Plastic and nonmetallic article shaping or treating: processes – Mechanical shaping or molding to form or reform shaped article – To produce composite – plural part or multilayered article
Reexamination Certificate
1998-09-03
2001-02-13
Ortiz, Angela (Department: 1732)
Plastic and nonmetallic article shaping or treating: processes
Mechanical shaping or molding to form or reform shaped article
To produce composite, plural part or multilayered article
C264S261000, C264S277000
Reexamination Certificate
active
06187242
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of molding a connector.
The present application is based on Japanese Patent Application No. Hei. 9-238510, which is incorporated herein by reference.
2. Description of the Related Art
There have heretofore been known various methods of molding a connector used for electrical connection purposes in an electric system in an automobile and so on. For example, Unexamined Japanese Patent Publication No. Hei. 6-223903 discloses a connector having a plurality of metal terminals, and the connector that is formed by insert-molding at a time.
In the above method, however, molding the connector by a mold while accurately positioning the metal terminals in the mold may be difficult. Therefore, there is a possibility that the terminals are displaced out of position by jets of a molding material during the molding operation is formed.
SUMMARY OF THE INVENTION
With the above problems in view, it is an object of this invention to provide a connector molding method in which the accuracy of the positioning of a plurality of metal terminals is enhanced.
According to the present invention, there is provided a method of molding a connector comprising a housing having fitting recesses formed respectively in opposite ends thereof for respectively receiving mating connectors, and a plurality of male metal terminals each of which is embedded in the housing, and has connection portions projecting respectively into the fitting recesses, wherein a primary molded body is molded in such a manner that the male metal terminals are kept insulated from one another, and the primary molded body is positioned, and subsequently a secondary molded body is molded on the primary molded body; wherein a core portion of a thickened portion of the housing is molded at the time of molding the primary molded body, and a shell portion of said thickened portion, having a generally uniform thickness, is molded at the time of molding the secondary molded body.
In the above method of molding the connector, the primary molded body, in which the male metal terminals are properly positioned, with the connection portions exposed from the primary molded body, is first formed. Then, the secondary molded body, in which the primary molded body is properly positioned and inserted, is molded, thereby providing a final molded product.
More specifically, the male metal terminals are held in a primary mold in such a manner that these terminals are kept out of contact with one another, that is, insulated from one another, and in this condition the primary molding is effected. Then, the primary molded body is positioned and held in a secondary mold, and in this condition the secondary molding is effected, thereby forming the secondary molded body. Accordingly, the male metal terminals can be positioned highly precisely.
Additionally, the whole of the thickened portion is not molded in at one molding step (that is, the step of forming the primary molded body or the step of forming the secondary molded body), and therefore, a shrink mark and a warp are prevented from developing in the housing. In addition, since the core portion of the primary molded body is utilized of the positioning for the secondary molding, the metal terminals can be positioned highly precisely. Therefore, the number of the defective connectors can be reduced, and the yield can be enhanced, and the connector of a high reliability can be obtained.
REFERENCES:
patent: 5201883 (1993-04-01), Atoh et al.
patent: 5527502 (1996-06-01), Kiuchi et al.
patent: 5709559 (1998-01-01), Fujitani et al.
patent: 6-223903 (1994-08-01), None
patent: 8-250193 (1996-09-01), None
Ortiz Angela
Sughrue Mion Zinn Macpeak & Seas, PLLC
Yazaki -Corporation
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