Abstract:
The present invention provides a method of performing terminal insert molding in which the correct position of the hoop terminal is maintained and any deformation thereof is prevented until its integration with the synthetic resin is attained, and an insert molding apparatus in which the hoop terminal is reliably inserted into predetermined grooves of the mold, making it always possible to secure accurate alignment of the hoop terminal with the mold. According to the terminal row insert molding method, on one side of a carrier base plate for conveying terminal materials to a processing position of an insert molding machine, a predetermined number of terminals to be subjected to insert molding are formed at a minute pitch alternately with and parallel to open grooves and are grouped into terminal rows, each terminal row being composed of an intermediate portion near the carrier base plate and a free end far from the carrier base plate, in which, in performing successive bending on the intermediate portion through intermittent feeding by a conveying mechanism for forward feeding, a dummy terminal plate, which binds the free ends for each feeding pitch of the conveying mechanism, is bonded to forward end portions of the free ends not affected by the bending with connecting means allowing separation along the feeding direction.

Description:
BACKGROUND OF THE INVENTION  
     Field of the Invention  
       [0001]     The present invention relates to successive molding of connector terminal units each composed of terminals arranged at a minute pitch and, more specifically, to a method and apparatus for successively performing insert molding on terminal rows formed on a carrier structured by a continuous strip-like thin plate (hereinafter referred to as a hoop terminal) through successive intermittent automatic feeding to form connector terminal units out of the terminal rows.  
         [0002]      FIG. 11  shows a conventional method of performing insert molding on a hoop terminal. As shown in the drawing, in the method, a hoop terminal  302  structured by terminals with a width w 0  formed by punching, at a requisite pitch p 0 , of a highly conductive thin plate  300  with a thickness t 0 , is integrated with synthetic resin through insert molding. When forming the hoop terminal  302  into a connector terminal unit  304  through insert molding, the hoop terminal is bent in a direction perpendicular to the plane of the drawing (Although its sectional configuration is not specifically shown, it is bent into, for example, an L-shape, a reversed-L-shape, a U-shape, a reversed-U-shape, or a combination thereof) to align a comb-teeth-like terminal row  302 , structured by a plurality of terminals  303  extending in parallel from one side of a carrier base plate  306 , with a synthetic resin molding mold.  
         [0003]     As schematically shown in  FIG. 13 , in an insert molding apparatus  400  for use in this hoop terminal molding method, a hoop terminal  401 , stocked in the form of a spiral roll in which in-mold terminal rows are arranged at equal intervals on a carrier structured by a strip-like metal thin plate, is fed intermittently from an unwinding device  402  in synchronism with the molding cycle of an injection molding machine  403  (as indicated by the arrow f) to produce connector terminal units  404  (depicted in a somewhat exaggerated fashion in the drawing) as resin molding products with electrical connection terminals embedded therein as indicated by symbol w, the terminal units being formed automatically through successive molding, and successively sent to a take-up device  405 . Symbol g indicates a horizontal installation surface for the hoop terminal insert molding apparatus  400 .  
         [0004]     Transfer devices  406  and  407  for feeding the hoop terminal  401  intermittently forwards are respectively installed on the input side I and the output side O with respect to the feeding direction, and the hoop terminal  401  to be subjected to insert molding is retained on either side of a mold  408  by pressing it by clamp mechanisms  409  and  410  against horizontally reciprocating conveyance bases  414  and  415 , which reciprocate in a pair and in synchronism with each other from clamp positions a to release positions b by a stroke S as indicated by the arrows h, to thereby feed the hoop terminal  401  intermittently forwards; at the same time, they ascend and descend vertically (as indicated by the arrow V) to fit in the hoop terminal to be inserted at a predetermined position provided in the cavity of the mold  408 , with the above process being repeated for each injection molding shot.  
         [0005]     [Patent Document 1] JP 3,338,667 B  
         [0006]     It should be noted, however, that, as a result of the recent demand for a reduction in the size of an electronic apparatus, such as a mobile phone, electrical connection terminal portions are required to be further reduced in size; for example, the above terminals  303  must be of such an extremely fine configuration as to have a width w 0  of 0.2 mm or less and an inter-terminal pitch p 0  of 0.3 mm or less. In this case, assuming that the thickness t 0  of a highly conductive thin plate  100  constituting the terminal material is, for example, 0.1 mm, there is the possibility of the terminal free end portions being deformed by an unexpected slight external force during movement in the feeding direction indicated by the arrow A as in the case of the terminals  303 - 1  and  303 - 2  shown in  FIG. 12A .  
         [0007]     As a result, the adjacent terminals of the hoop terminal  302 , extending from the carrier base plate  306 , are allowed to come into contact with each other during the process, or, as in the case of the terminals  303 - 1  and  303 - 2  shown in  FIG. 12A , the positions of a synthetic resin mold  310  where fitting is to be effected are deviated, resulting in the fitting being hindered; if an upper mold  312  were closed in this state (as indicated by the arrow B), not only would the expensive mold be damaged, but also the expensive highly conductive material forming the hoop terminal  302  could not be formed into a product, resulting in a rather serious loss when the downtime of the manufacturing machine is taken into account.  
         [0008]     Further, in the insert molding apparatus  400  shown in  FIG. 13 , the conventional transfer devices  406  and  407  are formed integrally with a base  424  of the main body of an injection molding machine  403 , so that each time the mold  408  of the injection molding machine  403  is replaced due to a change in the production lot amount, model changes, a deterioration in the mold  408 , etc., it is necessary to modify and adjust the mounting positions of the transfer devices  406  and  407 , the movement stroke s, the installation interval of the clamp mechanisms  409  and  410  for grasping the hoop terminal  402  at the proper position, etc. so as to adapt them to the specifications of the new mold  408 . Thus, when the requirements for the connector terminal units  404  are of various kinds, the requisite flexibility is not available, resulting in a delay or difficulty in meeting such requirements. Further, there is a need for adjustment time for adjusting the operation of the transfer devices  406  and  407  in correspondence with the mold  408 , resulting in an increase in the downtime of the injection molding machine  403  for the replacement of the mold  408  and in a deterioration in production efficiency.  
         [0009]     Further, the injection molding machine  403  is integrated with the transfer devices  406  and  407  and provided separately from the mold  408 , so that it is necessary to secure their positional relationship accurately in conformity with the movement of the mold, which means it is by no means easy to accurately adjust the positional relationship of the transfer devices  406  and  407 , fixedly provided on the injection molding machine  403 , in conformity with the movement of the mold each time the mold  408  is replaced by a new one. Further, the positions of the transfer devices  406  and  407  at which the hoop terminal  402  is supported are outside the injection molding machine  403 , so that the support span m is rather long, and the relative replacement of the hoop terminal  402  due to the central load generated by the ascent/descent movement (indicated by the arrow V) at the time of insertion/detachment of the mold  408  is rather large, resulting in the clamp positions for the transfer devices  406  and  407  being unstable. As a result, the accuracy in the repeated transfer deteriorates, and it is impossible to avoid the possibility of generation of deviation of the clamp position for the hoop terminal  402  and misalignment thereof with the mold  408  due to accumulative errors. Thus, for their correction, it is necessary to station an inspection worker to perform checking frequently, resulting in an increase in cost in any way.  
         [0010]     The transfer devices  406  and  407  in the insert molding apparatus are of the type in which the hoop terminal  402  is maintained horizontal on either side of the mold  408 , the terminal row being lowered in the cavity from above the mold  408 ; when the terminals forming the terminal row are of a minute dimension (e.g., when a plurality of terminals with a width of 0.2 mm are arranged at a pitch of 0.3 mm), the support is rather unstable, and, if the side walls of terminal row fitting grooves formed in the cavity are touched even slightly, reliable fitting is hindered; or dregs in the previous process, or inadvertent, slight deformation caused during transfer can hinder the normal accommodation of the terminals, which can lead to not only a defective product but also damage of the mold  408 .  
       SUMMARY OF THE INVENTION  
       [0011]     The present invention has been made in view of the above problems in the prior art. It is an object of the present invention to provide a method of performing terminal insert molding in which the correct position of the hoop terminal is maintained and any deformation thereof is prevented until its integration with the synthetic resin is attained, and to provide an insert molding apparatus in which the hoop terminal is reliably inserted into predetermined grooves of the mold, making it always possible to secure accurate alignment of the hoop terminal with the mold.  
         [0012]     To attain the above object, according to the present invention, there is provided a terminal row insert molding method in which, on one side of a carrier base plate for conveying terminal materials to a processing position of an insert molding machine, a predetermined number of terminals to be subjected to insert molding are formed at a minute pitch alternately with and parallel to open grooves and are grouped into terminal rows, each terminal row being composed of an intermediate portion near the carrier base plate and a free end far from the carrier base plate, wherein, in performing successive bending on the intermediate portion through intermittent feeding by a conveying mechanism for forward feeding, a dummy terminal plate, which binds the free ends for each feeding pitch of the conveying mechanism, is bonded to forward end portions of the free ends not affected by the bending with connecting means allowing separation along the feeding direction.  
         [0013]     The above object of the present invention can be attained by a structure where the carrier base plate is a highly conductive metal strip, a structure where the metal strip forming the terminals is a highly conductive metal strip, and a structure where the connecting means allowing separation effects a temporary connection by crimping.  
         [0014]     Further, the above object can be attained by a terminal row insert molding method in which, on one side of a carrier base plate for conveying terminal materials to a processing position of an insert molding machine, a predetermined number of terminals to be subjected to insert molding are formed at a minute pitch alternately with and parallel to open grooves and are grouped into terminal rows, each terminal row being composed of an intermediate portion near the carrier base plate and a free end far from the carrier base plate, a process of successive bending being performed on the intermediate portion through intermittent feeding by a forward-feeding pressing machine, wherein a process for insert molding on each terminal row formed of a highly conductive metal strip material together with synthetic resin comprises the steps of: bonding a dummy terminal plate long enough to effect binding of the intermediate portion for each feeding pitch of the forward-feeding pressing machine to a forward end portions of the free end; bending the intermediate portion; putting the intermediate portion that has undergone bending into a mold for the synthetic resin; injecting the synthetic resin into the mold to integrally mold the terminal row into a terminal unit; and removing the dummy terminal.  
         [0015]     Further, according to the present invention, there is provided an insert molding apparatus, including an automatic terminal transfer mechanism for successively and intermittently feeding a hoop terminal to an injection molding machine, wherein a device for transferring a hoop terminal intermittently and automatically is directly fixed to a mold itself attached to the injection molding machine.  
         [0016]     Further, in the insert molding apparatus, the device for transferring a hoop terminal intermittently and automatically includes a pair of devices driven on the input side and the output side of the mold in synchronism with each other and respectively and directly fixed to side surfaces on the input side and the output side of the mold.  
         [0017]     Further, the mis-insert-molding preventing mechanism of the present invention includes an in-mold hoop mechanism for automatic production of connector terminal units by performing insert molding on minute-pitch terminal rows arranged at equal intervals on a carrier structured by a strip-like metal thin plate and fed to the injection molding machine intermittently and continuously, wherein there is provided a sensing device for confirming correct alignment of the terminal row with a mating position of the mold cavity prior to clamping when the terminal row is fed automatically and intermittently to the mold of the injection molding machine and fitted in at the proper mating position of the mold cavity while in a still state.  
         [0018]     Further, when the upper surface of the terminal row inserted is pressurized by a head at the forward end of an elastically urged presser arm toward the fit-engagement position of the mold cavity, the sensing device issues an alarm if the presser arm does not reach a predetermined position but stops outside a predetermined permissible range, thereby stopping the operation of the in-mold hoop mechanism.  
         [0019]     The hoop terminal insert molding method of the present invention allows insert molding of minute-pitch terminals with high accuracy, so that the method is effective in the molding of a connector terminal unit in which terminals with a width of 0.2 mm or less are arranged at a pitch of 0.3 mm or less on a conductive plate with a thickness of 0.1 mm or less.  
         [0020]     Further, in the method of the present invention for performing insert molding on minute-pitch terminals with high accuracy, a dummy terminal is bonded to the terminals inserted to bind the terminals with each other, whereby the terminals are reinforced, thereby preventing deformation of the terminals with bent portions arranged at a minute pitch and maintaining the requisite positional accuracy.  
         [0021]     Thus, in the method of the present invention for performing insert molding on minute-pitch terminals with high accuracy, when fitting the terminals in the synthetic resin mold, it is possible to prevent “galling” caused by defective alignment of the terminals with the mold and damage of the mold, thereby making it possible to achieve an improvement in terms of mass-productivity with safety.  
         [0022]     Further, the terminal transfer mechanism incorporated into the insert molding apparatus of the present invention is integrated with the mold to form a hoop terminal intermittent automatic transfer device while securing accuracy in its relationship with the mold, so that the terminal transfer mechanisms can be integrally attached and detached to and from an arbitrarily selected injection molding machine while maintaining the requisite positional accuracy with respect to the mold, and there is no need to adjust the terminal transfer device each time the mold is replaced by a new one, making it possible to immediately perform insert molding on a hoop terminal.  
         [0023]     Further, in the prior art, due to the incorporation of the transfer device in the molding machine, the alignment of the mold with respect to the transfer device is rather unstable and inaccurate, whereas, in the in-mold hoop mechanism of the present invention, the transfer-device is incorporated into the mold and operates integrally with the mold, so that there is no fear of the positional accuracy of the transfer device with respect to the mold deteriorating, making it possible to secure the requisite transfer accuracy.  
         [0024]     Thus, in the terminal transfer mechanism of the present invention incorporated into the mold, the width of the portion thereof constituting the fulcrum when transferring the hoop terminal is substantially reduced, thereby making it possible to markedly improve the accuracy in repeated transfer.  
         [0025]     In the mis-insert-molding preventing mechanism of the present invention, any abnormality is sensed prior to clamping, at the time of insertion of the insert terminals into the mold, and an alarm is issued, so that it is possible to prevent molding of a defective product, and no wasteful injection of resin is involved; further, the mold suffers no damage, so that it is possible to achieve a reduction in production cost and an improvement in production efficiency. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0026]     In the accompanying drawings:  
         [0027]      FIG. 1  is a schematic explanatory view of an injection molding machine according to an embodiment of the present invention in which a mis-insert-molding preventing mechanism is applied to an insert molding apparatus;  
         [0028]      FIG. 2A  is a plan view of a mis-insert-molding preventing mechanism according to an embodiment of the present invention;  
         [0029]      FIG. 2B  is a side view, partly in section, of the same;  
         [0030]      FIG. 3  is a partially enlarged side view of a terminal presser head in a mis-insert-molding preventing mechanism according to an embodiment of the present invention;  
         [0031]      FIG. 4  is a flowchart for illustrating molding operation in a mis-insert-molding preventing mechanism according to the present invention;  
         [0032]      FIG. 5  is a schematic explanatory side view of a terminal transfer mechanism incorporated in a mold of an insert molding apparatus according to an embodiment of the present invention;  
         [0033]      FIG. 6  is a schematic partial side view showing the output side of a transfer device of a terminal transfer mechanism incorporated in a mold according to the present invention;  
         [0034]      FIG. 7  is a flowchart illustrating operation of a terminal transfer mechanism incorporated in a mold according to the present invention;  
         [0035]      FIGS. 8A and 8B  are plan views of a hoop terminal in a terminal transfer mechanism incorporated in a mold according to an embodiment of the present invention;  
         [0036]      FIGS. 9A, 9B , and  9 C illustrate a terminal row insert molding method according to the present invention, showing a terminal row prior to insert molding, of which  FIG. 9A  is a plan view of terminals that have undergone bending, showing unbent portions on the right-hand end,  FIG. 9B  is a sectional view taken along the line B-B of  FIG. 9A , and  FIG. 9C  is a sectional view taken along the line C-C of  FIG. 9A ;  
         [0037]      FIG. 10  is a schematic plan view illustrating a terminal row insert molding method according to the present invention, showing a production process for a four-terminal-integrated type connector terminal unit;  
         [0038]      FIG. 11  is an explanatory view illustrating a problem involved in a terminal row prior to a conventional insert molding;  
         [0039]      FIG. 12  is an explanatory view illustrating a problem involved in a conventional terminal row insert molding method; and  
         [0040]      FIG. 13  is a schematic explanatory side view illustrating a conventional insert molding method. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0041]     The best mode for realizing a terminal insert molding method according to the present invention and an apparatus for the method will be described with reference to the drawings.  
         [0042]      FIG. 1  is a front view of an insert molding apparatus according to the present invention, showing an in-mold hoop mechanism  10  fixedly provided on a horizontal installation surface G.  FIGS. 2A and 2B  are a plan view and a side view, partly in section, of a mis-insert-molding preventing mechanism  40  of an insert molding apparatus according to a first embodiment of the present invention. In the in-mold hoop mechanism  10  shown in  FIG. 1 , a spiral-ring-like stock of a hoop terminal  12  in which a plurality of terminal rows  13  are arranged at equal intervals on a carrier  11  (strip-like thin metal plate) shown in  FIGS. 2A and 2B  is transferred from an unwinding device  14  intermittently in synchronism with the molding cycle of an injection molding machine  16  (in the direction of the arrow F), and resin-molded connector terminal units  18  with the terminal rows  13  for electrical connection embedded therein (somewhat exaggerated in their depiction in  FIG. 1 ) are formed successively and automatically before being sent to a successive take-up device  20 .  
         [0043]     The in-mold hoop mechanism  10  is the same as the conventional apparatus shown in  FIG. 13  except for the mis-insert-molding preventing mechanism  40 . The mechanism will be schematically described; a feeding mechanism for feeding the hoop terminal  12  intermittently forwards is formed by one-way transfer devices  28  and  30  fixedly provided on the input side I and the output side O of a mold  22  with respect to the horizontal feeding direction (the arrow F) and having clamp mechanisms  24  and  26  each of which moves from a clamp position (start point) a to a release position (end point) b in a pair and in synchronism with each other.  
         [0044]     The clamp mechanism  24  and  26  are fixedly provided on conveyance bases  32  and  34 , and move integrally in the horizontal direction (the arrow L) and the vertical direction (the arrow P). At the start points a of the conveyance bases  32  and  34 , the clamp mechanisms  24  and  26  retain the carrier  11  portion of the hoop terminal  12  by pressing the same against the conveyance bases  32  and  34 . When the conveyance bases  32  and  34  move to the end points b to complete clamping, the clamp mechanisms  24  and  26  release the carrier  11  portion of the hoop terminal  12  from the conveyance bases  32  and  34 .  
         [0045]     When the curing/cooling process of the injection molding machine  16  is completed and the mold  22  is opened, raising/lowering bases  36  and  38  raise the conveyance bases  32  and  34  holding the hoop terminal  12  on either side of the mold  22  by means of the clamp mechanisms  24  and  26  to a height where the connector terminal unit  18  injection-molded and pushed out beyond the hoop terminal  12  does not interfere with the mold  22 , and the conveyance bases  32  and  34  move as they are to the endpoints b. As a result of this movement, the subsequent terminal row  13  faces the fitting position of the mold  22 , and then the raising/lowering bases  36  and  38  descend vertically to fit in the subsequent terminal row  13  at a predetermined position of the cavity of the mold  22 . The mis-insert-molding preventing mechanism  40  of the present invention is interlocked with this fitting operation.  
         [0046]     At the rear of the mold  22 , the mis-insert-molding preventing mechanism  40  of the present invention, shown in an enlarged state in  FIGS. 2A and 2B , is fixed to an injection molding machine bed  17  by means of a base  42 , with the functional axes (the horizontal direction L and the vertical direction P) being perpendicular to the transfer direction (the arrow F) of the hoop terminal  12  in a plane parallel to the transfer plane for the hoop terminal  12 . A hydraulically or pneumatically controlled horizontal cylinder  46  is attached to a bracket  44  fixedly provided on the base  42 , and the forward end of a piston  48  is connected to a joint  51  of a horizontal movement base  50 , which reciprocates (the arrow L) in a horizontal plane perpendicularly to the transfer direction (the arrow F) of the hoop terminal  12 . The horizontal movement base  50  is supported by a slide bearing  52  and slides smoothly along a horizontal guide rail  54 .  
         [0047]     A hydraulically or pneumatically controlled vertical cylinder  58  is attached to a bracket  57  extending horizontally from a column frame  56  fixedly provided on the horizontal movement base  50 , and a vertical movement base  62  is connected to the forward end of a piston  60 , with a terminal presser arm  64 , which extends in the direction of the mold  22 , being connected to the vertical movement base  62 . Guide plates  66  and  67  are provided on both side surfaces of the terminal presser arm  64  so as to extend vertically, and vertical guide rails  68  and  69  fixedly provided on their respective inner sides are held in slide contact with a slide bearing  70  provided on an opposing surface of the column frame  56  so as to be smoothly slidable in the vertical direction. On the guide plate  66 , which is caused to ascend and descend in the vertical direction (the arrow P) integrally with the terminal presser arm  64  by the piston  60  driven by the vertical cylinder  58  integrally with the terminal presser arm  64 , there is installed a detection plate  72  for descent position detection, which optically cooperates in a non-contact manner with a photo micro sensor  78  mounted through a pedestal  76  to a rear wall  74  extending from the column frame  56 .  
         [0048]      FIG. 3  is a partially enlarged side view of a terminal presser head  80  in the mis-insert-molding preventing mechanism  40  according to an embodiment of the present invention. Numeral  82  indicates a contact member, which is arranged at the forward end of the terminal presser arm  64  so as to be opposed to the terminal rows  13  arranged on the carrier  11  of the hoop terminal  12 ; the terminal presser arm  64 , to either end of which the terminal presser head  80  is fixed, is caused to vertically ascend and descend through translation by the vertical cylinder  58  mounted on the horizontal movement base  50  shown in  FIGS. 2A and 2B , and, with respect to the feeding direction of the hoop terminal  12  (the arrow F), the horizontal movement base  50  is caused to horizontally enter the route of the hoop terminal  12  in a horizontal plane parallel to the feeding plane of the hoop terminal  12  by the piston  48  of the horizontal cylinder  46 , and is separated from the route of the hoop terminal  12  to be restored to the origin B (indicated by the chain double-dashed line).  
         [0049]     With the mold  22  of the injection molding machine  16  being open (see  FIG. 1 ), when the conveyance bases  32  and  34 , retaining the hoop terminal  12  on either side of the mold  22  by the clamp mechanisms  24  and  26 , descend through operation of the ascent/descent bases  36  and  38 , and a positioning pin  86  protruding at a predetermined position in the cavity of the mold  22  is fitted into the corresponding pilot hole  15  of the carrier  11 , the correct insert position for the terminal row  13  of the hoop terminal  12  to be inserted is set. Here, the mis-insert-molding preventing mechanism  40  is programmed so as to drive the piston  48  by means of the horizontal cylinder  46  to cause the horizontal movement base  50  to advance toward the mold  22 , causing the contact member  82  at the forward end of the terminal presser arm  64  to be positioned directly above the terminal row  13  to be insert-molded, and then operating the vertical cylinder  58  to lower the terminal presser head  80  toward the terminal row  13 .  
         [0050]     When the insert alignment of the terminal row  13  to be inserted with the mold  22  is correctly effected, the terminal presser head  80  smoothly descends integrally with the terminal presser arm  64  to be fit-engaged with the positioning pin  86 , and the terminal presser arm  64  reaches a predetermined descent position A (indicated by the chain double-dashed lines) Thus, the detection plate  72 , simultaneously descending integrally with the vertical movement base  62 , intercepts the optical path of the photo micro sensor  78 .  
         [0051]     When it senses the intrusion of the detection plate  72 , the photo micro sensor  78  issues a signal to operate the vertical cylinder  58 , raising the vertical movement base  62  to a height where the terminal presser head  80  does not interfere with the mold  22 ; then, the horizontal cylinder  46  is operated to cause the horizontal movement base  50  to retreat, and the terminal presser arm  64  is moved to the origin B (indicated by the chain double-dashed line) spaced apart from the mold  22  and set on standby. Here, the injection molding machine  16  immediately executes clamping without a hitch, making it possible to perform the production of the connector terminal unit  18  through injection molding reliably without involving any problem.  
         [0052]     Conversely, when the photo micro sensor  78  does not sense the intrusion of the detection plate  72 , it is determined by the program that there is some abnormality, and an alarm is issued, the terminal presser arm  64  being restored to the origin B (indicated by the chain double-dashed line) by procedures reverse to the above and set on standby. At the same time, the injection molding machine  16  stops the operation of the clamping/transfer devices  28  and  30 .  
         [0053]     The operation of mis-insert-molding preventing mechanism  40  of the present invention is executed according to a program by a microcomputer control in interlock with the operation of the in-mold hoop mechanism  10 . Thus, the operation of the in-mold hoop mechanism  10  including the mis-insert-molding preventing mechanism  40  of the present invention will be described with reference to the flowchart of  FIG. 4 . The initial setting is started in step  100 , and the conveyance bases  32  and  34  are moved to the end points b in step  102 , and, in step  104 , the carrier  11  of the hoop terminal  12  is fixed by being pressed against the conveyance bases  32  and  34  by the clamp mechanisms  24  and  26 . In step  106 , the ascent/descent bases  36  and  38  of the transfer devices  28  and  30  are lowered to the lowermost end. In step  108 , the pilot hole  15  corresponding to a predetermined terminal row  13  is aligned with the positioning pin  86  of the mold  22 , and the terminal row  13  to be inserted is fit-engaged at a predetermined position in the cavity of the mold  22 , with which the initial setting is completed.  
         [0054]     In step  110 , the mold  22  is raised together with the transfer devices  28  and  30  by a well-known means, and press-fitted to a runner plate  90  together with the upper mold  88 , fixing the hoop terminal  12  by retaining it with the mold  22 ; in step  112 , resin supplied from a pre-plash ring  92  is injected from the nozzle of an injection cylinder  94  into the cavity of the mold  22  where the hoop terminal  12  is set, thereby effecting molding.  
         [0055]     In step  110 , the hoop terminal  12  is fixed by clamping, and, in step  118 , a stage is attained where the clamp mechanisms  24  and  26  release the carrier  11  of the hoop terminal  12 ; in step  120 , the conveyance bases  32  and  34  move to the start points a, keeping the clamp mechanisms  24  and  26  released. In step  122 , the clamp mechanisms  24  and  26  are operated again, and the carrier  11  of the hoop terminal  12  is fixed by being pressed against the conveyance bases  32  and  34  for standby.  
         [0056]     When, in step  114 , the molding is completed, and an appropriate curing/cooling period has elapsed, the mold  22  is opened by a well-known means in step  116 , and, in step  124 , the molded connector terminal unit  18  formed by molding is pushed out; at the same time, while fixing the hoop terminal  12  on the conveyance bases  32  and  34  by the clamp mechanisms  24  and  26 , the ascent/descent bases  36  and  38  are raised, and the hoop terminal  12  is retained at a height where the connector terminal unit  18  formed by insert molding does not come into contact with the mold  22 .  
         [0057]     In step  126 , while keeping the hoop terminal  12  at a high position in the clamp mechanisms  24  and  26  by the ascent/descent bases  36  and  38 , the conveyance bases  32  and  34  move by a predetermined stroke S to reach the end points b. Of the hoop terminal  12 , successively fed by the predetermined stroke S, the subsequent terminal row  13  is matched with the insert position, and the corresponding pilot hole  15  is aligned with the positioning pin  86  of the mold  22 . In step  128 , the ascent/descent bases  36  and  38  descend to the lowermost position while retaining the hoop terminal  12  with the clamp mechanisms  24  and  26 , and the terminal row  13  of the hoop terminal  12  is correctly fitted in at the insert position of the mold  22 .  
         [0058]     In step  130 , the horizontal cylinder  46  is operated to cause the horizontal movement base  50  to advance, together with the horizontal movement base  50 , the terminal presser arm  64  by the piston  48  from the origin B where it has been on standby, causing the terminal presser head  80  to stop directly above the carrier  11  of the hoop terminal  12  successively fed inside the mold  22 . The position of the terminal presser head  80  coincides with the vertical line of the positioning pin  86 , and the contact member  82  is situated directly above the corresponding terminal row  13 . In step  132 , the vertical cylinder  58  is operated, and the terminal presser arm  64  starts to descend. When, in step  134 , the sensor for sensing contact of the contact member  82  with the terminal row  13  does not operate, the procedure returns to step  134 , and the descent is continued until contact of the contact member  82  with the terminal row  13  is sensed.  
         [0059]     In step  136 , at a predetermined descent position A, contact of the contact member  82  with the terminal row  13  is sensed, and the presser arm  64  stops descending. There is a time delay between the point in time when the contact of the contact member  82  with the terminal row  13  is sensed and the point in time when the terminal presser arm  64  mechanically stops descending, so that this time delay is electronically controlled, absorbing minute stress or deformation generated in the contact member  82  in the meantime through cooperation with an elastic buffer mechanism contained in the contact member  82 .  
         [0060]     In step  138 , the stop position of the presser arm  64 , that is, the stop position A of the terminal presser head  80 , is confirmed. Thus, it is checked whether or not the photo micro sensor  78  has sensed the stop position A of the detection plate  72 , which descends integrally with the presser arm  64  before stopping. When the terminal row  13  is correctly fitted in at a predetermined position in the mold  22  and there is no abnormality, the detection plate  72  descends to and stops at the position A, where it intercepts the optical path of the photo micro sensor  78  installed at a predetermined height, so that the photo micro sensor  78  operates. Thus, in step  140 , the vertical cylinder  58  is operated to raise the presser arm  64 , raising the terminal presser head  80  to a height where it does not interfere with the mold  22 ; then, the horizontal cylinder  46  is operated to drive the piston  48 , thereby causing the horizontal movement base  50  to retreat to the standby position at the origin B. When the operation in step  140  is completed, the procedure returns to step  110 , where clamping is effected; from this onward, a production cycle starts in which the operations of steps  110  to step  140  are automatically repeated.  
         [0061]     When, in step  138 , the stop position of the detection plate  72  is not detected by the photo micro sensor  78 , the terminal row  13  is held between the edge portions of the fitting grooves formed in the mold  22  and the contact member  82  to hinder descent of the presser arm  64 , so that an alarm is immediately issued in step  142 , and the procedure advances to step  144 . As in step  140 , in step  144 , the vertical cylinder  58  is operated to raise the presser arm  64 , raising the terminal presser head  80  to a height where it does not interfere with the mold  22 ; then, the horizontal cylinder  46  is operated to drive the piston  48 , causing the horizontal movement base  50  to retreat to and remain on standby at the origin B. In step  146 , a signal is sent to the control program for the injection molding machine  16  to stop the clamping, and the conveyance bases  32  and  34  are stopped at the clamp positions a, causing the ascent/descent bases  36  and  38  to stop at the raised position to stop the operation of the in-mold hoop mechanism.  
         [0062]     As stated above, the same operations are repeated continuously and automatically, and it is ascertained for each shot of the injection molding machine  16  that the hoop terminal  12  has been inserted into the mold  22  reliably prior to clamping, and then the connector terminal unit  18  is molded, sending it successively to take-up device  20 , so that a reliable successive automatic molding is realized.  
         [0063]     As can be seen from the above description, in the mis-insert-molding preventing mechanism of the present invention, it is possible to markedly simplify the mechanism through interlock with the molded product pushing-up mechanism of the injection molding machine, and it is possible to perform a safe and reliable insert molding successively and reliably. As a result, an improvement in terms of duty cycle is achieved, which is effective in shortening delivery times.  
         [0064]     Next, a terminal transfer mechanism (hereinafter referred to as the in-mold hoop system) incorporated in a mold according to a second embodiment of the present invention will be described with reference to  FIGS. 5 through 8 . The components that are the same as those of the hoop terminal successive injection molding mechanism of  FIGS. 1, 2A , and  2 B described above are indicated by the same reference numerals, and a description thereof will be omitted.  
         [0065]     As shown in  FIGS. 8A and 8B , the hoop terminal  12  has the terminal rows  13  arranged at equal intervals on the carrier  11  structured by a thin strip material, which is prepared as a spirally wound stock, and is transferred (in the direction of the arrow F) from the unwinding device  14  intermittently in synchronism with the molding cycle of the injection molding machine  16  to successively form resin-molded connector terminal units  18  (somewhat exaggerated in their depiction in  FIG. 5 ), which are sent to the take-up device  20 . Numeral  21  indicates inter-layer sheet reels; on the unwinding device  14  side, the reel peels off a protective sheet held between the layers of the wound hoop terminal  12  and takes it up; and, on the take-up device  20  side, the reel feeds the protective sheet and inserts it between the layers of the wound hoop terminal  12 , thereby preventing the products from being damaged by inter-surface rubbing caused by the contact due to the winding.  
         [0066]     The feeding mechanisms for feeding the hoop terminal  12  intermittently forwards are fixedly provided on the input side I and the output side O of the mold  22  with respect to the feeding direction (the arrow F), and are formed by one-way transfer devices  28  and  29  in which the clamp mechanisms  24  and  26  are operated in a pair and in synchronism with each other so as to move from the clamp positions (start points) a to the release positions (end points) b. The support span M of the hoop terminal  12  at the clamp positions (start points) a of the clamp mechanisms  24  and  26  can be set considerably smaller as compared with the support span m in the above-described conventional example. The transfer device  28  on the input side I and the transfer device  30  on the output side O are fixed to the side surfaces of the mold  22  by means of mounting bolts  35  through the intermediation of an input side mounting seat  32  and an output side mounting seat  34 , respectively, and ascend and descend integrally with the mold  22  independently of the main body base  17  of the injection molding machine  16 .  
         [0067]      FIG. 6  is a partially enlarged side view of an embodiment of the transfer device  30  arranged on the output side O; the reference numerals in parentheses indicate the components of the input side transfer device  28 , which is equivalent to the output side transfer device  30 . The transfer device  28  on the input side I is formed in mirror symmetry with respect to the central plane CP, and solely the horizontal movements of the clamp mechanisms  26  ( 24 ′) are effected in the same direction in synchronism with each other; as to the vertical movements and the operation of clamping or releasing the hoop terminal  12 , which are effected by hydraulic or pneumatic cylinders (hereinafter simply referred to as the cylinders), are completely the same as those of the above embodiment, and are computer-controlled. Numeral  37  ( 36 ′) indicates a horizontal feed cylinder, which reciprocates an ascent/descent base  47  ( 46 ′) with the conveyance base  43  ( 42 ′) mounted thereon vertically (in the direction of the arrow V) along a guide column  49  ( 48 ′). Numeral  41  ( 40 ′) indicates a clamp cylinder, which raises and lowers a clamp pressure plate  51  ( 50 ′) (as indicated by the arrow C) to press the carrier  11  portion of the hoop terminal  12  against the conveyance base  43  ( 42 ′) or release it therefrom.  
         [0068]     The clamp cylinder  41  ( 40 ′) is fixedly provided on the conveyance base  43  ( 42 ′), and moves integrally with the conveyance base  43  ( 42 ′) in the horizontal direction (the arrow H) and in the vertical direction (the arrow V), and the clamp pressure plate  51  ( 50 ′) is lowered at the start point a of the conveyance base  43  ( 42 ′) to press the carrier  11  portion of the hoop terminal  12  against the conveyance base; when the conveyance base  43  ( 42 ′) moves to the end point b, the clamp pressure plate  51  ( 50 ′) is raised to release the carrier  11  portion of the hoop terminal  12  from the conveyance base  43  ( 42 ′). The movable range for the conveyance base  43  ( 42 ′), which is between the start point a and the end point b, can be set through fine adjustment by a screw mechanism of the length by which a stopper bolt  53  ( 52 ′) protrudes toward the conveyance base  43  ( 42 ′) from a bracket  55  ( 54 ′) threadedly engaged therewith. The set position of the stopper bolt  53  ( 52 ′) is fixed by a lock nut  57  ( 56 ′).  
         [0069]     Similarly, at the lowermost descent position of the ascent/descent base  47  ( 46 ′), to place the terminal row  13  of the hoop terminal  12  to be inserted into the mold  22  at the correct fitting position with respect to the mold  22  prior to clamping, the length of a stopper bolt  59  ( 58 ′) vertically screwed into a support base  61  ( 60 ′) and upwardly protruding therefrom is set through fine adjustment by a screw mechanism, and positional fixation thereof is effected by a lock nut  63  ( 62 ′). Fixed to the support base  61  ( 60 ′) is a guide bush  65  ( 64 ′) supporting an ascent/descent cylinder  39  ( 38 ′) and a guide column  49  ( 48 ′) vertically and slidably, with the support base being supported and fixed by at least four columns  67  ( 66 ′) (two of which are shown) at appropriate positions vertically spaced apart from the mounting seat  34  ( 32 ′) of each transfer device  30  ( 28 ′).  
         [0070]     Next, the operation of the in-mold hoop system of the present invention will be described with reference to the flowchart of  FIG. 7 .  
         [0071]     As shown in  FIGS. 8A and 8B , the insert terminal rows  13  are arranged using as the reference the pilot holes  15  formed in the carrier  11  at predetermined intervals.  FIG. 8A  shows the hoop terminal  12  in the state prior to molding, and  FIG. 8B  shows the hoop terminal  12  in the state in which it has been insert-molded into a connector terminal unit  18 . The initial setting is started in step  150 . In step  151 , the ascent/descent base  47  ( 46 ′) of each transfer device  30  ( 28 ′) is lowered to the lowermost end, and, in step  152 , a pilot hole  15  corresponding to a predetermined terminal row  13  and a positioning pin (not shown) of the mold  22  are aligned with each other, and the terminal row  13  to be inserted is placed at a predetermined position in the cavity of the mold  22 . In step  153 , the conveyance base  43  ( 42 ′) is moved to the end point b, and the positioning pin P of the clamp pressure plate  51  ( 50 ′) is brought into correspondence with the pilot hole  15 . At this time, the setting position of the stopper bolt  53  ( 52 ′) is adjusted as needed. In step  154 , the clamp cylinder  41  ( 40 ′) is operated, and the carrier  11  of the hoop terminal  12  is fixed by pressing it against the conveyance base  43  ( 42 ′) by the clamp pressure plate  51  ( 50 ′), with which the initial setting is completed.  
         [0072]     In step  155 , the mold  22  is raised together with the transfer device  30  ( 28 ′) by a well-known means, and is pressed against a runner plate  70  together with the upper mold  68  to effect clamping, with the hoop terminal  12  being fixed while held by the mold  22 , and, in step  156 , resin supplied from a pre-plash ring  71  is injected from a nozzle of an injection cylinder  73  into the cavity of the mold  22 , where the hoop terminal  12  is placed, to perform molding.  
         [0073]     On the other hand, at the stage where the hoop terminal  12  is fixed by the clamping in step  155 , the clamp mechanism  26  ( 24 ′) raises the clamp pressure plate  51  ( 50 ′) in step  159 , and the procedure advances to the stage where the carrier  11  of the hoop terminal  12  is released; when, in step  160 , the conveyance base  43  ( 42 ′) is moved to the start point a, the clamp mechanism  26  ( 24 ′) is operated again in step  121 , and the carrier  11  of the hoop terminal  12  is fixed by being pressed against the conveyance base  43  ( 42 ′) by the clamp pressure plate  51  ( 50 ′) for standby.  
         [0074]     When the molding is completed in step  157 , and an appropriate curing/cooling period has elapsed, the mold  22  is opened in step  158  by a well-known means, and the connector terminal unit  18  formed of molding is pushed out in step  162 , and, at the same time, the ascent/descent base  47  ( 46 ′) is raised while fixing the hoop terminal  12  to the conveyance base  43  ( 42 ′) by the clamp mechanism  26  ( 24 ′), retaining the hoop terminal  12  at a height where the insert-molded connector terminal unit  18  does not come into contact with the mold  22 .  
         [0075]     In step  163 , the conveyance base  43  ( 42 ′) moves by a predetermined stroke S while holding the hoop terminal  12  by the clamp mechanism  26  ( 24 ′) before reaching the end point b. The position of the end point b is determined by the stopper bolt  53  ( 52 ′), and, of the hoop terminal  12  successively fed by the predetermined stroke S, the subsequent terminal row  13  is matched with the insert position, and the corresponding pilot hole  15  is aligned with the positioning pin of the mold  22 . In step  164 , the ascent/descent base  47  ( 46 ′) descends to the lowermost end position while holding the hoop terminal  12  by the clamp mechanism  26  ( 24 ′), and the terminal row  13  of the hoop terminal  12  is accurately fitted in at the insert position in the cavity of the mold  22 .  
         [0076]     When the operation of step  164  is completed, the procedure returns to step  155  again, and from this onward, a production cycle starts in which the processes of step  155  to step  164  are automatically repeated. The adjustment positions for the stopper bolt  53  ( 52 ′) for setting the horizontal movement range of the conveyance base  43  ( 42 ′) and a stopper bolt  59  ( 58 ′) for setting the lowermost end of the ascent/descent base  47  ( 46 ′) are intrinsic to the mold  22 , so that they are not altered unless there is some unexpected change or intentional positional displacement regarding the transfer device  30  ( 28 ′), which moves together with the mold  22 .  
         [0077]     Here, as stated above, clamping is effected on the mold  22  and resin is injected into the mold  22  by the injection cylinder  73  to insert-mold the subsequent hoop terminal  12  to produce a connector terminal unit  18 . In the meantime, the hoop terminal  12  is held by and fixed to the mold  22 , so that if the clamp mechanism  26  ( 24 ′) raises the clamp pressure plate  51  ( 50 ′) to release the hoop terminal  12 , there is no change in the positional relationship between the hoop terminal  12  and the mold  22 . Thus, the transfer device  30  ( 28 ′) releases the hoop terminal  12 , and returns to the start point a together with the clamp mechanism  26  ( 24 ′), which has become free after releasing the hoop terminal  12 , and the clamp pressure plate  51  ( 50 ′) is lowered again to fix the hoop terminal  12  to the conveyance base  43  ( 42 ′) by press-fitting until the molding is completed. From this onward, similar operations are successively repeated, and each resultant connector terminal unit  18  intermittently moves through the movement stroke S of the conveyance base  43  ( 42 ′) for each molding cycle, and is successively sent to the take-up device  20 .  
         [0078]     The buffer devices  75  and  76  provided between the unwinding device  16  and the take-up device  20  and the transfer devices  30  and  28  are equipped with sensors  78   a  and  78   b  at positions vertically spaced apart from each other, and send a signal to the unwinding device  16  and the take-up device  20  so that slack is always maintained through intermittent feed, sequentially controlling their respective drive motors (not shown) and guaranteeing smooth unwinding and take-up. For example, when the hoop terminal  12  touches the upper sensor  78   a  of the buffer device  75  on the unwinding device  16  side, the drive motor of the unwinding device  16  is operated to pay out the hoop terminal  12 , and, when the hoop terminal  12  touches the lower sensor  78   b , the drive motor is stopped. On the other hand, on the take-up device  20  side, when the hoop terminal  12  sent out from the transfer device  30  touches the lower sensor  78   b  of the buffer device  77 , the drive motor of the take-up device  20  is operated to take up the hoop terminal  12 , and, when it touches the upper sensor  78   a , the drive motor is stopped. Thus, no excessive tension is applied to the hoop terminal  12 .  
         [0079]     As can be seen from the above description, in the terminal transfer mechanism incorporated into the mold of the present invention, the transfer mechanism is in one-to-one correspondence with the mold, and the transfer mechanism is formed with an accuracy suitable for each of different molds, so that, in the case of products automatically manufactured through successive and intermittent feeding of the terminal rows  13  by means of the strip-like carrier  11 , it is possible to efficiently and quickly cope with the replacement of the mold, which is required in the case of the production of various types of products, or due to an abrupt change in the specifications or the production lot amount, thus shortening the downtime of the injection molding machine.  
         [0080]     Next, a method of insert-molding terminal units by the insert molding apparatus constructed as described above will be described with reference to  FIGS. 9 and 10 .  
         [0081]      FIGS. 9A through 9C  are diagrams showing a first embodiment of the insert molding method, of which  FIG. 9A  is a plan view showing a terminal row  210 , and  FIGS. 9B and 9C  are sectional views thereof. At the right-hand end of the plan view of  FIG. 9A , apart of a terminal row  212  prior to bending is shown, and the rest has undergone bending, with the result that an original longitudinal (vertical direction in the drawing) length N 1  is reduced to an apparent length N 2  after the bending due to the provision of a bent portion  214 . For example, one longitudinal side (the lower side in the drawing) of a highly conductive metal strip material  216  with a thickness t 1  of 0.1 mm constitutes a carrier base plate  218 , and along an end portion  220  thereof on the opposite side, a dummy terminal  222  formed of an inexpensive material (e.g., a thin brass plate) with an appropriate width B 1  is bonded to the end portion  220  in an appropriate overlapping width F 1 , crimp bonding being effected at crimp positions  224  distributed at a pitch S 1 , which corresponds to a predetermined terminal interval. Alternatively, the dummy terminal is bonded so as to extend over the entire bonding surface by an appropriate adhesive. A length D 1  of the dummy terminal plate  222  is set substantially equal to a width D 2  of the terminal row  212  ( 210 ) on which bending is effected by a pressing machine (not shown).  
         [0082]     Parallel grooves  226  with a width K 1  of 0.2 mm are formed by punching at equal intervals S 2  to form terminal members  228  with a width W 1  of 0.2 mm arranged at a predetermined pitch p 1  (=S 1 =S 2 ) of 0.3 mm so as to be aligned in parallel in a plane, thus forming the terminal row  212 . The grooves  226  are open at an end edge  229  of the metal strip material  216 , with each terminal member  228  extending independently from the carrier base plate  218 ; free end portions  230  of the terminal members  228  are held by the dummy terminal plates  221  and  222  so as to be protected from unexpected external forces. The portion of the highly conductive metal strip material  216  bonded to the dummy terminal plate  222  (in the overlapping width of F 1 ) is punched to form the terminal row  212 , which is fed, by feeding its carrier base plate  218 , to the pressing machine at an intermittent feeding pitch of D 3  in the direction of the arrow M 1 , and positioning is accurately effected thereon by means of pilot holes  219 .  
         [0083]     The pressing machine bends an intermediate portion  232  of the terminal row  212  near the carrier base plate  218  at one stroke at a point e at right angles (as indicated by the arrow E), and bends it at a point f at right angles (as indicated by the arrow F) so as to make it parallel to the carrier base plate  218 , thus providing a planar step between the carrier base plate  218  and the free ends  230  of the terminal row  212 . A point g on the free end  230  side moves in the direction of the carrier base plate  218  (as indicated by the arrow G). Thus, the preceding dummy terminal plate  221  is pulled by the terminal row  212  at the point G to move in the direction of the carrier base plate  218 , whereas, the succeeding dummy terminal plate  222 , which is independent, is not influenced, and remains on standby for the next bending stroke. Regarding the terminal row  210  which has undergone bending, the corresponding portion of the dummy terminal plate  222  is cut off together with a portion of the free ends  230  of the terminal members  228  at a severing position  234  near the end edge  229  of the terminal row  210 .  
         [0084]      FIG. 10  is a schematic plan view illustrating a manufacturing method according to an embodiment in which, as in the insert molding method shown in  FIG. 9 , bending is effected as indicated by symbols e and f to integrally form a terminal unit by insert molding. Numeral  240  indicates a preparation material for a terminal row, which, in the example shown, is situated at a bending station  241  of a pressing machine and in the state prior to bending. That is, although not shown, the side constituting a carrier  244  of a highly conductive metal strip material  242  is set beforehand, and a brass strip material  248  which is generally inexpensive and which has a width of, for example, B 2 , and an appropriate thickness is bonded thereto as a dummy terminal plate  250  in an appropriate overlapping width F 2  so as to extend along a side edge  246  on the opposite side. The bonding is effected by crimping at crimp positions  254  provided for each four-terminal set  252 , or glued by adhesive so as to extend over the entire bonding surface.  
         [0085]     Subsequently, parallel grooves  256  with a gap K 2  of 0.2 mm are formed by punching to thereby form a terminal row  260  in an effective length of H 1  in which terminal members  258  with a width W of 0.2 mm are aligned in parallel in a plane at a predetermined pitch p 2  of 0.3 mm. Further, regarding the terminal row  260 , the dummy terminal  250  is cut off to a length H 2  at a position corresponding to a length D 4 , which corresponds to eight sets of four-terminal groups  252 , the end line of the highly conductive metal strip material  242  being completely severed for each four-terminal set  252 .  
         [0086]     The preparation material  240  prior to bending, only a part of which is shown in the drawing, is processed at a stroke by the length D 4 , which is equal to the dummy length corresponding to eight four-terminal sets  252  facing the bending station  241  of the pressing machine, so that it is possible to achieve an improvement in efficiency and the service life of the mold. The dummy terminal plate  250  is independent by the length D 4 , so that the bending of the preceding terminal row  260  including eight four-terminal sets  252  does not affect the subsequent preparation material  240  which is adjacent thereto and which has not undergone bending.  
         [0087]     A carrier  262  for successive insert molding, which runs parallel to the carrier  244  of the highly conductive metal strip  242 , is fed intermittently forwards in the direction of the arrow M 2  in synchronism with the molding cycle of the injection molding machine. A carrier  264  constituting a press-fitting station, severing the carrier  244  and the dummy terminal  250  corresponding to the four-terminal sets  252 , moves along a stopper  266  toward the molding carrier  262  (the direction indicated by the arrow L), until it abuts an abutment member  263 . Positioning holes  268  previously provided in the carrier  244  and guide holes  270  of the molding carrier  262  are aligned with each other to thereby accurately effect positioning, and the four-terminal sets  252  are bonded to the molding carrier  262  by a crimping means  272 .  
         [0088]     The molding carrier  262  feeds the four-terminal sets  252  forwards to introduce them into the insert molding mold of an injection molding station  273 . Pilot holes  274  of the molding carrier  262  are engaged with a positioning pin  276  of the mold (not shown) to accurately position with respect to the mold the four-terminal set  252  aligned by the guide holes  270  in an accurate positional relationship with the pilot holes  274 . Then, the mold is closed by a well-known pressurizing means, and a connector terminal unit  278  is formed by injection molding.  
         [0089]     As can be seen from the above description, in the method of the present invention for insert-molding a minute-pitch terminal unit, products are automatically manufactured through forward and intermittent feeding of a strip-like carrier integrated with successively arranged terminal rows, wherein the free ends of the terminals are held by dummy terminals to thereby reinforce the terminals, insert molding being performed on fine-structure parts through a process requiring high accuracy, so that the method is applicable to any product in which thin members extend in a comb-like fashion from a base member and in which bending is effected in a middle portion thereof while accurately maintaining the relative positions of the free ends of the thin members.  
         [0000]    
       FIG. 4 
     
         [0000]    
       
           100  START  
           102  CONVEYANCE BASE END POINT  
           104  FIX HOOP TERMINAL BY CLAMPING  
           106  ASCENT/DESCENT BASE LOWERMOST POINT  
           108  ALIGN FIRST INSERT TERMINAL ROW WITH MOLD  
           110  CLAMPING  
           112  INJECTION MOLDING  
           114  CURING/COOLING  
           116  MOLD OPENING  
           118  RELEASE HOOP TERMINAL  
           120  MOVE TO CONVEYANCE BASE START POINT  
           122  FIX HOOP TERMINAL BY CLAMPING  
           124  PUSH-OUT MOLDED ARTICLE 
        RAISE ASCENT/DESCENT BASE      
           126  MOVE TO CONVEYANCE BASE END POINT  
           128  ASCENT/DESCENT BASE LOWERMOST POSITION 
        ALIGN SUBSEQUENT TERMINAL ROW WITH MOLD      
           130  ADVANCE PRESSER ARM/STOP  
           132  LOWER PRESSER ARM  
           134  ACTIVATE CONTACT MEMBER SENSOR  
           136  STOP PRESSER ARM  
           138  ACTIVATE PHOTO MICRO SENSOR  
           140  RAISE PRESSER ARM 
        RETREAT TO ORIGIN/STANDBY      
           142  ALARM  
           144  RAISE PRESSER ARM 
        RETREAT TO ORIGIN/STOP      
           146  STOP CLAMPING 
        RAISE ASCENT/DESCENT BASE/STOP     STOP CONVEYANCE BASE MOVEMENT      
          INITIAL SETTING  
          PRODUCTION CYCLE  
          MIS-INSERT-MOLDING PREVENTING MECHANISM 
 
  FIG. 7  
 
           150  START  
           151  ASCENT/DESCENT BASE LOWERMOST POINT  
           152  ALIGN FIRST INSERT TERMINAL ROW WITH MOLD  
           153  CONVEYANCE BASE END POINT  
           154  FIX HOOP TERMINAL BY CLAMPING  
           155  CLAMPING  
           156  INJECTION MOLDING  
           157  CURING/COOLING  
           158  MOLD OPENING  
           159  RELEASE HOOP TERMINAL  
           160  MOVE TO CONVEYANCE BASE START POINT  
           161  FIX HOOP TERMINAL BY CLAMPING  
           162  PUSH-OUT MOLDED ARTICLE 
        RAISE ASCENT/DESCENT BASE      
           163  MOVE TO ASCENT/DESCENT BASE END POINT  
           164  ASCENT/DESCENT BASE LOWERMOST POSITION 
        ALIGN SUBSEQUENT TERMINAL ROW WITH MOLD      
          INITIAL SETTING  
          PRODUCTION CYCLE