Cable assembly, cable connector and manufacturing method

Abstract

To provide a cable assembly, a cable connector, and a production method.SOLUTION: A cable assembly according to an embodiment includes a plurality of conductor wires, an exterior layer, a braided layer, and a fixation block. The conductor wire includes a core wire for conduction and an insulating layer coating the core wire. The exterior layer coats the plurality of conductor wires. The braided layer coats the exterior layer. The fixation block is injection-molded in the braided layer. A part of material of the fixation block infiltrates the braided layer such that the braided layer and the exterior layer are integrated. Accordingly, the structure reliability of the cable assembly according to the embodiment is high.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a cable assembly, a cable connector and a manufacturing method thereof, and belongs to the technical field of connectors. [Background technology]

[0002] A cable connector in the related art typically includes a connector adapter and a cable assembly connected to the connector adapter. The cable assembly typically includes a plurality of conductors and an armor layer covering the plurality of conductors. The armor layer is typically a thermoplastic polyurethane (TPU) armor layer.

[0003] With the development of technology, in order to obtain better visual and tactile sensation, higher safety and longer service life, related technologies have been researching to cover the armor layer with another braided layer, but the braided layer has a soft structure, high elasticity, and very little adhesion to the armor layer, so that the braided layer is easy to slip on the armor layer, which results in the cable assembly shrinking during the front-end process, which damages the appearance and related functions of the product. Summary of the Invention [Problem to be solved by the invention]

[0004] An object of the present invention is to provide a cable assembly, a cable connector, and a method for manufacturing the cable assembly, which have a highly reliable structure. [Means for solving the problem]

[0005] In order to achieve the above object, the present invention adopts the following technical solutions: A cable assembly, comprising: A plurality of conductors each including a conductive core wire and an insulating layer covering the core wire; an exterior layer covering the plurality of conductors; A braided layer covering the armor layer; a fastener block that is injection molded onto the braided layer, a portion of the material of which penetrates the braided layer to unite the braided layer with the armor layer.

[0006] As a further improved technical solution of the present invention, the conductor includes a protruding wire, which extends and protrudes from a first end of the armor layer and a second end of the braided layer, and at least a portion of the fixing block is molded at the first end, the second end and a root portion of the protruding wire.

[0007] As a further improved technical solution of the present invention, the root portion of the protruding wire is a portion close to the first end and the second end of the protruding wire, and at least a portion of the fixing block is molded into the insulating layer of the protruding wire.

[0008] As a further improved technical solution of the present invention, the protruding wires of at least some of the conductors include a curved portion and an extension portion extending from the curved portion, and the fixing block is molded to the curved portion of the protruding wire to maintain the position of the extension portions relative to each other.

[0009] As a further improved technical solution of the present invention, said outer layer is a silica gel outer layer.

[0010] As a further improved technical solution of the present invention, said braided layer is a PET braided layer.

[0011] As a further improved technical solution of the present invention, said anchoring block is a polyamide anchoring block, an acrylic resin anchoring block or an epoxy resin anchoring block.

[0012] The present invention further discloses the following technical solutions: A cable connector, comprising a connector adapter and the cable assembly, wherein the core wire is directly or indirectly electrically connected to the connector adapter.

[0013] The present invention further discloses the following technical solutions: A method for manufacturing a cable assembly, comprising: providing a carrier, the carrier having a plurality of cable locating grooves and a molded groove communicating with the plurality of cable locating grooves; providing a cable, the cable including a plurality of conductors, an armor layer covering the plurality of conductors, and a braided layer covering the armor layer, the conductors including a core for electrical conduction and an insulating layer covering the core; mounting the plurality of conductors of the cable within the plurality of cable locating grooves and extending an end of the armor layer and an end of the braid layer into the shaping grooves; providing a mold, the mold being attached to the carrier and including an injection mold port and an injection mold runner, the injection mold runner communicating the injection mold port with the mold channel; injecting a liquid filler material into the injection molding port, the filler material being injected through the injection molding runner into the molding groove, and the filler material permeating the braided layer; and curing the filler material to obtain the cable assembly.

[0014] As a further improved technical solution of the present invention, when the liquid filler is injected into the injection mould port, the temperature of the filler is T, T≦260° C., and the viscosity of the filler is η, η≦5000 mPa.s.

[0015] In a further improved technical solution of the present invention, 210°C≦T≦260°C, 1 mPa.s≦η≦2000 mPa.s. Effect of the Invention

[0016] Compared with the prior art, the present invention provides a fixing block that is injection molded onto the braided layer, and a portion of the material of the fixing block penetrates the braided layer to integrate the braided layer and the exterior layer. The provision of the fixing block enables the braided layer and the exterior layer to be firmly fixed together, thereby preventing the braided layer from slipping relative to the exterior layer and shrinking. [Brief description of the drawings]

[0017] [Figure 1] 1 is an example of a schematic perspective view of a cable connector according to an embodiment of the present invention; [Diagram 2] FIG. 2 is an example of a schematic perspective view of the device shown in FIG. 1 after a shell has been removed. [Diagram 3] 3 is an example of a partially enlarged view of a framed portion A in FIG. 2. [Figure 4] FIG. 2 is an example of a schematic perspective view of a cable assembly according to an embodiment of the present invention. [Diagram 5] FIG. 5 is an exploded perspective view of FIG. [Figure 6] FIG. 6 is a further example of an exploded perspective view of FIG. 5. [Figure 7] FIG. 2 is an example of a plan view of a cable of the present invention attached to a carrier. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] Hereinafter, exemplary specific embodiments of the present invention will be described in detail with reference to the drawings. When multiple specific embodiments exist, the features of these embodiments can be combined with each other unless inconsistent. When the description refers to the drawings, the same numerals in different drawings indicate the same or similar elements unless otherwise specified. The contents described in the following exemplary specific embodiments do not represent all embodiments consistent with the present invention, but rather are merely examples of devices, products and / or methods consistent with some aspects of the present invention as recited in the claims of the present invention.

[0019] The terms used in the present invention are merely intended to describe specific embodiments, and are not intended to limit the scope of protection of the present invention. The singular forms "a kind," "the," and "the" used in the present specification and claims also include the plural forms unless the context clearly dictates otherwise.

[0020] It should be understood that terms such as "first", "second" and similar terms used in the present specification and claims do not indicate any order, quantity or importance, but are merely designations to distinguish features. Similarly, similar terms such as "one" or "one" do not indicate a quantity limit, but indicate at least one. Unless otherwise specified, similar terms such as "front", "back", "upper", "lower" and the like appearing in the present invention are merely for ease of description and are not limited to a specific location or a specific spatial orientation. Similar terms such as "comprise" or "inclusive" are open ended and mean that the element appearing before "comprise" or "inclusive" covers the element appearing after "comprise" or "inclusive" and equivalents thereof, and do not exclude that the element appearing before "comprise" or "inclusive" further includes other elements. In the present invention, when "plurality" appears, its meaning refers to two or more.

[0021] 1 to 6, the present invention discloses a cable assembly 100, which includes a plurality of conductors 1, an armor layer 2 that covers the plurality of conductors 1, a braided layer 3 that covers the armor layer 2, and a fixing block 4 that is injection molded onto the braided layer 3. A portion of the fixing block 4 penetrates into the braided layer 3 to integrate the braided layer 3 and the armor layer 2.

[0022] In the illustrated embodiment of the invention, each conductor 1 includes an electrically conductive core 11 and an insulating layer 12 covering said core 11 .

[0023] Specifically, each conductive wire 1 includes a protruding wire 111, which extends and protrudes to the first end 21 of the armor layer 2 and the second end 31 of the braided layer 3. At least a portion of the fixing block 4 is molded into the first end 21, the second end 31 and a root portion 112 of the protruding wire 111. The root portion 112 of the protruding wire 111 is a portion close to the first end 21 and the second end 31 of the protruding wire 111. At least a portion of the fixing block 4 is molded into the insulating layer 12 of the protruding wire 111 and covers both the first end 21 of the armor layer 2 and the second end 31 of the braided layer 3.

[0024] In the illustrated embodiment of the present invention, the protruding wires 111 of at least some of the conductors 1 include a curved portion 1111 and an extending portion 1112 extending from the curved portion 1111. The fixing block 4 is molded to the curved portion 1111 of the protruding wire 111, thereby maintaining the relative positions of the extending portions 1112. In the illustrated embodiment of the present invention, the armor layer 2 is cylindrical, and the plurality of conductors 1 are housed therein. With respect to the extending portions 1112, the extending portions 1112 of the plurality of conductors 1 are sequentially spaced apart (e.g., spaced apart from one another). The relative positions of the extending portions 1112 include, but are not limited to, the spacing between the extending portions 1112 of the plurality of conductors 1 and the flatness of the extending portions 1112 of the plurality of conductors 1.

[0025] In the illustrated embodiment of the present invention, the armor layer 2 is a silica gel armor layer, and the braided layer 3 is a PET (Polyethylene Terephthalate) braided layer. The fixing block 4 is a polyamide fixing block, an acrylic resin fixing block, or an epoxy resin fixing block. When the fixing block 4 is a polyamide fixing block, if molding defects occur, it can be treated with alcohol and redone. Although polyamide is insoluble in alcohol, it softens under the action of alcohol, so that defective polyamide fixing blocks can be easily decomposed.

[0026] The present invention discloses a cable connector 200, which includes a connector adapter 300 and the cable assembly 100, and the core wire 11 is directly or indirectly electrically connected to the connector adapter 300. For example, the core wire 11 of the cable assembly 100 is welded to the connector adapter 300, or the core wire 11 of the cable assembly 100 is connected to the connector adapter 300 via a built-in circuit board 600 (see FIG. 2). As shown in FIG. 3, a plurality of conductive sheets 601 are provided on the built-in circuit board 600, and the core wires 11 of the cable assembly 100 are welded and fixed to the corresponding conductive sheets 601.

[0027] In addition, as shown in FIGS. 4 to 7, the present invention further discloses a method for manufacturing the cable assembly 100, providing a carrier 400, the carrier 400 having a plurality of cable locating grooves 401 and a molding groove 402 communicating with the plurality of cable locating grooves 401; providing a cable, the cable including a plurality of conductors 1, an armor layer 2 covering the plurality of conductors 1, and a braided layer 3 covering the armor layer 2, each conductor 1 including a core 11 for electrical conduction and an insulating layer 12 covering the core 11; mounting the plurality of conductors 1 of the cable in the plurality of cable positioning grooves 401, and extending a first end 21 of the armor layer 2 and a second end 31 of the braided layer 3 into the forming groove 402; providing a molding die (not shown), the molding die being attached to the carrier 400 and including an injection molding port and an injection molding runner, the injection molding runner communicating with the injection molding port and the molding groove 402; injecting a liquid filler into the injection molding port, the filler being injected into the molding groove 402 through the injection molding runner, and the filler permeating the braided layer 3.

[0028] After the filling material is cured, the mold and the carrier 400 are removed to obtain the cable assembly 100.

[0029] In an illustrated embodiment of the present invention, before mounting the conductors 1 of the cable into the cable positioning grooves 401, the manufacturing method includes: providing a clamp 700 and fastening said clamp 700 to said braided layer 3; The method further includes a step of laser cutting the armor layer 2 and the braided layer 3 to a required length to expose the protruding wires 111.

[0030] The carrier 400 is further provided with a positioning groove 403 for positioning the clamp 700 and a positioning locking groove 404 for positioning the braided layer 3 .

[0031] Preferably, in the illustrated embodiment of the present invention, two sets of the cable assemblies 100 can be injection molded simultaneously with the carrier 400 and the mold, thereby improving production efficiency.

[0032] When the liquid filler is injected into the injection nozzle, the temperature of the filler is T, where T≦260° C., and the viscosity of the filler is η, where η≦5000 mPa.s. As can be understood by those skilled in the art, by setting the temperature of the filler to T≦260° C., damage to the braided layer 3 and / or the armor layer 2 due to high temperature can be avoided. Preferably, 210° C.≦T≦260° C., 1 mPa.s≦η≦2000 mPa.s. The inventors have conducted intensive research and found that when 1 mPa.s≦η≦2000 mPa.s, the viscosity of the filler can penetrate the braided layer 3 relatively well and coat and integrate the braided layer 3.

[0033] Compared with the prior art, the present invention provides a fixing block 4 that is injection molded on the braided layer 3, and a part of the material of the fixing block 4 penetrates into the braided layer 3 to integrate the braided layer 3 and the armor layer 2. The provision of the fixing block 4 can firmly fix the braided layer 3 and the armor layer 2, and prevent the braided layer 3 from slipping against the armor layer 2 to cause a shrinkage phenomenon. In addition, the fixing block 4 can fix the positions of the protruding wires 111 of the plurality of conductors 1, which is advantageous for welding the core wire 11 of the cable assembly 100 to the built-in circuit board 600. As can be further understood by those skilled in the art, the provision of the fixing block 4 to integrate the braided layer 3 and the armor layer 2 is advantageous for improving the toughness and service life of the product.

[0034] The above embodiments are only for illustrating the present invention, and do not limit the technical solutions described in the present invention. The present invention should be understood based on those skilled in the art. Although the present invention has been described in detail in this specification with reference to the above embodiments, those skilled in the art can understand that they can make modifications and equivalent replacements to the present invention. All technical solutions and improvements thereto that do not depart from the spirit and scope of the present invention should be included in the scope of the claims of the present invention.

Claims

1. 1. A cable assembly comprising: A plurality of conductors (1) including a conductive core wire (11) and an insulating layer (12) covering the core wire (11); An exterior layer (2) that covers the plurality of conductors (1); A braided layer (3) that covers the exterior layer (2); a fixing block (4) that is injection molded onto the braided layer (3) and a part of its material penetrates into the braided layer (3) to integrate the braided layer (3) and the armor layer (2), The cable assembly is characterized in that the conductor (1) includes a protruding wire (111), the protruding wire (111) of at least a portion of the conductor (1) includes a curved portion (1111) and an extension portion (1112) extending from the curved portion (1111), and the fixed block (4) is molded to the curved portion (1111) of the protruding wire (111), thereby maintaining the position of the extension portions (1112) relative to each other.

2. The cable assembly described in claim 1, characterized in that the protruding wire (111) extends and protrudes from a first end (21) of the armor layer (2) and a second end (31) of the braided layer (3), and at least a portion of the fixed block (4) is molded into the first end (21), the second end (31) and a root portion (112) of the protruding wire (111).

3. The cable assembly of claim 2, characterized in that the protruding wire (111) has a root portion (112), the root portion (112) being a portion of the protruding wire (111) close to a first end (21) of the armor layer (2) and a second end (31) of the braided layer (3), and at least a portion of the fixing block (4) is molded into the insulating layer (12) of the protruding wire (111).

4. 2. The cable assembly according to claim 1, wherein the armor layer (2) is a silica gel armor layer and the braided layer (3) is a PET braided layer.

5. 2. A cable assembly according to claim 1, characterized in that the fixing block (4) is a polyamide fixing block, an acrylic resin fixing block or an epoxy resin fixing block.

6. A cable connector comprising a connector adapter (300) and the cable assembly according to any one of claims 1 to 5, wherein the core wire (11) is electrically connected directly or indirectly to the connector adapter (300).

7. A method for manufacturing a cable assembly, comprising: providing a carrier (400), the carrier (400) having a plurality of cable locating grooves (401) and a molding groove (402) communicating with the plurality of cable locating grooves (401); A step of providing a cable, the cable including a plurality of conductors (1), an armor layer (2) covering the plurality of conductors (1), and a braided layer (3) covering the armor layer (2), the conductors (1) including a conductive core (11) and an insulating layer (12) covering the core (11); mounting the plurality of conductors (1) of the cable in the plurality of cable positioning grooves (401) and extending the end of the armor layer (2) and the end of the braided layer (3) into the forming groove (402); providing a mold, the mold being attached to the carrier (400) and including an injection mold port and an injection mold runner, the injection mold runner communicating the injection mold port with the molding groove (402); Injecting a liquid filler into the injection molding port, the liquid filler is injected into the molding groove (402) through the injection molding runner, and the liquid filler penetrates into the braided layer (3); and curing the liquid filling material to obtain the cable assembly (100) according to any one of claims 1 to 5.

8. 8. The method according to claim 7, wherein when the liquid filler is injected into the injection mould hole, the temperature of the liquid filler is T, T≦260° C., and the viscosity of the liquid filler is η, η≦5000 mPa.s.

9. 9. The method according to claim 8, wherein 210° C.≦T≦260° C. and 1 mPa.s≦η≦2000 mPa.s.

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