Method for manufacturing a cable connector assembly

Metal working – Method of mechanical manufacture – Electrical device making

Reexamination Certificate

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Details

C029S857000, C264S255000, C264S308000

Reexamination Certificate

active

06230405

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method, and particularly to a method for manufacturing a cable connector assembly which prevents overflow of material during an insertion molding procedure.
2. Description of Prior Art
An electrical connector assembly commonly includes a cover assembled to an end of a connector and an end of a cable for facilitating manual manipulation thereof. For a miniaturized electrical connector assembly, the cover is often formed by insertion molding as disclosed in Taiwan Patent Application Nos. 80204102 and 80205362.
Referring to
FIGS. 1-3
, to form a cover
100
of a conventional cable connector assembly
102
is by insertion molding. A front portion of the connector
104
which extends beyond the cover
100
is received in a receiving cavity (not shown) of top and bottom molds
106
. A rear portion of the connector
104
which is enclosed by the cover
100
and an end portion of a cable
108
are received in a molding chamber
110
. The cable
108
extends through two semi-circular recesses
112
of the top and bottom molds
106
. The radius of each recess
112
is slightly smaller than that of the cable
108
for snugly retaining the cable
108
therein when the top and bottom molds
106
are coupled thereby preventing overflow of material through the recess
112
during an insertion molding procedure. The cable
108
is a pipe-type cable, namely a plurality of wires
114
is received in a flexible plastic pipe
116
. Since the wires
114
are received in the pipe
116
, a clearance
118
is formed between the wires
114
.
However, due to the flexibility and size of the cable
108
and the shape of the recess, the pipe
116
is easily compressed out of the recesses
112
when the top and bottom molds
106
are coupled together. On the other hand, due to the size of the cable
108
, the pipe
116
is also easily deformed to form an interspace
120
between the recess
112
and the cable
108
. Thus, plastic material may flow out of the molding chamber
110
during the insertion molding procedure.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a method for manufacturing a cable connector assembly, which can prevent molding material from overflowing during an insertion molding procedure.
In the preferred embodiment of the present invention, a method for manufacturing a cable connector assembly comprises an intercepting cable step, a connecting cable and contact step, and a molding cover step. During the intercepting cable step, a tubular cable is provided with an appropriate length. During the connecting cable and contact step, a body is provided to receive the cable and contacts. During the molding cover step, a second mold assembly comprising a top mold and a bottom mold is provided. The second mold assembly includes a second molding chamber for receiving the body and an end portion of the cable therein, and an elliptical passageway in communication with the second molding chamber for extension of the cable therethrough. A rib is formed in the passageway for compensating deformation of the flexible plastic pipe.


REFERENCES:
patent: 1601255 (1926-09-01), Marra
patent: 2502860 (1950-04-01), Leithiser, Jr.
patent: 2700206 (1955-01-01), Gilbert
patent: 3093432 (1963-06-01), King
patent: 3093434 (1963-06-01), Francis
patent: 3141054 (1964-07-01), Francis
patent: 3668779 (1972-06-01), Turner
patent: 4398785 (1983-08-01), Hedrick
patent: 4411608 (1983-10-01), Yanagaisawa
patent: 4574474 (1986-03-01), Langham

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