Cable Connector Strain Relief Molding with Dowel Pin Fixturing
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Solution Overview
Problem
Existing methods for manufacturing cable connector assemblies face issues with uneven strain relief formation due to high pressure, leading to adhesion problems with the outer boot, as the shielding shell and cable may drift during the molding process, resulting in thick and thin areas.
Innovation Solution
A method involving connecting a mating member to a cable through a printed circuit board, enclosing a shell, fixing dowel pins, molding a strain relief, removing the pins to create pinholes, and telescoping an outer over-mold along the front-to-back direction to stabilize the strain relief formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high pressure is applied during molding the strain relief, then the strain relief is formed more completely, but the shielding shell and cable drift causing uneven thickness
Solution Approach 1:
The patent applies preliminary action by fixing the shielding shell and cable in their proper positions before the molding process begins.定位 fixtures are used to pre-position these components, ensuring they remain stable during subsequent high-pressure molding operations, thus preventing drift and achieving uniform strain relief thickness.
Solution Approach 2:
The patent introduces an intermediary element - the molding fixture with定位 features - that mediates between the molding process and the components being molded. This fixture transfers and distributes the molding pressure uniformly while maintaining component positions, preventing direct pressure-induced drift of the shielding shell and cable.
2Productivity
If the strain relief is formed unevenly, then the molding process is faster, but the adhesion of the outer boot is affected
Solution Approach 1:
By pre-positioning the shielding shell and cable using fixtures before molding, the patent ensures uniform strain relief formation from the start. This preliminary positioning prevents the need for rework or adjustments, maintaining both high productivity and reliable outer boot adhesion through consistent strain relief quality.
3Manufacturing precision
If dowel pins are used to fix the shell during molding, then the strain relief forms uniformly, but additional steps are required to remove the pins
Solution Approach 1:
The patent applies the extraction principle by using removable dowel pins that are taken out after serving their positioning function. The pins are inserted during molding to ensure uniform strain relief formation, then removed in a separate step, leaving pinholes in the strain relief. This separates the positioning function from the final product structure.
Solution Approach 2:
The dowel pins serve as temporary intermediary elements that facilitate uniform strain relief formation during molding. They mediate the positioning requirement without becoming permanent part of the final product, as they are removed after serving their purpose, leaving only pinholes that may serve functional purposes.
Data Source
AI summary
A method of manufacturing a cable connector assembly including the steps of: connecting a mating member to a cable through an internal printed circuit board; enclosing a shell over the mating member and the cable; fixing a number of dowel pins to the shell; molding a strain relief over the shell; removing the dowel pins to form a number of pinholes in the strain relief; and telescoping an outer over-mold on the strain relief along a front-to-back direction.