WO2017029538A1

WO2017029538A1 - Electrical connection for a cable

Info

Publication number: WO2017029538A1
Application number: PCT/IB2015/056280
Authority: WO
Inventors: Chia JEN LIN
Original assignee: Ascent Star Limited
Priority date: 2015-08-18
Filing date: 2015-08-18
Publication date: 2017-02-23
Also published as: CN207474708U

Abstract

Disclosed is a high quality over-mould electrical connection for a cable and particularly but not exclusively to an electrical connection for a cable having a varying outer surface. Also disclosed is a method for manufacturing such an electrical connection.

Description

ELECTRICAL CONNECTION FOR A CABLE

FIELD OF THE INVENTION

[0001 ] The present invention relates to an electrical connection for a cable, and particularly but not exclusively to an electrical connection for a cable having a varying outer surface. The present invention also relates to a method for manufacturing such an electrical connection.

BACKGROUND TO THE INVENTION

[0002] Standard cables have one or more wires bound by an outer jacket made of plastic. Such standard cables are inherently weak. To address this issue, an additional outer sheath wrapping the cable is provided. The outer sheath increases strength and durability. The outer sheath provides an additional layer above the cable which wears before the wear can reach the cable. Further more, the outer sheath can be provided in a variety of materials, textures, colours such that it is aesthetically pleasing.

[0003] The outer sheath helps address yet further problems of the cable as given below.

[0004] The wire(s) of a cable include conductive materials in the core. These conductive materials have the dominant force and effect on the shape of the cable. When handled regularly, the wire curls and causes the cable to bend to a final undesirable and untidy shape. The cable can be forced to another shape. However, it is very difficult to bring the cable back to its original shape. [0005] With the use of an outer sheath, for example made of leather, an additional countering force is effected on the cable. The conductive material contained in the wire(s) of the cable is unable to overcome the countering force of the outer sheath. Therefore, the outer sheath helps in reducing/eliminating bending of the cable to undesirable shapes. In other words, the outer sheath provides a more pliable effect which balances the force of the conductive material which results in a tangle free cable. Therefore, the outer sheath can help in reducing the entanglement of the cable over a period of time.

[0006] In many applications, a cable and a connector are over-moulded to form a single part. Over-moulding of the cable provides a strain relief which is important to the electrical and mechanical integrity and overall performance of the cable assembly. Furthermore, such over-moulded strain relief also provides good moisture resistance to the location where wires are attached to the connector.

[0007] The method of manufacturing such an over-moulded strain relief is as follows. The wires at an end of a cable are attached to the connector. The end of the cable connected to the connector is placed in a mould. Molten material having insulating properties, such as PVC, is injected into the mould cavity. Once the molten material cools and solidifies, an over-moulded terminator is formed at the end of the cable. Such over-moulded electrical connection may be provided for a plug or a socket.

[0008] Such over-moulding works well with cables having smooth and even outer surface.

[0009] However, it is very difficult to over-mould the end connection if the cable has an outer sheath provided to increase the strength and durability, or improve aesthetics, of the cable as mentioned above. The outer sheath creates a varying, uneven or inconsistent outer surface of the cable, as the outer sheath has a stitched surface, a braided surface, a structured surface, beads or some other uneven surface.

[0010] The main difficulty is forming an exact joint between the mould cavity and the cable outer surface. The over-moulding material tends to eject out of the mould through the gaps between the uneven cable outer surface and mould- cavity. This causes a poor quality seal between the cable and the over-moulded material. Furthermore, the cable gets damaged by the hot molten material flowing unrestrainedly over the cable.

[001 1 ] It is further difficult to over-mould the end connection if the outer sheath of the cable is made of a material which does not readily adhere to over-moulding material such as leather, PU leather, fabric, metal, glass, timber or stone.

[0012] There is yet another difficulty when the outer sheath is made of materials such as leather. During over-moulding process the temperature of the over- moulding plastic is generally in excess of 200°C. This temperature can melt or burn the outer sheath material situated outside the mould by escaping through the gaps between the mould and the outer sheath.

[0013] Furthermore, the over-moulding plastic is injected into the over-moulding mould cavity with great force. If this hot molten plastic escapes from the gaps between the mould can the outer-sheath it can easily become a safety hazard.

[0014] Furthermore, the pressure inside the over-moulding mould can cause a loosely fitted cable to dislodge from the mould cavity whereby the over-moulding material is spilt outside the mould cavity. SUMMARY OF THE INVENTION

[0015] It is desirable to provide a high quality over-moulded electrical connection to a cable having varying outer surface.

[0016] It is further desirable to provide such a high quality over-moulded electrical connection to a cable having outer sheath made of leather, PU leather, fabric, metal, glass, timber or stone.

[0017] It is further desirable to provide such a high quality over-moulded electrical connection for small as well as large cables.

[0018] It is further desirable to provide a method for over-moulding an electrical connection on to a cable having uneven outer surface such that the molten material is restricted from ejecting out of the mould during over-moulding process.

[0019] It is further desirable to provide a method for over-moulding an electrical connection on to a cable such that the cable is not damaged by the heat of the over-moulding material/process.

[0020] With the aforementioned in mind, a first aspect of the present invention provides an electrical connection for a cable having varying outer surface, the connection including:

a pre-fabricated portion which securely surrounds the cable proximate to an end of the cable such that wires of the cable at said end are connectable to an electrical component, and

wherein the pre-fabricated portion restricts molten over-moulding material from flowing beyond the pre-fabricated portion during an over-moulding operation for over-moulding an insulating portion which adheres to the prefabricated portion, the electrical component, and a section of the cable/wires extending from the prefabricated portion to the electrical component.

[0021 ] Advantageously, the pre-fabricated portion helps in arresting the molten material. The molten material is restrained from flowing over the exposed cable beyond the pre-fabricated portion. The portion of the cable located beyond the pre-fabricated portion is isolated from the heat and the pressure of the molten over-moulding plastic. Therefore, heat damage to cable and poor quality adhesion of the over-moulded material is restricted.

[0022] The pre-fabricated portion may include a body and protrusion(s) extending from the body for increasing adhesion strength between the pre-fabricated portion and the over-moulded insulating portion. Preferably, the protrusion(s) is/are Ί- shaped' with a base of the Ί-shape' positioned on the body of the pre-fabricated portion. The protrusions may be provided on either side of the cable when seen in a plan view. The pre-fabricated portion may have a higher melting point than that of the over-moulding portion so that the pre-fabricated portion does not melt during over-moulding process.

[0023] The over-moulding material solidifies in the crevices provided by the protrusions and surrounds the protrusions from several other sides. Therefore, the joining of pre-fabricated portion and the over-moulded portion is strengthened. Thus, strain relief provided at the end connection is increased.

[0024] The pre-fabricated portion may have an aperture through which the cable is inserted. Preferably, the shape and size of the aperture is selected to suit the shape and size of the cable. Preferably, the cross-sectional shape of the aperture is circular, polygonal, oval, or has a combination of arcuate and straight portions. [0025] The connection of the present invention can therefore be made suitable for various sizes and shapes of cables. For example, larger diameter apertures may suit cables having larger cylindrical cross-sections. Also the size and shape f the pre-fabricated portion can be selected to suit a variety of sheath materials including leather, bi-cast leather such as PU leather, metal, fabric, glass, timber, stone etc.

[0026] The electrical connection may include a shell covering the over-moulded insulating portion. The shell may be made of any material including metal.

[0027] The pre-fabricated portion may include a membrane for piercing by the cable. The membrane may be flexible such that the membrane collapses on the cable after being pierced by the cable.

[0028] The electrical component may be a connector plug.

[0029] The electrical connection may be provided for connecting a cable to a dongle, a cable to a device, a cable to a terminating plug or socket, two or more cables, two or more cables with in-line dongles. The electrical connection may be provided to cables for speakers, charging cable, earplugs, extension cables, LAN, HDMI and many others.

[0030] A cable having the electrical connection as per the first aspect of the present invention.

[0031 ] The cable may have a sheath. The sheath is made of stitched material, beads, structured material or braided material. The sheath may be plastic, leather, PU leather, fabric, metal, glass, timber or stone. The sheath may be glued, slid, stitched, braided, woven, sewn on or around the cable depending on material and/or application.

[0032] A second aspect of the present invention provides a method of

manufacturing an electrical connection for a cable having varying outer surface, the method including the steps of:

(a) securely surrounding a pre-fabricated portion proximate to an end of a cable,

(b) connecting wires of the cable at said end to an electrical component, and

(c) over-moulding with an insulating portion such that the insulting portion adheres to the prefabricated portion, the electrical component, and a section of the cable/wires extending from the prefabricated portion to the electrical component, wherein the pre-fabricated portion restricts molten over-moulding material from flowing beyond the pre-fabricated portion during the over-moulding operation.

[0033] The method may include the step of covering the over-moulded portion with a shell. The shell may be made of a rigid or flexible material. The shell may be made of metal. The over-moulded portion may be inset from the prefabricated portion such that the metal shell is rests on the pre-fabricated portion.

[0034] Step (a) may include inserting the cable into the pre-fabricated portion. Preferably, the pre-fabricated portion includes a membrane which is pierced by the cable such that the membrane collapses on the cable.

[0035] Step (a) may include the further step of pulling back the cable inserted in the pre-fabricated portion in order to roll the collapsed membrane on the cable. [0036] A third aspect of the present invention provides a pre-fabricated portion for use in forming an electrical connection on a cable having varying outer surface, wherein the pre-fabricated portion is provided for securely surrounding the cable proximate to an end of the cable such that wires of the cable at said end are connectable to an electrical component, and

wherein the pre-fabricated portion is provided for restricting molten over- moulding material from flowing beyond the pre-fabricated portion during an over- moulding operation for over-moulding an insulating portion which adheres to the prefabricated portion, the electric component and a section of the cable/wires extending from the prefabricated portion to the electrical component.

[0037] The prefabricated portion may have an aperture smaller than an outer diameter of the cable.

[0038] The pre-fabricated portion may include one or more protrusion(s) extending from a body of the pre-fabricated portion for engaging with the over- moulded portion. Further preferably, the pre-fabricated portion includes a member may extending from the body in a direction opposite to that of the protrusion(s), the member for lengthening said aperture.

[0039] The pre-fabricated portion may have higher melting point than that of the over-moulded portion.

[0040] The pre-fabricated portion may include a membrane which covers the aperture, the membrane being breakable/tearable by pushing a cable through the aperture. [0041 ] The broken/torn membrane may assists in sealing any gap between the cable and the aperture. Preferably, the broken/torn membrane may be rolled on the cable by moving the cable relative to the pre-fabricated portion in order to further assist in sealing any gap between the cable and the aperture.

[0042] The membrane may be integrally formed to the pre-fabricated portion.

[0043] A yet further aspect of the present invention provides an electrical cable having a PVC jacket, the electrical cable having an outer sheath.

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] These and other features, aspects and advantages of the present invention are better understood when the following detailed description of the invention is read with reference to the accompanying drawings, in which:

[0045] Figures 1 A to 1 D each show a length of a cable having varying outer surface. Particularly, figures 1 A to 1 D show a cable having stitched outer sheath, beads, structured outer sheath and braided outer sheath, respectively.

[0046] Figures 2A to 2E show progressive stages of assembly of an electrical connection for a cable according to one embodiment of the present invention.

[0047] Figure 2A shows an end of a cable.

[0048] Figure 2B shows the end of the cable inserted in a pre-fabricated portion. [0049] Figure 2C shows the embodiment of figure 2B with the wires of the cable attached to a connector.

[0050] Figure 2D the embodiment of figure 2C and an over-moulded portion adhering to the pre-fabricated portion, the connector and a section of the cable/wires extending from the prefabricated portion to the connector.

[0051 ] Figure 2E shows the embodiment of figure 2D with a shell covering the over-moulded portion. This is a completed end connection for a plug according to one embodiment of the present invention.

[0052] Figures 3A and 3B show a front view and a sectional view, respectively, of a pre-fabricated portion of an electrical connection for a cable according to one embodiment of the present invention.

[0053] Figures 4A to 4D show an end view of a pre-fabricated portion of an electrical connection for a cable according to four embodiments of the present invention. Particularly, figures 4A to 4D each show a pre-fabricated portion having an aperture, the cross-section of the aperture is a larger circle, a smaller circle, a pentagon, and a combination of arcuate and straight sections, respectively.

[0054] Figures 5A, 5B and 5C show a top view, a front view and a sectional view, respectively, of a pre-fabricated portion of an electrical connection for a cable according to a second embodiment of the present invention.

[0055] Figures 6A, 6B, 6C and 6D show progressive steps of assembling a cable and a pre-fabricated portion, according to the second embodiment of the present invention, prior to the step of over-moulding. [0056] Figure 7 shows the concept of the present invention as applied to connect two cables having varying outer surfaces.

[0057] Figure 8 shows the concept of the present invention as applied to connect a cable to a 'dongle'.

[0058] Figure 9 shows the concept of the present invention as applied to connect two cables to a common 'dongle'.

[0059] Figure 10 shows the concept of the present invention as applied to connect a cable to a device. In figure 8, only a partial view of the device is shown. The device may be any electrical or electronic device.

DESCRIPTION OF PREFERRED EMBODIMENT

[0060] A cable 10 has one or more insulated wires 12 held together in a plastic jacket 14. A sheath 16 covering the jacket 14 may be provided for functional purposes such as attaining a specific strength, flexibility or rigidity of the cable, abrasion resistance, or providing an outer surface which is engageable with ancillary components for mounting etc. Moreover, the sheath 16 may be provided for decorative purposes, attractive visual appearance, or colour coding the cable 10. The sheath 16 is generally tightly mounted on the jacket 14 such that the cable behaves as a single part.

[0061 ] 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 having varying outer surfaces are shown in figures 1 A to 1 D. [0062] In figure 1 A, the sheath 16.1 is made of a stitched material. The stitching projects from the jacket 14 thus providing a varying outer surface to the cable 10. The sheath 16.1 material may be leather, fabric or some other flexible material.

[0063] In figure 1 B, the sheath 16.2 has a plurality of beads. Each bead has an independent curved outer surface thus providing a varying outer surface to the cable 10. The bead sheath 1 6.2 may be made of suitable plastic, metal or a combination of plastic and metal.

[0064] In figure 1 C, the sheath 16.3 is made of a structured material which has a plurality of radial corrugations. The outer surface of the cable 10 is thus uneven due to the corrugations. The structured sheath 16.3 may be made of plastic such as PVC, or metal such as aluminium or galvanised steel.

[0065] In figure 1 D, the sheath 16.4 is a braided material. The braided material includes a plurality of strands of material which are woven together to provide a flexible sheath 16.4. The braided sheath 16.3 may be made of metal or plastic.

[0066] The outer sheath 16.1 , 16.2, 16.3, 16.4, 16 may be made of plastic of any form or type.

[0067] As mentioned in the background section, it is difficult to provide a high quality over-moulding to cables having varying outer surface such as those shown in figures 1 A to 1 D, and/or those having an outer material which is not conducive to adhering to the over-moulded material such as leather, fabric, timber, stone, or metal. [0068] Referring to figures 2A to 2E, in one embodiment, the present invention provides a pre-fabricated portion 20 which securely surrounds the cable 10 having uneven outer surface, prior to over-moulding, in order to restrict the over- moulding material 40 from flowing over the exposed cable 10. The pre-fabricated portion 20 is made of a material having higher melting point than the material of the over-moulding portion 40 so that the pre-fabricated material does not collapse during over-moulding process. The pre-fabricated portion 20 may be an injection moulded plastic piece.

[0069] An end of the cable 10 is inserted through an aperture 24 of the prefabricated portion 10. The pre-fabricated portion 20 is located proximate to the end of the cable 12. The pre-fabricated portion surrounds the sheath 16 of the cable 10. The aperture 24 is of a size and shape which results in a tight fit between the cable 10 and the pre-fabricated portion 20, and there are no gaps or minimum gaps between the cable 10 and the pre-fabricated portion 20. This fitment between the aperture 24 of the pre-fabricated portion 20 and the cable 10 restricts the molten material from ejecting beyond the pre-fabricated portion 20 during over-moulding process.

[0070] Wires 12 of the cable 10 protrude away from the pre-fabricated portion 20. The wires 12 are connected to the connector 30 subsequent to positioning of the pre-fabricated portion 20 (a) as the connector 30 is larger than the aperture 24 of the pre-fabricated portion 30, and (b) to avoid loosening of the joints between the wires 12 and the connector 30 prior to over-moulding process. The wires 12 may be joined to the connector 30 or the PCB of the connector 30 by way of simple mechanical contact, soldering, or any other known way.

[0071 ] Subsequently, the end of the cable 10, having the pre-fabricated portion 20 and wires 12 connected to the connector 30, is placed in an injection moulding mould (not shown). The pre-fabricated portion 20 and the connector 30 are rigid materials having a definite shape and even outer surface. The edge of the mould is able to create a definite barrier and a seal with the outer surface of the prefabricated portion 20 and the connector 30 in order to prevent any moulding material from overflowing outside from the edge regions of the mould.

Importantly, the tight fit between the prefabricated portion 20 and the sheath 16 of the cable 10 restricts moulding material from escaping beyond the pre-fabricated portion 20 onto the cable 10. This minimizes the chances of damage to cable 10 due to hot molten moulding material flowing unrestrainedly over the cable 10 which could otherwise damage the cable 10.

[0072] Once the end of cable 10 is held properly in the mould, molten material is injected to form the over-moulded portion 40. The over-moulded portion 40 extends between the pre-fabricated portion 20 and the connector 30. The over- moulded portion 40 covers a section of the cable 10 including wires 12 between the pre-fabricated portion 20 and the connector 30 as well as the areas on joining of the wires 12 to the connector 30. The over-moulded portion 40 has insulating properties to isolate the electrical current being passed from any particular wire 12, and to provide safety to the user.

[0073] The prefabricated portion 20 includes two protrusions 26 extending from the body 22 of the prefabricated portion 20. The over-moulded portion 40 solidifies around the protrusions 26 in order to strengthen the bond between the pre-fabricated portion 20 and the over-moulded portion 40. Likewise, the connector 30 has apertures 32 around which the over-moulded portion 40 solidifies in order to strengthen the bond between the connector 30 and the over- moulded portion 40. [0074] Alternatively, the pre-fabricated portion 20 may be provided with a recess to engage with the over-moulded portion 40.

[0075] Alternatively, the connector 30 may be provided with projections to engage with the over-moulded portion 40.

[0076] The over-moulded portion 40 is slightly inset from the pre-fabricated portion 20 such that a peripheral edge region on at least one side of the prefabricated portion 20, the side on which over-moulded portion adjoins, remains exposed. In the preferred embodiment, the exposed peripheral edge region is provided on all sides of the pre-fabricated portion 20. A metal shell 50 is slipped over the over-moulded portion 40 such that it is rested at the at least one expose edge region of the pre-fabricated portion 20.

[0077] Dimensions of the metal shell 50 and the over-moulded portion 40 or the protrusion 26 (the top face of protrusion 26 may remain exposed as explained later) are controlled such that there is an interference fit between the metal shell 50 and the over-moulded portion 40 or the protrusion 26. Thereby, the metal shell 50 is securely held at the end of the cable 10 covering the over-moulded portion 40.

[0078] It will be appreciated that the shell 50 covering the solidified over-moulding portion 40 may be optional.

[0079] This electrical connection 100 provides strain relief to the wires 12 of the cable 10 connected to the connector 30. [0080] The application of the present invention seen in figure 2E is a plug.

However, the application of the present invention is not limited to a plug. It can also be used to create a socket.

[0081 ] Referring to figures 3A and 3B, the pre-fabricated portion 20 has a 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 component 30. The second side, in the assembled state, faces the cable 10 extending from the electrical connection 100. The second side 22.2 is positioned oppositely to the first side 22.1 . The prefabricated portion 20 includes two protrusions 26 extending from the first side 22.1 of the body 22 - in use that is in the assembled state, the protrusions 26 are located towards the end of the cable 10 connected to the electrical component 30. The pre-fabricated portion 20 includes a member 28 extending from the second side 22.2 of the body 22 - in use that is in the assembled state, the member 28 is located away towards the cable 10 extending from the electrical connection 100. The pre-fabricated portion 20 includes an aperture 24 which passes through the member 28 and the body 22. The aperture 22 is located centrally to the pre-fabricated portion 20.

[0082] The body 22 is a flat rectangular piece. The first side 22.1 is a flat surface in order to provide a sealing engagement with the edge of the mould during over- moulding process. The shape and configuration of the second side 22.2, in this embodiment, is not relevant to the sealing between the pre-fabricated portion 20 and the mould during over-moulding process.

[0083] The member 28 extending from the body 22 is provided in order to provide sufficient length to the aperture 24 which, in use, is required to properly grip the cable 10. This additional length is required particularly for small electrical connections. [0084] The protrusions 26 are Ί-shaped' and positioned on either side of the aperture 24. Each Ί-shape' has two bases connected with a rib. Each 'I-shape' has a thickness. A base of each of the Ί-shaped' protrusion 26 adjoins the first side 22.1 of the body 22 of the pre-fabricated portion 20. The two 'I-shaped' protrusions 26 are parallel to each other such that the four ends of the two Ί- shaped' protrusions 26, located on a top side, form a first plane 26.1 ; and four ends of the two Ί-shaped' protrusions 26, located on a bottom side, form a second plane 26.2. In use, the first plane 26.1 can be rested on a surface of the mould, and an opposing surface of the mould can be rested on the second plane 26.2. Such arrangement makes it easy to locate the pre-fabricated portion 20 in the mould and vice-versa. It also assists in providing good sealing / engagement / disengagement between the mould and the flat side 22.1 as the angle between each of the planes 26.1 and 26.2 with the flat side 22.1 is known. In this embodiment, the angle between the plane 26.1 and the flat side is 90°, also the angle between the plane 26.2 and the flat side is 90°. Thereby, efficiency of over- moulding process is increased.

[0085] Referring to figures 4A and 4B, the cross-section of the aperture 24 of the pre-fabricated portions 20 seen in these figures is circular. The aperture 24 has a straight profile in the longitudinal direction that is the cross-section of the aperture 24 does not vary in the longitudinal direction. The aperture 24.1 of the prefabricated portion 20 figure 4A has a diameter D1 . The aperture 24.2 of the prefabricated portion 20 figure 4B has diameter D2. D1 is larger than D2. Therefore, the pre-fabricated portion 20 having diameter D1 is selected for larger cables which are difficult to accommodate in pre-fabricated portion 20 having diameter D2. Equally, the pre-fabricated portion 20 having diameter D2 is selected for smaller cables which are unable to be securely held in per-fabricated portion 20 having diameter D1 . [0086] The aperture diameter D1 or D2 of a pre-fabricated portion 20 can accommodate a range of cables 10 due to the flexible nature of cable material. Therefore, ends of larger cables 10 (to an extent) can also be squeezed into a smaller aperture of the pre-fabricated portion 20.

[0087] For example, a pre-fabricated portion 20 having a circular aperture 24.1 or 24.2 is suitable for a cable 10 having a braided outer sheath 16.4. The aperture 24.1 having diameter 3mm could accommodate cable 10 having a braided outer sheath 16.4 having diameter of diameter 3.5mm to 5mm due to flexible nature of cable 10 and its ability to be squeezed in the aperture 24.1 .

[0088] If the outer diameter of the cable 10 was less than 3.5mm a smaller aperture 24.2 would be required to provide sufficient tight fit to restrict over- moulding material from ejecting out from the gap / loose fit between the cable 10 and the aperture 24.1 .

[0089] Referring to figure 4C, aperture 24.3 of the pre-fabricated portion 20 has a pentagonal cross-section. This pre-fabricated portion 20 having pentagonal aperture 24.3 is suitable for accommodating cables having pentagonal cross- section of a size equal to or slightly larger than aperture 24.3.

[0090] Referring to figure 4D, aperture 24.4 of pre-fabricated portion 20 is partly oval and partly flat. Particularly, aperture 24.4 has a cross-section having an arcuate section connected to a straight/flat section. Cross-sectional profile of aperture 24.4 is suitable for a cable 10 having a stitched sheath 16.1 for example as seen in figure 1 A. In use, when an end of such a cable 1 0 is inserted in aperture 24.4, the stitched portion folds in the aperture 24.4 to provide a tight fit between the cable 10 and the aperture 24.4 which restricts ejection of molten material beyond the pre-fabricated portion 20 during over-moulding process. [0091 ] Alternatively or additionally, the aperture 24 may have a profile other than a straight profile in the longitudinal direction which extends along the length of the cable, in use. In other words, the cross-section may have a varying profile in the longitudinal direction. For example, the aperture 24 may have a curved inner profile in the longitudinal direction to match the profile of beaded sheath 16.2 seen in figure 1 B. Once a bead of sheath 16.2 is squeezed into the aperture 24, the bead reforms to take its original shape or near original shape to which the profile of the aperture 24 conforms.

[0092] Referring to figures 5A to 5C, in a second embodiment of the present invention, the pre-fabricated portion 20 includes a membrane 29. The prefabricated portion 20 is otherwise similar in construction to the pre-fabricated portion 20 described above.

[0093] The membrane 29 covers the aperture 24 at the first side 22.1 of the prefabricated portion 20. The membrane 29 bulges from the first side 22.1 of the body 22 of the pre-fabricated portion 20. The bulge of the membrane 29 is on the same side as the protrusions 26 that is the side which in use will be facing the electrical component 30.

[0094] The membrane 29 is about 0.08mm thick. The membrane 29 has a degree of flexibility.

[0095] The membrane 29 is made of the same material as the pre-fabricated portion 20. For example, the membrane 29 and the pre-fabricated portion 20 may be made of PVC. The membrane 29 and the pre-fabricated portion 20 are created as a single part. [0096] In an alternative embodiment, the membrane 29 may be made of a different material to that of the pre-fabricated portion 20. Such membrane 29 would be bonded to the pre-fabricated portion 20 by known means.

[0097] In a further alternative embodiment, the pre-fabricated portion 20 may include a plurality of membranes 29 along the aperture 24. Such construction would add to the gap closing capability of the pre-fabricated portion 20.

[0098] In a further alternative embodiment, the membrane 29 may be located at the second side 22.2 of the pre-fabricated portion 20.

[0099] Referring to figure 6A to 6D, the method of assembling the cable 10 an a pre-fabricated portion 20 of the second embodiment is shown.

[00100] Initially, the pre-fabricated portion 20 is positioned in front of an end of the cable 10 having exposed wires 12. The core of the wires 12 may also be exposed. At this stage, the second side 22.2 of the pre-fabricated portion 20 faces the end of the cable 10.

[00101 ] Then, the cable 10 is inserted into the aperture 24 of the prefabricated portion 20 in a direction 19 as shown in figure 6B. When the exposed wires 12 of the cable 10 encounter the membrane 29, the cable 10 is forced in order to pierce/tear/break the membrane 29.

[00102] Then, the end of the cable 10 is moved further into the prefabricated portion 20 until a section of the outer sheath 16 of the cable 10 protrudes from the aperture 24 of the pre-fabricated portion 20. At this stage, the outer sheath 16 is surrounded by the pre-fabricated portion 20. [00103] The membrane 29 to collapses around the outer sheath 16 of the cable 10. This helps in closing the gaps between the outer sheath 16 of the cable 10 and the pre-fabricated portion 20. This is a first stage barrier provided by the pierced membrane 29.

[00104] Subsequently, the cable 10 is pulled in an opposite direction 19 as indicated in figure 6D. The cable is pulled to an extent that some portion of the outer sheath 16 is still extending from the first side 22.1 of the body 22 of the prefabricated portion 20. This movement of the cable 10 relative to the prefabricated portion 20 causes the collapsed membrane 29 to roll around the outer sheath 16 in order to provided additional closing of the gaps between the outer sheath 16 and the pre-fabricated portion 20. This is a second stage barrier provided by the pierced membrane 29.

[00105] The collapsed membrane helps increase the strength of the seal between the cable 10 and the pre-fabricated portion. Thus, the membrane 29 helps in restricting the over-moulding material 40 or residual over-moulding material 40 from escaping beyond the pre-fabricated portion 20 during the over- moulding process.

[00106] Once the pre-fabricated portion 20 and the cable 10 are assembled as seen in figure 6D, the next steps in creating the electrical connection 100 are as described with reference to figures 2C, 2D and 2E that is connecting the wires 12 to an electrical component 30, over-moulding the connection, and covering the solidified over-moulding material 40 with a shell 50, respectively. It will be appreciated that the shell 50 is optional.

[00107] Referring to figures 7 to 10, various further applications of the present invention are disclosed. [00108] Figure 7 discloses an application in which the present invention is employed to connect two cables 10 having varying outer surface. Each of the two cables 10 have a different varying outer surface. Particularly, one cable 10 has a stitched outer sheath 16.1 and the other cable 10 has a braided outer sheath 16.4. A pre-fabricated portion 20 is mounted on the end of each cable 10. Wires of the two cables are joined directly or through a PCB. Subsequently, a PVC over-moulded portion 40 is formed between the two pre-fabricated portions 20 covering the wires joining. This electrical connection 100 provides strain relief to the wires of the two cables 10 being joint.

[00109] The present invention may also be applied to connect a cable 10 having varying outer surface to a cable 10 which has a consistent outer surface.

[001 10] The present invention may also be applied to connect a cable 10 having varying outer surface to two or more cables 10 which may or may not have varying outer surface.

[001 1 1 ] The present invention may also be applied to connect two or more cables 10 have consistent outer surface.

[001 12] Figure 8 discloses an application in which the present invention is employed to connect a cable 10 having varying outer surface to a dongle. A dongle is a small electrical device.

[001 13] Figure 9 discloses an application in which the present invention is employed to connect two cables 10, having varying outer surface, of an in-line dongle. [001 14] Figure 10 discloses an application in which the present invention is employed to connect a cable 10 having a varying outer surface to an electrical device larger than a dongle.

[001 15] Some other relevant applications of the present invention include providing such an electrical connection for connecting earphones and/or headphone jack to a suitable cable.

[001 16] Yet further applications of the present invention include connections provided at the end of data cables such as HDMI cable, USB cable, Micro USB cable, Mini USB cable, Ethernet cable, Optical fibre cable, co-axial cable, etc.

[001 17] In an alternative embodiment, the pre-fabricated portion is made of two parts which are fastened together to provide a tight fit between the cable and the pre-fabricated portion, prior to over-moulding. The fastening means may also be over-moulded to prevent access to the fastening means, in order to maintain the tight connection between the pre-fabricated portion and the cable, post over- moulding process.

[001 18] In the drawings and specification, there have been disclosed typical embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims.

Reference Number table

No. Feature

10 Cable

12 Wire(s)

14 Jacket

16 Sheath

16.1 Stitched sheath

16.2 Bead sheath

16.3 Structured sheath

16.4 Braided sheath

19 Direction of movement of cable

20 Pre-fabricated portion

22 Body of the pre-fabricated portion

22.1 First side of the body

22.2 Second side of the body

24 Aperture

24.1 Large diameter aperture

24.2 Small diameter aperture

24.3 Pentagonal aperture

24.4 Aperture having arcuate and flat portions

26 Protrusion

26.1 First plane

26.2 Second plane

28 Member

29 Membrane

30 Connector

32 Apertures in the connector

40 Over-moulded portion

50 Metal shell

100 Electrical connection

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1 . An electrical connection for a cable having varying outer surface, the connection including:

2. The electrical connection according to claim 1 , wherein the pre-fabricated portion includes a body and protrusion(s) extending from the body for increasing adhesion strength between the pre-fabricated portion and the over-moulded insulating portion.

3. The electrical connection according to claim 2, wherein said protrusion(s) is/are Ί-shaped' with a base of the Ί-shape' positioned on the body of the prefabricated portion.

4. The electrical connection according to any one of the preceding claims, wherein the pre-fabricated portion has an aperture through which the cable is inserted.

5. The electrical connection according to claim 4, wherein the shape and size of the aperture is selected to suit the shape and size of the cable.

6. The electrical connection according to claim 4 or 5, wherein cross- sectional shape of the aperture is circular, polygonal, oval, or has a combination of arcuate and straight portions.

7. The electrical connection according to any one of the preceding claims, including a shell covering the over-moulded insulating portion.

8. The electrical connection according to any one of the preceding claims, wherein the pre-fabricated portion includes a membrane for piercing by the cable.

9. The electrical connection according to claim 8, wherein the membrane is flexible such that the membrane collapses on the cable after being pierced by the cable.

10. The electrical connection according to any one of the preceding claims, wherein the electrical component is a connector plug.

1 1 . The electrical connection according to any one of the preceding claims for connecting a cable to a dongle, a cable to a device, a cable to a terminating plug or socket, two or more cables, two or more cables with in-line dongles.

12. A cable having the cable connection as per any one of the preceding claims.

13. The cable of claim 12, wherein the cable has a sheath.

14. The cable of claim 13, wherein the sheath is made of stitched materials, beads, structured materials or braided materials.

15. The cable of claim 13 or 14, wherein the sheath is made of plastic, leather, PU leather, fabric, metal, glass, timber or stone.

16. A method of manufacturing an electrical connection for a cable having varying outer surface, the method including the steps of:

(b) connecting wires of the cable at said end to an electrical component, and

17. The method of claim 16, including the steps of covering the over-moulded portion with a shell.

18. The method of claim 17 or 18, wherein the over-moulded portion is inset from the pre-fabricated portion such that the metal shell is rests on the prefabricated portion.

19. The method according to any one of the claims 16 to 18, wherein step (a) includes inserting the cable into the pre-fabricated portion.

20. The method according to claim 19, wherein the pre-fabricated portion includes a membrane which is pierced by the cable such that the membrane collapses on the cable.

21 . The method according to claim 20, wherein step (a) further includes the step of pulling back the cable inserted in the pre-fabricated portion in order to roll the collapsed membrane on the cable.

22. A pre-fabricated portion for use in forming an electrical connection on a cable having varying outer surface,

wherein the pre-fabricated portion is provided for securely surrounding the cable proximate to an end of the cable such that wires of the cable at said end are connectable to an electrical component, and

23. The pre-fabricated portion of claim 22, wherein the prefabricated portion has an aperture smaller than an outer diameter of the cable.

24. The pre-fabricated portion of claim 23, wherein the pre-fabricated portion includes one or more protrusion(s) extending from a body of the pre-fabricated portion for engaging with the over-moulded portion.

25. The pre-fabricated portion of claim 24, including a member extending from the body in a direction opposite to that of the protrusion(s), the member for lengthening said aperture.

26. The pre-fabricated portion of any one of claims 22 to 25, wherein the prefabricated portion has higher melting point than that of the over-moulded portion.

27. The pre-fabricated portion of claim 23 including a membrane which covers the aperture, the membrane being breakable/tearable by pushing a cable through the aperture.

28. The pre-fabricated portion of claim 27, wherein the broken/torn membrane assists in sealing any gap between the cable and the aperture.

29. The pre-fabricated portion of claim 28, wherein the broken/torn membrane can be rolled on the cable by moving the cable relative to the pre-fabricated portion in order to further assist in sealing any gap between the cable and the aperture.

30. The pre-fabricated portion of any one of claims 27 to 29 wherein the membrane is integrally formed to the pre-fabricated portion.

31 . An electrical cable having a PVC jacket, the electrical cable having an outer sheath.

32. The electrical cable of claim 31 , wherein the outer sheath is made of leather, PU leather, fabric, metal, glass, timber or stone.

33. The electrical cable of claim 31 or 32 wherein, the sheath is made of stitched materials, beads, structured materials or braided materials.

34. The electrical cable of any one of claims 31 to 33, wherein the cable is provided for speakers, charging cable, earplugs, extension cables, LAN, or HDMI.

35. The electrical cable of any one of claims 31 to 34 having an end

connection according to any one of claims 1 to 1 1 .

ASCENT STAR LIMITED

P40701 AU00