METHOD FOR MANUFACTURING A CONNECTOR

Abstract

The present invention relates to a method for manufacturing a connector (1) comprising a cable (2) having at least one signal line (3) and a cable sheath (4) enclosing the signal line (3), and a contact element (5) that is connectable to a mating connector and is conductively connected to the signal line (3) at a cable end (6) of the cable (2), comprising at least the following steps: arranging the cable (2) and the contact element (5) between two tool halves (7; 8); closing the tool halves (7; 8), wherein a cavity (9) is formed between the tool halves (7; 8) in which the cable (2) and the contact element (5) are at least partially arranged; and forming a housing (10) that is positively and / or materially connected to the contact element (5) and / or the cable (2) by introducing an injection molding material (11) into the cavity (9).At least one tool half (7; 8) has at least one deformation element (12) arranged within the cavity (9) which presses at least one trough-shaped recess (13) into the cable sheath (4) before the forming of the housing (10) step. The deformation element (12) remains in the cavity (9) during the forming of the housing (10) step. The injection molding material (11) is introduced at least partially into the recess (13) between the deformation element (12) and the cable sheath (4). The deformation element (12) is removed from the recess (13) after the forming of the housing (10) step, immediately after the injection molding material (11) has been introduced into the cavity (9), and before the injection molding material (11) has cured. The invention further relates to a connector manufactured according to such a method.

Description

Technical field

[0001] The invention relates to a method for manufacturing a connector and a connector manufactured according to such a method. State of the art

[0002] For the detachable connection of signal lines, especially electrical and optical ones, connectors have long been established in practice. A connector comprises at least one plug contact that can be connected to a corresponding mating connector via a signal conductor. The plug contact is in turn connected via a signal conductor to at least one signal conductor of the signal line. To protect the plug contact and the signal line from environmental influences and damage, the plug contact, and possibly the section where the plug contact and the signal line are connected, is enclosed in a housing. A particularly advantageous way to provide such a housing is to position the plug contact and the signal line as desired. Subsequently, the housing is produced in an injection molding process, whereby the plug contact and the signal line are embedded within it.While this offers a simple and cost-effective way to form a housing, this manufacturing process also has some disadvantages. The holding force of the housing on the signal conductor is essentially generated by frictional forces between the housing material and the signal conductor. Therefore, if significant tensile forces act on the connector during use, there is an increased risk of the signal conductor being pulled out of the housing. Although it is known in the art to increase the bond strength between the overmolded housing and the signal conductor, for example by roughening the signal conductor, introducing grooves and notches into the signal conductor, and / or by chemical surface treatments of the signal conductor before the injection molding process, this requires additional process steps, which increases the complexity of the manufacturing process.

[0003] US 3,093,432 A discloses an electrical connector and terminal for a photographic release cable, wherein the camera-side contact end of the release cable is provided with a design that uses a molded plug with a flexible, tapered sleeve featuring a plurality of holes or openings extending completely through the sleeve. This design increases bending and strain relief.

[0004] JP S53 - 98 360 A discloses a method for manufacturing and providing a cable lug suitable for attaching a power cord that is frequently pulled during use, for example in a vacuum cleaner, to the housing of a cleaning device in order to prevent the electrical connection from being disconnected.

[0005] US 2016 / 0181755 A1 discloses an overmolded electrical connector with integrated strain relief. The strain relief may have multiple protrusions that extend through the overmolded housing and are visible to users. The strain relief may employ a locking mechanism that permanently secures it to the power cord. The strain relief may be partially pre-assembled in a pre-locking configuration on the power cord, with the strain relief positioned on the power cord and then further pressed into a locked configuration where it is securely attached. During the assembly process, the strain relief aligns itself with the electrical connector. Description of the invention

[0006] It is therefore an object of the present invention to provide a method for manufacturing a connector and a connector manufactured according to such a method which overcomes at least one disadvantage mentioned in the prior art and in particular ensures that the connection effect between an overmolded housing and the signal connection is increased, so that the manufactured connector is more resistant to tensile forces and / or torsional forces.

[0007] The object of the invention is achieved by a method for manufacturing a connector and by a connector manufactured according to such a method, having the features of the independent claims. Further advantageous embodiments of the invention can be found in the dependent claims, the description, and the drawings.

[0008] A method according to the invention is suitable for manufacturing a connector comprising a cable and a contact element. The cable has at least one signal line, in particular for transmitting electrical and optical signals. Furthermore, the cable has a cable sheath enclosing the signal line. The cable sheath encloses the signal line, preferably along a longitudinal axis of the cable. The contact element is connectable to a mating connector, in particular a detachable connection. In addition, the contact element is connected, in particular a permanent connection, to the signal line at one end of the cable. The method according to the invention includes the step of arranging the cable and the contact element between two tool halves. The tool halves are preferably movable relative to each other between an open and closed position along an axis of movement.A further step of the method consists of closing the tool halves, whereby a cavity is formed between the tool halves in which the cable and the contact element are at least partially arranged. Preferably, the cable and the contact element are already positioned between the tool halves during the arrangement step such that, after the tool halves are closed, the cable and the contact element are correctly positioned in the cavity. The cavity can be formed, for example, by each of the two tool halves having a partial cavity which, when the tool halves are closed, together create the cavity. The method according to the invention further comprises the step of forming an outer housing that is positively and / or materially connected to the contact element and / or the cable.The housing is formed by introducing an injection molding material into the cavity and allowing it to cure. At least one mold half has at least one deformation element. This deformation element is located within the cavity and, prior to the housing formation step, presses a trough-shaped recess into the cable sheath. This can be achieved, for example, by pressing the deformation element into the cable sheath when the mold halves are closed. The deformation element can be designed as a rigid element that projects into the cavity. Alternatively, the deformation element can be formed integrally with the mold half. The deformation element remains in the cavity during the housing formation step. Preferably, the deformation element remains in the recess during the housing formation step.The injection molding material is, at least partially, introduced into the recess between the deformation element and the cable sheath and preferably hardens.

[0009] The deformation element is removed from the cavity immediately after the injection molding material is introduced. This removal takes place while the injection molding material is still liquid, i.e., not yet cured. Preferably, the deformation element is removed after the injection molding material has been introduced into the cavity, but before it has cured. This prevents a recess from remaining in the housing after the deformation element is removed.

[0010] The inventive method enables the provision of a connector that easily exhibits increased resistance, particularly against tensile and torsional forces that may act upon it. The trough-shaped recesses, into which the injection-molded material is partially inserted, create an additional positive-locking connection between the cable and the housing. This is possible because signal cables, especially optical and electrical ones, typically have cable sheaths made of durable and relatively dimensionally stable material compositions based, for example, on polyethylene, polyvinyl chloride, polyamide, or polypropylene.Thus, pressing the deformation element into the cable sheath results in the cable sheath not fitting snugly against the deformation element laterally, but rather a certain gap remains into which injection molding material can penetrate during the housing formation step. A further advantage of the method according to the invention is that no downstream processing steps are necessary, since the creation of the additional positive-locking connection occurs automatically during the forming of the housing. Likewise, no pre- and / or post-processing of the connector or the cable is required.

[0011] A groove can be formed between the deformation element and the cable sheath, at least partially enclosing the deformation element. The injection molding material can be introduced into the groove. The groove preferably completely surrounds the deformation element, and its shape can be essentially determined by the shape of the deformation element.

[0012] The deformation element can be moved into the cavity before the housing formation step. It can also be moved into the cavity before or after the tool halves are closed. If the deformation element is moved into the cavity before the closing step, the indentation in the cable sheath is pressed in by the closing movement of both tool halves. Conversely, if the deformation element is moved into the cavity after the closing step, the indentation in the cable sheath is pressed in by the movement of the deformation element into the cavity.

[0013] The deformation element can be removed from the recess, and in particular from the cavity, after the housing has been formed. After removal of the deformation element, a recess may remain in the housing, which corresponds at least partially to the negative shape of the deformation element. This recess can be filled in a step performed after the deformation element has been removed from the recess and / or cavity. This step can be carried out within the closed tool halves or, alternatively, in a downstream tool.

[0014] The deformation element can eject the housing or connector from the cavity after the housing formation step, particularly during or after the tool halves have been opened. This has the advantage that no additional ejectors need to be provided in the tool halves. Ejection can be achieved, for example, by moving the deformation element further out of the tool half in which it is located, either during or after the tool halves have been opened.

[0015] According to a non-inventive embodiment, the deformation element can be removed from the recess once the injection-molded material has cured. This removal is preferably carried out with the mold halves closed. This ensures a reliable, positive-locking connection between the housing and the cable and, for example, reduces the risk of the recess reverting to its original shape due to the elasticity of the cable sheath material while the injection-molded material is still soft.

[0016] Multiple deformation elements can be moved into the cavity, creating several indentations in the cable sheath. These elements can be located entirely within one of the mold halves. Alternatively, they can be distributed across both mold halves. The deformation elements can be moved into the cavity simultaneously or sequentially, so that at intervals, each element presses a trough-shaped indentation into the cable sheath. Similarly, the removal of the deformation elements from the cavity can occur simultaneously or sequentially. Particularly when the deformation elements are removed during the injection of the molding material, staggered removal can promote melt flow within the cavity.

[0017] The multiple deformation elements can create indentations in the cable sheath that differ in their shape and / or depth. The spacing between the deformation elements can be chosen, at least partially, such that the indentations are adjacent to one another.

[0018] The cable and the contact element can be connected by a connecting section in which the signal line is free of the cable sheath. During the housing formation step, the connecting section can be enclosed by the injection-molded material. It is particularly preferred that the connecting section be enclosed by the injection-molded material in a fluid-tight manner.

[0019] In addition to the inventive method for manufacturing a connector, the invention comprises a connector manufactured according to the inventive method.

[0020] A connector according to the invention, manufactured according to a method according to the features mentioned above, has a contact element. The contact element is connectable to a mating contact element of a mating connector. The connector further has a cable comprising at least one signal line and a cable sheath enclosing the signal line. The signal line is preferably made of an electrically or optically conductive material. The connector also has a housing. The contact element is connected to the signal line at one end of the cable in a signal-conducting manner. The housing is arranged at the end of the cable. The contact element and the cable are at least partially embedded in the housing. The contact element and / or the cable are connected to the housing by a material-locking and / or form-fit connection. The cable sheath has at least one trough-shaped recess in which the housing is at least partially arranged.

[0021] The contact element and the cable can be connected to each other by a connecting section in which the cable sheath is removed and the connecting section is enclosed by the housing, in particular in a fluid-tight manner.

[0022] The cable sheath can have several recesses in which the outer casing is, at least partially, arranged. Preferably, the recesses are completely filled by the outer casing.

[0023] The indentations can differ in shape and / or depth. They can be arranged along the longitudinal axis of the cable.

[0024] The recesses can be arranged opposite each other. Furthermore, the recesses can be offset from each other. Likewise, recesses arranged opposite each other can be offset from each other.

[0025] Unless otherwise stated, the features described for the method according to the invention can be considered in combination with the features of the connector according to the invention, and vice versa, provided they do not contradict each other. Furthermore, additional advantages and features of the present invention will become apparent from the following description of preferred embodiments. The features described there and above can be implemented individually or in combination, provided they do not contradict each other. The following description of the preferred embodiments is given with reference to the accompanying drawings. These show: Fig. 1 to 5 represent an embodiment of the method according to the invention in several process steps; Fig. Figures 6 to 8 show a first embodiment of creating depressions on a cable sheath according to the inventive method; and Fig. Figures 9 to 11 show a second embodiment of creating depressions on a cable sheath according to the inventive method.

[0026] The Fig. Figures 1 to 5 show an embodiment of a method according to the invention for manufacturing a connector 1. The method according to the invention comprises a step of arranging a cable 2 and a contact element 5 between two tool halves 7; 8, as shown in Fig. Figure 1 shows the cable 2. The cable 2 comprises a signal conductor 3, which is connected to the contact element 5 at one end 6 of the cable 2. In this embodiment, the signal conductor 3 is an insulated copper conductor. The signal conductor 3 is enclosed by a cable sheath 4, which protects it from damage and environmental influences. A connection section 15 is located between the contact element 5 and the cable sheath 4, in which the signal conductor 3 is exposed. This facilitates easier connection of the signal conductor 3 to the contact element 5. The contact element 5 is made of metal and can be detachably connected to a mating contact element.

[0027] After the arranging step, the tool halves 7 and 8 are closed. The tool halves 7 and 8 are moved towards each other and form, as shown in Fig. As shown in Figure 2, a cavity 9 is formed. Both the contact element 5 and the cable 2 are partially located within the cavity 9. The connecting section 11 is completely located within the cavity 9. The tool halves 7 and 8 are closed in such a way that the cavity 9 is sealed to such an extent that any casting material that can be introduced into the cavity 9 remains within the cavity 9 and cannot escape at any point between the tool halves 7 and 8, or between a tool half 7 and 8 and the cable 2 or the contact element 5.

[0028] Both tool halves 7; 8 have deformation elements 12 which, after the tool halves 7; 8 are closed, are moved into the cavity 9 and press indentations 13 into the cable sheath 4, as shown in Fig. Figure 3 shows the deformation elements 12, which are designed as metal bolts extending from the tool halves 7;8.

[0029] As in Fig. As shown in Figure 4, the next step involves forming an outer housing by injecting injection molding material 11 into the cavity 9, completely filling it. The contact element 5 and the cable 2 are enclosed within the cavity 9 by the injection molding material 11. Furthermore, the signal line 3 is completely embedded within the connection section 15 in the injection molding material 11. The deformation elements 12 are also enclosed by the injection molding material 11. The injection molding material 11 also partially penetrates the recesses 13 that are formed in the cable sheath 4 by the deformation elements 12. After the injection molding material 11 has been introduced into the cavity 9, the mold halves 7 and 8 remain closed until the injection molding material 11 has cured.In the present embodiment, the injection molding material 11 is a thermoplastic, so that curing occurs by cooling the plastic below its melting temperature. Once the injection molding material 11 has cured, the mold halves 7 and 8 are opened. During this opening, the deformation elements 12 are moved out of the cavity 9 and back into their respective mold halves.

[0030] The manufactured connector 1 can then be removed from the tool halves. Fig. Figure 5 shows the connector 1 immediately after removal. The housing 10, formed from the cured injection-molded material, encloses both the cable sheath 4 and the contact element 5. The signal line 3 within the connection section 15 is fluid-tight and embedded in the housing 10.

[0031] Fig. Figures 6 to 8 show an embodiment of creating recesses 13 in the cable sheath 4, as applied in the method according to the invention, in an enlarged schematic representation. As in Fig. As shown in Figure 6, the recess 13 is formed by pressing the deformation element 12 into the cable sheath 4. Pressing in the cable sheath 4 creates grooves 14 between the deformation element 12 and the cable sheath 4.

[0032] Will be, as in Fig. As shown in Figure 7, when the injection molding material 11 is introduced into the cavity, part of the injection molding material 11 enters the grooves 14 and thus partly enters the recess 13. Due to the pressure that injection molding material 12 typically has when introduced into a cavity, these grooves 14 can enlarge further as a result of the introduction of the injection molding material 11.

[0033] In Fig. 8 The injection molding material has already cured and forms the housing 10. The deformation element 12 is moved out of the recess 13 and, in the present embodiment, leaves a recess in the housing 10. The material, which forms the housing 10 and is partially located in the recess 13, thus creates an additional positive-locking connection between the housing 10 and the cable.

[0034] Fig. Figures 9 to 11 show a second embodiment of creating recesses 13 in the cable sheath 4, as applied in the method according to the invention. As in Fig. As shown in Figure 9, a recess 13 is pressed into the cable sheath 4. The deformation element 12 has additional flow grooves 16 that facilitate the introduction of the injection molding material 11. As shown in Fig. As shown in Figure 10, the injection molding material 11 is drawn even deeper into the recess 13 through the flow grooves 16. After the injection molding material 11 has hardened to form the housing 10, the deformation element 12 is formed, as shown in Figure 10. Fig. 11 shown, removed. Since in the illustrated embodiment more material forming the housing 10 has entered the recess, there is an improved positive-locking connection between the cable and the housing. REFERENCE MARK LIST 1 connector 2 cables 3 Signal line 4 cable sheath 5 contact element 6 cable ends 7 Tool half 8 Tool half 9 Cavity 10 enclosures 11 Injection molding material 12 Deformation element 13. Further Study 14 gully 15 Connecting section 16 Flow groove

Claims

[1] Method for manufacturing a connector (1) comprising a cable (2) having at least one signal line (3) and a cable sheath (4) enclosing the signal line (3), and a contact element (5) that is connectable to a mating connector and is connected in a signal-conducting manner to the signal line (3) at a cable end (6) of the cable (2), comprising at least the following steps: Arranging the cable (2) and the contact element (5) between two tool halves (7; 8); Closing the tool halves (7; 8), wherein a cavity (9) is formed between the tool halves (7; 8) in which the cable (2) and the contact element (5) are at least partially arranged; and Forming a housing (10) that is positively and / or materially connected to the contact element (5) and / or the cable (2) by introducing an injection molding material (11) into the cavity (9), where at least one tool half (7; 8) has at least one deformation element (12) which is arranged inside the cavity (9) and presses at least one trough-shaped depression (13) into the cable sheath (4) before the step of forming the housing (10), the deformation element (12) remains in the cavity (9) during the step of forming the housing (10) and the injection molding material (11) is at least partially introduced into the recess (13) between the deformation element (12) and the cable sheath (4), characterized by , that the deformation element (12) is removed from the recess (13) after the step of forming the housing (10), immediately after the injection molding material (11) has been introduced into the cavity (9) and before the injection molding material (11) has hardened. [2] Method according to the preceding claim, wherein a groove (14) is formed between the deformation element (12) and the cable sheath (4), which at least partially encloses the deformation element (12) and the injection molding material (11) is introduced into the groove (14). [3] Method according to any one of the preceding claims 1 to 2, wherein several deformation elements (12) are moved into the cavity (9) which create several depressions (13) in the cable sheath (4). [4] Method according to the preceding claim, wherein the multiple deformation elements (12) create depressions (13) in the cable sheath (4) which differ from each other in their shape and / or depth. [5] Method according to one of the preceding claims, wherein the cable (2) and the contact element (5) are connected by a connecting section (15) in which the signal line (3) is free from the cable sheath (4), which is enclosed by the injection molding material (11) during the step of forming the housing (10). [6] Connectors (1) manufactured according to a method according to claims 1 to 5, with a contact element (5) that can be connected to a mating contact element of a mating connector, a cable (2) which has at least one signal line (3) and a cable sheath (4) enclosing the signal line (3) and a housing (10) wherein the contact element (5) is connected to the signal line (3) at one cable end (6) in a signal-conducting manner, the housing (10) is arranged at the cable end (6), the contact element (5) and the cable (2) are at least partially embedded in the housing (10), the contact element (5) and / or the cable (2) are connected to the housing (10) in a material- or form-fitting manner and the cable sheath (4) has at least one trough-shaped depression (13) in which the outer casing (10) is at least partially arranged. [7] Connector (1) according to claim 6, wherein the contact element (5) and the cable (2) are connected to each other by a connecting section (15) in which the cable sheath (4) is removed from the signal line (3) and the connecting section (15) is enclosed by the housing (10), in particular in a fluid-tight manner. [8] Connector (1) according to claim 6 or 7, wherein the cable sheath (4) has several recesses (13) in which the housing (10) is at least partially arranged. [9] Connector (1) according to claim 8, wherein the recesses (13) differ from each other in their shape and / or depth. [10] Connector (1) according to claim 8 or 9, wherein the recesses (13) are arranged opposite each other.

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