Multi-Wire Cable Connector Overmolding With Integrated Die Forming
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Solution Overview
Problem
The complexity and cost of manufacturing electrical connectors for multi-wire cables are increased due to the need for various manufacturing machines for different processes such as deformation and overmolding, which complicates the assembly and integration of connector components.
Innovation Solution
A method that combines selective deformation of the outer conductor using dies and overmolding in a single operation within a mold, where the dies position to form a sealed cavity for injection molding, ensuring the plasticized compound does not cover the deformed regions, thereby simplifying the manufacturing process and reducing equipment requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple manufacturing machines are used for deformation and overmolding processes, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent combines the deformation process (using dies) and the overmolding process (using injection mold parts) into a single integrated mold assembly. The dies remain positioned on the outer conductor after deformation to serve as part of the mold cavity boundaries during the subsequent overmolding operation, eliminating the need for separate manufacturing machines and reducing overall device complexity while maintaining manufacturing precision.
2Manufacturing precision
If multiple manufacturing machines are used for deformation and overmolding processes, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent integrates deformation and overmolding into a single operational step using an integrated mold assembly containing both dies and injection mold parts. This consolidation reduces the number of required manufacturing machines and operational steps, thereby reducing manufacturing costs while maintaining the precision benefits of controlled deformation and overmolding processes.
3Manufacturing precision
If the mold cavity is properly bounded to prevent compound coverage of deformed regions, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The dies serve multiple functions: they perform the deformation of the outer conductor during the first operation, and then remain positioned to act as boundary-defining elements for the mold cavity during the subsequent overmolding operation. This multi-functionality of the dies simplifies the overall mold assembly design while ensuring precise positioning of the overmold relative to the deformed regions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces manufacturing complexity and costs by integrating deformation and overmolding steps, allowing for efficient production of electrical connectors with improved impedance and strain relief, while maintaining electrical contact and shielding integrity.
Implementation Method 1
a mold cavity to be filled with a plasticized molding compound to form the overmold
Data Source
AI summary
A method can be applied for manufacturing an electrical connector on an end portion of a multi-wire electrical cable whose wires are surrounded annularly in cross section in the end portion by an outer conductor. The outer conductor is partially radially compressed toward the wires by at least one die, and is also partially provided with an overmold in an injection mold. In the method, after the outer conductor is deformed, the die is positioned on the outer conductor in such a way that the die partially bounds a mold cavity to be filled with a plasticized molding compound to form the overmold. At least one mold part of the injection mold is moved toward the outer conductor and the mold part is positioned in a vicinity of the outer conductor so to further bound the mold cavity.