the electrical assembly in a narrow space cannot be satisfied, the cables at the end of the cable assembly are bent and tied and then subjected to bent injection molding. Of course, it is also possible not to perform the bent binding molding, but to perform non-bent binding molding or to perform injection molding of the inner and outer molds after folding. Moreover, for the end of the cable assembly, whether it is bent or non-bent injection molding, preferably, the width of the cable at the end of the cable assembly is required to be smaller than the width of the electrical connector. This also requires that before injection molding, the cables at the end of the cable assembly must first be bent or non-bent according to actual use, and the width of the cable after molding does not exceed the width of the electrical connector. Moreover, preferably, one end of the cable extending from the bent binding molding is perpendicular to the end connected to the electrical connector; or at any desired angle.

[0010] In addition, the utility model also provides an injection mold for the above-mentioned injection-molded protected cable assembly terminal. The mold is divided into a fixed mold (lower mold) and a movable mold (upper mold), and the mold formed by merging the fixed mold and the movable mold includes a positioning plate, a positioning hole, a main flow channel, a branch flow channel, a detachable fixing clamp, a detachable net tail mold, an inner mold main body, and an outer mold main body. The positioning plate is used for inserting and placing the electrical connector terminal during the injection molding process; the detachable fixing clamp is used for gathering and placing the cables extending out of the injection molding inner mold cavity; the detachable net tail mold is used for gathering and placing the cables extending out of the injection molding outer mold cavity and for transition molding between the injection molding outer mold and the cables.

[0011] Preferably, according to the sizes of the inner mold main body part and the outer mold main body part, the inner mold main body part and the outer mold main body part can be arranged on the same mold or on different molds.

[0012] Preferably, the shapes of the inner mold main part and the outer mold main part are set according to the desired outer shapes of the injection inner and outer molds, and are respectively provided with draft bodies and friction bodies for forming the injection shapes of draft grooves and friction lines, so that the injection inner mold and the injection outer mold can be bitten and the friction of the injection outer mold can be increased.

[0013] Preferably, the inner mold body part and the outer mold body part can be set as a curved injection cavity according to actual needs; of course, they can also be set as a non-curved injection cavity form.

[0014] The utility model provides an injection-molded protected cable assembly end. By injection-molding the cable assembly end, the cable and shielding layer of the cable assembly end can be fixed and protected, so that the cable assembly can be buffered during bending and swinging, thereby improving the quality and reliability of the product and extending the service life of the product. At the same time, the cable assembly end is realized by an inner and outer double-layer injection mold. After the injection inner mold is formed, the difficulty of the outer mold can be reduced, and the appearance effect of the entire product after the injection outer mold is formed is enhanced.

[0015] In addition, in order to solve the problem that the bending radius of the cable at the electrical connector end of the cable assembly is too large and cannot meet the electrical assembly requirements in a narrow space, the cable assembly process operability and assembly performance are analyzed, and the cables at the end of the cable assembly are bent and tied. After the bent and tied molding, a bent injection mold with suitable injection thickness, length and shape is designed and manufactured according to the external dimensions of the cable assembly end and the actual installation dimensions of the electrical equipment, so that the injection-molded bent injection body can not only achieve good protection of the docking points and cables, but also meet the actual electrical assembly requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic diagram (partial perspective) of a first embodiment of an injection-molded protective cable assembly end of the utility model.

[0017] Figure 2 yes Figure 1 A schematic diagram (partial perspective) of an injection molded inner mold of a first embodiment of an injection molded protective cable assembly terminal of the utility model is shown.

[0018] Figure 3 yes Figure 1 A schematic diagram of an upper mold (with a fixing clip and a mesh tail) of an injection mold of a first embodiment of an injection-molded protective cable assembly terminal of the utility model is shown.

[0019] Figure 4 yes Figure 1 A schematic diagram of a lower mold (with a fixing clip and a mesh tail) of an injection mold of a first embodiment of an injection-molded protective cable assembly terminal of the utility model is shown.

[0020] Figure 5 yes Figure 1 A three-dimensional schematic diagram of a positioning plate in an injection mold of a first embodiment of an injection-molded protective cable assembly terminal of the utility model is shown.

[0021] Figure 6 yes Figure 1 A three-dimensional schematic diagram of a fixing clip (half) in an injection mold of a first embodiment of an injection-molded protective cable assembly terminal of the utility model is shown.

[0022] Figure 7 yes Figure 1 A three-dimensional schematic diagram of a mesh tail mold (half) in an injection mold of a first embodiment of an injection-molded protective cable assembly terminal of the utility model is shown.

[0023] Figure 8 It is a schematic diagram (partial perspective) of a second embodiment of an injection-molded protective cable assembly terminal of the utility model.

[0024] Fig. 9 yes Figure 8 A schematic diagram of an upper mold of an inner mold in an injection mold of a second embodiment of an injection-molded protective cable assembly terminal of the utility model is shown.

[0025] Fig.10 yes Figure 8 A schematic diagram of the lower mold of the inner mold in the injection mold of the second embodiment of an injection-molded protective cable assembly terminal of the utility model is shown.

[0026] Fig.11 yes Figure 8 A schematic diagram of an upper mold of an outer mold in an injection mold of a second embodiment of an injection-molded protective cable assembly terminal of the utility model is shown.

[0027] Fig.12 yes Figure 8 A schematic diagram of the lower mold of the outer mold in the injection mold of the second embodiment of an injection-molded protective cable assembly terminal of the utility model is shown.

[0028] Among them, 1. cable; 2. electrical connector; 3. injection molding inner mold; 4. injection molding outer mold; 5. net tail; 6. tail cover; 7. demolding groove; 8. friction pattern; 11. positioning plate; 12. positioning hole; 13. main flow channel; 14. branch flow channel; 15. fixing clip; 16. net tail mold; 17. inner mold body; 18. outer mold body; 19. demolding body; 20. friction body; 21. cable; 22. electrical connector; 23. injection molding inner mold; 24. injection molding outer mold; 25. net tail; 26. friction pattern; 27. demolding groove; 31. positioning plate; 32. positioning hole; 33. main flow channel, 34. branch flow channel; 35. fixing clip; 36. net tail mold; 37. inner mold body; 38. outer mold body; 39. demolding body; 40. friction body. DETAILED DESCRIPTION

[0029] The specific implementation methods of the utility model are further described below in conjunction with the examples. The following examples are only used to more clearly illustrate the technical solutions of the utility model, and cannot be used to limit the protection scope of the utility model; ordinary technicians in the relevant technical field can also make various changes and modifications without departing from the spirit and scope of the utility model, so all equivalent technical solutions also belong to the scope of the utility model, and the patent protection scope of the utility model should be defined by the claims.

[0030] Embodiment 1

[0031] See also Figure 1-2 The utility model first provides an injection-molded protective cable assembly end, which does not involve the need for curved binding. The cable assembly end includes a cable 1, an electrical connector 2, an injection-molded inner mold 3 and an injection-molded outer mold 4. The cable 1 is connected to the electrical connector 2 by crimping or welding. First, the injection-molded inner mold 3 is used to achieve at least the connection between the cable 1 and the rear cover 6 of the electrical connector 2 (see Figure 2 ) is wrapped and fixedly protected. Then, the outer injection mold 4 further wraps and fixes the cable 1 extending out of the inner injection mold 3, part of the tail cover 6 and the entire inner injection mold 3 through injection molding. Figure 2 The outer surface of the injection inner mold 3 is provided with a draft groove 7, so that the injection outer mold 4 can be engaged with the injection inner mold 3 after molding.

[0032] Preferably, the injection outer mold 4 also has a mesh tail 5 at the lower end to increase the transition between the injection molded body and the cable 1. Preferably, the outer surface of the injection outer mold 4 is also provided with friction lines 8.

[0033] In addition, the width of the cable 1 at the end of the cable assembly is required to be smaller than the width of the electrical connector 2; this also requires that before injection molding, the cable 1 at the end of the cable assembly must first be bundled and molded (no bending requirements are involved in this example), and the width of the cable after molding generally does not exceed the width of the electrical connector 2.

[0034] Furthermore, this embodiment also provides an injection mold for the cable assembly terminal with the above-mentioned injection molding protection. Figure 3-7 The mold is divided into a lower mold and an upper mold, and the combined mold includes a positioning plate 11, a positioning hole 12, a main flow channel 13, a branch flow channel 14, a detachable fixing clip 15, a detachable net tail mold 16, an inner mold body 17 and an outer mold body 18. Among them, the positioning plate 11 is used for inserting and placing the end of the electric connector 2 during the injection molding process; the fixing clip 15 is used for collecting and placing the cables extending out of the cavity of the injection inner mold; the net tail mold 16 is used for collecting and placing the cables 1 extending out of the cavity of the injection outer mold 4 and for transition molding between the injection outer mold 4 and the cables 1. Preferably, the inner mold body 17 and the outer mold body 18 are respectively provided with a draft body 19 and a friction body 20, which are used to form the injection shape of the draft groove 7 and the friction pattern 8, so that the injection inner mold 3 and the injection outer mold 4 are engaged and the plug-in and pull-out gripping friction of the injection outer mold 4 is increased.

[0035] Embodiment 2

[0036] For the requirement of large bending radius of the cable at the electrical connector end of the cable assembly, see Figure 8 The utility model also provides an injection-molded protective cable assembly terminal (curved injection molding), including a cable 21, an electrical connector 22, an injection inner mold 23 and an injection outer mold 24. The cable 21 is connected to the electrical connector 22 by crimping or welding. First, the injection inner mold 23 is used for wrapping and fixing protection of at least the connection between the cable 21 and the electrical connector 22 by injection molding. Then, the injection outer mold 24 is used for further wrapping and fixing protection of the cable 21 extending out of the injection inner mold 23, part of the tail cover of the electrical connector 22 and the entire injection inner mold 23 by injection molding. The outer surface of the injection inner mold 23 is provided with a draft groove 27, so that the injection outer mold 24 can be engaged with the injection inner mold 23 after molding.

[0037] Preferably, the injection mold 24 also has a detachable mesh tail 25 at the lower end to increase the transition between the injection molded body and the cable 21. Preferably, the outer surface of the injection mold 24 is also provided with friction lines 26. Preferably, the end of the curved injection molded body extending out of the cable 21 as a whole is perpendicular to the end connected to the electrical connector 22, or at any desired angle.

[0038] In addition, the width of the cable 21 at the end of the cable assembly is required to be smaller than the width of the electrical connector; this also requires that before injection molding, the cable 21 at the end of the cable assembly must first be bent and tied into shape according to actual usage conditions, and the width of the molded cable 21 generally does not exceed the width of the electrical connector 22.

[0039] Furthermore, this embodiment also provides an injection mold for the cable assembly terminal with the above-mentioned injection molding protection. Figure 9-12 The mold is divided into a lower mold and an upper mold, and the combined mold includes a positioning plate 31, a positioning hole 32, a main flow channel 33, a branch flow channel 34, a detachable fixing clip 35, a detachable net tail mold 36, an inner mold body 37 and an outer mold body 38. Among them, the positioning plate 31 is used for inserting and placing the end of the electrical connector 22 during the injection molding process; the fixing clip 35 is used for collecting and placing the cable 21 extending out of the cavity of the injection inner mold; the net tail mold 36 is used for collecting and placing the cable 21 extending out of the cavity of the injection outer mold 24 and the transition molding between the injection outer mold 24 and the cable 21.

[0040] Preferably, the shapes of the inner mold body 37 and the outer mold body 38 are set according to the desired outer shapes of the inner and outer molds for injection molding, and are respectively provided with a draft body 39 and a friction body 40 for forming the injection shapes of the draft groove 27 and the friction pattern 26, so that the injection inner mold 23 and the injection outer mold 24 are engaged with each other and the insertion, extraction and gripping friction of the injection outer mold 24 is increased.

[0041] In view of the above two embodiments, the utility model provides (two embodiments) an injection molding protection process for an injection molding protected cable assembly end, comprising the following steps:

[0042] Step (S1): Check whether the cable assembly has any scratches, dents or other defects on its appearance.

[0043] Step (S2): pour the outer layer injection molding pellets into a material barrel and pre-bake at 65° C. for 4 hours.

[0044] Step (S3): Clamp and fix the inner layer injection mold on the injection molding machine, then insert the ends of the electrical connectors 2 and 22 of the cable assembly into the positioning plates 11 and 31 of the injection mold, and place the entire assembly flatly into the cavity of the inner layer injection mold, and place the tail ends of the cables 1 and 21 in the fixing clamps 15 and 35.

[0045] Step (S4): melt the inner layer injection molding pellets using an injection molding machine, and then inject the inner layer injection molding melt into the injection mold, and maintain the pressure at a pressure of 15Bar to 25Bar for 1s.

[0046] Step (S5): Cool the inner layer injection mold naturally for 90 seconds, and demold after cooling. When demolding, hold the ends of the cables 1 and 21 with one hand and the positioning plates 11 and 31 of the injection mold with the other hand to smoothly remove the injection inner molds 3 and 23 from the mold cavity.

[0047] Step (S6): Clamp and fix the outer injection mold on the injection molding machine, insert the ends of the electrical connectors 2 and 22 of the cable assembly into the positioning plates 11 and 31 of the injection mold, place the entire assembly flat into the cavity of the outer injection mold, and place the tail of the cables 1 and 21 in the net tail mold 16 and 36.

[0048] Step (S7): Use an injection molding machine to melt the pre-baked outer layer injection molding pellets, and then inject the outer layer injection molding melt into the injection mold, and maintain the pressure for 2.5 seconds at a pressure of 15Bar to 20Bar.

[0049] Step (S8): Cool the outer layer injection mold naturally for 60 seconds, and demold it after cooling. When demolding, hold the ends of the cables 1 and 21 with one hand and the positioning plates 11 and 31 of the injection mold with the other hand to smoothly remove the injection outer molds 4 and 24 from the mold cavity.

[0050] Step (S9): After the injection molding outer mold is surface treated, the cable assembly end is injection-molded for protection, and the cable assembly end is wrapped and protected with a bubble bag or sponge.

[0051] Specifically, in step (S3), the inner layer injection mold is additionally provided with draft bodies 19, 39, so that the outer injection molds 4, 24 can engage with the inner injection molds 3, 23 after molding, thereby strengthening the bonding strength between the inner injection molds 3, 23 and the outer injection molds 4, 24.

[0052] Specifically, the inner layer injection plastic in step (S4) is low-density polyethylene granules, which have good softness, extensibility, electrical insulation, and have the advantages of low molding temperature and low injection pressure, which can avoid the risk of the glue liquid directly rushing into the plug part of the electrical connector due to excessive pressure. The temperature of the inner layer injection plastic melted by the injection molding machine is 155°C to 165°C.

[0053] Specifically, the mesh tails 5 and 25 in step (S3) and step (S6) can increase the transition between the injection molded body and the cables 1 and 21, increase the bending life of the cables 1 and 21, and reduce the risk of damage caused by frequent plugging and unplugging of the plugs. At the same time, the mesh tail molds 16 and 36 are detachable mesh tails. For the same type of electrical connector, when there are one or more tail cables 1 and 21, only the mesh tail needs to be replaced to complete the injection molding, avoiding repeated mold opening and greatly reducing the cost.

[0054] Specifically, in step (S7), the outer layer injection molding material is a polyvinyl chloride elastomer, which has the advantages of short molding time, wide processing temperature, high wear resistance, high tear strength, high elasticity and flexibility, excellent dimensional stability and consistency, etc. The temperature of the outer layer injection molding material melted by the injection molding machine is 200°C to 215°C.

[0055] The utility model performs injection molding protection on the end of the cable assembly through the end injection molding protection process of the cable assembly, realizes the reinforcement of the connection part between the cable assembly cables 1, 21 and the electric connector tail cover, completes the protection of the cable assembly end, makes the cables 1, 21 play a buffering role in the bending and swinging process, prolongs the service life of the cable, and improves the quality and reliability of the product. At the same time, by performing bending binding molding and bending injection molding protection on the cables at the electric connector end of the cable assembly, the cable assembly can be adapted to electrical assembly in a narrow space.

[0056] It should be understood that the "lower end" and other position indications described herein are divided according to the device's own direction as shown in the figure. It should be understood that in the solution of the utility model, the so-called upper and lower positions are interchangeable and do not constitute a substantial limitation to the solution.

Claims

1. An injection-molded protective cable assembly terminal, characterized in that: The cable assembly end includes a cable, an electrical connector, an injection inner mold and an injection outer mold; wherein the cable is connected to the electrical connector by crimping or welding; the injection inner mold is injection molded to achieve at least wrapping and fixing protection of the connection between the cable and the electrical connector; the injection outer mold is injection molded to further achieve wrapping and fixing protection of the cable extending out of the injection inner mold, part of the tail cover of the electrical connector and the entire injection inner mold.

2. The cable assembly terminal with injection molding protection according to claim 1, characterized in that: The outer surface of the injection inner mold is provided with a draft groove, so that the injection outer mold can be engaged with the injection inner mold after molding.

3. The cable assembly terminal with injection molding protection according to claim 2, characterized in that: The draft groove is perpendicular to an extension direction of the inner cavity of the injection inner mold.

4. The cable assembly terminal with injection molding protection according to claim 1, characterized in that: The injection molding outer mold has a mesh tail at one end of the extended cable, so as to increase the transition between the injection molding body and the cable.

5. The cable assembly terminal with injection molding protection according to claim 1, characterized in that: The inner injection mold and the outer injection mold are curved injection molded bodies or non-curved injection molded bodies.

6. The cable assembly terminal with injection molding protection according to claim 5, characterized in that: One end of the curved injection molding body extending out of the cable and one end connected to the electrical connector are perpendicular to each other, or are at any desired angle.

7. The cable assembly terminal with injection molding protection according to claim 1, characterized in that: The outer surface of the injection outer mold is also provided with friction lines.

8. An injection mold for an injection-molded protective cable assembly terminal, characterized in that: The mold is used for injection molding of the injection-molded protected cable assembly end according to any one of claims 1-7; wherein the mold is divided into a fixed mold and a movable mold, and includes a positioning plate, a positioning hole, a main flow channel, a branch flow channel, a detachable fixing clamp, a detachable net tail mold, an inner mold main body and an outer mold main body; wherein the positioning plate is used for inserting and placing the end of the electrical connector during the injection molding process; the detachable fixing clamp is used for gathering and placing the cables extending out of the injection molding inner mold cavity; the detachable net tail mold is used for gathering and placing the cables extending out of the injection molding outer mold cavity and for transition molding between the injection molding outer mold and the cables.

9. The injection mold for the injection-molded protective cable assembly terminal according to claim 8, characterized in that: The inner mold body and the outer mold body are respectively provided with a draft body and a friction body for forming the injection shape of the draft groove and the friction pattern, so that the injection inner mold and the injection outer mold are engaged and the friction force of the injection outer mold is increased.

10. The injection mold for the injection-molded protective cable assembly terminal according to claim 8, characterized in that: The inner mold body part and the outer mold body part are configured as curved or non-curved injection cavities.

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