# US 11,077,586 B2 · Molded wire harness tool assembly

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- Number: US 11,077,586 B2
- Document ID: US11077586B2
- Status: Granted
- Kind: B2
- Application number: 14/190,813
- Filed: 2014-02-26
- Published: 2014-08-28
- Granted: 2021-08-03
- Earliest claimed: 2013-02-26
- Assignees: CVG Management Corporation
- Applicants: Ted Messerly
- Inventors: Ted Messerly
- Web page: https://patentgrep.com/patent/US11077586B2

## CPC

- B29C 33/306: {Exchangeable mould parts, e.g. cassette moulds, mould inserts (moulds with exchangeable mould parts for injection moulding B29C45/2673; mounting of exchangeable mould inserts for injection moulding B29C45/2675)}
- B29C 33/301: {Modular mould systems [MMS], i.e. moulds built up by stacking mould elements, e.g. plates, blocks, rods (B29C33/0088 takes precedence)}
- B29C 44/58: Moulds
- B29C 33/34: movable, e.g. to or from the moulding station
- B29L 2031/3462: {Cables}
- B60R 16/0215: {Protecting, fastening and routing means therefor}
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR

## Abstract

A system and method of manufacturing an over molded wire harness is disclosed herein. The system and method includes designing and manufacturing a positive mold made from interchangeable and reusable modular blocks. The positive mold is used to create a negative mold tool die, whereby the wire harness can be assembled in the negative mold and overmold material can be injected into the negative mold.

## Claims

### Claim 1

An overmold system for producing an over molded wire harness comprising:
a positive mold including a plurality of interchangeable modular positive molds;
a negative mold tool die produced from the positive mold and adapted to receive a wire harness and an overmold material that forms the overmold for the wire harness;
at least one shut-off insert placed in the negative mold tool die to prevent the overmold material from overflowing from the negative mold tool die;
an assembly board that receives the negative mold tool die; and
at least one formable insert comprising:
a pliable material that holds a shape once formed and substantially maintains that shape during application of the overmold material, disposed around at least a portion of a wire bundle of the wire harness to form a three dimensional shape for the wire harness that conforms to a shape of a vehicle component prior to application of the overmold material, and
at least one notch to identify a bending point of the wire bundle,
wherein the plurality of interchangeable modular positive molds includes at least one section that allows a portion of the wire harness to extend out over the overmold facilitating a connection to a component.

### Claim 2 (depends on 1)

The overmold system of claim 1, wherein the formable insert comprises copper.

### Claim 3 (depends on 1)

The overmold system of claim 1, wherein the plurality of interchangeable modular positive molds include an alignment notch and a connection notch defined in each end face.

### Claim 4 (depends on 3)

The overmold system of claim 3 further comprising an alignment device that aligns adjacent modular positive molds when connected and a connection device providing a connection between adjacent modular positive molds, wherein the alignment notch is adapted to receive the alignment device and the connection notch is adapted to receive the connection device.

### Claim 5 (depends on 4)

The overmold system of claim 4, wherein the connection device includes a first part inserted into the connection notch such that the first part extends beyond the end face of the modular positive mold and a second part inserted into the connection notch of an end face of an adjacent modular positive mold such that the second part is indented into the end face.

### Claim 6 (depends on 5)

The overmold system of claim 5, wherein the alignment device is an alignment pin and the first part of the connection device is a magnet and the second part of the connection device is a plug made from a material that attracts the magnet.

### Claim 7 (depends on 1)

The overmold system of claim 1 further comprising an assembly line system including:
a plurality of assembly boards adapted to receive the negative mold tool die;
a plurality of workstations for performing different functions; and
a carousel that transports the plurality of assembly boards between workstations.

### Claim 8 (depends on 7)

The overmold system of claim 7, wherein at least one of the plurality of workstations is an injection mold workstation that injects the overmold material into the negative mold tool die.