A cylindrical male terminal manufacturing method and a cylindrical male terminal

Abstract

The application discloses a cylindrical male terminal manufacturing method, which comprises the following steps: a metal base material is in the shape of a rectangle; first, symmetric mounting positions are formed on the edges of the two sides of the metal base material by a stamping process, and the metal base material is divided into blank one and blank two by taking the two symmetric mounting positions as a boundary; second, the blank one is formed into a cylindrical contact part by the stamping process twice, and the blank two is formed into a V-shaped connecting part by the stamping process; and third, the terminal in the shape of a roughcast is formed into an insulating head and a sealing plug at the two ends of the contact part by an injection molding process, and a fixing column connected with the insulating head and the sealing plug is formed in the inner cavity of the contact part. The metal base material is used as a raw material, compared with the existing solid metal rod, cost can be saved, and the stamping process is more efficient than the machining process.

Description

Technical Field

[0001] This invention belongs to the field of terminal processing technology, specifically a method for manufacturing a cylindrical male terminal and a cylindrical male terminal. Background Technology

[0002] Terminals are components that enable the transmission of current and signals between multiple electronic devices, such as terminals for charging guns. These terminals are usually cylindrical and are generally machined from metal rods in one piece. The machining process is time-consuming and costly. After the initial cylindrical shape is formed, insulating pads and other components need to be manually fixed to the terminal. Since the insulating pads are made of materials such as silicone, they are prone to cracking or even falling off after a period of use when bonded with ordinary adhesives. Summary of the Invention

[0003] The purpose of this invention is to provide a method for manufacturing a cylindrical male terminal and a cylindrical male terminal, so as to solve the problems mentioned in the background art.

[0004] To achieve the above objectives, the present invention provides the following technical solution: A method for manufacturing a cylindrical male terminal includes a rectangular plate-shaped metal substrate; The first step is to form symmetrical mounting positions on both sides of the metal substrate through a stamping process, and divide the metal substrate into blank one and blank two by using the two symmetrical mounting positions as the dividing line. The second step involves stamping the blank one into a cylindrical contact part twice, and stamping the blank two into a "V" or "U" shaped connection part. The third step involves using an injection molding process to form an insulating head and a sealing plug at both ends of the contact portion of the rudimentary terminal, while a fixing post connecting the insulating head and the sealing plug is formed inside the contact portion.

[0005] This invention uses a metal substrate as the raw material, which saves costs compared to existing solid metal rods. Furthermore, the stamping process is more efficient than machining. Since the contact area is hollow, injection molding creates a fixing post within it, providing both support and connecting the insulating heads and sealing plugs at both ends, preventing them from falling off. Injection molding also replaces manual installation of the insulating heads and sealing plugs, allowing for mass production and further improving efficiency. A further technical solution involves forming a blank three between the two mounting positions. In the second step, when blank one and blank two are stamped, the two sides of blank three will be pushed upwards. Then, the upward-pushed part is squeezed inwards through the stamping process to form a connecting rib. The connection between the connecting rib and the connecting part and the contact part is an arc transition.

[0006] In a further technical solution, in the second step, before forming the connecting part, the surface of the blank two is first processed to form several transversely distributed grooves, which are located inside the connecting part.

[0007] A further technical solution includes an insulating strip that is fitted into the groove, with a gap between the insulating strip and the sidewall of the groove, and the height of the insulating strip being greater than the depth of the groove.

[0008] In a further technical solution, in the third step, adhesive is applied to both ends and the inner cavity of the shaped terminal, and then it is heated to make the adhesive viscous. After injection molding, it cools and solidifies, bonding it together with the insulating head, sealing plug and fixing post.

[0009] In a further technical solution, the area of ​​billet one is larger than that of billet two.

[0010] A cylindrical male terminal includes a through contact portion, the end of which is connected to a connecting portion via a connecting rib. An insulating head and a sealing plug are provided at both ends of the contact portion. The insulating head and the sealing plug are connected by a fixing post located in the inner cavity of the contact portion, thereby preventing them from falling off during use.

[0011] In a further technical solution, adhesive is applied to the contact points where they contact the insulating head, sealing plug, and fixing post, respectively.

[0012] In a further technical solution, the inner side of the connecting part is provided with several grooves.

[0013] Other features and advantages of the present invention will be described in detail in the following detailed description section. Attached Figure Description

[0014] Figure 1 : Schematic diagram of the metal substrate processing of the present invention.

[0015] Figure 2 : Schematic diagram of the first stamping of the blank of the present invention.

[0016] Figure 3 : Schematic diagram of the second stamping of the blank of the present invention.

[0017] Figure 4 : Structural diagram of the terminal of the present invention before injection molding.

[0018] Figure 5 : Complete structural diagram of the terminal of the present invention.

[0019] Figure 6 : A cross-sectional view of the terminal of the present invention.

[0020] Figure 7 : Schematic diagram of the insulating strip under pressure deformation of the present invention.

[0021] Reference numerals: 1-Metal substrate, 11-Mounting position, 12-Blank 1, 13-Blank 2, 14-Blank 3, 21-Contact part, 22-Connecting part, 23-Connecting rib, 24-Groove, 31-Insulating head, 32-Sealing plug, 33-Fixing post, 34-Insulating strip, 41-Slot 1, 42-Punch 1, 43-Slot 2, 44-Punch 2. Detailed Implementation

[0022] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0023] Please refer to Figure 1-7 ; This invention discloses a method for manufacturing a cylindrical male terminal, comprising a rectangular plate-shaped metal substrate 1, wherein the metal substrate 1 can be made of copper. The specific manufacturing steps are as follows: Example 1:

[0024] The first step is to form symmetrical mounting positions 11 on both sides of the metal substrate 1 by stamping process. In this embodiment, the shape of the mounting positions 11 is not limited. The metal substrate 1 is divided into blank one 12 and blank two 13 by the two symmetrical mounting positions 11 as the dividing line. The second step involves stamping the blank 12 twice to form the cylindrical contact portion 21 and the blank 23 to form the "V"-shaped connecting portion 22. In this embodiment, two sets of molds are used to stamp the blank 12. The lower mold of the first set has a narrow arc-shaped groove 41, which is matched with a punch 42 that conforms to the shape of the arc-shaped groove 41. The punch 42 presses the blank into the arc-shaped groove 41, forming the blank 12 into a shape that conforms to the arc-shaped groove 41. The first set of molds performs the initial deformation of the blank 12. After that, the arc-shaped blank 12 is transferred to the other mold. The lower mold of this other mold has a semi-circular groove 43, which is matched with a punch 44 that also has a semi-circular shape. The semi-circle of the punch 44 and the lower mold The two semicircles are reversed and combined to form a circle. After the blank 12 is transferred to the lower die of the semicircular groove 43, it is pressed down by the punch 44. The downward-curving part of the blank 12 will first contact the punch 44. Then the punch 44 and the lower die close together, causing the blank 12 to be squeezed to form a cylindrical contact part 21. At this time, the contact part 21 is in a through state. When the blank 12 is processed for the second time, the blank 23 can be stamped at the same time. It is also processed using the lower die with the "V" shaped groove 24 and the corresponding punch. It should be noted that the selected metal substrate 1 can be formed in the strip. By pulling the strip, the switching of different stamping dies can be realized. It is already widely used in actual production. Those skilled in the art can realize it according to the existing technology, and it will not be described in detail here. Of course, the above is only one implementation method for stamping, and there should be other implementation methods, which are not limited here.

[0025] The third step involves using an injection molding process to form an insulating head 31 and a sealing plug 32 at both ends of the contact portion 21 from the rudimentary terminal. During the injection molding process, the molten material enters and fills the inner cavity of the contact portion 21, forming a fixing post 33 that connects the insulating head 31 and the sealing plug 32.

[0026] This invention uses a metal substrate 1 as the raw material, which saves costs compared to the existing use of solid metal rods. Furthermore, the production process by stamping is more efficient than machining. In addition, since the contact part 21 is hollow, a fixing post 33 is formed inside the contact part 21 by injection molding. This post serves as a support and connects the insulating head 31 and the sealing plug 32 at both ends, preventing them from falling off. Injection molding can also replace manual installation of the insulating head 31 and the sealing plug 32, and batch injection molding can be performed to further improve production efficiency.

[0027] Example 2:

[0028] The first step is to form symmetrical mounting positions 11 on both sides of the metal substrate 1 by stamping process. The metal substrate 1 is divided into blank one 12 and blank two 13 by the two symmetrical mounting positions 11 as the dividing line, and blank three 14 is formed between the two mounting positions 11. In the second step, since the third blank 14 is located between the first blank 12 and the second blank 13, but when the third blank 14 is processed alone, there is a possibility of changing the shape of the contact part 21 and the connecting part 22. Therefore, in this embodiment, when the first blank 12 is processed for the second time, the second blank 13 and the third blank 14 are stamped simultaneously. The shape of the contact part 21 and the connecting part 22 formed can be fixed by the mold. When the first blank 12 and the second blank 13 are stamped, that is, bent and curved upward, the two sides of the third blank 14 will be curved upward. Then, the curved part is squeezed inward by the stamping process to form the connecting rib 23. The connection of the connecting rib 23 with the connecting part 22 and the contact part 21 is an arc transition. The first blank 12 forms a cylindrical contact part 21, and the second blank 13 is stamped to form a "V" shaped connecting part 22. The third step involves using injection molding to form an insulating head 31 and a sealing plug 32 at both ends of the contact portion 21 from the rudimentary terminal. The sealing plug 32 also partially covers the connecting rib 23, and a fixing post 33 connecting the insulating head 31 and the sealing plug 32 is formed in the inner cavity of the contact portion 21.

[0029] Example 3:

[0030] In the second step, before forming the connecting part 22, the surface of the blank 13 is first processed to form several transversely distributed grooves 24. These grooves 24 are located inside the connecting part 22. The grooves 24 can play a role in preventing slippage and strengthening fixation. In this embodiment, the grooves 24 can be straight strips or "V" shapes, etc. Furthermore, an insulating strip 34 is attached within the groove 24, with a gap between the insulating strip 34 and the side wall of the groove 24, and the height of the insulating strip 34 is greater than the depth of the groove 24. It should be noted that the insulating strip 34 is only slightly higher than the inner surface of the connecting part 22, and the insulating strip 34 is relatively soft, capable of deformation under pressure. In use, the external connector is placed inside the connecting part 22, and then the connecting part 22 wraps around it. Simultaneously, the inner wall of the connecting part 22 applies pressure to the external connector. First, the insulating strip 34 contacts the connector, and the reaction force of the external connector acts on the insulating strip 34, squeezing it into the groove 24. The insulating strip 34 deforms and extends into the gap, filling the groove 24. At this point, the connector can contact the metal exterior of the connecting part 22 to achieve communication. The insulating strip 34 increases friction, thereby improving the connection tightness. Additionally, the insulating strip 34 fills the gap between the groove 24 and the connector, preventing electric arcing.

[0031] Furthermore, the area of ​​billet 12 is larger than that of billet 2 13.

[0032] Example 4:

[0033] The first step is to form symmetrical mounting positions 11 on both sides of the metal substrate 1 through a stamping process, and divide the metal substrate 1 into blank one 12 and blank two 13 with the two symmetrical mounting positions 11 as the dividing line. The second step involves stamping the blank 12 into a cylindrical contact part 21 in two separate processes, and stamping the blank 23 into a "V" shaped connecting part 22. The third step involves applying adhesive to both ends and the inner cavity of the nascent terminal, followed by heating. A brief period of high temperature evaporates some of the moisture in the adhesive, thickening it and significantly increasing its viscosity. Injection molding then occurs, forming an insulating head 31 and a sealing plug 32 at both ends of the contact portion 21. A fixing post 33 connecting the insulating head 31 and the sealing plug 32 is formed within the inner cavity of the contact portion 21. The insulating head 31, sealing plug 32, and fixing post 33 can fully bond with the adhesive. During injection molding, extremely fine cracks may exist at the connection between the plastic and metal parts, affecting waterproofing. Adding adhesive serves as a bridge between the plastic and metal parts and can also bridge these cracks. After the adhesive is fully applied and bonded to the plastic part, it solidifies upon cooling. During use, the terminal generates heat, but this heat is not evenly distributed, leading to uneven heating of the plastic part and irregular expansion. Over time, this can cause cracks at the connection between the plastic part and the terminal. This invention addresses this by applying adhesive to the connection between the plastic part and the terminal. When heated, the adhesive melts into a gel-like consistency, but contains very little water, so it does not flow. Even when the plastic part expands due to heat, it remains bonded to the adhesive. As the terminal cools, the plastic part shrinks, and the adhesive re-solidifies. This adhesive design accommodates varying degrees of expansion in the plastic part, ensuring no cracks form between the plastic part and the terminal and improving waterproofing.

[0034] The present invention also discloses a cylindrical male terminal made by the above manufacturing method, including a through contact portion 21, a connecting portion 22 connected to the end of the contact portion 21 by a connecting rib 23, an insulating head 31 and a sealing plug 32 provided at both ends of the contact portion 21, the insulating head 31 and the sealing plug 32 being connected by a fixing post 33 located in the inner cavity of the contact portion 21, the fixing post 33 connecting the insulating head 31 and the sealing plug 32 to prevent them from falling off during use.

[0035] Furthermore, adhesive is applied to the contact parts 21 where they contact the insulating head 31, the sealing plug 32, and the fixing post 33, respectively. The adhesive can make the plastic parts and metal parts more securely connected and improve the waterproof performance.

[0036] Furthermore, the inner side of the connecting part 22 is provided with several grooves 24.

[0037] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0038] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for manufacturing a cylindrical male terminal, comprising a rectangular plate-shaped metal substrate (1), characterized in that: The first step is to form symmetrical mounting positions (11) on both sides of the metal substrate (1) by stamping process, and divide the metal substrate (1) into blank one (12) and blank two (13) by the two symmetrical mounting positions (11) as the dividing line; The second step is to form the cylindrical contact part (21) of the blank one (12) twice through the stamping process, and to stamp the blank two (13) into a "V" or "U" shaped connecting part (22); The third step is to use injection molding to form an insulating head (31) and a sealing plug (32) at both ends of the contact part (21) of the terminal that has formed a prototype. A fixing post (33) connecting the insulating head (31) and the sealing plug (32) is formed in the inner cavity of the contact part (21). In the second step, before forming the connecting part (22), the surface of the blank two (13) is processed to form several transversely distributed grooves (24), which are located inside the connecting part (22); The terminal also includes an insulating strip (34) fitted into the groove (24), the insulating strip (34) having a gap with the side wall of the groove (24), and the height of the insulating strip (34) being greater than the depth of the groove (24); The insulating strip (34) is relatively soft and can deform under pressure.

2. The method for manufacturing a cylindrical male terminal according to claim 1, characterized in that: A blank three (14) is formed between the two mounting positions (11). In the second step, when blank one (12) and blank two (13) are stamped, the two sides of blank three (14) will be pushed upwards. Then, the upward part is squeezed inwards through the stamping process to form a connecting rib (23). The connection between the connecting rib (23) and the connecting part (22) and the contact part (21) is an arc transition.

3. The method for manufacturing a cylindrical male terminal according to claim 1, characterized in that: In the third step, adhesive is applied to both ends and the inner cavity of the terminal that has formed the prototype. Then, it is heated to make the adhesive viscous. After injection molding, it is cooled and solidified, and bonded together with the insulating head (31), sealing plug (32) and fixing post (33).

4. The method for manufacturing a cylindrical male terminal according to claim 1, characterized in that: The area of ​​billet one (12) is larger than that of billet two (13).

5. A cylindrical male terminal, based on a method for manufacturing a cylindrical male terminal according to any one of claims 1-4, wherein a through contact portion (21) is formed by the manufacturing method, and a connecting portion (22) is connected to the end of the contact portion (21) by a connecting rib (23), and an insulating head (31) and a sealing plug (32) are provided at both ends of the contact portion (21), and the insulating head (31) and the sealing plug (32) are connected by a fixing post (33) located in the inner cavity of the contact portion (21).

6. A cylindrical male terminal according to claim 5, characterized in that: The contact portion (21) is coated with adhesive at the points where it contacts the insulating head (31), the sealing plug (32), and the fixing post (33).

7. A cylindrical male terminal according to claim 6, characterized in that: The inner side of the connecting part (22) is provided with several grooves (24).

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