CN207474708U - Electrical connection structure of cable - Google Patents

Abstract

The utility model discloses a high-quality overmolded electrical connection structure for a cable, in particular but not exclusively relates to an electrical connection structure on a cable with a variable outer surface, and also discloses a method for manufacturing the electrical connection structure.

Description

The electrical connection structure of the cable

technical field

The utility model relates to an electrical connection structure of cables, in particular but not exclusively to an electrical connection structure of cables with varying outer surfaces. The utility model also relates to a manufacturing method of the electrical connection structure.

Background technique

A standard cable has one or more wires secured by a jacket made of plastic. This standard cable has inherent fragility. To solve this problem, an extra jacket is often provided to wrap the cable. Sheath adds strength and durability. The jacket provides an extra layer of protection over the cable jacket and does not wear down on the cable until the jacket wears down. Furthermore, the sheath can be provided in various materials, textures, colors, making it aesthetically pleasing.

Jackets help with other cable issues given below.

The wires of the cable consist of conductive material in an inner core. These conductive materials have a dominant role and influence on the shape of the cable. During normal use, the wires crimp and cause the cable to bend into ultimately unwanted and messy shapes. Cables can be forced to another shape. However, it is difficult to restore the cable to its original shape.

Additional resistance can be achieved on the cable by using a sheath, for example made of leather. The conductive material in the wires of the cable cannot overcome the resistance of the sheath. Thus, the jacket helps to reduce/eliminate unwanted bending of the cable. In other words, the sheath provides a softer effect that balances the forces of the conductive material, resulting in a tangle-free cable. So the jacket can help reduce tangling of the cable over time.

In many applications, cables and connectors are overmolded to form a single part. Overmolding of the cable provides stress relief, which is important to the electrical and mechanical integrity and overall performance of the cable assembly. Additionally, this overmolded strain relief provides good moisture resistance where the wires connect to the connector.

The method of making this overmolded stress relief is as follows. The wires at the end of the cable connect to the connector. The end of the cable connected to the connector is placed in the mold. Molten insulating material such as PVC is injected into the mold cavity. Once the molten material cools and solidifies, an overmolded termination is formed at the end of the cable. Such overmolded electrical connection structures can be provided for plugs or sockets.

Such overmolding works well for cables with a smooth and uniform outer surface.

However, it is very difficult to overmold the end connections if the cable has a sheath that increases the strength and durability of the cable or improves aesthetics as described above. Because the jacket has a stitched surface, a braided surface, a structured surface, beads, or some other uneven surface, the jacket can create an uneven or inconsistent outer surface on the outside of the cable.

The main difficulty is to form a precise connection between the mold cavity and the outer surface of the cable. Overmolded material tends to eject from the mold through the gap between the uneven outer surface of the cable and the cavity. This results in a poor quality seal between the cable and the overmolding material. Furthermore, the cable is damaged by the unrestricted flow of heat-fused material through the cable.

It is further difficult to cover the end connections if the sheath of the cable is made of a material that does not adhere easily to the overmolding, such as leather, PU leather, fabric, metal, glass, wood or stone.

Another difficulty exists when the sheath is made of a material such as leather. During the overmolding process, the temperature of the overmolding material usually exceeds 200°C. This temperature can melt or burn the jacket material located outside the mold by escaping from the gap between the mold and the jacket.

Additionally, when overmolding plastic is injected into the overmolding cavity with great force, the sheath can easily become a safety hazard if this hot molten plastic escapes from the gap between the moulds.

Additionally, the pressure inside the overmolding mold can cause a loosely fitted cable to eject from the mold cavity, allowing the overmolding material to spill out of the cavity.

Contents of the invention

The present invention seeks to provide high quality overmolded electrical connection structures for cables with varying outer surfaces.

It would also be desirable to provide such a high quality overmolded electrical connection structure for cables with sheaths made of leather, PU leather, fabric, metal, glass, wood or stone.

It is also desirable to provide such high quality overmolded electrical connection structures for small and large cables.

It would also be desirable for a cable having an uneven outer surface to provide a means of overmolding the electrical connection structure such that molten material is confined during the overmolding process so as not to escape from the mold.

It is further desirable to provide a method of overmolding electrical connection structures on cables such that the cables are not damaged by the heat of the overmolding material/processing.

Considering the above situation, the first aspect of the utility model provides an electrical connection structure applicable to cables with varying outer surfaces, the connection structure comprising:

a prefabricated part which securely surrounds the end of the cable so that the wires at the end of the cable can be connected to the electrical part, and

Wherein the prefabrication restricts molten overmolding material from flowing through the prefabrication during overmolding, the overmoulding forms an insulation which is attached to the prefabrication, the electrical part and the cables/wires from the prefabrication section extending to the electrical section.

Advantageously, the preform helps to prevent the flow of molten material over the preform to the exposed cable. The cables located outside the preform are insulated from the heat and pressure of the molten overmolding material. Thus, thermal damage of the cable by the overmolding material is reduced and the quality of adhesion of the overmolding to the cable is improved.

The preform may include a main body, a protrusion extending from the main body for increasing the adhesion strength between the preform and the overmolded insulating part. Preferably, the raised portion is an "I"-shaped base, and the "I"-shaped base is formed on the main body of the prefabricated portion. The protrusions may be provided on either side of the cable when viewed in plan. The preform may have a higher melting point than the overmolding so that the preform does not melt during the overmolding.

The overmold material cures into the gap provided by the raised portion and surrounds the raised portion from multiple sides. Thus, the joining of the prefabricated part and the overmolded part is strengthened. Therefore, the stress relief capability at the end connection is improved.

The prefabrication can have holes into which the cables are inserted. Preferably, the shape and size of the hole is chosen to suit the shape and size of the cable. Preferably, the cross-sectional shape of the hole is circular, polygonal, elliptical, or has a combination of arcuate and rectilinear portions. Therefore, the connection of the present invention can be adapted to cables of various sizes and shapes. For example, larger diameter holes may fit cables with larger cylindrical cross-sections. The size and shape of the prefab can also be selected to suit various sheathing materials including leather, split leather such as PU leather, metal, fabric, glass, wood, stone, etc.

The electrical connection structure may include a housing encased in an overmolded insulation. The housing may be made of any material including metal.

The preform may comprise a membrane which is piercable by the cable. The membrane may be flexible such that the membrane wraps around the cable after being pierced by the cable.

The electrical part may be a connector plug.

Electrical connection structures may be provided to connect a cable to a dongle, to connect a cable to a device, to connect a cable to a terminal plug or socket, to connect two or more cables to an in-line dongle. The electrical connection structure may be applicable to cables for speakers, charging cables, earbuds, extension cables, LAN, HDMI, and the like.

The present invention also provides a cable according to the electrical connection structure of the first aspect of the present invention.

The cable may have a jacket. Sheaths are made of suture, beaded, structured or woven material. The sheath can be plastic, leather, PU leather, fabric, metal, glass, wood or stone. Sheathing can be glued, sleeved, stitched, braided, interwoven, stitched to the cable.

A second aspect of the present invention provides a method for forming an electrical connection structure in a cable having a varying outer surface, the method comprising the steps of:

(a) securely wrap the preform around the end of the cable,

(b) connecting the wires at the ends of said cables to the electrical part,

(c) Overmolding the insulation so that the insulation is attached to the preform, the electrical part, and the portion of the cable/wire extending from the preform to the electrical part, wherein the preform restricts the flow of molten overmolding material during the overmolding process through the prefabrication department.

The method may comprise the step of covering the overmolding with the housing. The housing can be made of rigid or flexible material. The housing can be made of metal. The overmolding may be recessed relative to the preform such that the metal housing rests on the preform.

Step (a) may comprise inserting the cable into the prefabrication. Preferably, the preform comprises a membrane which can be pierced by the cable such that the membrane wraps around the cable.

Step (a) may comprise further pulling back the cable inserted into the preform so as to cause the film to produce a folded wrap over the cable.

A third aspect of the present invention provides a prefabricated part for forming an electrical connection structure on a cable having a varying outer surface, wherein the prefabricated part is arranged to firmly surround the end of the cable such that the end where the wires of the cable can be connected to the electrical part, and

wherein the preform is arranged to restrict the flow of molten overmolding material through the preform during an overmolding process which forms an insulation which is attached to the preform, the electrical part and the cable/ The part of the wire that extends from the prefabricated part to the electrical part.

The preform may have an aperture smaller than the outer diameter of the cable.

The preform may comprise a main body, one or more protrusions extending from the main body of the preform for engagement with the overmolded part. It is further preferred that the preform comprises a member extending from the main body in a direction opposite to the projection, which member serves to elongate said hole.

The preformed part may have a higher melting point than the overmolded part.

The preform may comprise a membrane covering the hole, which may be pierced/teared by the cable being pushed in.

The pierced/teared membrane can help seal any gaps between the cable and the hole. Preferably, the punctured/torn membrane can be folded back onto the cable by moving the cable relative to the preform to further help seal any gaps between the cable and the hole.

The membrane may be integrally formed with the preform.

Another aspect of the present invention provides a cable with a PVC jacket, the cable has a sheath.

Description of drawings

The utility model will be described in detail below by referring to the accompanying drawings and examples. The advantages and implementation methods of the present utility model will be more obvious. Any sense of limitation, in the attached drawing:

Figures 1A to ID show a section of cable with varying outer surfaces. In particular, FIGS. 1A to 1D show cables having stitched, beaded, structured, and braided jackets, respectively.

2A to 2E show the steps of assembling an electrical connection structure for cables according to an embodiment of the present invention, wherein:

Figure 2A shows the end of the cable;

Figure 2B shows the insertion of the end of the cable into the preform;

Figure 2C shows the wires of the cable shown in Figure 2B connected to the connector;

Figure 2D shows the embodiment in Figure 2C and the resulting overmolded insulation attached to the preform, the connector and the portion of the cable/wire extending from the preform to the connector.

Fig. 2E shows the embodiment of Fig. 2D with the housing covering the overmolding. This is complete with end connections available for plugs.

3A and 3B respectively show a front view and a cross-sectional view of a prefabricated part of an electrical connection structure for cables according to an embodiment of the present invention.

4A to 4D respectively show the end views of the prefabricated part of the electrical connection structure for cables according to the four embodiments of the present invention. In particular, FIGS. 4A to 4D all show prefabricated parts having holes whose cross-sections are respectively larger circles, smaller circles, pentagons and combinations of arcuate and straight lines.

5A, 5B and 5C respectively show a top view, a front view and a cross-sectional view of a prefabricated part of an electrical connection structure for cables according to a second embodiment of the present invention.

Figures 6A, 6B, 6C and 6D show the progressive steps of assembling the cable and prefabrication prior to overmolding according to a second embodiment of the invention.

Fig. 7 shows a schematic diagram of connecting two cables with changed outer surfaces using the technical solution of the present invention.

Fig. 8 shows a schematic diagram of applying the technical solution of the present invention to connecting the cable to the "dongle".

Fig. 9 shows a schematic diagram of applying the technical solution of the present invention to connect two cables to the same "dongle".

Fig. 10 shows a schematic diagram of the technical solution of the present invention applied to connecting cables to devices. In Fig. 8, only a partial view of the device is shown. The device can be any electrical or electronic device.

Detailed ways

The cable 10 has one or more insulated wires 12 held in a plastic jacket 14 . A sheath 16 covering the outer jacket 14 may be provided for functional purposes, such as to achieve a certain strength, flexibility or stiffness, abrasion resistance of the cable, or to provide an outer surface engageable with auxiliary components for mounting or the like. Additionally, the jacket 16 may be provided for decorative purposes, for an attractive visual appearance or to color code the cable 10 . Jacket 16 generally fits snugly over jacket 14 so that the cable acts as a single piece.

Some cables 10 have smooth and consistent outer surfaces, while other cables 10 have varying, uneven, or otherwise inconsistent outer surfaces. Examples of cables 10 with varying outer surfaces are shown in FIGS. 1A to 1D .

In Fig. 1A, the sheath 16.1 is made of suture material. The seams of the sheath 16.1 protrude from the sheath 14 thereby causing the cable 10 to have a varying outer surface. The sheath 16.1 material can be leather, fabric or some other flexible material.

In Fig. IB, the sheath 16.2 has a plurality of beads. Each bead has an independently curved outer surface, resulting in the cable 10 having a varying outer surface. The beaded sheath 16.2 may be made of suitable plastic, metal or a combination of plastic and metal.

In Fig. 1C, the sheath 16.3 is made of a structured material with a plurality of radial corrugations. Therefore, the outer surface of the cable 10 is not uniform due to corrugations. The structured sheath 16.3 may be made of plastic such as PVC or metal such as aluminum or galvanized steel.

In Fig. 1D, the sheath 16.4 is a braided material. The braided material comprises multiple strands of material that are braided together to provide a flexible sheath 16.4. The braided sheath 16.4 can be made of metal or plastic.

The sheaths 16.1, 16.2, 16.3, 16.4 may be made of any form or type of plastic.

As mentioned in the Background section, it is difficult to adapt cables with varying outer surfaces (such as those shown in Figures 1A to 1D) and/or with outer materials such as leather, fabric, wood, stone, etc. Cables such as metal or metal provide high-quality overmolding.

Referring to Figures 2A to 2E, in one embodiment, the present invention provides a preform 20 that securely surrounds the uneven outer surface of the cable 10 prior to overmolding to limit the flow of overmolding material 40 through the exposed the cable10. The prefabricated part 20 is made of a material having a higher melting point than the material of the overmolded part 40 so that the prefabricated material does not melt during the overmoulding process. The preform 20 may be an injection molded plastic part.

The end of the cable 10 is inserted through the hole 24 of the prefab 10 . The preform 20 is located near the end of the cable 12 . The size and shape of the hole 24 of the sheath 16 of the preform surrounding the cable results in a tight fit between the cable 10 and the preform 20 with no or minimal clearance between the cable 10 and the hole 24 of the preform 20 . The fit between the aperture 24 of the preform 20 and the cable 10 limits the ejection of molten material beyond the preform 20 during the overmolding process.

The wires 12 of the cable 10 protrude from the prefabrication 20 . After the preform 20 is positioned, the wire 12 is connected to the connector 30 to avoid loosening of the joint between the wire 12 and the connector 30 prior to the overmolding process. The connector 30 is larger than the hole 24 of the preform 20 . The wires 12 can be connected to the connector 30 or the PCB of the connector 30 by simple mechanical contact, soldering or any other known means.

After the wires 12 of the cable 10 are connected to the connector 30, the cable 10 with the prefabricated part 20 and the connector 30 are placed in an injection molding mold (not shown). The preform 20 and the connector 30 are rigid materials with a defined shape and a uniform outer surface. The edges of the mold are able to create a defined barrier and seal with the outer surfaces of the preform 20 and the connector 30 to prevent any overmolding material from escaping from the edge area of the mould. Importantly, the tight fit between the preform 20 of the cable 10 and the jacket 16 limits spillage of overmold material from the preform 20 onto the cable 10 . This minimizes the chance of damage to the cable 10 due to unrestricted flow of hot-melt molding material through the cable 10 , which could damage the cable 10 .

Once the end of the cable 10 is properly held in the mould, molten material is injected to form the overmold 40 . The overmolded part 40 extends between the prefabricated part 20 and the connector 30 . The overmolded part 40 covers the wire 12 between the prefabricated part 20 of the cable 10 and the connector 30 , as well as the area where the wire 12 connects to the connector 30 . The overmold 40 has insulating properties to isolate the current passing from any particular wire 12, providing safety to the user.

The preform 20 includes a main body 22 and two raised portions 26 extending from the main body 22 . The overmold 40 is cured around the raised portion 26 in order to strengthen the bond between the prefabricated portion 20 and the overmold 40 . Similarly, the connector 30 has a hole 32 over which the overmold 40 is cured so as to strengthen the bond between the connector 30 and the overmold 40 .

Alternatively, the preformed part 20 may be provided with a recess to engage the overmolded part 40 .

Alternatively, the connector 30 may be provided with a protrusion to engage the overmold 40 .

The overmolding part 40 is connected to the prefabricated part 20 such that the edge of the side of the prefabricated part 20 adjoining the overmolding part is exposed outside the overmolding part 40 . In a preferred embodiment, all outer edges of this side of the preformed part 20 are exposed outside the overmolded part 40 . The metal shell 50 is slid over the overmold 40 and rests on the exposed outer edge of the side of the preform 20 .

Control the size of the metal shell 50 and the overmolded portion 40 or the raised portion 26 (the top surface of the raised portion 26 may be exposed, which will be explained below) so that the metal shell 50 and the overmolded portion 40 or the raised portion 26 Form an interference fit. As a result, the metal shell 50 is firmly held on the overmolding 40 at the end of the cable 10 .

It should be understood that the housing 50 covering the cured overmold 40 is optional.

The electrical connection structure 100 provides strain relief for the wires 12 of the cable 10 connected to the connector 30 .

Shown in Fig. 2E is the plug applying the technical solution of the utility model. However, the application of the present invention is not limited to plugs. It can also be used for sockets.

Referring to FIGS. 3A and 3B , the preform 20 has a main body 22 . The body 22 has a first side 22.1 and a second side 22.2. The first side 22 . 1 in the assembled state faces the electrical part 30 . The second side in the assembled state faces the cable 10 extending from the electrical connection structure 100 . The second side 22.2 faces away from the first side 22.1. The preform 20 comprises two raised portions 26 extending from the first side 22.1 of the main body 22. In the assembled state, the raised part 26 is located at the end of the cable 10 connected to the electrical part 30 . The prefabricated part 20 comprises a member 28 extending from the second side 22.2 of the main body 22. In the assembled state, the member 28 faces the cable 10 extending from the electrical connection structure 100 . The preform 20 includes an aperture 24 through a member 28 and the body 22 . The hole 24 is located in the center of the prefabricated part 20 .

The main body 22 is a flat rectangular piece. The first side 22.1 is a flat surface to provide a sealing engagement with the edge of the mold during overmolding. In this embodiment, the shape and configuration of the second face 22.2 is independent of the sealing between the preform 20 and the mold during the overmoulding process.

A member 28 extending from the body 22 is provided to provide sufficient length for the aperture 24 required to properly grip the cable 10 in use. This extra length is especially suitable for small electrical connection structures.

Protrusions 26 are "I" shaped and located on either side of aperture 24 . Each "I" shaped boss 26 includes a rib, two bases connected to the rib. Each "I" shaped protrusion 26 has a certain thickness. The base of each "I" shaped protrusion 26 is connected to the first side 22 . 1 of the body 22 of the preform 20 . The two "I" shaped protrusions 26 are parallel to each other, so that the four upper end surfaces of the two "I" shaped protrusions 26 form the first plane 26.1, and the four bottom end surfaces of the two "I" shaped protrusions 26 A second plane 26.2 is formed. In use, the first plane 26.1, the second plane 26.2 may rest on two opposite surfaces of the mould, respectively. This arrangement makes it easy to position the preform 20 in the mould, and vice versa. It also helps to provide a good seal/engagement/separation between the mold and the first side 22.1 since the angle of the first plane 22.1 between the planes 26.1 and 26.2 is known. In this embodiment, the angle between the plane 26.1 and the plane is 90°, and the angle between the plane 26.2 and the plane is 90°. Thus, the efficiency of the overmolding process is improved.

Referring to Figures 4A and 4B, the cross-section of the hole 24 of the preform 20 seen in these figures is circular. The holes 24 have a straight profile in the longitudinal direction, ie the cross-section of the holes 24 does not change in the longitudinal direction. The hole 24.1 of the preform 20 in FIG. 4A has a diameter D1. The hole 24.2 of the preform 20 of Fig. 4B has a diameter D2. D1 is greater than D2. Therefore, the preformed part 20 with the diameter D1 may be selected for a larger cable that is difficult for the prefabricated part 20 with the diameter D2 to accommodate. Likewise, for smaller cables that cannot be held securely in a preform 20 of diameter D1, a preform 20 of diameter D2 may be selected.

Due to the flexibility of the cable material, the hole diameter D1 or D2 of the preform 20 can accommodate a range of cables 10 . Thus, the ends of the larger cables 10 can also (to some extent) be squeezed into the smaller holes of the preform 20 .

For example, a preform 20 with a circular hole 24.1 or 24.2 is suitable for a cable 10 with a braided sheath 16.4. The hole 24.1 with a diameter of 3mm can accommodate a cable 10 with a diameter of 3.5mm to 5mm with a braided sheath 16.4 due to the flexibility of the cable 10 and its squeezeability in the hole 24.1.

If the outer diameter of the cable 10 is less than 3.5 mm, a smaller hole 24.2 is required to provide a sufficient tight fit to limit the flow of overmolding material from the gap/loose fit between the cable 10 and the hole.

Referring to Figure 4C, the hole 24.3 of the preform 20 has a pentagonal cross-section. The prefabricated part 20 with a pentagonal hole 24.3 is suitable for accommodating cables with a pentagonal cross-section equal to or slightly larger in size than the hole 24.3.

Referring to Figure 4D, the hole 24.4 of the preform 20 is partly oval and partly flat. In particular, the cross-section of the hole 24.4 has an arcuate portion connected to a straight/flat portion. The cross-sectional profile of the hole 24.4 is suitable for a cable 10 with a stitched sheath 16.1, eg as shown in Fig. 1A. In use, when the end of such a cable 110 is inserted into the hole 24.4, the seam folds over the hole 24.4 to provide a tight fit between the cable 10 and the hole 24.4, which limits the flow of molten material during the overmolding process from the hole 24.4. The precast section 20 is ejected.

Additionally, the hole 24 may have a profile other than a straight line profile along the length of the cable. In other words, the cross-section may have a varying profile in the longitudinal direction of the hole. For example, the bore 24 may have a curved inner profile in the longitudinal direction to match the profile of the beaded sheath 16.2 shown in Figure IB. Once the beads of the sheath 16.2 are squeezed into the hole 24, the beads will change their original or near-original shape to fit the hole 24 contour.

Referring to FIGS. 5A to 5C , in a second embodiment of the present invention, the preform 20 includes a membrane 29 . Other than that, the prefabrication section 20 is structurally similar to the prefabrication section 20 of the above-described embodiment.

The membrane 29 covers the holes 24 at the first side 22 . 1 of the preform 20 . The membrane 29 protrudes from the first side 22 . 1 of the body 22 of the prefab 20 . The protrusion direction of the film 29 is the same as the protrusion direction of the protrusion part 26, and both are located on the side facing the electric part 30.

The thickness of the membrane 29 is about 0.08mm. The film 29 has softness.

The membrane 29 is made of the same material as the prefab 20 . For example, the membrane 29 and the preform 20 can be made of PVC. The membrane 29 and the preform 20 are manufactured as a single part.

In alternative embodiments, the membrane 29 may be made of a different material than that of the preform 20 . This membrane 29 will be joined to the prefabricated part 20 by known means.

In another alternative embodiment, the preform 20 may include a plurality of membranes 29 along the aperture 24 . Such a structure will increase the gap closing capability of the precast part 20 .

In another alternative embodiment, the membrane 29 may be located at the second side 22 . 2 of the preform 20 .

Referring to Figures 6A to 6D, a method of assembling the cable 10 to the prefab 20 of the second embodiment is shown.

Initially, the preform 20 is located in front of the cable 10 with the wires 12 exposed. The core of the wire 12 may also be exposed. At this stage, the second face 22 . 2 of the preform 20 faces the end of the cable 10 .

Then, as shown in FIG. 6B , the cable 10 is inserted in the hole 24 of the prefabricated part 20 in the direction 19 . When the exposed wires 12 of the cable 10 encounter the membrane 29 , the cable 10 is forced to pierce/tear/break the membrane 29 .

The end of the cable 10 is then moved further into the preform 20 until a portion of the sheath 16 of the cable 10 protrudes from the hole 24 of the preform 20 . At this stage, the outer sheath 16 is surrounded by the preform 20 .

A film 29 surrounds the sheath 16 of the cable 10 . This helps to close the gap between the sheath 16 of the cable 10 and the preform 20 . Thus, membrane 29 provides a first level barrier.

Subsequently, the cable 10 is pulled back in the opposite direction 19 as shown in Figure 6D. The cable is pulled back to the extent that some parts of the sheath 16 still extend from the first side 22 . 1 of the body 22 of the preform 20 . This movement of the cable 10 relative to the preform 20 causes the membrane 29 to fold over and roll around the sheath 16 to provide additional sealing of the gap between the sheath 16 and the preform 20 . This is the secondary barrier provided by the perforated membrane 29 .

The folded film helps to increase the strength of the seal between the cable 10 and the preform. Thus, the membrane 29 helps to limit spillage of the overmold material 40 or residual overmold material 40 beyond the preform 20 during the overmolding process.

As shown in FIG. 6D, once the prefabricated part 20 and the cable 10 are assembled, the steps of forming the electrical connection structure 100 shown in FIG. 2C, FIG. 2D and FIG. 2E can be followed to connect the electric wire 12 to the electrical part 30 for overmolding. , and cover the cured overmolded part 40 with the casing 50 . It should be understood that housing 50 is optional.

Referring to Figures 7 to 10, various other applications of the invention are disclosed.

Figure 7 discloses an application in which the invention is used to connect two cables 10 with varying outer surfaces. Each of the two cables 10 has a different varying outer surface. In particular, one cable 10 has a stitched sheath 16.1 and the other cable 10 has a braided sheath 16.4. A preform 20 is mounted on the end of each cable 10 . The wires of the two cables are connected directly or through the PCB. Subsequently, a PVC overmold 40 is formed between the two preforms 20 covering the wire joint. The electrical connection structure 100 provides strain relief for the wires of the two cables 10 being connected.

The invention can also be applied to connecting a cable 10 with a varying outer surface to a cable 10 with a uniform outer surface.

The invention can also be applied to connecting a cable 10 with a varying outer surface to two or more cables 10 which may or may not have a varying outer surface.

The utility model can also be applied to connect two or more cables with consistent outer surfaces.

Figure 8 discloses an application in which the invention is used to connect a cable 10 with a varying outer surface to a dongle. A dongle is a small electrical appliance.

Figure 9 discloses an application in which the invention is used to connect two cables 10 of a dongle with varying outer surfaces.

Figure 10 discloses an application where the invention is used to connect a cable 10 with a varying outer surface to an electrical device larger than a dongle.

Some other related applications of the invention include providing such electrical connection structures for connecting earphones and/or earphone jacks to suitable cables.

Additional applications of the invention include connections provided at the end of data cables such as HDMI cables, USB cables, Micro USB cables, mini USB cables, Ethernet cables, fiber optic cables, coaxial cables, and the like.

In an alternative embodiment, the preform consists of two parts which are fastened together prior to overmoulding to provide a tight fit between the cable and the preform. Fasteners may also be overmolded to prevent exposure in order to maintain a tight connection between the preform and the cable after overmolding.

In the drawings and specification, there have been disclosed typical embodiments of the invention and, although specific terms have been employed, they have been used in a generic and descriptive sense only and not for purposes of limitation, and the scope of the invention is set forth in the following claims.

Table of Reference Numbers:

Claims (35)

1. An electrical connection structure for cables with varying outer surfaces, said connection structure comprising: a prefabricated part, which surrounds the cable firmly, near the end of the cable, so that the wires at the end of the cable can be connected to the electrical part, and wherein the preform restricts molten overmolding material from passing over the preform during overmolding, the overmolding forms the overmolded part, the overmolded part is attached to the preform, electrical part, cable/wire The part extending from the prefabrication department to the electrical department; Wherein the prefabricated part includes a main body and a protruding part extending from the main body, and the protruding part is used to increase the adhesion strength between the prefabricated part and the overmolded part. 2. The electrical connection structure according to claim 1, wherein the protrusion is an "I" shaped protrusion, and the "I" shaped protrusion includes a rib and two bases connected to the rib , one of the bases is located on the main body of the prefabricated part. 3. The electrical connection structure according to claim 1, wherein the main body has a first side and a second side facing away from the first side, the first side faces the electrical part, and the second side faces For cables extending from the electrical connection structure; the raised portion extends on the first side. 4. The electrical connection structure of claim 3, wherein the prefabricated portion includes a member extending from the second side, the member facing the cable extending from the electrical connection structure. 5. The electrical connection structure according to claim 1, wherein said prefabricated part has a hole into which said cable is inserted. 6. The electrical connection structure of claim 5, wherein the shape and size of the aperture is selected to fit the shape and size of the electrical cable. 7. The electrical connection structure according to claim 6, wherein the cross-sectional shape of the hole is a circle, a polygon, an ellipse or a combined shape having an arcuate portion and a straight portion. 8. The electrical connection structure of claim 1, wherein the preformed portion has a higher melting point than the overmolded portion. 9. The electrical connection structure according to claim 1, wherein the preformed part is provided with a recess to engage with the overmolded part. 10. The electrical connection structure of claim 1, comprising a housing covering the overmold. 11. The electrical connection structure according to claim 10, wherein an outer edge of a side of the prefabricated portion adjacent to the overmolded portion is exposed outside the overmolded portion, and the housing slides over the overmolded portion to rest to the exposed outer edge of that side of the preform. 12. The electrical connection structure according to claim 1, wherein said prefabricated part comprises a membrane which can be pierced by said cable being pushed in. 13. The electrical connection structure of claim 12, wherein the film is flexible such that the film wraps around the cable after being pierced by the cable. 14. The electrical connection structure according to claim 1, wherein the electrical part is a connector plug. 15. The electrical connection structure of claim 1 for connecting a cable to a dongle, connecting a cable to a device, connecting a cable to a terminal plug or socket, a connection between two or more cables, Connect two or more cables to the tethering dongle. 16. A cable with an electrical connection structure according to any one of claims 1-15. 17. The cable of claim 16, wherein the cable has a jacket. 18. The cable of claim 17, wherein the jacket is made of suture material, beading, structured material or braided material. 19. The cable according to claim 17 or 18, wherein the sheath is made of plastic, leather, PU leather, fabric, metal, glass, wood or stone. 20. A prefabricated part for forming an electrical connection structure on an electrical cable having a varying outer surface, wherein said prefabricated part is arranged to securely surround an end of a cable such that wires at the end of said cable can be connected to an electrical part, and Wherein the preform is arranged to restrict the flow of molten overmolding material through the preform during an overmolding process, the overmolding forms adhering to the preform, the electrical part and the cables/wires extending from the preform to Partial overmolding of electrical parts; Wherein the prefabricated part includes a main body and a protruding part extending from the main body, and the protruding part is used to increase the adhesion strength between the prefabricated part and the overmolded part. 21. The preform of claim 20, wherein the preform has a hole smaller than the outer diameter of the cable. 22. A preform according to claim 21, wherein the preform includes one or more protrusions extending from the body for engaging the overmold. 23. A preform according to claim 22, comprising a member extending from the body in a direction opposite to the raised portion, the member for elongating the aperture. 24. A preform according to any one of claims 20 to 23, wherein the preform has a higher melting point than the overmoulding. 25. A precast section according to claim 22, comprising a membrane covering said hole, said membrane being pierceable/tearable by a cable pushing through said hole. 26. A preform as claimed in claim 25, wherein the pierced/torn membrane helps to seal the gap between the cable and the hole. 27. The preform of claim 25, wherein the body includes a first side and a second side facing away from the first side, the raised portion extends on the first side, the membrane covers The hole at the first side. 28. The preform according to claim 27, wherein the raised direction of the membrane is the same as the raised direction of the raised portion. 29. The preform of claim 25, wherein the body includes a first side and a second side facing away from the first side, the raised portion extends on the first side, the membrane covers The hole at the second side. 30. A preform according to claim 26, wherein said pierced/teared membrane can be flipped over said cable by moving over said cable relative to said preform to further facilitate Seal any gaps between the cable and the hole. 31. A preform as claimed in any one of claims 25 to 30, wherein the membrane is integrally formed with the preform. 32. A cable with a PVC jacket, the cable has a sheath; the cable end has an electrical connection structure as claimed in any one of claims 1 to 15. 33. The cable according to claim 32, wherein the sheath is made of leather, PU leather, fabric, metal, glass, wood or stone. 34. A cable as claimed in claim 32 or 33, wherein the sheath is made of suture material, beading, structured material or braided material. 35. A cable as claimed in claim 32 or 33, wherein the cable is for a speaker, charging cable, earbuds, extension cable, LAN or HDMI.