(19)
(11)EP 3 211 732 B1

(12)EUROPEAN PATENT SPECIFICATION

(45)Mention of the grant of the patent:
26.06.2019 Bulletin 2019/26

(21)Application number: 16157213.6

(22)Date of filing:  24.02.2016
(51)International Patent Classification (IPC): 
H01R 43/00(2006.01)
H01R 43/24(2006.01)
H01R 43/18(2006.01)
B29C 45/16(2006.01)

(54)

CONNECTOR AND METHOD FOR PRODUCING A CONNECTOR

KONNEKTOR UND VERFAHREN ZUR HERSTELLUNG EINES KONNEKTORS

CONNECTEUR ET PROCÉDÉ DE FABRICATION D'UN CONNECTEUR


(84)Designated Contracting States:
AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

(43)Date of publication of application:
30.08.2017 Bulletin 2017/35

(73)Proprietor: PROTECH GmbH
72793 Pfullingen (DE)

(72)Inventors:
  • Mentzel, Jürgen
    72793 Pfullingen (DE)
  • Rudin, Benjamin
    72793 Pfullingen (DE)

(74)Representative: Witte, Weller & Partner Patentanwälte mbB 
Postfach 10 54 62
70047 Stuttgart
70047 Stuttgart (DE)


(56)References cited: : 
EP-A2- 0 183 553
DE-A1- 10 041 812
US-A- 5 902 276
US-A1- 2008 102 235
US-A1- 2015 158 221
WO-A1-86/03628
US-A- 1 601 255
US-A1- 2003 066 504
US-A1- 2012 040 571
  
  • Werner Hofmann: "Rubber Technology Handbook" In: "Rubber Technology Handbook", 1 January 1994 (1994-01-01), Hanser Publishers, XP055513106, pages 4-7,
  • S Koch: "Manual for the rubber industry" In: "Manual for the rubber industry", 1 January 1993 (1993-01-01), Bayer AG Rubber Business Group, XP055513115, pages 38-39,
  
Note: Within nine months from the publication of the mention of the grant of the European patent, any person may give notice to the European Patent Office of opposition to the European patent granted. Notice of opposition shall be filed in a written reasoned statement. It shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention).


Description


[0001] The present application relates to a method of producing a connector having at least one conductor and at least one contact pin which are electrically connected at a contact point, and a corresponding connector.

[0002] Connectors are used today in all technological areas. They allow to connect different electrical components in a simple manner even after assembly. Further, many connectors are removable, so that an existing connection can be separated easily, for example during maintenance or repair.

[0003] A connector comprises an electrical connection around which a thermoplast is injection-molded. During use the connector is subject to environmental conditions, for example humidity or liquids. While the connector side can usually be sealed well, e.g. using radial sealing rings, humidity and liquids can enter e.g. along the insulating sheath of the conductor or even within the conductor. Since these interspaces are very small, the entering of humidity and liquids may be accelerated by capillary action. Therefore, humidity or liquids can slowly advance through the connector and can potentially reach the connector side and thus electrical contacts of connected electrical components which can thereby be damaged, e.g. due to a short. In particular the tight sealing of conductors with multiple wires - in contrast to a single solid wire - poses a significant challenge.

[0004] In general, there is the possibility to use a thermoset instead of a thermoplast, which may render a better material connection to the electrical element. However, a thermoset material is very hard and stiff after curing and does not allow to provide any flexible elements, for example a spring hook. Therefore, such solution is suitable only for very few applications.

[0005] DE 100 41 812 A1 discloses a connector having a housing made of a hard plastic material into which a conductor element is fed. The free space between the conductor and the housing is filled with a soft plastic material in order to achieve a seal between the open connector side and the rear of the connector where the conductor exits.

[0006] US 2003/0066504 A1 discloses a single piece intake manifold with a core and a seal. Material of the seal and material of the core are intermixed to bond the core to the seal. The core is a plastic material such as polyamide and/or a thermoplastic material. The seal is rubber, plastic or a thermoplastic elastomer.

[0007] It is an object of the present invention to disclose an improved method for producing a connector and a corresponding resulting connector. In particular it is desired to achieve the effect that humidity or liquids entering the connector are stopped at least when trying to propagate to the connector side. It is therefore intended to mitigate or reduce the problem that humidity or liquids advance within the connector and reach the contacts of a connected electrical component, thereby potentially damaging it, e.g., due to immediate shorts or due to slow corrosive impact.

[0008] The object is achieved by a method for producing a connector using injection-molding according to claim 1.

[0009] One aspect to be noted is that the conductor and the contact pin receive a thermoset via injection-molding, so that the resulting thermoset premold encloses at least a first section of the at least one connector and/or at least a second section of the at least one contact pin, in particular enclosing a section of the conductor and a section of the contact pin including the contact point. Prior to the thermoset premold reaching a degree of curing of 90% a thermoplast is injection-molded onto the thermoset premold. This early injection-molding provides a good adhesion or attachment between the thermoset and the thermoplast. The resulting thermoplast shape on the thermoset premold can be considered as a thermoplast overmold or a thermoplast aftermold.

[0010] The expression "degree of curing" is known to the skilled person in the field of material science, in particular in the field of producing electrical connectors via injection-molding. However, in particular, the expression is to be understood in the sense of a chemical cross-linking or a chemical cross-linking of molecules. The expression "degree of curing" can also be understood as the degree of polymer cross-linking by applying thermal energy. The cross-linking may in particular be understood as a chaining or concatenation of simple molecules to complex three dimensional macro molecule chains.

[0011] Concerning the technical background regarding the expression "degree of curing" reference is made to the standard literature, for example "Die Kunststoffe - Chemie, Physik, Technologie - Kunststoff-Handbuch Band 1 - ", Becker, G.W., Braun, D., Carl Hanser Verlag, 1990, "Duroplaste - Aushartung - Prufung - Eigenschaften", Ehrenstein, G.W., Bittmann, E., Carl Hanser Verlag, 1997, "Kunststoffprüfung", Grellmann, W., Seidler, S., 2. Auflage, Carl Hanser Verlag, 2011 und "Praxis der Thermischen Analyse von Kunststoffen", Ehrenstein G.W., Riedel G., Trawiel P., 2. Auflage, Carl Hanser Verlag, 2003.

[0012] The degree of curing of a material can be determined by taking the material to be analyzed and determining the remaining enthalpy of reaction (RE), indicating the enthalpy of reaction which can still be set free. Further, the total enthalpy of reaction (TE) of a fresh material, in particular a resin compound, is determined. The ratio of remaining enthalpy of reaction and total enthalpy of reaction is subtracted from one, i.e., degree of curing = 1 - RE/TE.

[0013] During the making of the present invention it was determined that a surprisingly good cross-linking between the thermoset premold and the thermoplast can be achieved when applying the thermoplast via injection-molding before, in particular well before, the thermoset has cured. The invention is applicable to male contact pins as well as female contact pins having openings.

[0014] Therefore, the object is achieved in full.

[0015] In a preferred refinement the thermoset premold is produced in a first injection-molding tool and the thermoplast is injection-molded around the thermoset premold in a second injection-molding tool, wherein the thermoset premold is removed from the first injection-molding tool.

[0016] This process allows for an effective production.

[0017] In a preferred refinement the step of injection-molding is performed before the thermoset premold has reached a degree of curing of 80%, preferably 70%, more preferably 67% and in particular 64%.

[0018] This refinement allows for a good adhesion or attachment between the thermoset and the thermoplast.

[0019] In a further advantageous refinement the step of injection-molding is performed after the thermoset premold has reached a degree of curing of 40%, preferably 50%, more preferably 55% and in particular 57%.

[0020] During the making of the invention it was determined as one aspect that the bonding between the thermoset and the thermoplast seems to be the better the lower the degree of curing is before the step of injection-molding. At the same time, a boundary condition of the manufacturing process was detected in that the thermoset premold must have a sufficient form stability or shape stability, before the transfer to the injection-molding step can be performed, in particular so that the thermoset premold can be removed from the first injection-molding tool without being damaged. The given values provide a starting point for a weighting between having a sufficient form stability without the curing having progressed too far.

[0021] In a preferred refinement the step of injection-molding is performed after the thermoset premold has reached a degree of curing of 57.5%, but before the thermoset premold has reached a degree of curing of 63.5%.

[0022] Applicant believes that this refinement may provide advantages for a typical connector which is used in the automotive industry.

[0023] In a further advantageous refinement the step of injection-molding is performed while the thermoset premold has at least 50%, preferably at least 60%, more preferably at least 70% and in particular more than 75% of its thermal energy which was present right after the step of producing.

[0024] This refinement may allow for a good bonding between the thermoset and the thermoplast. In order to implement this feature, or even without implementing this feature, it is believed to be advantageous that a cooling of the thermoset premold is avoided as much as this is practical from a process perspective. In particular it seems advantageous that a cooling phase is avoided, in particular an active cooling phase involving a cooling medium is avoided.

[0025] In an advantageous refinement the step of injection-molding is performed when the thermoset premold has not more than 99%, preferably not more than 95%, more preferably not more than 90% and in particular not more than 85% of its thermal energy which was present right after the step of producing.

[0026] This refinement may be advantageous in view of the following injection-molding using the thermoplast. This may be the case, because the production of the thermoset premold may require, in some embodiments, a temperature between 160 °C and 190 °C, whereas the injection-molding using the thermoplast takes place at a temperature between 75 °C and 100 °C.

[0027] In a further advantageous refinement the step of injection-molding takes place while the thermoset premold has a temperature of at least 100 °C, preferably at least 125 °C, more preferably at least 150 °C and in particular at least 160 °C.

[0028] This refinement allows for a good bonding between the thermoset and the thermoplast and can be achieved, as explained above, by avoiding a cooling phase.

[0029] In a further preferred refinement the step of injection-molding takes place while the thermoset premold has a temperature of not more than 250 °C, preferably not more than 225 °C, more preferably not more than 200 °C and in particular not more than 190 °C.

[0030] This refinement is believed to be advantageous from a production perspective.

[0031] In a further advantageous refinement the step of producing lasts at least 8 seconds, preferably at least 9 seconds, more preferably at least 10 seconds and in particular at least 11 seconds.

[0032] This refinement is believed to be advantageous in view of the desired form stability.

[0033] In a further advantageous refinement the step of production lasts not more than 20 seconds, preferably not more than 18 seconds, more preferably not more than 16 seconds, and in particular not more than 14 seconds.

[0034] In a further advantageous refinement the time between the end of the step of producing and the start of the step of injection-molding is not more than 30 seconds, preferably not more than 20 seconds, more preferably not more than 15 seconds and in particular not more than 10 seconds.

[0035] This refinement takes into account that the curing of the thermoset premold progresses even after the thermoset premold has been removed from the first injection-molding tool. The reason is that the thermoset premold still has a significant amount of thermal energy even after the removal which advances the curing and thus the process of creating cross-links as explained above. This refinement may avoid that despite an early removal of the thermoset premold from the first injection-molding tool the curing continues as time passes by and reaches a degree of curing that does not allow for a good bonding between the thermoset and the thermoplast anymore.

[0036] In an advantageous refinement the thermoset is an epoxy resin, in particular an epoxy resin molding material for injection-molding.

[0037] This refinement has produced good results.

[0038] In an advantageous refinement the thermoplast is a filled PA66 or PBT material and is selected in particular from the group comprising PA66 GF35, PBT GF30, and similar materials.

[0039] This refinement has provided good results.

[0040] In a further advantageous refinement the step of injection-molding is followed by a step of tempering or malleablizing.

[0041] This refinement may allow for an improved bonding between the thermoset and the thermoplast for particular combinations of materials. This step can also be understood as a post-curing.

[0042] According to a second aspect, there is provided a connector according to claim 12.

[0043] Such connector may provide the advantage that humidity or liquids are hindered to advance within the connector to the connector side. Further, due to the injection-molding using the thermoplast flexible elements can be provided. A good adhesion or attachment between the thermoset and the thermoplast and the resulting sealing can be obtained using the process described above.

[0044] In accordance with the invention the degree of curing of the thermoset is less than 95%, preferably less than 90%, more preferably less than 85% and in particular less than 80%.

[0045] In this refinement the difference between the maximum degree of curing, i.e. close to or substantially 100%, is present, since the full curing of the thermoset is not being waited for, but the injection-molding using the thermoplast is performed rather early.

[0046] In a further preferred embodiment a first degree of curing of the thermoset at a joint face - also called (phase) surface or boundary (surface) - between the thermoset and the thermoplast is at least substantially the same as a second degree of curing of the thermoset at a location which is at a distance from the joint face, in particular at a maximum distance from the joint face.

[0047] Having a substantially similar degree of curing of the thermoset at different locations of the thermoset premold may be achieved, as explained above, by avoiding a cooling phase, in particular an active cooling phase.

[0048] In a further preferred refinement the conductor comprises a plurality of wires, i.e., comprising a plurality of individual wires, wherein the conductor is in particular a stranded wire.

[0049] It is understood that the features explained above and the features explained in the following can be used in different combinations or in isolation, only the claims defining the scope of protection.

[0050] Embodiments of the invention are shown in the drawings and will be further explained in the following. The figures show:
Fig. 1
is an embodiment of a connector; and
Fig. 2
is an embodiment of a method for producing a connector.


[0051] Fig. 1 shows a connector 10 having a conductor 12 and a contact pin 14. The conductor 12 comprises a plurality of single wires 16 which extend from the nonconducting conductor sheath 18 within the connector 10. The side of the connector 10 exposing the contact pin 14 for connection to another electrical component is called connector side 29. In exemplary embodiments, a connector will have multiple contact pins each with a corresponding conductor.

[0052] The conductor 12 is electrically connected to the contact pin 14 at a contact point 20. The contact point 20 is provided as a soldering point or welding point. Other preferred embodiments may use a crimp-connection. The contact point 20 can also be obtained in other ways.

[0053] A first section of the conductor 12 and a second section of the contact pin 14 are embedded in a thermoset 22 via injection-molding. In this preferred embodiment all exposed single wires 16, a section of the single wires 16 within the conductor sheath 18, a section of the conductor sheath 18 and the contact point 20 are also surrounded by thermoset. The shape of the thermoset which results from injection-molding the thermoset around a section of the at least one conductor 12 and/or the section of the at least one contact pin 14 is called thermoset premold 24.

[0054] It is further noted that thermoset premold 24 can comprise a plurality of separate individual parts. Also, there are embodiments where the thermoset premold 24 does not surround the contact pin 14, the contact point 20 nor the exposed sections of the single wires 16. However, it is believed to be advantageous from a process perspective, if the thermoset is injection-molded around the multiple elements as shown.

[0055] The thermoset 22 or the thermoset premold 24 receives a thermoplast 26 cover via injection-molding. While the thermoset 22 is very hard and stiff without any flexible properties when the production of the connector 10 is finished, the thermoplast 26 allows to provide flexible elements, for example a spring hook (not shown).

[0056] Fig. 1 shows five different joint faces between the different materials which are indicated with reference numerals 1 to 5. The joint faces are present between the following elements: 1) outside of conductor sheath 18 and thermoset 22, 2) inside of conductor sheath 18 and thermoset 22, 3) single wires 16 and thermoset 22, 4) contact pin 14 and thermoset 22, and 5) thermoset 22 and thermoplast 26.

[0057] The joint faces 1 and 2 will typically not provide a good sealing, since neither the neither thermoset 22 nor the thermoplast 26 have a fully tight bonding to the conductor sheath 18. However, a good sealing is provided at the joint face 3, since the thermoset 22 has a low viscosity during injection-molding and also has good adhesion or attachment characteristics on metal. In addition, the thermoset 22 may also be pulled into very small cavities due to capillary action.

[0058] At the joint face 4 a good sealing is given, because the thermoset 22 has good adhesion or attachment characteristics on metal. A good bonding between the thermoset 22 and the thermoplast 26 is present at joint face 5, because the thermoplast 26 is applied to the thermoset premold 24 before the thermoset premold 24 is fully cured.

[0059] Therefore, there is substantially no possibility for humidity or liquids, indicated with big arrows 28, to enter the connector 10, advance within the connector 10 and reach the connector side 29. Therefore, electric components which are electrically connected to the connector 10 are protected, even if the connector 10 is subjected to environmental conditions.

[0060] For the shown embodiment of the connector 10 a first degree of curing of the thermoset 22 at the joint face 10, an exemplary location is indicated with reference numeral 30, between the thermoset 22 and the thermoplast 26 is at least substantially the same as a second degree of curing of the thermoset 22 at a location 32 which is at a distance from the joint face 5. Here, the location 32 is at a maximum distance from the joint face 5, because the joint face 5 surrounds the elements enclosed therein in the manner of a cylinder.

[0061] Fig. 2 shows a method for producing a connector 10 using injection-molding. The method starts with providing S10 at least one conductor 12 and at least one contact pin 14, which are electrically connected at a contact point 20. In a subsequent step S12 the thermoset premold 24 is produced from a thermoset 22 using injection-molding, wherein the thermoset 22 is applied around at least a first section of the at least one conductor 12 and/or at least a second section of the at least one contact pin 14.

[0062] A step of injection-molding S14 of a thermoplast 26 on the thermoset premold 24 follows. The step of injection-molding S14 takes place before the thermoset premold 24 has reached a degree of curing of 90%. Optionally, the step of injection-molding S14 may be followed by a step of annealing S16. Further preferred embodiments of the method 40 can be derived from the above explanations.


Claims

1. Method (40) for producing a connector (10) using injection-molding, the method comprising the steps:

- providing (S10) at least one conductor (12) and at least one contact pin (14) which are electrically connected at a contact point (20),

- producing (S12) a thermoset premold (24) from a thermoset (22) using injection-molding, wherein the thermoset (22) is injection-molded around at least a first section of the at least one conductor (12) and/or around at least a second section of the at least one contact pin (14), wherein the thermoset premold (24) is very hard and stiff without any flexible properties when the production of the connector (10) is finished, and

- injection-molding (S14) of a thermoplast (26) on the thermoset premold (24),

wherein the step of injection-molding (S14) takes place before the thermoset premold (24) has obtained a degree of curing of 90%.
 
2. Method according to claim 1, wherein the thermoset premold (24) is produced in a first injection-molding tool and the thermoplast (26) is injection-molded around the thermoset premold (24) in a second injection-molding tool, wherein the thermoset premold (24) is removed from the first injection-molding tool.
 
3. Method according to any preceding claim, wherein the step of injection-molding (S14) is performed before the thermoset premold (24) has reached a degree of curing of 80%, preferably 70%, more preferably 67% and in particular 64%.
 
4. Method according to any preceding claim, wherein the step of injection-molding is performed after the thermoset premold (24) has reached a degree of curing of 40%, preferably 50%, more preferably 55% and in particular 57%.
 
5. Method according to any preceding claim, wherein the step of injection-molding (S14) is performed after the thermoset premold (24) has reached a degree of curing of 57.5%, but before the thermoset premold (24) has reached a degree of curing of 63.5%.
 
6. Method according to any preceding claim, wherein the step of producing (S12) lasts at least 8 seconds, preferably at least 9 seconds, more preferably at least 10 seconds and in particular at least 11 seconds.
 
7. Method according to any preceding claim, wherein the step of producing (S12) lasts not more than 20 seconds, preferably not more than 18 seconds, more preferably not more than 16 seconds and in particular not more than 14 seconds.
 
8. Method according to any preceding claim, wherein the time between the end of producing (S12) and the start of the step of injection molding (S14) is not more than 30 seconds, preferably not more than 20 seconds, more preferably not more than 15 seconds and in particular not more than 10 seconds.
 
9. Method according to any preceding claim, wherein the thermoset (22) is an epoxy resin, in particular an epoxy resin molding material for injection-molding.
 
10. Method according to any preceding claim, wherein the thermoplast (26) is filled PA66 or PBT material and, in particular, is selected from the group comprising PA66 GF35 and PBT GF30.
 
11. Method according to any preceding claim, wherein the step of injection-molding (S14) is followed by a step of tempering (S16) or malleablizing.
 
12. Connector (10) comprising at least one conductor (12) and at least one contact pin (14) which are electrically connected to one another at a contact point (20), wherein at least a section of the at least one conductor (12) and/or at least a section of the at least one contact pin (14) is surrounded by a thermoset (22) applied via injection-molding, wherein a thermoplast (26) is injection-molded onto the thermoset (22), characterized in that the degree of curing of the thermoset (22) is less than 90%, preferably less than 85%, and more preferably less than 80%, and wherein the thermoset (22) is very hard and stiff without any flexible properties.
 
13. Connector according to claim 12, wherein a first degree of curing of the thermoset (22) at a joint face (5) between the thermoset (22) and the thermoplast (26) is at least substantially the same as a second degree of curing of the thermoset (22) at a location which is at a distance from the joint face (5), in particular at a maximum distance from the joint face (5).
 
14. Connector according to any of claims 12 to 13, wherein the conductor (12) comprises a plurality of wires (16), wherein the conductor (12) is in particular a stranded wire.
 


Ansprüche

1. Verfahren (40) zum Herstellen eines Steckers (10) unter Verwendung von Spritzgießen, wobei das Verfahren die Schritte aufweist:

- Bereitstellen (S10) mindestens eines Leiters (12) und mindestens eines Kontaktstiftes (14), die an einer Kontaktstelle (20) elektrisch verbunden sind,

- Herstellen (S12) eines Duroplast-Vorformlings (24) aus einem Duroplast (22) im Spritzgussverfahren, wobei der Duroplast (22) um mindestens einen ersten Abschnitt des mindestens einen Leiters (12) und/oder um mindestens einen zweiten Abschnitt des mindestens einen Kontaktstiftes (14) gespritzt ist, wobei der Duroplast-Vorformling (24) nach Beendigung der Herstellung des Steckers (10) sehr hart und steif ohne jede flexible Eigenschaften ist, und

- Spritzgießen (S14) eines Thermoplasts (26) auf den Duroplast-Vorformling (24),

wobei der Schritt des Spritzgießens (S14) stattfindet, bevor der Duroplast-Vorformling (24) einen Härtungsgrad von 90% erreicht hat.
 
2. Verfahren nach Anspruch 1, wobei der Duroplast-Vorformling (24) in einem ersten Spritzgießwerkzeug hergestellt wird und der Thermoplast (26) in einem zweiten Spritzgießwerkzeug um der Duroplast-Vorformling (24) herum gespritzt wird, wobei der Duroplast-Vorformling (24) aus dem ersten Spritzgießwerkzeug entfernt wird.
 
3. Verfahren nach einem der vorhergehenden Ansprüche, wobei der Schritt des Spritzgießens (S14) durchgeführt wird, bevor der Duroplast-Vorformling (24) einen Aushärtungsgrad von 80%, vorzugsweise 70%, bevorzugter 67% und insbesondere 64% erreicht hat.
 
4. Verfahren nach einem der vorhergehenden Ansprüche, wobei der Schritt des Spritzgießens durchgeführt wird, nachdem der Duroplast-Vorformling (24) einen Aushärtungsgrad von 40%, vorzugsweise 50%, bevorzugter 55% und insbesondere 57% erreicht hat.
 
5. Verfahren nach einem der vorhergehenden Ansprüche, wobei der Schritt des Spritzgießens (S14) durchgeführt wird, nachdem der Duroplast-Vorformling (24) einen Härtegrad von 57,5% erreicht hat, aber bevor der Duroplast-Vorformling (24) einen Härtegrad von 63,5% erreicht hat.
 
6. Verfahren nach einem der vorhergehenden Ansprüche, wobei der Schritt der Herstellung (S12) mindestens 8 Sekunden, vorzugsweise mindestens 9 Sekunden, besonders vorzugsweise mindestens 10 Sekunden und insbesondere mindestens 11 Sekunden dauert.
 
7. Verfahren nach einem der vorhergehenden Ansprüche, wobei der Schritt der Herstellung (S12) nicht länger als 20 Sekunden, vorzugsweise nicht mehr als 18 Sekunden, besonders vorzugsweise nicht mehr als 16 Sekunden und insbesondere nicht mehr als 14 Sekunden dauert.
 
8. Verfahren nach einem der vorhergehenden Ansprüche, wobei die Zeit zwischen dem Ende der Herstellung (S12) und dem Beginn des Schrittes des Spritzgießens (S14) nicht mehr als 30 Sekunden, vorzugsweise nicht mehr als 20 Sekunden, vorzugsweise nicht mehr als 15 Sekunden und insbesondere nicht mehr als 10 Sekunden beträgt.
 
9. Verfahren nach einem der vorhergehenden Ansprüche, wobei der Duroplast (22) ein Epoxidharz ist, insbesondere eine Epoxidharz-Formmasse zum Spritzgießen.
 
10. Verfahren nach einem der vorhergehenden Ansprüche, wobei der Thermoplast (26) mit PA66 oder PBT-Material gefüllt ist und insbesondere aus der Gruppe ausgewählt ist, die PA66 GF35 und PBT GF30 aufweist.
 
11. Verfahren nach einem der vorhergehenden Ansprüche, wobei auf den Schritt des Spritzgießens (S14) ein Schritt des Härtens (S16) oder Temperns folgt.
 
12. Stecker (10) mit mindestens einem Leiter (12) und mindestens einem Kontaktstift (14), die an einer Kontaktstelle (20) elektrisch miteinander verbunden sind, wobei mindestens ein Abschnitt des mindestens einen Leiters (12) und/oder mindestens ein Abschnitt des mindestens einen Kontaktstiftes (14) von einem im Spritzguss aufgebrachten Duroplast (22) umgeben ist, wobei ein Thermoplast (26) auf den Duroplast (22) gespritzt ist, dadurch gekennzeichnet, dass der Aushärtungsgrad des Duroplastes (22) weniger als 90%, vorzugsweise weniger als 85% und bevorzugter als 80% beträgt, und wobei der Duroplast (22) sehr hart und steif ohne jede flexiblen Eigenschaften ist.
 
13. Stecker nach Anspruch 12, wobei ein erster Aushärtungsgrad des Duroplasts (22) an einer Verbindungsfläche (5) zwischen dem Duroplast (22) und dem Thermoplast (26) mindestens im Wesentlichen gleich einem zweiten Aushärtungsgrad des Duroplasts (22) an einer Stelle ist, die in einem Abstand von der Verbindungsfläche (5), insbesondere in einem maximalen Abstand von der Verbindungsfläche (5) liegt.
 
14. Stecker nach einem der Ansprüche 12 bis 13, wobei der Leiter (12) eine Vielzahl von Drähten (16) aufweist, wobei der Leiter (12) insbesondere ein Litzenleiter ist.
 


Revendications

1. Procédé (40) de fabrication d'un connecteur (10) par moulage par injection, le procédé comprenant les étapes suivantes :

- comportant (S10) au moins un conducteur (12) et au moins une broche de contact (14) qui sont reliés électriquement en un point de contact (20),

- la fabrication (S12) d'un pré-moulage thermodurcissable (24) à partir d'un thermodurcissable (22) par moulage par injection, le thermodurcissable (22) étant moulé par injection autour d'au moins une première section du au moins un conducteur (12) et/ou autour d'au moins une deuxième section du au moins une broche de contact (14), le pré-moulage thermodurcissable (24) étant très dur et rigide sans aucune propriété flexible lorsque la production du connecteur (10) est terminée, et

- moulage par injection (S14) d'un thermoplastique (26) sur le pré-moulage thermodurcissable (24),

dans laquelle l'étape de moulage par injection (S14) a lieu avant que le pré-moulage thermodurcissable (24) ait obtenu un degré de durcissement de 90%.
 
2. Procédé selon la revendication 1, dans lequel le pré-moulage thermodurcissable (24) est fabriqué dans un premier outil de moulage par injection et le thermoplastique (26) est moulé par injection autour du pré-moulage thermodurcissable (24) dans un deuxième outil de moulage par injection, le pré-moulage thermodurcissable (24) étant retiré du premier outil de moulage par injection.
 
3. Procédé selon l'une quelconque des revendications précédentes, dans lequel l'étape de moulage par injection (S14) est réalisée avant que le pré-moulage thermodurcissable (24) ait atteint un degré de durcissement de 80%, de préférence de 70%, plus préférablement de 67% et en particulier de 64%.
 
4. Procédé selon l'une quelconque des revendications précédentes, dans lequel l'étape de moulage par injection est effectuée après que le pré-moulage thermodurcissable (24) a atteint un degré de durcissement de 40 %, de préférence de 50 %, plus préférablement de 55 % et en particulier de 57 %.
 
5. Procédé selon l'une quelconque des revendications précédentes, dans lequel l'étape de moulage par injection (S14) est effectuée après que le pré-moulage thermodurcissable (24) ait atteint un degré de durcissement de 57,5 %, mais avant que le pré-moulage thermodurcissable (24) ait atteint un degré de durcissement de 63,5 %.
 
6. Procédé selon l'une quelconque des revendications précédentes, dans lequel l'étape de production (S12) dure au moins 8 secondes, de préférence au moins 9 secondes, plus préférablement au moins 10 secondes et en particulier au moins 11 secondes.
 
7. Procédé selon l'une quelconque des revendications précédentes, dans lequel l'étape de production (S12) ne dure pas plus de 20 secondes, de préférence pas plus de 18 secondes, plus préférablement pas plus de 16 secondes et en particulier pas plus de 14 secondes.
 
8. Procédé selon l'une quelconque des revendications précédentes, dans lequel le temps entre la fin de la production (S12) et le début de l'étape de moulage par injection (S14) n'est pas plus de 30 secondes, de préférence pas plus de 20 secondes, plus préférablement pas plus de 15 secondes et en particulier pas plus de 10 secondes.
 
9. Procédé selon l'une quelconque des revendications précédentes, dans lequel le thermodurcissable (22) est une résine époxy, en particulier un matériau de moulage de résine époxy pour moulage par injection.
 
10. Procédé selon l'une quelconque des revendications précédentes, dans lequel le thermoplastique (26) est un matériau PA66 ou PBT chargé et, en particulier, est choisi dans le groupe comprenant PA66 GF35 et PBT GF30.
 
11. Procédé selon l'une quelconque des revendications précédentes, dans lequel l'étape de moulage par injection (S14) est suivie d'une étape de recuire (S16) ou de malléabilisation.
 
12. Connecteur (10) comprenant au moins un conducteur (12) et au moins une broche de contact (14) qui sont reliés électriquement l'un à l'autre en un point de contact (20), au moins une section du au moins un conducteur (12) et/ou au moins une section de la au moins une broche de contact (14) étant entourée par un thermodurcissable (22) appliqué par injection, dans laquelle un thermoplastique (26) est moulé par injection sur le thermodurcissable (22), caractérisé en ce que le degré de durcissement du thermodurcissable (22) est inférieur à 90%, de préférence inférieur à 85%, et plus préférablement inférieur à 80%, et dans lequel le thermodurcissable (22) est très dur et rigide sans aucune propriété flexible.
 
13. Connecteur selon la revendication 12, dans lequel un premier degré de durcissement du thermodurcissable (22) sur une face de joint (5) entre le thermodurcissable (22) et le thermoplastique (26) est au moins environ le même qu'un second degré de durcissement du thermodurcissable (22) à un endroit qui est à une distance de la face de joint (5), en particulier à une distance maximale de la surface de joint (5).
 
14. Connecteur selon l'une quelconque des revendications 12 à 13, dans lequel le conducteur (12) comprend une pluralité de fils (16), dans lequel le conducteur (12) est en particulier un fil toronné.
 




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