Modular injection moulding tool and method for producing a plug connector housing

Abstract

The invention relates to a modular injection moulding tool (100) for producing a plug connector housing (10) having a first and a second tool half (110, 120), which can be brought into a closed tool position relative to each other, the first tool half (110) having a first number of first mould insert spaces (111) each for receiving a first plug module mould (130; 131, 132, 133), the second tool half (120) having a second number of second mould insert spaces (121) each for receiving a second plug module mould (140; 141, 142, 143), wherein a first mould insert space (111) and a second mould insert space (121) lie opposite one another in the closed tool position and form a mould insert space pair, wherein a plurality of first plug module moulds (130; 131, 132, 133) and a plurality of associated second plug module moulds (140; 141, 142, 143) are provided, wherein a respective first and the associated second plug module mould (130; 131, 132, 133; 140; 141, 142, 143) form a plug module mould pair (170; 171, 172, 173), wherein a plug module mould pair (170; 171, 172, 173) can be inserted into each mould insert space pair, wherein, in the closed tool position (S2), a cavity (K) for receiving injection-moulding material is formed between the first plug module mould (130; 131, 132, 133) and the associated second plug module mould (140; 141, 142, 143) of a plug module mould pair (170; 171, 172, 173).

Description

[0001] R.414798

[0002] - 1 -

[0003] Description

[0004] title

[0005] Modular injection mold and method for manufacturing a connector housing

[0006] The present invention relates to a modular injection molding tool for manufacturing a connector housing and a method for manufacturing a connector housing.

[0007] Background of the invention

[0008] Connector assemblies typically comprise a connector and a mating connector. Connecting the connector and mating connector, for example by tucking them together along an axis or in a specific direction, creates a plug connection. One application of such connectors (especially electrical ones) is, for example, in the automotive sector, connecting various components, control units, or wiring harnesses.

[0009] DE 20 2023 103 558 U1 discloses a modularly constructed connector in the form of a (cable harness) plug for connecting to a mating connector in the form of a blade connector, comprising a housing with a plurality of cup-shaped slots, wherein the slots are each defined by a surrounding wall arrangement, at least one plug module which is arranged in a slot and which is designed for receiving, in particular in a captive, at least one plug element, preferably a plurality of plug elements, and a mechanical coding device which is formed between each slot and each inserted plug module in order to provide a defined assignment between the plug module and the slot, wherein the mechanical coding device comprises a first coding element and a second coding element complementary to the first coding element R.414798

[0010] - 2 - wherein the first coding element is located on the cup-shaped slot and the second coding element is located on the plug module, and wherein each first and complementary second coding element is designed differently and / or located in a different position on the slot. This allows different plugs or different plug configurations to be assembled very easily, quickly and cost-effectively with a fundamentally identical design and external dimensions, but this creates the need for different matching mating connectors in the form of male connectors.

[0011] Disclosure of the invention

[0012] According to the invention, a modular injection mold for manufacturing a connector housing and a method for manufacturing a connector housing with the features of the independent claims are proposed. Advantageous embodiments are the subject of the dependent claims and the following description.

[0013] The invention significantly simplifies the manufacture of a male or female connector (hereinafter referred to as a connector) for receiving a (cable harness) plug (hereinafter referred to as a mating connector). The connector housing is, in particular, a connector housing of a male or female connector.

[0014] According to a first aspect of the invention, a modular injection mold is proposed which is set up to produce a connector housing for an electrical connector, in particular a knife-edge housing or a spring-edge housing, and which has a first mold half and a second mold half which can be brought into a closed mold position relative to each other, in particular parallel to a closing direction.

[0015] The closing direction is referred to below as the z-direction, and the x- and y-directions perpendicular to it define a plane parallel to which a base surface of the connector housing runs or in which the base surface of the connector housing lies. For example, see R.414798.

[0016] - 3 - oBdA the x-direction or x-axis can be used to designate a longer side of the connector housing, and the y-direction or y-axis can be used to designate a shorter side of the connector housing.

[0017] In a male connector housing, (usually metallic) contact elements ("male" contacts) are inserted or fitted into the connector housing. These can be, for example, flat blades, contact blades, pins, round pins, RF modules (high-frequency modules), etc. In a female connector housing, (usually metallic) contact elements ("female" contacts) are inserted or fitted. These can be, for example, socket-shaped. If the connector is designed as a male connector with male contact elements, these (male) contact elements typically protrude perpendicularly from the x / y plane or base of the connector housing, parallel to the z-direction, and especially pointing towards the mating connector.

[0018] The first tool half has a first number of mold insert positions for receiving one first connector module form each, and the second tool half has a second number of mold insert positions for receiving one second connector module form each. The first and second numbers are, in particular, equal. For example, there can be four, six, eight, or nine first mold insert positions and nine second mold insert positions, although other numbers are also possible. The first number can also differ from the second number.

[0019] A first (second) mold insert position can, for example, be set up so that a first (second) plug module mold, which will be described further below, can be inserted into it.

[0020] Furthermore, a first mold insert position of the first tool half and a second mold insert position of the second tool half are located opposite each other, particularly in the closed tool position, and form a mold insert position pair, wherein several first connector module shapes, particularly of different designs, are provided, wherein for each of the several first connector module shapes an associated second connector module shape R.414798

[0021] - 4 - is provided, wherein a first plug module shape and the associated second plug module shape form a plug module shape pair.

[0022] The modular injection mold is designed so that a pair of connector module molds can be inserted into each mold insert pair, wherein, in the closed mold position, a cavity for receiving injection molding material is formed between the first connector module mold and the associated second connector module mold. This cavity in the closed mold position is specifically formed between the first connector module mold and the associated second connector module mold of a pair of connector module molds inserted into a mold insert pair.

[0023] In particular, at least two connector module pairs of different designs are inserted into the mold insert pairs. Of course, in principle, all mold insert pairs can also be populated with connector module pairs of the same design (depending on the application).

[0024] In other words, the respective (first) connector module shape can, for example, be designed as a component that, particularly in conjunction with the associated (second) connector module shape, defines a geometry within a specific area of ​​the connector housing during the injection molding process. This geometry can be populated with contact elements during the injection molding process itself or subsequently. For example, defined positions (or even just a single defined position) can be specified within the defined space of the connector module shape, in which (or in which) one or more contact blades or pin(s) are molded or overmolded, or where such contact elements (or a single contact element) can be pressed ("stitched") in after the injection molding process. These defined positions (orThe single defined position can be characterized, for example, by a targeted weakening or excess of material compared to the rest of the plug-in module mold. It is also conceivable that contact elements designed as inserts (or as the only insert) are held at the defined positions (there may also be only a single defined position in the plug-in module mold) during the injection molding process, and are thus integrally or integrally formed in the finished, molded connector housing. R.414798.

[0025] - 5 -

[0026] It is understood that the (first and second) connector module forms can be of different designs. For example, one connector module form can be designed to define a large number (e.g., ten or more) contact elements, such as miniature contact elements, or their positions for the connector. Another connector module form can be designed to define only one or a few (e.g., fewer than five) contact elements, such as power contact elements, or their positions for the connector. It is further understood that such a first (second) connector module form can be used, mounted, or coupled, for example, at or in any first (second) mold insert position of the first (second) tool half.

[0027] The production of connector housing variants (especially for male or female connectors) with different contact element configurations (e.g., in one case a configuration with a high number of miniature contacts, in another exemplary case with a small number of power contacts with a large contact cross-section, in yet another exemplary case with a mixture of miniature and power contacts) while maintaining the same connector housing frame or external geometry and control unit connection geometry, typically requires the production of a new, independent injection mold for each variant. In the case of modular (mother) connectors (e.g., on the wiring harness side), such as...As demonstrated in the aforementioned DE 20 2023 103 558 U1, the advantageously simple production of a high variety of variants on the side of the cable harness connector (here, the mating connector) requires a large number of connector housing tools (here, exemplified here on the side of the blade or spring strip). High costs per tool and long tool production times can lead to a commercial problem (especially with small production runs of individual connector variants). This can, under certain circumstances, reduce or negate the advantages of the modular assembly of the mating connector on the cable harness side (see DE 20 2023 103 558 U1).

[0028] With the aid of the invention, it is advantageously possible to significantly reduce the tooling costs and tooling production times for the manufacture of the suitable connector (especially on the knife strip side or spring strip side) and R.414798

[0029] - 6 - to generate a high degree of variety with simple means. Different configuration and design variants are produced using the plug-in module form pairs as module-specific tool change inserts with identical external geometries, which can be fitted into any pair of mold insert positions in the two tool halves. Preferably, it is even possible to equip different tools (e.g., with different numbers of mold insert positions) with the same set of plug-in module form pairs, since the external geometries are always the same.

[0030] Any of the provided connector module form pairs can be inserted into the mold insert slots, especially identical or different ones, or of the same or different design. This allows for the advantageously simple and cost-effective production of different connector housings. The rapid changeover of the injection mold by inserting different connector module form pairs enables cost-effective production of such connector housings, even for small batches.

[0031] It is understood that an injection mold for such connector housings may include additional elements besides the proposed modular injection mold. For example, the modular injection mold may be inserted into a recess of a higher-level injection mold. This allows, for instance, the particularly simple production of an outer wall of the connector housing.

[0032] It goes without saying that the two tool halves can basically be used in different injection molds to create, for example, different wall thicknesses, wall shapes, etc.

[0033] According to one embodiment, one of the first and second mold halves, particularly the second mold half, forms a nozzle side, and the other of the first and second mold halves, particularly the first mold half, forms an ejector side. In injection molding technology, nozzle side and ejector side denote two distinct sides, with the liquid injection molding material being supplied via the nozzle side and the manufactured injection molded part (here: R.414798) being extruded.

[0034] - 7 -

[0035] (Connector housing) remains on the ejector side after the injection molding tool is opened and is ejected or stripped from there by means of mechanical plungers (ejectors).

[0036] According to one embodiment, all first mold insert positions (of the first tool half) have the same first mold insert cross-section, and all second mold insert positions (of the second tool half) have the same second mold insert cross-section. This allows for a very high degree of modularity, where all mold insert positions of a (respective) tool half are the same size and / or have the same design. The identical cross-section advantageously enables any permutation and / or arrangement of different connector module shapes, according to customer requirements, at various but defined locations within the connector housing.

[0037] According to one embodiment, the first mold insert cross-section and the second mold insert cross-section are identical.

[0038] This allows for even greater modularity, with the mold insert positions of both tool halves having the same cross-section, so that the first and second connector module forms also have the same cross-section. To prevent a first connector module form from being accidentally inserted into a second mold insert position, or vice versa, the fully configured tool can be monitored by a camera, and an automatic evaluation can be performed, for example, based on machine learning. Alternatively or additionally, the depth or insertion depth of the first and second mold insert positions can differ, so that the height of the first and second connector module forms would also differ accordingly.

[0039] According to another embodiment, the first mold insert cross-section and the second mold insert cross-section are designed differently (e.g., at least one lateral projection and / or at least one lateral recess), which makes it very easy to prevent a first connector module form from being accidentally inserted into a second mold insert position. R.414798

[0040] - 8 - or a second plug module form is accidentally inserted into a first form insert slot.

[0041] Alternatively or additionally, it is provided that all first connector module shapes have the same first connector module shape cross-section and all second connector module shapes have the same second connector module shape cross-section. This allows for a very high degree of modularity, where all connector module shapes of a tool half are the same size and therefore interchangeable. The identical cross-section advantageously enables any permutation and / or arrangement of different connector module shapes at various, but defined, locations within the connector housing, according to customer requirements.

[0042] The individual plug-in module shapes can be of the same design or of different designs, particularly with regard to the arrangement of contacts within the space provided by the respective plug-in module shape in the finished connector housing.

[0043] According to one embodiment, the cross-section of the first connector module form and the cross-section of the second connector module form are identical. This allows for even greater modularity, as the first and second connector module forms have the same cross-section, meaning that the mold insert positions of both tool halves (first and second mold insert positions) also have the same cross-section. To prevent a first connector module form from being accidentally inserted into a second mold insert position, or vice versa, the described camera monitoring can be used, or the height of the first and second connector module forms can be different, resulting in correspondingly different depths or insertion depths of the first and second mold insert positions.

[0044] According to another embodiment, the first connector module cross-section and the second connector module cross-section are designed differently, which makes it very easy to prevent a first connector module from being accidentally inserted into a second mold slot, or R.414798

[0045] - 9 - a second plug module form is accidentally inserted into a first form insert slot.

[0046] According to one embodiment, the first connector module form has one or more protrusions, in particular a plurality of protrusions, and the associated second connector module form has one or more corresponding recesses. In the closed tool position, at least one protrusion engages in the corresponding recess; in particular, a plurality of protrusions engage in their respective corresponding recesses; and furthermore, in particular, all protrusions engage in their respective corresponding recesses. This engagement stabilizes the protrusions during the injection molding process and improves their shape retention. In particular, a type of two-sided clamping is created, similar to Euler's fourth buckling case (the free end of the protrusion can—at the latest after a small displacement—be supported against the edge of the recess). This reduces bending of the protrusions during injection molding due to (e.g.,The flow front impacting the raised areas from the side, and the post-molding pressure at the end of the injection molding process (this post-molding pressure, in particular, exerts a force laterally on the raised area), can advantageously increase the tool life and / or allow for higher injection speeds and / or higher post-molding pressures.

[0047] The raised section can be designed, for example, as a self-supporting element, such as a knife, lance, rod, or the like. It can, in particular, have a taper at its free end. For example, the raised section can be designed to maintain a space in the injection-molded material within the base of the connector housing, into which a contact element can be inserted. In other words, the raised section can, for example, maintain a contact chamber for the contact element during the injection molding process. The tip or free end of the raised section can, for example, create a through-opening in the base of the injection mold, especially if the raised section engages in the corresponding recess or cutout of the second connector module. In other embodiments, it is possible that the base is initially closed (before the contact element is inserted) at some or all points where a contact element is provided.However, it may be provided that the free end of the survey, especially if it is tapered, is an R.414798.

[0048] - 10 - defined recess for precise positioning of the contact element in the ground (especially in its component-side part).

[0049] However, it should be noted that the first plug module shape may also have one or more second protrusions that do not engage in a corresponding recess, but stand freely, e.g. if they are very massive and do not require clamping on both sides.

[0050] It is also possible that the second plug-in module shape has no recesses or indentations whatsoever, or that none of the protrusions of the first plug-in module shape engage with any recess or indentation of the second module shape. For example, it may be possible that one, several, or all of the protrusions of the first module shape are located on a flat surface of the second module shape.

[0051] According to one embodiment, at least one raised section is designed or serves to form a recess in the connector housing, particularly in the base of the connector housing, for receiving a (metallic) contact element. The contact element can be inserted into the recess after injection molding or can be overmolded. Particularly if the contact element is a knife-shaped, pin-like, etc., male contact element as described above, it projects through the base of the connector housing to the other side (particularly from the component side (where the connector can be located, for example) towards the mating connector on the cable harness side). Specifically, the raised section does not engage completely, but only partially, in the corresponding recess.Even in the closed tool position, the first section of the raised section remains outside the recess, and only the second section (e.g., a tapered end section as described above) engages within the recess. The first raised section largely defines, for example, the connector housing recess.

[0052] It is understood that the raised sections can also be designed to accommodate female contact elements in the connector housing. R.414798

[0053] - 11 -

[0054] The first raised section can, for example, have a greater length or height in or parallel to the closing direction (which can also correspond to a plugging direction for connecting the connector 1 with the mating connector) than the second raised section.

[0055] For example, the first raised section can have a uniform or variable profile along its height extending in the z-direction. A uniform profile means that the first raised section has, for example, the overall shape of a cuboid or a cylinder, etc. A variable profile means that the first raised section has, for example, the overall shape of a truncated cone, a stepped shape, etc. It has been shown that a variable profile is advantageous for creating, for example, a slightly larger cavity to accommodate a lower part of the contact element and any cables connected to it, while requiring a smaller opening through the housing base.

[0056] According to one embodiment, the first raised section has a stepped shape with a first raised subsection and a second raised subsection, wherein the second raised subsection adjoins the second raised section and, in particular, has the same cross-section (section perpendicular to the closing direction z or in the x / y plane) as the second raised section. In other words, the raised section in a side view (i.e., on a z / x or z / y plane) can have a stepped rectangular shape (in the manner of a stepped tower) with the first raised subsection at the bottom and the second raised subsection and the second raised section above it. The second raised section can, for example, be the end section described above, especially the tapered one.

[0057] The first raised subsection can have a greater length or height in or parallel to the closing direction z (which can also correspond to a plugging direction for connecting the connector 1 with the mating connector) than the second raised subsection.

[0058] A cross-section of the first survey section and / or second survey section and / or first survey subsection and / or second R.414798

[0059] - 12 -

[0060] The raised subsection can have a rectangular or rounded rectangular shape (although round, oval, or polygonal cross-sections, etc., are also possible). This allows the use of easily manufactured contact elements (e.g., as stamped parts) with a rectangular cross-sectional shape (or round, oval, or polygonal cross-sectional shape): Such contact elements can be produced easily and cost-effectively, for example, by stamping them from a sheet of metal or by cutting them to length from a drawn part, etc.

[0061] For example, the second raised section, the end section, or the free end of the raised section (in which, for example, the contact element can be centered) can have a cross-section that, for example, is only about 0.5 mm * 0.4 mm for very thin or small contact elements, and about 0.5 mm * 0.4 mm for larger contact elements.

[0062] The contact elements have a cross-section of 1.2 mm x 0.6 mm, and for even larger contact elements, a size of, for example, approximately 2.8 mm x 0.8 mm. This allows for advantageous control of the current-carrying capacity of the contact elements. Of course, other cross-sections are also possible. For round or oval contact elements, for example, the cross-section of the second raised section or the end section can be only 0.4 mm or 0.5 mm, or 1.2 mm or 2.00 mm, etc.

[0063] Advantageously, at least one protrusion, or all protrusions, or the first protrusion segment of one or more, or all protrusions, has an aspect ratio such that a height in or parallel to the closing direction z (which may, for example, also correspond to a mating direction for connecting the connector to the mating connector) is greater than a width in the x-direction and a depth in the y-direction, preferably at least twice as large, at least three times as large, or even greater. In other words, the protrusion or the first protrusion segment can have the shape of an elongated needle or plate. This allows the depth of the recess defined by the protrusion in the connector housing to be predetermined, which is at least partly responsible for the stability and fixation of the inserted contact element.

[0064] The raised areas and recesses can be arranged, for example, in one or more rows, in particular two or three or more than three rows, wherein R.414798

[0065] - 13 - the one or more first connector module shapes having at least one, preferably at least two and / or at most thirty, preferably at most twenty, protrusions, and / or the one or more second connector module shapes having at least one, preferably at least two and / or at most thirty, preferably at most twenty, recesses. In this way, a large set of connector module shape pairs of different designs can be provided, from which the required connector module shape pairs for the specific application can then be selected and inserted into the tool halves or the mold insert pairs.

[0066] According to one embodiment, in the closed tool position, a gap with a maximum distance, particularly in an x / y plane perpendicular to the closing direction z, is formed between the raised section and the corresponding recess. This maximum distance is dimensioned such that the injection molding material does not flow through the gap, and in particular, the maximum distance is at most 0.01 mm. In other words, the gap can be formed in a radial direction (perpendicular to the closing direction) or laterally next to the raised section. This prevents the recess from being filled with injection molding material, which would lead to an undesirable closure of the recesses in the connector housing. The aforementioned gap width is particularly well-suited for this purpose because commonly used injection molding materials, such as...Polyamide (PA), polybutylene terephthalate (PBT), polyoxymethylene (POM), polystyrene (PS, HIPS, GPPS), acrylonitrile butadiene styrene (ABS), polypropylene (PP), polyethylene (PE), or thermoplastic polyurethane (TPU) may only flow through openings of at least 0.02 mm. It is understood that the aforementioned plastics may be filled with glass fibers, but this is not mandatory.

[0067] According to one embodiment, an additional blind module form pair is provided, consisting of a first blind module form and an associated second blind module form, which can be inserted into a mold insert pair. The blind module form pair is used in particular when no contact elements are provided at the location of the mold insert pair. In the closed tool position, a gap exists between the first blind module form and the associated second blind module form of a blind module form pair inserted into a mold insert pair. R.414798

[0068] - 14 -

[0069] A cavity is formed to receive injection molding material, wherein the cavity has, in particular, the shape of a base or a section thereof of the base of the connector housing. This base or section thereof can have a specifically selected thickness and / or structure, which is determined by the shaping of the first dummy module shape, the second dummy module shape, and the cavity arranged between them (especially when viewed in the z-direction). By setting this defined thickness and / or shape, warpage after completion of the injection molding process in the base or this section thereof can, for example, be minimized. The flow behavior during the injection molding process can also be positively influenced by the design of the dummy module shapes.

[0070] According to one embodiment, a connector module mold pair is inserted into each mold insert pair. According to another embodiment, either a connector module mold pair or a dummy module mold pair is inserted into each mold insert pair. In both cases, a fully populated injection mold is obtained with which a desired connector housing can be manufactured. To verify that connector module mold pairs with corresponding connector module shapes are indeed inserted, the fully configured mold can, for example, be monitored by camera, sensor, induction, or magnetic detection, and an automated evaluation can be performed, based, for example, on machine learning.

[0071] According to one embodiment, the first and second mold insert positions are arranged in a grid or matrix-like arrangement in a specified number of rows and a specified number of columns, wherein the rows and columns are arranged perpendicular to each other. For example, the rows run in the x-direction and the columns in the y-direction. Suitable configurations of the number of rows and columns can be selected depending on the application. In typical embodiments, the number of columns is at most equal to the number of rows. For typical applications, numbers of rows from 1 to 5, preferably 1 to 10, have proven advantageous. For typical applications, numbers of columns from 1 to 10, preferably 1 to 5, and particularly preferably 1 to 3, have proven advantageous. R.414798

[0072] - 15 -

[0073] According to one embodiment, at least one of the first tool half and the second tool half, in particular the second tool half, has a third set of coding insert positions for receiving a coding module form. It should be emphasized at this point that coding insert positions are not form insert positions within the meaning of the present invention, and coding module forms are not connector module forms within the meaning of the present invention. Rather, connector module forms within the meaning of the present invention always serve to form structures, in particular connector housing recesses, which serve to receive contact elements. Coding module forms can advantageously be used to create a coding structure that controls the mechanical fit of the connector with a mating connector.In particular, the coding structure serves to identify the connector depending on the connector module form pairs used in its manufacture, so that only a mating connector with matching mating contact elements will mechanically fit the connector. The coding module forms can be configured, in particular, to form grooves or ridges as a coding structure in the connector housing, especially in a mounting wall of the connector housing, wherein a mechanically matching mating connector (e.g., a cable harness-side mating connector, e.g., as described in DE 20 2023 103 558 U1) has ridges and grooves congruent with, matching with, or complementary to these grooves and ridges (in the manner of a tongue-and-groove connection).The coding module shapes can therefore form a unique coding structure on the inner collar edge of the connector housing that matches the chosen pin assignment.

[0074] The third number can be, in particular, four, with two coding positions provided on each of two opposite sides of at least one half of the tool. This allows for a sufficient number of different configurations to be coded. However, it is understood that the third number can also be, for example, one, two, three, five, or more than five.

[0075] According to one embodiment, at least one of the first tool half and the second tool half, in particular the second tool half, has a fourth number of connector insert positions for receiving one R.414798 each.

[0076] - 16 -

[0077] Connector module shapes. It should also be emphasized at this point that connector insert positions are not mold insert positions within the meaning of the present invention, and connector module shapes are not plug module shapes within the meaning of the present invention. Connector module shapes can be advantageously used to create a connector structure that supports the mechanical connection of the connector to a mating connector. In particular, the connector module shapes serve to create a connector structure, a connector, an engagement element, or an engagement structure with which a mating connector structure, a mating connector, a mating engagement element, or a mating engagement structure of the mating connector, e.g., of a cable harness connector, can couple. Possible embodiments of a connector structure comprise at least one element selected from a rack, a shaft, e.g., for driving a gear, a bearing opening, e.g.,for a wave, a backdrop, e.g. a backdrop that extends through the wall or is closed, a bolt, a projection, etc.

[0078] The fourth number can, in particular, be two, with one connector insertion point being provided on each of two opposite sides of at least one tool half. This ensures a sufficiently stable connection. Preferably, one connector insertion point is located between two coding insertion points. However, it is understood that the fourth number can also be, for example, one, two, three, five, or more than five. It is further understood that, for example, a coding insertion point can also be located between two connector insertion points (on one side of the tool half).

[0079] According to one embodiment, one of the first tool half and the second tool half, in particular the second tool half, has a housing outer wall recess, wherein the housing outer wall recess surrounds the first or second mold insert positions (depending on which of the first and second tool half it is located in). The housing outer wall recess serves to form a housing outer wall of the connector housing, in particular the wall in which the coding structure and / or the connector structure are formed. This wall can, for example, form a mating collar of the connector. R.414798

[0080] - 17 -

[0081] As described above, the housing wall recess, or the mold half in which the housing wall recess is located, can itself be surrounded by another element of a higher-level injection mold or the injection mold itself. Between the mold half and this other element, a cavity is formed, for example in the area of ​​the housing wall recess, into which injection molding material can flow during the injection molding process, thus forming the housing wall.

[0082] It goes without saying that the two tool halves can basically be used in different injection molds to create, for example, different wall thicknesses, wall shapes, etc.

[0083] According to one embodiment, one of the first tool half and the second tool half, in particular the second tool half, has at least one housing partition cavity, wherein the at least one housing partition cavity is arranged between two first mold insert positions or between two second mold insert positions (depending on which of the first and second tool half it is located in). The at least one housing partition cavity serves to form at least one housing partition. A housing partition can, for example, provide electrical insulation, for instance to prevent short circuits, between contact elements of different mold insert positions. Alternatively or additionally, it can serve as a handle guard or touch guard to, for example, prevent or hinder the penetration of fingers or objects into individual sections of the connector.Alternatively or additionally, it can be designed to reduce distortion of the connector housing by balancing the material distribution on a front side of the connector housing (e.g. facing the mating connector) and a rear side of the connector housing (e.g. facing a component such as a control unit, an inverter, an electric machine, a battery, etc.) and thus canceling out the distortion of the front and back sides when the injection molding material cools and / or shrinks.

[0084] According to a second aspect of the invention, a method for manufacturing a connector housing for an electrical connector, in particular a blade or spring-loaded connector housing, is described using R.414798

[0085] - 18 - A modular injection mold according to the first aspect of the invention is proposed, wherein the method comprises inserting a connector module mold pair, or each pair of connector module molds, into at least one mold insert pair, bringing the injection mold into the closed mold position, and injecting the injection molding material into the injection mold. This allows the advantages of the injection mold according to the invention to be transferred to the manufacturing process as well. In other words, the mold insert pairs are populated, and to form a connector housing in which at least one contact element is to be arranged, a connector module mold pair should be inserted into at least one mold insert pair. It can be provided that one connector module mold pair is inserted into each mold insert pair. It can also be provided that one connector module mold pair is inserted into several, but not all, mold insert pairs.The remaining mold insert pairs can, for example, contain or be used to contain a dummy module mold pair. If the dummy module mold pair is considered a plug-in module mold pair, it can be provided – merely as an example – that all mold insert pairs are equipped with a plug-in module mold pair each, or that a plug-in module mold pair is inserted into all mold insert pairs.

[0086] In one embodiment, a connector module mold pair is inserted into each mold insert pair. In another embodiment, either a connector module mold pair or a dummy module mold pair is inserted into each mold insert pair. In both cases, a fully populated injection mold is obtained with which a desired connector housing can be manufactured simply and reliably. A quick, cost-effective, and simple reconfiguration of the injection mold (through a rapidly changing configuration of the individual mold insert pairs with connector module mold pairs) enables the production of many different connector housing configurations with a single injection mold (especially with one or more sets of connector module mold pairs, whereby, in particular, different designs of the connector module mold pairs can be provided).

[0087] According to one embodiment, the method further comprises inserting a coding module form into at least one coding insertion site. This results in a simple and reliable coded connector housing. (R.414798)

[0088] - 19 -

[0089] This effectively prevents connection with an incorrect or incompatible mating connector. Damage to the contact elements is thus advantageously prevented.

[0090] In principle, such a coding module shape can be formed on an inside of a connector housing wall and / or on an outside of a connector housing wall (collar wall) in the finished manufactured state.

[0091] According to one embodiment, the method further comprises inserting a connector module into at least one connector slot. This results in a connector housing with a connector structure that is simple and reliable. This can advantageously achieve, for example, a reduction in operating force when mating the connector and mating connector. For instance, an operating element, such as a lever or a slider, can be arranged on the connector or the mating connector. This operating element can couple with the connector structure and facilitate the mating of the connector and mating connector.

[0092] In principle, such a connector module shape can be formed on an inside of a connector housing wall and / or on an outside of a connector housing wall (collar wall) in the finished manufactured state.

[0093] According to one embodiment, inserting the connector module pair into at least one mold insert slot comprises inserting at least two connector module pairs, particularly of different designs, into at least two different mold insert slot slots. This allows for the very simple and cost-effective production of different connector housings. For example, all connector module pairs can be of the same design. If, for instance, the first and second mold insert slots are arranged in a 3x3 matrix, all nine connector module pairs can be identical in design (e.g., each having space for 20 miniature contacts when using a first design, or space for 3 power contacts when using a second design, or space for 10 medium-sized signal contacts when using a third design, etc.). In other configurations or...However, in some assembly variants, the mold insert slots may also be occupied by pairs of plug modules that have at least partially different designs. This is R.414798.

[0094] - 20 - It is possible that all - in the example 3x3, i.e., nine - connector module pairs differ from one another, meaning that there are nine different designs (including a potentially used dummy module pair). However, it is also possible to use several connector module pairs of the same design, e.g., three connector module pairs each of the first, second, and third designs described above. Overall, this allows for a very large variety of connector housing configurations in a short time with minimal effort, similar to a modular system. New designs, contact types, or contact layouts can be created and tested with minimal effort upon customer request or for experimental purposes. This does not require the creation of a completely new tool, but only the cost-effective and quickly implementable, possibly...The creation of a new type of connector module form pair, achievable in a 3D printing process.

[0095] According to a third aspect of the invention, a set of at least two connector housings of different designs is proposed, which are manufactured according to a method according to the invention, in particular wherein the different connector housings or connector housings of different designs are configured, especially in the state fitted with contact elements, to be plugged together with a modularly populated (and suitable for the respective design of the connector housing) mating connector housing, in particular a modularly populated mating connector, as described, for example, in the introductory DE 202023 103558 U1, to form a connector arrangement. In particular, the different connector housings fitted with contact elements constitute a set of connectors (of different designs ordifferent contact element configurations and, in particular, the same external shape) which are designed to be plugged together with the modularly equipped mating connectors - as described, for example, in the introductory DE 202023 103 558 U1 - to form a connector arrangement with different contact element and mating contact element configurations or configurations.

[0096] Tool halves, plug module shapes, coding module shapes and connector module shapes that can be advantageously used within the scope of the invention expediently comprise a metal, for example steel, or consist of a R.414798

[0097] - 21 - such. They can be manufactured, for example, by a subtractive manufacturing process (e.g., milling, drilling, EDM, etc.). However, it may be possible—especially for rapid trials or small production runs—to manufacture individual elements of these components, in particular, for example, a first and / or second connector module form, a coding module form, and / or a connector module form, using a 3D printing process. This is particularly feasible because the aforementioned components have relatively small dimensions. In this way, small production runs or experiments regarding a contact element configuration or a new type of contact element can be carried out quickly and at low cost.

[0098] Further advantages and embodiments of the invention will become apparent from the description and the accompanying drawing.

[0099] The invention is schematically illustrated in the drawing using exemplary embodiments and is described below with reference to the drawing.

[0100] Brief description of the drawings

[0101] Figure 1 shows a modular injection mold for producing a connector housing for an electrical connector with a first tool half and a second tool half according to an embodiment of the invention and a connector housing produced therewith, in particular a knife strip housing, in a perspective overview view.

[0102] Figure 2 shows the injection mold from Fig. 1 with separate plug module molds, coding module molds and connector module molds.

[0103] Figure 3 shows selected first and second connector module shapes, which together form three connector module shape pairs, with a cross-sectional view of connector housing recesses of a connector housing that can be manufactured with them. R.414798

[0104] Figure 4A shows a perspective view of a first tool half with first plug module forms inserted into first plug module form slots.

[0105] Figure 4B shows a perspective view of a second tool half with second plug module forms inserted into second plug module mold slots.

[0106] Figures 5A to 5C show in a schematic sectional view three steps of a method for manufacturing a connector housing according to an embodiment of the invention.

[0107] Figures 6A and 6B show a connector housing with contact elements produced according to an embodiment of a method for manufacturing a connector housing before and after assembly from a bottom side.

[0108] Figures 7A and 7B show the connector housing from Fig. 6 with contact elements before and after assembly from a top view.

[0109] embodiment(s) of the invention

[0110] A preferred embodiment of a modular tool 100 or injection mold, and of a method for manufacturing a connector housing 10 for an electrical connector 1, is described below with reference to Figures 1 to 7, in which the tool 100 is shown in different views, as explained above. It is understood that for manufacturing the connector housing 10, in particular its outer wall or its mating collar, a further element of the higher-level injection mold, not shown here, may be provided. The modular injection mold 100 can, for example, interact with the element not shown here. This element may, for example, be a cavity or recess into which the modular injection mold is inserted, is inserted, or can be inserted. For the modular concept and for R.414798

[0111] - 23 - However, this additional element is not essential for the achievable variety of variants.

[0112] The modular injection mold 100 is configured to produce a connector housing 10 for an electrical connector 1 (see Figs. 6A, 6B, 7A, 7B), where a knife-edge connector housing is shown as the connector housing 10 in the figures. During the production of the connector 1, contact elements 2 (here, by way of example, "male" contacts) are inserted into the knife-edge connector housing, which is shown here only as an example. These contact elements are, by way of example, knife-shaped or flat-knife-shaped. They can also be round pins or pins with a square cross-section, etc. They can be, for example, stamped or stamped-bent parts or drawn parts. The injection mold 100 has a first mold half 110 and a second mold half 120, which are shown by way of example in an open mold position S1 in Fig. 1 with the (finished and demolded) connector housing 10 between them.It is understood that the connector housing 10 can also be designed as a spring-loaded terminal housing or as a connector housing for fitting with female contact elements or for mixed fitting with male contact elements and female contact elements.

[0113] According to the illustrated, merely exemplary, embodiment, the second tool half 120 forms a nozzle side through which the liquid injection molding material is supplied, and the first tool half 110 forms an ejector side on which the manufactured connector housing 10 initially remains after the injection mold has been opened and is ejected or stripped from there by means of mechanical plungers (not shown) (see Figs. 5A to 5C).

[0114] The first tool half 110 and the second tool half 120 can be brought into a closed tool position S2 (see Fig. 5A) relative to each other, for example, parallel to a closing direction z. The closing direction is referred to below as the z-direction, and the x- and y-directions perpendicular to it define a plane parallel to which a base surface of the connector housing 10 runs, or in which, by way of example, the base surface of the connector housing 10 lies. Here, the x-direction or x-axis is used only as an example to refer to a longer side of the connector housing 10. R.414798

[0115] - 24 - is designated and with the y-direction or y-axis a shorter side of the connector housing 10.

[0116] The first tool half 110 has a first number, here nine, of first mold insert positions 111 for receiving one first connector module form 130, 131, 132, 133 each. In principle, the first number can also be greater or less than nine. In particular, it can be, for example, one, two, three, four, five, six, seven, eight, ten, eleven, twelve, or more than twelve. Preferably, the first number is greater than one, in particular greater than two.

[0117] Likewise, the second tool half 120 has a second number, also nine, of second mold insert positions 121 for receiving a second connector module form 140, 141, 142, 143 each. In principle, the second number can also be greater or less than nine. In particular, it can be, for example, one, two, three, four, five, six, seven, eight, ten, eleven, twelve, or more than twelve. Preferably, the second number is greater than one, in particular greater than two.

[0118] In the example shown, the first mold insert positions 111 and the second mold insert positions 121 are arranged in a grid or matrix-like configuration with three rows and three columns (3 x 3 = 9), where the rows and columns are perpendicular to each other. For example, the rows run in the x-direction and the columns in the y-direction. Thus, the columns and rows are arranged perpendicular to each other.

[0119] Each first mold insert position 111 of the first tool half 110 and a second mold insert position 121 of the second tool half 120 are opposite each other in the closed tool position S2 or are opposite each other in the closed tool position S2 and form a mold insert position pair.

[0120] To enable numerous different configurations of the connector housing 10, several first connector module forms 130, 131, 132, 133 are provided, which in particular have a different design (here each of the different designs shown is designated with its own reference numeral 131, 132, 133), from which any selection can be made for R.414798

[0121] - 25 -

[0122] The first mold insert positions 111 can be populated. For each of the several first connector module shapes 131, 132, 133, a corresponding second connector module shape 140, 141, 142, 143 is provided for populating the second mold insert positions 121, wherein the second connector module shapes 140, 141, 142, 143 have, in particular, different designs (here, each of the different designs shown is designated with its own reference numeral 141, 142, 143). Each first connector module shape 131, 132, 133 and the corresponding second connector module shape 141, 142, 143 form a connector module shape pair 171, 172, 173 or connector module shape pairs 170.

[0123] Each of the first connector module forms 130, 131, 132, 133 shown here as examples has several projections 200, and the corresponding second connector module forms 140, 141, 142, 143 have several corresponding recesses 300. The projections 200 are designed here as examples of elongated elements, e.g., needle-shaped, knife-shaped, or plate-shaped. They are connected to the first tool half 110 at a root of the respective projection and each has a free or cantilevered end. It is shown here as examples that the cantilevered end is formed in an end section and that the cantilevered end is tapered relative to the root.

[0124] In principle, it is also conceivable that a first plug module form 130 has no protrusion 200 (e.g. a dummy module form) or has exactly one single protrusion 200.

[0125] The protrusions 200 serve to form connector housing recesses 11 or connector housing indentations for receiving the contact elements 2 in the connector housing 10, in particular in a base 14 of the connector housing 10. In other words, each protrusion 200 creates a kind of contact chamber into which (e.g., each) a contact element 2 can be inserted (but does not have to be). In the example shown according to Fig. 6A, the contact elements 2 are subsequently inserted into the connector housing recesses 11 after injection molding, in particular by pressing, shooting, stitching, or similar means, and then project (from one side, in particular the component side, rear side 30 of the connector housing 10) through the base 14 of the connector housing 10 to the other side, which R.414798

[0126] - 26 - for example, a front side 31 of the connector housing 10, which here is shown as an example facing the mating connector (e.g. a cable harness connector).

[0127] The raised areas 200 and recesses 300 are arranged in the example shown in one (first and second plug module shape 131; 141 of a first design) or two (first and second plug module shape 132, 133; 142, 143 of a second and third design) rows and in three (plug module shape 131; 141), five (plug module shape 132; 142) or ten (plug module shape 133; 143) columns.

[0128] The first connector module type 131 (first design) has three protrusions 200, as does the second connector module type 141 (first design) which has three recesses. The first connector module type 132 (second design) has ten protrusions 200, as does the second connector module type 142 (second design) which has ten recesses. The first connector module type 133 (third design) has twenty protrusions 200, as does the second connector module type 143 (third design) which has twenty recesses. In this way, a large set of connector module form pairs 170, 171, 172, 173 of different designs (here designated by reference numerals 171, 172, 173) can be provided, from which the required connector module form pairs for the specific application can then be selected and inserted into the tool halves 110, 120 or the mold insert pairs 111, 121.It goes without saying that, in principle, more than three construction types are conceivable, or in other applications, fewer than three. Furthermore, a construction type (or several construction types) not shown here may have a different arrangement of raised features than depicted here.

[0129] The modular injection mold 100 is designed such that a pair of connector module molds 170, 171, 172, 173 can be inserted into each mold insert pair, wherein, in the closed mold position S2, a cavity K (see Fig. 5A) for receiving injection molding material is formed between the first connector module mold 130, 131, 132, 133 and the associated second connector module mold 140, 141, 142, 143. This cavity K is – in the closed mold position S2 – specifically between the first connector module mold 130, 131, 132, 133 and the associated second connector module mold 140, 141, 142, 143, a [R.414798]

[0130] - 27 -

[0131] Form insert place pair of inserted plug module form pair 170, 171, 172, 173 formed.

[0132] In the illustrated embodiment, which is merely an example, all first mold insert positions 111 have the same first mold insert cross-section, and all second mold insert positions 121 have the same second mold insert cross-section. The first mold insert cross-section and the second mold insert cross-section can be identical, for example. However, it is also conceivable that they differ, e.g., to prevent accidental loading of a second plug-in module form 140, 141, 142, 143 into a first mold insert position 111 and / or e.g., to prevent accidental loading of a second mold insert position 121 with a first plug-in module form 130, 131, 132, 133.

[0133] Furthermore, all first connector module forms 130, 131, 132, 133 have the same first connector module cross-section, and all second connector module forms 140, 141, 142, 143 have the same second connector module cross-section. The first and second connector module cross-sections can be identical, for example. However, it is also conceivable that they differ, e.g., to prevent incorrect assembly on or in the wrong tool half 110, 120.

[0134] In particular, cross-section refers to a section through or a projection onto the x / y plane.

[0135] In the closed tool position S2, at least one projection 200 engages in the corresponding recess 300 (see Fig. 5A-C). In the embodiment shown, all projections 200 engage in their respective corresponding recesses 300. This engagement stabilizes the projections 200, particularly their free ends, during the injection molding process and improves their shape retention. Specifically, it creates a clamping action on both sides, similar to Euler's fourth buckling case (or, in the event of a lateral or radial force, e.g., from a flow front, the free end can, after a short (lateral) displacement, be supported against an edge of the recess 300, thus creating a clamping action). This advantageously reduces the degree of bending of the projections 200 during injection molding, e.g., due to R.414798.

[0136] - 28 -

[0137] Flow front and / or post-pressure at the end of injection molding. This can advantageously increase the service life of the mold 100 or individual raised sections 200. Furthermore, it allows for higher injection speeds and / or higher post-pressures, enabling greater flexibility in injection molding. Finally, it allows for raised sections with smaller cross-sections (in the xy-plane) and / or greater lengths (parallel to the z-direction), and / or it allows for the selection of a less stable and potentially more cost-effective material for the mold 100 or for the respective plug-in module shape 130, 131, 132, 133. In other words, the degrees of freedom in the production of individual elements of the mold halves are increased.

[0138] Figure 5A shows a situation in which, during a method for manufacturing the connector housing 10 according to an embodiment of the invention using the injection mold 100, the two mold halves 110, 120 are in the closed mold position S2 and injection molding material is received or injected into the cavity K between the first connector module shape 133 and the associated second connector module shape 143, forming the connector housing 10 or a part thereof.

[0139] Figure 5B shows a situation in which the two tool halves 110, 120 are in the open tool position S1 and the connector housing 10 remains on the ejector side formed here by the first tool half 110.

[0140] Finally, Figure 5C shows a situation in which the connector housing 10 was ejected by means of ejectors A.

[0141] As can be seen in Fig. 5A, the protrusions 200 do not fully engage, but only partially, in their respective corresponding recesses 300. Thus, even in the closed tool position S2, a first protrusion section 210 of each protrusion 200 remains outside the recess 300, and only a second protrusion section 220 of each protrusion 200 engages in the recess 300. The first protrusion section 210 then defines the connector housing recesses 11 (on the back side 31) or the exemplary contact chambers in the finished connector housing 10. R.414798

[0142] - 29 -

[0143] The first raised section 210, for example, has a greater length or height in or parallel to the closing direction z (which can also correspond, for example, to a plug-in direction for connecting the connector 1 to the mating connector) than the second raised section 220. The first raised section 210 has a variable profile along its height extending parallel to the z-direction. Specifically, the first raised section 210 has a stepped or tapered shape with a first raised subsection 211 (which can, for example, define a stitch area in the connector housing 10 in which a pressed-in contact element 2 can be held, for example, by interlocking) and a second raised subsection 212 (which can, for example, define a centering area in the connector housing 10 that can serve for the precise positioning of a contact element 2 during assembly).The second raised section 212 adjoins the second raised section 220 and has the same cross-section (section perpendicular to the closing direction z or in the x / y plane) as the second raised section 220. In other words, the raised section 200 (see Fig. 5A-C) has a stepped rectangular shape in a side view on an x / z plane, resembling a stepped tower, with the first raised section 211 at the bottom and the second raised section 212 and the second raised section 220 above it. The second raised section 220 here exemplifies the free or cantilevered end of the raised section 200 (and engages in the recess 300). The roots of the respective elevations 200 can be clearly seen in Fig. 5C: they are located on the underside of the elevations 200, where they are connected to a plug-in module base of the plug-in module form 133 of the third type shown here.

[0144] The first elevation subsection 211 (which can, for example, define a stitch area in the connector housing 10) has, as an example, a greater length or height in or parallel to the closing direction z (which can, for example, also correspond to a plugging direction for connecting the connector 1 with the mating connector) than the second elevation subsection 212 (which can, for example, define a centering area in the connector housing 10).

[0145] A cross-section of the first survey subsection 211 and the second survey subsection 212 and the second survey section 220 shows R.414798

[0146] - 30 - Here, a rectangular or rounded rectangular shape is shown as an example (although round or oval cross-sections, polygonal cross-sections, or the like are also conceivable). A rectangular cross-section results in rectangular openings into which easily manufactured contact elements 2 with a rectangular cross-section (e.g., as stamped or drawn parts) can be inserted. Round, oval, or polygonal cross-sections, etc., also allow for the simple manufacture of the contact elements, especially as drawn parts or as stamped (bent) parts.

[0147] For example, the second elevation subsection 212 and / or the second elevation section 220 can have a cross-section which, for example, in the case of connector module shape 133 (third design) for very thin or small contact elements (miniature contact elements) has a size of, for example, only about 0.5 mm * 0.4 mm, in the case of connector module shape 132 (second design) for larger contact elements has a size of, for example, about 1.2 mm * 0.6 mm and in the case of connector module shape 131 (first design) for even larger contact elements has a size of, for example, about 2.8 mm * 0.8 mm.

[0148] Here, all the raised sections, and in particular the first raised section 211 of all raised sections 200, exhibit an aspect ratio in which, for example, a height parallel to the closing direction z (which can also correspond to a plug-in direction for connecting the connector 1 to the mating connector) is significantly greater than a width in the x-direction and a depth in the y-direction, preferably at least twice as large, at least three times as large, at least five times as large, or even greater. In other words, the first raised section 210 can have the shape of an elongated needle, plate, knife, or flat knife, etc. Thus, the depth of the connector housing recess 11 defined by the raised section 200 (or...) can be significantly greater than the width in the x-direction and the depth in the y-direction.The contact chamber is defined in the connector housing 10, which is at least partly responsible for the stability, fixation, and necessary assembly force of the inserted contact element 2. The total length of the first raised section 210 and the second raised section 220 can, for example, be in the range of 5 mm to 20 mm, preferably 8 mm to 15 mm, and can be, for example, 1 cm.

[0149] In the closed tool position S2, there is a gap (not shown) between each protrusion 200 and the corresponding recess 300 with an R.414798

[0150] - 31 - the largest distance is formed in the x / y plane perpendicular to the closing direction z, wherein this largest distance is dimensioned such that the gap is not penetrated by the injection molding material. For example, the largest distance can be at most 0.01 mm. This prevents the recess 300 from being filled with injection molding material, which would lead, for example, to an undesirable closure of the connector housing recesses 11 (then the bottom 14 of the connector housing 10 would be closed above the connector housing recess 11). Furthermore, it is advantageously ensured that the protrusion 200 abuts the edge of the recess 300 after only a (very) short lateral displacement and is prevented from displacing further. The protrusion 200 is thus effectively clamped in the recess 300, thereby causing the fourth Euler buckling case described above for the bending or kinking of the protrusion.

[0151] Furthermore, in the example shown, the second tool half 120 has a third set of four coding insert positions 122, each for receiving a coding module form 150. The coding module forms 150 are used to create a coding structure 15 (see Fig. 3) that controls the mechanical fit of the connector 1 (see Figs. 6A to 7B) with a mating connector. In particular, the coding structure 15 serves to identify the connector 1 depending on the connector module form pairs 170, 171, 172, 173 used in its manufacture, so that only a mating connector with matching contact elements for the contact elements 2 (poka-yoke) will mechanically fit the connector 1. The coding module shapes 150 can be used in particular to form grooves or ridges and ribs as a coding structure 15 in the connector housing 10, especially in a housing outer wall 12 or enclosing wall ora collar or a plug-in collar of the connector housing 10 must be provided (e.g., on the inside of the aforementioned structures). A mechanically matching mating connector must then have congruent or complementary ribs and grooves (in the manner of a tongue-and-groove connection) to these grooves and ridges.

[0152] Furthermore, in the example shown, the second tool half 120 has a fourth set of two connector insert positions 123, each for receiving a connector module shape 160. Connector module shapes 160 are designated R.414798.

[0153] - 32 - is used to create a connector structure 16 that supports or facilitates the mechanical connection of the connector 1 with a mating connector (e.g., reduces the operating force required when connecting and / or disconnecting connector 1 and mating connector). In particular, the connector module shapes 160 serve to create a connector structure 16 with which a mating connector structure of the mating connector, e.g., a cable harness connector, can couple. In the embodiment shown, the connector structure 16 comprises, for example, two lateral racks into which, for example, a gear of a mating connector structure can engage. This enables force transmission, especially if, for example, an operating element, e.g., in the form of a lever and / or a slider, is coupled to the mating connector structure.

[0154] Furthermore, in the example shown, a housing outer wall recess 180 is formed in the second tool half 120. This recess surrounds the second mold insert positions 121 and serves to form the housing outer wall 12, the collar, or the plug-in collar of the connector housing 10. As described above, this housing wall recess 180 can interact with another element of the (superior) tool in such a way that a housing outer wall cavity is formed between the housing wall recess 180 and this other element (during the injection molding process). Injection material can be injected into this cavity, and after the injection molding compound has hardened, it forms the housing wall 12, the surrounding wall, the collar, or the plug-in collar.

[0155] Furthermore, in the example shown, six housing partition cavities 181 are formed in the second tool half 120, each of which is arranged between two second mold insert positions 121 (viewed here in the y-direction) and serves to form (here six) housing partition walls 13.

[0156] The solution according to the invention makes it possible, in particular, to provide a set of at least two connector housings 10 of different designs. These connector housings 10 (of different designs or contact element configurations) are then, in particular, configured to be fitted, especially in the state fitted with contact elements 2, each with a modularly configurable mating connector housing, in particular a modularly configurable R.414798

[0157] - 33 -

[0158] Mating connectors, to be plugged together to form a connector assembly. In particular, the different connector housings 10 equipped with contact elements 2 (or with at least one contact element 2) constitute a set of connectors 1 (of different design or different contact element configuration and in particular the same external shape) which are designed to be plugged together with the modularly equipped mating connectors - as described, for example, in the aforementioned DE 20 2023 103 558 U1 - to form a connector assembly with different contact element and mating contact element configurations or configurations.

Claims

R.414798 - 34 - Claims 1. Modular injection mold (100), configured for producing a connector housing (10) for an electrical connector (1), in particular a blade connector housing or a spring connector housing, the injection mold (100) comprising a first mold half (110) and a second mold half (120) which can be brought into a closed mold position (S2) relative to each other, in particular parallel to a closing direction (z), wherein the first mold half (110) has a first number of first mold insert positions (111) for receiving one first connector module shape (130; 131 , 132 , 133) each, wherein the second mold half (120) has a second number of second mold insert positions (121) for receiving one second connector module shape (140;141, 142, 143), wherein a first mold insert position (111) of the first tool half (110) and a second mold insert position (121) of the second tool half (120) are opposite each other in the closed tool position (S2) and form a mold insert position pair, wherein several first connector module shapes (130; 131, 132, 133) are provided, wherein for each of the several first connector module shapes (130; 131, 132, 133) an associated second connector module shape (140; 141, 142, 143) is provided, wherein each first connector module shape (130; 131, 132, 133) and the associated second connector module shape (140; 141, 142, 143) form a connector module shape pair (170; 171) , 172, 173) form, wherein the modular injection mold (100) is designed such that a plug module mold pair (170; 171 , 172, 173) can be inserted into each mold insert pair, wherein in the closed mold position (S2) between the first plug module mold (130;131 , 132, 133) and the associated second connector module form (140; 141 , 142, 143), in particular one into a; R.414798 - 35 - The mold insert place pair of the inserted plug module mold pair (170; 171 , 172, 173) forms a cavity (K) for receiving injection molding material.

2. Modular injection mold (100) according to the preceding claim, wherein all first mold insert positions (111) have the same first mold insert cross-section, wherein all second mold insert positions (121) have the same second mold insert cross-section, in particular wherein the first mold insert cross-section and the second mold insert cross-section are identical, and / or wherein all first connector module shapes (130; 131 , 132, 133) have the same first connector module shape cross-section, wherein all second connector module shapes (140; 141 , 142, 143) have the same second connector module shape cross-section, in particular wherein the first connector module shape cross-section and the second connector module shape cross-section are identical.

3. Modular injection mold (100) according to one of the preceding claims, wherein the first connector module shape (130; 131 , 132, 133) has one or more protrusions (200), in particular a plurality of protrusions (200), wherein the associated second connector module shape (140; 141 , 142, 143) has one or more corresponding recesses (300), wherein in the closed mold position (S2) at least one protrusion (200) engages in the corresponding recess (300), in particular wherein a plurality of protrusions (200) engage in the respective corresponding recess (300).

4. Modular injection mold (100) according to the preceding claim, wherein in the closed mold position (S2) between the protrusion (200) and the corresponding recess (300) a gap with a maximum distance, in particular in a direction on the closing direction (z) R.414798 - 36 - perpendicular plane, is formed, wherein the largest distance is dimensioned such that the gap is not penetrated by the injection molding material and wherein the largest distance is in particular at most 0.01 mm.

5. Modular injection molding tool (100) according to one of the two preceding claims, wherein the at least one protrusion (200) is configured to form a connector housing recess (11) for receiving a contact element (2) in the connector housing (10), in particular in a base (14) of the connector housing (10).

6. Modular injection mold (100) according to one of the preceding claims, wherein the first mold insert positions (111) and the second mold insert positions (121) are arranged in a grid- or matrix-shaped arrangement in a number of rows and a number of columns, wherein in particular the rows and columns are arranged perpendicular to each other.

7. Modular injection mold (100) according to one of the preceding claims, wherein at least one of the first mold half (110) and the second mold half (120), in particular the second mold half (120), has a third number of coding insertion places (122) for receiving one coding module shape (150) each.

8. Modular injection molding tool (100) according to one of the preceding claims, wherein at least one of the first tool half (110) and the second tool half (120), in particular the second tool half (120), has a fourth number of connector insertion places (123) for receiving one connector module shape (160) each.

9. Modular injection mold (100) according to one of the preceding claims, R.414798 - 37 - wherein a housing outer wall recess (180) is formed in one of the first tool half (110) and the second tool half (120), in particular the second tool half (120), wherein the housing outer wall recess (180) surrounds the first and second mold insert positions (111 , 121).

10. Modular injection mold (100) according to one of the preceding claims, wherein at least one housing partition cavity (181) is formed in one of the first mold half (110) and the second mold half (120), in particular the second mold half (120), wherein the at least one housing partition cavity (181) is arranged between two first mold insert positions (111) or between two second mold insert positions (121).

11. Method for manufacturing a connector housing (10) for an electrical connector (1), in particular a blade connector housing or spring connector housing, using a modular injection mold (100) according to one of the preceding claims, the method comprising: -- Inserting a connector module form pair (170; 171 , 172, 173) into at least one form insert pair, -- Bringing the injection mold (100) into the closed mold position (S2), -- Injecting the injection molding material into the injection mold (100).

12. The method of claim 11 with reference to claim 7, further comprising: Inserting a coding module shape (150) into at least one coding insertion station (122).

13. The method of claim 11 or 12 with reference to claim 8, further comprising: Inserting a connector module shape (160) into at least one connector insertion position (123). R.414798 - 38 - 14. Method according to any one of claims 11 to 13, wherein the insertion of the connector module form pair (170; 171 , 172, 173) into at least one form insert pair comprises: -- Inserting at least two connector module form pairs (170; 171 , 172, 173), in particular of different designs, into at least two different form insert positions.

15. Set of at least two connector housings (10) of different designs, manufactured according to a method according to one of claims 11 to 14, in particular wherein the connector housings (10) of different designs are configured to be plugged together, in particular in the state fitted with contact elements (2), with a modularly populated mating connector housing, in particular a modularly populated mating connector, to form a connector arrangement.

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