Electrical connector and manufacturing method thereof

Abstract

The present invention discloses an electrical connector and a manufacturing method thereof, belonging to the technical field of electrical connectors. It comprises a housing and a connector body, wherein the connector body is installed in the housing, and is characterized in that a conductive terminal group is provided on the connector body, wherein the conductive terminal group comprises one or more first conductive terminals, and the front end of the first conductive terminal is a structure that is bent back. Compared with the prior art: First, the conductive terminals of the electrical connector of the present invention can realize the conductive function on both sides, which can simplify the structure and manufacturing process of the electrical connector, reduce raw materials, improve production efficiency, and save costs; second, the front ends of the second conductive terminal and the third conductive terminal in the conductive terminal group of the present invention are respectively placed on the front and back sides, and the functions of certain sequence and timing contact can be realized by any plug-in on the front and back sides; finally, the present invention has a simple structure, low cost, and is easy to use and promote.

Description

Technical Field

[0001] The present invention belongs to the technical field of electrical connectors, and in particular relates to an electrical connector and a manufacturing method thereof. Background Art

[0002] The internal conductive terminal group of the electrical connector needs to have the function of conducting electricity on both sides. The conductive terminal groups of existing electrical connectors are all provided with a group of conductive terminals on the front side, which are plastic injection molded into an insulator, and a group of conductive terminals on the back side, which are plastic injection molded into an insulator. The two groups of conductive terminals are then combined, a metal grounding plate is placed in the middle, and then placed into a mold cavity for injection molding to obtain a body with conductive surfaces on both sides. Then, conductive pads are placed on the front and back sides of a PCB board to weld the conductive terminals on the front and back to achieve mutual conduction between the terminals on the front and back. The internal conductive terminal structure of the electrical connector in the above manner is complex, and many materials are used, which has the disadvantages of high production cost and low production efficiency.

[0003] At the same time, the manufacturing process of the above-mentioned electrical connector requires multiple injection molding and welding after stamping. The manufacturing process is relatively complicated, and many defective products are produced and the product performance is poor. Summary of the Invention

[0004] To solve the above problems, the primary purpose of the present invention is to provide an electrical connector and a manufacturing method thereof, which can simplify the structure and manufacturing process of the electrical connector, reduce raw materials, improve production efficiency, and save costs;

[0005] Another object of the present invention is to provide an electrical connector and a method for manufacturing the same, which can achieve a certain order and timing of contact when plugged in either side.

[0006] To achieve the above object, the technical solution of the present invention is as follows:

[0007] The present invention provides an electrical connector comprising a housing and a connector body, the connector body being mounted within the housing. The connector body is provided with a conductive terminal group, the conductive terminal group including one or more first conductive terminals, the front ends of the first conductive terminals being bent backwards. In the present invention, by providing a backward-bending structure at the front ends of the first conductive terminals, both the front and back sides of the first conductive terminals have a conductive function. This eliminates the need for providing conductive terminals on both sides, simplifies the structure and manufacturing process, and saves on raw materials.

[0008] Furthermore, the first conductive terminal includes a terminal body and a folded portion, and a connection between the terminal body and the folded portion is in a U-shaped structure.

[0009] Furthermore, the conductive terminal group also includes a second conductive terminal and a third conductive terminal. The first conductive terminal, the second conductive terminal and the third conductive terminal are arranged side by side, the first conductive terminal is arranged on both sides, and the second conductive terminal and the third conductive terminal are arranged in the middle.

[0010] Furthermore, the front ends of the second and third conductive terminals are both vertically arcuate, with the arcuate structures of the second and third conductive terminals facing opposite directions. With this arrangement, the front ends of the second and third conductive terminals are positioned on the front and back sides, respectively, ensuring that connections can be made in a specific order and timing when plugged in from either side.

[0011] Furthermore, a conductive terminal fixing plate is provided on the connector body, a conductive terminal mounting position is provided on the conductive terminal fixing plate, the conductive terminal group is fixed on the conductive terminal mounting position, and the conductive terminal group and the conductive terminal fixing plate are injection molded.

[0012] Furthermore, a boss is provided on both the terminal body and the folded portion, and a groove adapted to the boss is also provided on the conductive terminal installation position, and the boss is snapped into the groove.

[0013] Furthermore, the ends of the first conductive terminal, the second conductive terminal, and the third conductive terminal are all provided with welding pins, and the welding pins are connected to soldering pads. A PCB board is also provided on the connector body, and the soldering pads are soldered to the PCB board, and the first conductive terminal, the second conductive terminal, and the third conductive terminal are all connected to the PCB board through the soldering pads.

[0014] Furthermore, a middle clip is provided on the connector body, and the middle clip is stacked above the conductive terminal fixing plate.

[0015] Furthermore, the connector body, the middle clip, the conductive terminal group, and the conductive terminal fixing plate are injection molded.

[0016] Furthermore, a limiting groove is provided on the connector body, and a limiting block is provided on the PCB board, and the limiting block is clamped in the limiting groove.

[0017] Furthermore, upper and lower guide blocks facing each other are provided on the contact surface between the connector body and the PCB board, a guide groove is formed between the guide blocks, and the contact end between the PCB board and the connector body is provided in the guide groove.

[0018] Furthermore, card slots are provided on both sides of the shell, and both sides of the PCB board are carded in the card slots.

[0019] The present invention provides a method for manufacturing an electrical connector, the method comprising the following steps:

[0020] S1: Preparation of conductive terminal group: Use high-speed cold stamping process to produce conductive terminal group with double-sided conductive function;

[0021] S2: One-shot injection molding: The conductive terminal group in S1 is subjected to the first in-mold injection molding;

[0022] S3: Secondary injection molding: The semi-finished product of S2 is placed in the middle clamping piece for the second injection molding;

[0023] S4: Testing: Remove waste tape, test and repair defective products of the secondary injection molded products in S3;

[0024] S5: Install the shell;

[0025] S6: Install the PCB board.

[0026] Furthermore, the high-speed cold stamping process in S1 includes punching, guiding, cutting, bending, shaping and other process steps. The production speed of the punch press depends on different models and conditions. The materials used include highly conductive copper alloys, and the stamping speed is 320-480 times / minute.

[0027] Furthermore, before the one-shot injection molding in S2, the conductive terminal group is electroplated to enhance conductivity, prevent corrosion and oxidation, and enhance tin solderability. The electroplated conductive terminal group is placed in a plastic mold for the first injection molding. The one-shot injection molding mold adopts a one-mold multi-cavity double-row material, with two rows of front and back rows set in the mold, each row with 8-24 cavities, and adopts automatic feeding and automatic receiving methods. The injection molding material includes but is not limited to high-temperature resistant, corrosion-resistant and friction-resistant high-quality engineering plastics. The injection molding temperature is above 330°C, the molding cycle is not less than 10 seconds, and the injection molding setting includes but is not limited to vertical or horizontal plastic molding injection molding machines, which can achieve efficient unmanned production operations.

[0028] Furthermore, in S3, the semi-finished product of the first injection molding in S2 is placed into the middle sandwich sheet metal part, and placed together into another plastic mold cavity for a second injection molding. The mold structure, material injection molding machine model, and molding temperature of the secondary injection molding are the same as those of the primary injection molding. The molding cycle of the secondary injection molding is 12 seconds, so that the secondary molded plastic and the primary molded plastic are completely fused into a whole.

[0029] Furthermore, the tests in S4 include but are not limited to circuit continuity test, short circuit test, high voltage resistance test, appearance inspection of the front and back conductive terminal contact surfaces using an image recognition detection system (CCD), and coplanarity inspection of the terminal solder feet, and repair of the test defective parts.

[0030] Furthermore, both the S4 testing and S5 housing assembly are completed using automated assembly equipment. The specific steps are: feeding the secondary molded product, removing the middle clip waste strip, front CCD inspection to check for debris on the conductive terminals, continuity, short circuit, open circuit, and withstand voltage testing, housing assembly, pushing the housing into place, removing the terminal waste strip, CCD inspection for solder pin flatness, and product packaging. This enables unmanned automated production, with a production speed exceeding 3,000 units per hour.

[0031] Furthermore, the secondary injection molding in S3 forms the connector body, and forms a guide groove and a limit groove in the connector body, and the PCB board is molded into the guide groove and the limit groove formed by the secondary in-mold in S6; the shell in S5 is provided with card slots on both sides, and the PCB board is carded into the card slots on both sides of the shell in S6, and the shell, conductive terminal group, etc. are tightly connected to the PCB board by welding.

[0032] The advantages of the present invention are that, compared with the prior art:

[0033] First, the conductive terminal assembly of the electrical connector of the present invention is provided with conductive terminals having a bent structure, which can realize the conductive function of both sides. This can simplify the structure and manufacturing process of the electrical connector, reduce raw materials, improve production efficiency, and save costs.

[0034] Secondly, the ends of the second and third conductive terminals in the conductive terminal set of the present invention are both arc-shaped and face oppositely. The front ends of the second and third conductive terminals are located on the front and back sides, respectively. Connecting them from either side can achieve a certain order and timing of contact.

[0035] Finally, the present invention has a simple structure, low cost, and is easy to use and promote. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 It is a structural schematic diagram of the present invention.

[0037] Figure 2 It is a structural schematic diagram of the connector body of the present invention.

[0038] Figure 3 It is a structural schematic diagram of the conductive terminal group of the present invention.

[0039] Figure 4 It is a schematic structural diagram of the first conductive terminal of the present invention.

[0040] Figure 5 It is a schematic structural diagram of the second conductive terminal and the third conductive terminal of the present invention.

[0041] Figure 6 It is a structural schematic diagram of the conductive terminal fixing plate of the present invention.

[0042] Figure 7 It is a structural schematic diagram of the clip in the present invention. DETAILED DESCRIPTION

[0043] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0044] To achieve the above object, the technical solution of the present invention is as follows:

[0045] See also Figure 1-7 As shown, the present invention provides an electrical connector comprising a housing 1 and a connector body 2, the connector body 2 being mounted within the housing 1. The connector body 2 is provided with a conductive terminal group 3, each including one or more first conductive terminals 31, each having a rearwardly bent front end. In the present invention, by providing a rearwardly bent structure at the front end of the first conductive terminal 31, both the front and back sides of the first conductive terminal 31 are electrically conductive. This eliminates the need for providing conductive terminals on both sides, simplifies the structure and manufacturing process, and saves on raw materials.

[0046] The first conductive terminal 31 includes a terminal body 311 and a folded portion 312 . The connection between the terminal body 311 and the folded portion 312 is a U-shaped structure 313 .

[0047] The conductive terminal group 3 also includes a second conductive terminal 32 and a third conductive terminal 33. The first conductive terminal 31, the second conductive terminal 32, and the third conductive terminal 33 are arranged side by side, with the first conductive terminal 31 being arranged on both sides and the second conductive terminal 32 and the third conductive terminal 33 being arranged in the middle.

[0048] The front ends of the second and third conductive terminals 32, 33 are each formed with a vertical arc-shaped structure 34, and the arc-shaped structure 34 of the second and third conductive terminals 32 and 33 are oriented in opposite directions. With this arrangement, the front ends of the second and third conductive terminals 32, 33 are positioned on the front and back sides, respectively, ensuring that connections can be made in a specific order and timing regardless of whether the terminals are plugged in or out.

[0049] The connector body 2 is further provided with a conductive terminal fixing plate 4 , on which a conductive terminal mounting position 41 is provided. The conductive terminal group 3 is fixed on the conductive terminal mounting position 41 , and the conductive terminal group 3 and the conductive terminal fixing plate 4 are injection molded.

[0050] The terminal body 311 and the folded portion 312 are both provided with a boss 314 . The conductive terminal mounting position 41 is further provided with a groove 42 adapted to the boss 314 . The boss 314 is snap-fitted into the groove 42 .

[0051] The ends of the first conductive terminal 31, the second conductive terminal 32, and the third conductive terminal 33 are all provided with welding pins 35, and the welding pins 35 are connected to the soldering pads 5. The connector body 2 is also provided with a PCB board 6, and the soldering pads 5 are soldered to the PCB board 6. The first conductive terminal 31, the second conductive terminal 32, and the third conductive terminal 33 are all connected to the PCB board 6 through the soldering pads 5.

[0052] The connector body 2 is further provided with a middle clip 7 , which is stacked above the conductive terminal fixing plate 4 .

[0053] The connector body 2, the middle clip 7, the conductive terminal group 3, and the conductive terminal fixing plate 4 are injection molded.

[0054] The connector body 2 is further provided with a limiting groove 21 , and the PCB board 6 is provided with a limiting block 61 , which is snap-fitted into the limiting groove 21 .

[0055] Upper and lower guide blocks 22 are provided on the contact surface between the connector body 2 and the PCB board 6 , and a guide groove 23 is formed between the guide blocks 22 . The contact end between the PCB board 6 and the connector body 2 is provided in the guide groove 23 .

[0056] The housing 1 is further provided with card slots 11 on both sides, and the two sides of the PCB board 6 are card-engaged in the card slots 11 .

[0057] The present invention provides a method for manufacturing an electrical connector, the method comprising the following steps:

[0058] S1: Preparation of conductive terminal group: Use high-speed cold stamping process to produce conductive terminal group with double-sided conductive function;

[0059] S2: One-shot injection molding: The conductive terminal group in S1 is subjected to the first in-mold injection molding;

[0060] S3: Secondary injection molding: The semi-finished product of S2 is placed in the middle clamping piece for the second injection molding;

[0061] S4: Testing: Remove waste tape, test and repair defective products of the secondary injection molded products in S3;

[0062] S5: Install the shell;

[0063] S6: Install the PCB board.

[0064] The S1 high-speed cold stamping process includes punching, cutting, bending, shaping and other process steps. The production speed of the punch press depends on different models and conditions. The materials used include highly conductive copper alloys, and the stamping speed is 320-480 times / minute.

[0065] In S2, the conductive terminal group is electroplated before the single injection molding to enhance the conductivity, prevent corrosion and oxidation, and enhance the solderability of tin. The electroplated conductive terminal group is placed in a plastic mold for the first injection molding. The mold for the single injection molding adopts a double-row mold with multiple cavities. The mold is provided with two rows, front and back, with 8-24 cavities in each row. Automatic feeding and automatic receiving methods are used. The injection molding materials include but are not limited to high-temperature, corrosion-resistant, and friction-resistant high-quality engineering plastics. The injection molding temperature is above 330°C, and the molding cycle is not less than 10 seconds. The injection molding setting includes but is not limited to vertical or horizontal plastic molding injection molding machines, which can achieve efficient unmanned production operations.

[0066] In S3, the semi-finished product of the first injection molding in S2 is placed into the middle sandwich sheet metal part, and placed together into another plastic mold cavity for a second injection molding. The mold structure, material injection molding machine model, and molding temperature of the secondary injection molding are the same as those of the primary injection molding. The molding cycle of the secondary injection molding is 12 seconds, so that the secondary molded plastic and the primary molded plastic are completely fused into a whole.

[0067] The tests in S4 include but are not limited to circuit continuity test, short circuit test, high voltage resistance test, visual inspection of the front and back conductive terminal contact surfaces using an image recognition detection system (CCD), and coplanarity inspection of the terminal solder feet, and repair of the defective parts.

[0068] The S4 testing and S5 housing assembly are both completed using automated assembly equipment. The specific steps are: feeding the secondary molded product, removing the scrap tape from the middle clip, front CCD inspection to check for debris on the conductive surfaces of the terminals, continuity, short circuit, open circuit, and withstand voltage testing, housing assembly, pushing the housing into place, removing the scrap tape from the terminals, CCD inspection for solder pin flatness, and product packaging. This allows for unmanned, automated production, with a production speed exceeding 3,000 units per hour.

[0069] The secondary injection molding in S3 forms the connector body, and forms a guide groove and a limit groove in the connector body. In S6, the PCB board is molded into the guide groove and the limit groove formed by the secondary in-mold molding. The shell in S5 is provided with card slots on both sides. In S6, the PCB board is inserted into the card slots on both sides of the shell, and the shell, conductive terminal group, etc. are tightly connected to the PCB board by welding.

[0070] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A method for manufacturing an electrical connector, the electrical connector comprising a housing and a connector body, wherein the connector body is installed in the housing, characterized in that: The connector body is provided with a conductive terminal group, the conductive terminal group includes one or more first conductive terminals, and the front end of the first conductive terminal is a structure bent back; The manufacturing method comprises the following steps: S1: Preparation of conductive terminal group: Use high-speed cold stamping process to produce conductive terminal group with double-sided conductive function; S2: One-shot injection molding: The conductive terminal group in S1 is subjected to the first in-mold injection molding; S3: Secondary injection molding: The semi-finished product of S2 is placed in the middle clamping piece for the second injection molding; S4: Testing: Remove waste tape, test and repair defective products of the secondary injection molded products in S3; S5: Install the shell; S6: Install PCB board; In S3, the secondary injection molding forms a connector body, and guide grooves and limit grooves are formed in the connector body. In S6, the PCB board is installed in the guide grooves and limit grooves formed by the secondary injection molding. In S5, the housing is provided with card slots on both sides. In S6, the PCB board is inserted into the card slots on both sides of the housing, and the housing and the conductive terminal group are connected to the PCB board by welding. The first conductive terminal includes a terminal body and a folded portion, wherein the connection between the terminal body and the folded portion is a U-shaped structure; The conductive terminal group further includes a second conductive terminal and a third conductive terminal, wherein the first conductive terminal, the second conductive terminal and the third conductive terminal are arranged side by side, the first conductive terminal is arranged on both sides, and the second conductive terminal and the third conductive terminal are arranged in the middle; The front ends of the second conductive terminal and the third conductive terminal are both vertically arc-shaped structures, and the arc-shaped structures of the second conductive terminal and the third conductive terminal are oriented in opposite directions; The connector body is further provided with a conductive terminal fixing plate, the conductive terminal fixing plate is provided with a conductive terminal mounting position, the conductive terminal group is fixed on the conductive terminal mounting position, and the conductive terminal group and the conductive terminal fixing plate are injection molded; The terminal body and the folded portion are both provided with bosses, and the conductive terminal mounting position is further provided with a groove adapted to the boss, and the boss is clamped in the groove; The ends of the first conductive terminal, the second conductive terminal, and the third conductive terminal are all provided with welding pins, the welding pins are connected to solder pads, and the first conductive terminal, the second conductive terminal, and the third conductive terminal are all connected to the PCB board through the solder pads; The middle clip is stacked on top of the conductive terminal fixing plate; The PCB board is provided with a limit block, and the limit block is clamped in the limit groove; The contact surface between the connector body and the PCB board is provided with upper and lower opposite guide blocks, a guide groove is formed between the guide blocks, and the contact end between the PCB board and the connector body is arranged in the guide groove.

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