1. A method of partially shielding a cable assembly, the method comprising the steps of: the method comprises the following steps of carrying out thermoplastic packaging molding on a to-be-processed part of a cable assembly part by adopting a thermoplastic packaging molding material to form a solid plastic sealing body, and connecting the to-be-processed part and a cable harness sheath into a whole by the solid plastic sealing body.

2. The method of claim 1, wherein the location of the cable assembly to be processed is an outlet portion of a cable connector.

3. The method of claim 1 or 2, wherein the thermoplastic molding material is selected from materials having a composition close to that of an outer skin material of the cable harness.

Preferably, the hot plastic package molding material can also meet the use requirement of a hot injection molding machine.

Preferably, the thermoplastic encapsulation molding is performed in a hot injection molding machine.

4. A method according to any of claims 1-3, characterized in that the thermoplastic encapsulation requires a mould set compatible with a hot injection moulding machine and the part to be processed.

Preferably, the material of the die set is stainless steel with rapid heat dissipation performance and high strength.

5. The method as claimed in claim 4, wherein the mold set comprises a female mold and a sub mold, the female mold is adapted to a hot injection molding machine structure, and a water cooling circulation system is integrated in the female mold, so as to facilitate the quick hot melting of the thermoplastic seal molding material and the quick cooling molding of the hot melted material; the sub-die is of a split structure and can be embedded into the female die and simultaneously matched with the surface structure of the part to be processed.

6. The method according to any one of claims 1 to 5, wherein the thermoplastic encapsulation molding comprises the steps of: and (3) putting the part to be processed of the cable assembly part into the sub-die, putting the sub-die into the female die, injecting a thermoplastic seal molding material in a molten state into the die by a hot injection molding machine, molding and cooling to form a solid plastic seal body.

7. The method of any of claims 1-6, wherein the shielding method further comprises a pre-treatment prior to thermoplastic encapsulation molding, the pre-treatment comprising:

(a) polishing and derusting: polishing and derusting the surface of the part to be processed until the surface roughness after polishing treatment is uniform and consistent, and the surface of the cable is not damaged; removing the grinded powder until no powder and excess residue remain on the surface;

(b) cleaning: scrubbing and polishing the derusted surface by using acetone, then cleaning the surface by using absolute ethyl alcohol, and drying to obtain the pretreated part to be processed.

8. The method according to any one of claims 1 to 7, wherein the protection method further comprises subjecting the pretreated member to be processed to a coating treatment;

preferably, the coating treatment comprises coating an adhesive on the surface of the pre-treated component to be processed to form an adhesive film layer and drying.

9. The method of any one of claims 1-8, wherein the shielding method further comprises installing a mold: winding sealing adhesive tapes at two ends of the cable head of the part to be processed and then installing the cable head in a clean sub-mold, and then installing the sub-mold in the female mold;

and putting the assembled die kit into a hot injection molding machine, additionally installing an extrusion molding port tool on the die, starting the plastic packaging machine, and pressing an injection port of the hot injection molding machine into the extrusion molding port tool.

10. The method according to any one of claims 1 to 9, wherein the protection method further comprises plastic molding: and pressurizing to inject the thermoplastic sealing molding material in a molten state into the extrusion molding opening tool through an injection opening of the hot injection molding machine, and then entering the mold, stopping injection molding until the thermoplastic sealing molding material in the molten state is filled in the whole mold, and simultaneously forming under the cooling of the water cooling circulation system to form the solid plastic sealing body. According to an embodiment of the invention, the protection method further comprises a shaping process: and (4) finishing the outer surface of the workpiece obtained by plastic package molding, wherein no redundant flash is required.

Background

The cable assembly is an integral body formed by processing an electric connector and a cable (conducting wire), is used for connecting the interior of various electrical equipment, the electrical equipment and an electrical system, and is mainly used for transmitting electric power energy, control signals and the like.

Since the electrical system tends to be complicated, the amount of cables used is large, and mass production is often required, the cable assembly is required to have high efficiency in response to mass production while satisfying quality reliability.

The quality reliability of the cable assembly is mainly reflected in the connection quality of the connector and the protection quality of the welding spots. The welding spot protection comprises the isolation protection of the outer surface of the welding spot and the pull protection of the external force of the welding spot.

At present, the commonly used methods for protecting the tail of the cable mainly include the following five methods:

(1) the welding spot is sleeved with a heat-shrinkable sleeve for isolation and protection;

(2) the tail clamp fixes the protection of the stress relief combination of the cable bundle;

(3) welding spots are encapsulated and isolated for protection;

(4) the wire outlet part at the tail part of the cable connector is reinforced and protected by a high-strength heat shrinkable tube;

(5) the cable outlet part of the cable connector is locally vulcanized at normal temperature.

The five methods have advantages and disadvantages, and generally, the tail part of the cable connector is comprehensively treated in one or more ways according to the installation and use environment of the cable and the processing requirement of a production workshop. In practical application, the five methods have the following defects:

according to the method (1), although the protection process is simple, the sealing effect is poor, the influence of moisture on welding points cannot be prevented, each welding point needs to be protected one by one, and the manufacturing efficiency is low;

the method (2) has a certain effect on the pull protection of the external force of the welding spot, but the protection is easy to lose efficacy after repeated insertion and extraction in the use process, and the manufacturing efficiency is low;

according to the method (3), the isolation and protection effect on welding spots is good, no protection effect on external force pulling is realized, the liquid glue solution for encapsulation is cured at normal temperature in the manufacturing process, the time for complete curing is over 36 hours, the time is too long, and the method is not beneficial to large-batch rapid manufacturing;

the method (4) can strengthen the integration degree of the connector and the cable, but the sleeve is easy to fall off after being aged in use and loses the protection effect;

the method (5) has better functions of solder joint isolation protection and external force pulling protection, does not need strict workshop processing environment and can adapt to field operation, and has the defects that double-component reaction type polyurethane rubber is adopted as a vulcanizing material, the double-component reaction is insufficient at normal temperature, and the solidified colloid has more bubbles, so that the integral protection performance is reduced. Meanwhile, the method has the defects of pure manual processing and low processing efficiency.

Disclosure of Invention

In order to improve the technical problem, the invention provides a method for protecting a cable assembly part, which comprises the following steps: the method comprises the following steps of carrying out thermoplastic packaging molding on a to-be-processed part of a cable assembly part by adopting a thermoplastic packaging molding material to form a solid plastic sealing body, and connecting the to-be-processed part and a cable harness sheath into a whole by the solid plastic sealing body.

According to an embodiment of the present invention, the portion to be processed of the cable assembly is an outlet portion (also referred to as a tail portion) of the cable connector.

According to an embodiment of the present invention, the thermoplastic molding material may be selected from materials having a composition close to that of the outer skin material of the electrical cable harness. The material is favorable for forming a unified structure with the cable sheath after being melted and crosslinked, and the gap of the connecting interface between the outgoing part of the cable connector and the cable harness sheath is eliminated. Furthermore, the hot plastic package molding material can also meet the use requirement of a hot injection molding machine.

According to an embodiment of the invention, said thermoplastic encapsulation molding is performed in a hot injection molding machine.

According to the embodiment of the invention, the thermoplastic package molding needs a mold set suitable for a hot injection molding machine and a part to be processed. Further, considering the problems of adaptability between the mold and the part to be added, adaptability between the mold and a hot injection molding machine, processing scale, cost and the like, it is preferable to select stainless steel with rapid heat dissipation performance and high strength as the mold material and adopt a machining molding mode.

Furthermore, the mold set comprises a female mold and a sub mold, the female mold is matched with a hot injection molding machine structure, and meanwhile, a water cooling circulation system is integrated in the female mold, so that the hot melting of the hot sealing molding material and the quick cooling molding of the hot melted material are facilitated; the sub-die is of a split structure, can be embedded into the female die and is matched with the surface structure of the part to be processed, and is beneficial to quick assembly and disassembly and efficient switching.

According to an embodiment of the present invention, the thermoplastic encapsulation molding comprises the steps of: and (3) putting the part to be processed of the cable assembly part into the sub-die, putting the sub-die into the female die, injecting a thermoplastic seal molding material in a molten state into the die by a hot injection molding machine, molding and cooling to form a solid plastic seal body.

According to an embodiment of the invention, the method of protecting further comprises a pre-treatment before the thermoplastic encapsulation is filled. Further, the pre-processing comprises:

(a) polishing and derusting: polishing and derusting the surface of the part to be processed (for example, polishing and derusting by adopting abrasive cloth) until the surface roughness after polishing treatment is uniform and consistent, and the surface of the cable is not damaged; removing (e.g., sweeping with a brush) the ground powder until the surface is free of powder and excess;

(b) cleaning: scrubbing and polishing the derusted surface by using acetone, then cleaning the surface by using absolute ethyl alcohol, and drying to obtain the pretreated part to be processed.

According to an embodiment of the present invention, the protection method further comprises a coating treatment of the pretreated member to be processed. Further, the coating treatment comprises the steps of coating an adhesive on the surface of the pre-treated component to be processed to form an adhesive film layer and drying. The adhesive can strengthen the bonding strength between the plastic package material and the cable sheath.

According to an embodiment of the invention, the shielding method further comprises installing a mold: winding sealing adhesive tapes at two ends of the cable head of the part to be processed and then installing the cable head in a clean sub-mold, and then installing the sub-mold in the female mold;

and putting the assembled die kit into a hot injection molding machine, additionally installing an extrusion molding port tool on the die, starting the plastic packaging machine, and pressing an injection port of the hot injection molding machine into the extrusion molding port tool.

According to the embodiment of the invention, the protection method further comprises the following steps of plastic molding: and pressurizing to inject the thermoplastic sealing molding material in a molten state into the extrusion molding opening tool through an injection opening of the hot injection molding machine, and then entering the mold, stopping injection molding until the thermoplastic sealing molding material in the molten state is filled in the whole mold, and simultaneously forming under the cooling of the water cooling circulation system to form the solid plastic sealing body.

According to an embodiment of the invention, the protection method further comprises a shaping process: and (4) finishing the outer surface of the workpiece obtained by plastic package molding, wherein no redundant flash is required.

According to a preferred embodiment of the present invention, the method for protecting the tail of the cable assembly comprises the following steps:

thermoplastic packaging molding is carried out on the part to be processed of the cable assembly part by adopting a thermoplastic packaging molding material to form a solid plastic sealing body, and the part to be processed and a cable harness sheath are connected into a whole by the solid plastic sealing body;

the hot plastic package molding material is selected from materials with the components close to those of the cable harness outer skin material and can meet the use requirements of a hot injection molding machine;

the thermoplastic encapsulation molding is carried out in a hot injection molding machine, and needs to be sleeved with a mold which is suitable for the hot injection molding machine and the part to be processed;

the mold set comprises a female mold and a sub mold, the female mold is matched with the hot injection molding machine structure, and meanwhile, a water cooling circulation system is integrated in the female mold; the sub-die is of a split structure and can be embedded into the female die and simultaneously adapt to the surface structure of the part to be processed;

and (3) loading the part to be processed of the cable assembly part into the daughter die, then loading the daughter die into the female die, injecting a molten thermoplastic seal molding material into the die by a hot injection molding machine, and molding and cooling the thermoplastic seal molding material by using the water-cooling circulation system to form a solid plastic sealing body.

Advantageous effects

The method mainly solves the problems of reliable protection of the tail part of the connector to welding spots and high-efficiency processing of the tail part protection of the connector in the cable assembly processing process. Particularly, on one hand, the problems of insufficient and unbalanced protection force for welding point isolation protection and external force pulling protection in the prior art are solved; on the other hand, the problem that the tail protection packaging processing efficiency of the cable assembly part is low is solved, and the overall processing efficiency is improved by more than 2 times.

The invention adopts a thermoplastic sealing process method, solid granular plastic raw materials are heated at high temperature to be in a sufficient molten state, the outlet part of the cable connector is integrally packaged and molded at one time by using an injection molding machine and a designed mold, so that the formed solid plastic sealing body can effectively isolate welding points from the external environment and prevent moisture, fine dust and the like from contacting the welding points, and the cable connector and a cable harness are connected into a whole by the solid plastic sealing body, so that the connection strength of the outlet part of the cable is effectively enhanced. The hot runner of the injection molding machine is almost free of air during continuous injection, so that the formed solid plastic sealing body is also nearly free of bubbles, and the anti-skid effect is excellent. Meanwhile, the hot injection molding process adopts a pneumatic auxiliary and water cooling system, so that the operation convenience is improved, the curing molding time is shortened to the second level, and the integral manufacturing efficiency is greatly improved by more than 2 times.

After the local integrated plastic package forming method of the cable connector is adopted, the sealing can reach the watertight requirement of 0.3mp, the isolation protection of welding spots and the external force pulling protection are enhanced, and the overall protection performance and the environmental applicability of the cable are improved. Meanwhile, the thermoplastic sealing and forming process can better adapt to large-batch high-efficiency manufacturing scenes, shortens the production period, improves the manufacturing efficiency and has application value.

Drawings

Fig. 1 is a schematic flow chart of a method for protecting a tail portion of a cable assembly according to embodiment 1.

Detailed Description

The technical solution of the present invention will be further described in detail with reference to specific embodiments. It is to be understood that the following examples are only illustrative and explanatory of the present invention and should not be construed as limiting the scope of the present invention. All the technologies realized based on the above-mentioned contents of the present invention are covered in the protection scope of the present invention.

Unless otherwise specified, the raw materials and parts used in the following examples are all commercially available products or can be prepared by known methods.

Example 1

A method for protecting the tail part of a cable assembly comprises the following steps:

(1) mixing and extrusion molding

Raw material particles (TECHNOMETT PA 6839BLACK in Germany, Hangao) are added into a hopper of a plastic packaging machine, and are heated, melted, mixed, extruded and the like to form colloidal fluid.

(2) Pretreatment of plastic packaging

(a) Derusting and polishing

Polishing the surface of the TPR material to be plastically packaged by using abrasive cloth for polishing and derusting, wherein the roughness of the polished surface is uniform and consistent, and the surface of the cable is not damaged; and cleaning the ground powder by using a brush, and requiring that the product has no powder and no residue.

(b) Cleaning of

Dipping acetone with a cotton swab, scrubbing and polishing the derusted surface to be subjected to plastic packaging; dipping a cotton swab in absolute ethyl alcohol to clean the surface of the workpiece; and after coating, drying at high temperature.

(3) Coating treatment

Dipping the adhesive with a painting brush, and uniformly coating an adhesive film layer on the surface to be plastically packaged. And (4) placing the workpiece coated with the adhesive in a drying box for complete drying.

(4) Mounting die

And after the mould is cleaned, the sealing adhesive tapes are wound at the two ends of the cable head, and the cable is installed in the mould.

And (3) putting the mounted die into a plastic packaging machine, additionally mounting an extrusion molding port tool on the die, starting the plastic packaging machine, and pressing an injection port of the plastic packaging machine into the extrusion molding port tool.

(5) Plastic package

The pressure is started and the heated and melted glue is injected into the mould from the mouth. And when the whole die is filled with the sizing material and the pressure reaches 0.4-0.8MPa, the plastic packaging machine is automatically closed. And opening the die and taking out the workpiece.

(6) Shaping treatment

Trimming the outer surface of the plastic-sealed cable by using a special cutter, wherein no excessive flash is required, and the plastic-sealed rubber at the root of the cable connection part is kept in a natural curing state as much as possible;

(7) appearance inspection after plastic packaging

The outer surface of a product with the cable is inspected to have no water mark, no collision, no corrosion and other defects, no excess residue is left on the plug, and the other surfaces have no abnormal phenomenon.

The raw material is melted and crosslinked with the cable sheath to form a unified structure by the method of the embodiment, and the gap of the connecting interface between the outgoing part of the cable connector and the cable harness sheath is eliminated.

And (3) performance testing:

1. and (3) testing the watertight performance:

the protection cable connector obtained in example 1 was immersed in water of 1m depth for 96 hours under an inflation pressure of 0.03MPa, with reference to the water-tight rating specified in the national military standard GJB 4.13 "ship electronic equipment environmental test enclosure waterproof test".

Tests show that the sealing of the cable connector can reach the water tightness requirement of 0.3 mp.

2. And (3) environmental test:

1) high and low temperature tests: the high-temperature test and the low-temperature test respectively refer to military standard GJB 150.3A-2009 part 3 of military equipment laboratory environment test method: high temperature test, GJB 150.4A-2009 military Equipment laboratory environmental test method part 4: low temperature test (LTD). The high-temperature test temperature is 65 ℃, and the duration time is 8 h; after cooling to room temperature, the low temperature test was started at-45 ℃ for 8 h.

2) Laboratory ultraviolet aging test: the ultraviolet aging test is carried out by referring to the national standard GB/T12831-91' aging test method for vulcanized rubber artificial climate (xenon lamp), and the aging test time is 360 h.

Through tests, after the cable connector obtained in the embodiment is subjected to a high-low temperature test and an ultraviolet aging test respectively, the protection position is not changed obviously, and the normal use of the cable connector is not influenced. The protected cable electric shock device has good environmental applicability.

Meanwhile, the peel strength of the cable connector protection part obtained by the embodiment is not lower than the effect achieved by the protection of the prior art.

The embodiments of the present invention have been described above. However, the present invention is not limited to the above embodiment. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.