Insert-molded terminal-equipped electric wire with smooth exposed conductor
A wire assembly having a metal terminal crimped or connected to a bare conductive wire and an insert-molded resin body that covers the terminal-to-wire connection; a smooth cylindrical section is formed on the bare conductor and inserted into the mold opening so the mold opening bears against the conductor to suppress resin leakage. Typical users include automotive and appliance wiring harness manufacturers producing sealed terminal assemblies.
(57) What the patent covered
This write-up was generated by AI from the patent's text and may contain mistakes, so check it against the original patent before relying on it.
The main independent claim requires a terminal-equipped conductive wire with (a) a terminal connected at one end via a terminal connection portion, (b) a molded resin member that covers the terminal connection portion and extends along the wire to a smooth portion, and (c) a non-conducting heat-shrink tube over the exposed conductor; the conductive wire must include, spaced away from the terminal connection portion, a smooth outer-circumferential surface (the smooth portion) whose outer shape corresponds to the mold opening so the molded resin covers from the terminal connection portion up to the smooth portion.
Distinguishing feature: Forming a smooth, mold-corresponding outer surface on the exposed conductor so the mold opening contacts the conductor and prevents insert-molding resin leakage.
Novelty 3/5. Insert-molded terminal covers and heat-shrink protection were common; the specific step of machining a smooth conductor section sized to seal against the mold opening is a practical improvement rather than a new product category.
Manufacturing
Prepare terminal-equipped bare conductor (crimp or weld terminal), form a smooth outer-circumferential section on the conductor (likely by turning, knurl-removal, reaming or swaging), place assembly into insert-molding tool with the smooth section seated in the mold opening, fill mold with thermoplastic resin to form the molded resin member, fit heat-shrink tube over exposed conductor and shrink.
Materials: Copper or copper-alloy conductor, metal terminal (brass, tin-plated copper alloy), thermoplastic molding resin (e.g. PBT, PA, or polypropylene), polyolefin heat-shrink tubing.
Manufacturability 4/5. Parts are simple (wire, terminal, molded resin body, heat-shrink); requires additional operation to form the smooth section (e.g. automated turning, swaging or dimpling) and standard insert-molding tooling and automation.
Market demand
Comparable products are on sale; this exact design was not found. No exact insert-molded wire terminal with smooth exposed conductor product listing found for sale in US e-commerce channels; related insert-mold/overmold cable assemblies and sealed harness services exist but not as a standard off-the-shelf item.
Demand check by web search, week of Oct 12, 2026. Listings change frequently.
Buyers: Wiring harness manufacturers, automotive suppliers, appliance and power-equipment assemblers.
Before manufacturing
No related continuation or divisional patents in force were found. Design patents, trademarks and unrelated patents may still cover the product.
None obvious; practical issues include controlling smooth-section diameter and concentricity to match mold openings and ensuring mold/tooling tolerances to prevent leaks.
About 1.5% of lapsed patents are later revived by their owners. This page is a research lead, not legal advice. Obtain a freedom-to-operate opinion before manufacturing.