Plug connector and manufacturing method

Abstract

The invention discloses a plug connector and a manufacturing method thereof. The manufacturing method of the plug connector comprises the following steps: S1, manufacturing a plurality of bent elastic conductors; s2, manufacturing an elastic base sleeve; a plurality of assembly through holes are formed in the elastic base sleeve; and S3, correspondingly and fixedly arranging a plurality of bent elastic conductors on the assembly through holes to manufacture the plug connector. By utilizing the bendability of the bending elastic conductor, the elasticity of the bending elastic conductor can be better, and when the elastic base sleeve is assembled between the male terminal and the female terminal, the elastic base sleeve can be contacted with the male terminal and the female terminal more tightly, so that the contact area between the bending elastic conductor and the male terminal and the female terminal is increased; connection of elastic points can be achieved as many as possible through the bent elastic conductors, the heat dissipation efficiency is improved, more heat generated by high current can be conducted and dissipated, the current bearing capacity is further enhanced, and more convenience and diversity are achieved.

Description

Technical Field

[0001] The invention relates to the field of electronic devices, and in particular to a plug-in connector and a manufacturing method thereof. Background Art

[0002] With the explosive growth of the electric vehicle market, high-current transmission on-board connectors specifically used for electric vehicles and charging infrastructure, as well as high-power connectors for fast charging have become key components. On-board connectors also need to have high reliability with high heat resistance, shock resistance and long life.

[0003] Renewable energy systems such as wind power and solar power generation need to handle high power transmission from the power generation device to the power grid. Connector technology becomes critical in such applications, especially for connectors used for a long time in harsh outdoor environments, which require higher reliability.

[0004] 5G base stations require high-power and high-frequency signal transmission, which drives the demand for high-power, high-frequency connectors. The relevant connectors not only need to support strong currents, but also have good signal transmission performance. High-power, high-current, high-reliability connectors are key components for transmitting power and signals in high-power applications, and are widely used in power electronics, aerospace, automotive, electric transportation, industrial automation, and communications.

[0005] However, the multi-point contact of some connectors only occurs at the elastic sheet or spring sheet of the female terminal, which is rigidly and elastically connected to the male terminal, so the number of multi-point contacts is limited, and the total equivalent contact resistance is limited, so the high-power carrying capacity is limited. Under multiple plug-in and unplug and long-term high-power, high-current working conditions, and harsh working environments, the limited number of contact points may cause reliability problems such as poor contact due to large uniformly distributed power and low conduction heat dissipation efficiency. Summary of the invention

[0006] The technical problem to be solved by the present invention is to provide a method for manufacturing a plug connector.

[0007] The technical solution adopted by the present invention to solve the technical problem is: constructing a method for manufacturing a plug connector, comprising the following steps;

[0008] S1: Make several curved elastic conductors;

[0009] S2: making an elastic base sleeve; and providing a plurality of assembly through holes on the elastic base sleeve;

[0010] S3: fixing a plurality of the curved elastic conductors correspondingly on the assembly through holes to form the connector.

[0011] Further, the step S1 comprises:

[0012] S11: forming the metal substrate into a metal wire; the diameter of the metal wire is equivalent to the diameter of the assembly through hole;

[0013] S12: cutting the metal wire into a plurality of metal wire segments of equal length;

[0014] S13: rolling the two ends of each of the metal wire segments into a flat head; the diameter of the flat head is larger than the diameter of the assembly through hole;

[0015] S14: bending the middle portion of each of the metal wire segments to obtain the curved elastic conductor 31 .

[0016] Furthermore, the step S1 further includes:

[0017] S15: performing gold plating on the surface of the curved elastic conductor obtained in step S14;

[0018] Wherein, the step S13 and the step S14 are performed sequentially or synchronously.

[0019] Further, the step S2 comprises:

[0020] S21: heating and melting the base material of the elastic base sleeve, and injecting it into the mold;

[0021] S22: after the base material of the elastic base sleeve is solidified in the mold, taking out the elastic base sleeve blank from the mold;

[0022] S23: removing burrs from the elastic base sleeve blank and cleaning it to obtain the elastic base sleeve.

[0023] Furthermore, the step S2 further includes:

[0024] S24: fixing the elastic base sleeve on a fixture;

[0025] S25: punching a plurality of through holes in the middle of the elastic base sleeve to form the assembly through hole;

[0026] or,

[0027] The mold is a top-bottom split mold structure and is provided with a plurality of smooth ejector pins; in the step S21, when the base material of the elastic base sleeve is injected into the mold, a plurality of assembly through holes are formed at the positions of the smooth ejector pins.

[0028] Further, the step S3 comprises:

[0029] S31: putting the elastic base sleeve on the positioning assembly jig;

[0030] S32: Assembling the curved elastic conductor into the corresponding assembly through hole of the elastic base sleeve;

[0031] S33: adding an adhesive made of the same material as the base material of the elastic base sleeve at each joint between the curved elastic conductor and the through hole of the elastic base sleeve;

[0032] S34: After the adhesive is cured, the elastic base sleeve is removed from the positioning and assembly jig to obtain the connector.

[0033] Further, the positioning and assembly jig is provided with an assembly step, and in the step S31, when the elastic base sleeve is sleeved on the periphery of the positioning and assembly jig, a positioning gap is formed between the outer wall of the positioning and assembly jig and the inner wall of the elastic base sleeve;

[0034] In the step S32, the curved elastic conductor is inserted into the assembly through hole until the end surface of the insertion end of the fully elastic conductor abuts against the outer wall of the positioning assembly fixture.

[0035] Furthermore, the positioning and assembly jig further comprises a positioning ring provided at the insertion end thereof;

[0036] In the step S31, the elastic base sleeve is positioned on the position of the positioning and assembly fixture by the positioning ring, and is retained in the elastic base sleeve.

[0037] In addition, the present invention also provides a connector made by a method for making a connector, which can be used for conductive connection between a male terminal and a female terminal. The connector includes an elastic base sleeve arranged between the male terminal and the female terminal, and a plurality of curved elastic conductors are glued onto the elastic base sleeve. When the male terminal and the female terminal are plugged together, a conductive connection is achieved by compressing the curved elastic conductors.

[0038] Furthermore, a detachable positioning block is installed inside one end of the elastic base sleeve; or a positioning block is integrally formed inside one end of the elastic base sleeve;

[0039] The curved elastic conductor comprises a cylindrical middle section and flat heads arranged at two ends of the middle section; the diameter of the flat heads is greater than the diameter of the middle section.

[0040] The implementation of the present invention has the following beneficial effects: by utilizing the bendability of the bendable elastic conductor, the elasticity of the bendable elastic conductor can be improved, and when the elastic base sleeve is assembled between the male terminal and the female terminal, the bendable elastic base sleeve can be more closely contacted with the male terminal and the female terminal, thereby increasing the contact area between the bendable elastic conductor and the male terminal and the female terminal, and by using a plurality of bendable elastic conductors, as many elastic point connections as possible can be achieved, thereby improving the heat dissipation efficiency, conducting more heat generated by high current, further enhancing the current carrying capacity, and being more convenient and diverse. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] In order to more clearly illustrate the technical solution of the present invention, the present invention will be further described below in conjunction with the accompanying drawings and embodiments. It should be understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without paying creative work.

[0042] In the attached figure:

[0043] Figure 1 This is a flow chart of manufacturing a plug-in connector provided by an embodiment of the present invention;

[0044] Figure 2 is a flow chart of manufacturing a curved elastic conductor provided by an embodiment of the present invention;

[0045] Figure 3 is a flow chart of making a transfer through hole provided by an embodiment of the present invention;

[0046] Figure 4 is a flow chart of assembling a connector provided by an embodiment of the present invention;

[0047] Figure 5 is a structural schematic diagram of a plug connector provided by an embodiment of the present invention;

[0048] Figure 6 is a structural schematic diagram of a positioning and assembly fixture provided by an embodiment of the present invention;

[0049] Figure 7 is a cross-sectional schematic diagram of a positioning assembly fixture and a connector provided by an embodiment of the present invention;

[0050] Figure 8 is a cross-sectional schematic diagram of an elastic base sleeve provided by an embodiment of the present invention;

[0051] Fig. 9 is a schematic structural diagram of a curved elastic conductor provided by an embodiment of the present invention;

[0052] Fig.10 The present invention Figure 7 A partial enlarged view of middle A;

[0053] Fig.11 It is a schematic structural diagram of a curved elastic conductor according to another embodiment of the present invention.

[0054] Description of symbols in the figure

[0055] Male terminal 1, female terminal 2, plug connector 3, curved elastic conductor 31, flat head 311, middle section 312, elastic base sleeve 32, assembly through hole 33, positioning block 34, positioning assembly fixture 4, assembly step 5, positioning ring 6. DETAILED DESCRIPTION

[0056] In order to have a clearer understanding of the technical features, purposes and effects of the present invention, the specific embodiments of the present invention are now described in detail with reference to the accompanying drawings. In the following description, it should be understood that the directions or positional relationships indicated by "front", "back", "up", "down", "left", "right", "longitudinal", "horizontal", "vertical", "horizontal", "top", "bottom", "inside", "outside", "head", "tail", etc. are based on the directions or positional relationships shown in the accompanying drawings, are constructed and operated in a specific direction, and are only for the convenience of describing the present technical solution, rather than indicating that the device or element referred to must have a specific direction, and therefore cannot be understood as a limitation to the present invention.

[0057] It should also be noted that, unless otherwise clearly specified and limited, the terms such as "installed", "connected", "connected", "fixed", "set" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral one; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. When an element is referred to as being "on" or "under" another element, the element can be "directly" or "indirectly" located on the other element, or there may be one or more intermediate elements. The terms "first", "second", "third", etc. are only for the convenience of describing the present technical solution, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first", "second", "third", etc. can explicitly or implicitly include one or more of the features. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances.

[0058] In the following description, specific details such as specific system structures, technologies, etc. are provided for the purpose of illustration rather than limitation, so as to provide a thorough understanding of the embodiments of the present invention. However, it should be clear to those skilled in the art that the present invention may be implemented in other embodiments without these specific details. In other cases, detailed descriptions of well-known systems, devices, circuits, and methods are omitted to prevent unnecessary details from obstructing the description of the present invention.

[0059] See also Figure 1-Figure 4 , the manufacturing method of the plug connector in the first embodiment of the present invention comprises the following steps;

[0060] S1: manufacturing a plurality of curved elastic conductors 31;

[0061] S2: manufacturing an elastic base sleeve 32; a plurality of assembly through holes 33 are provided on the elastic base sleeve 32;

[0062] S3: A plurality of curved elastic conductors 31 are fixedly arranged on the assembly through holes 33 to form the connector 3.

[0063] Among them, the curved elastic conductor 31 is a conductive material with compression and rebound effects. The bendability of the curved elastic conductor 31 can make the curved elastic conductor 31 more elastic. When the elastic base sleeve 32 is assembled between the male terminal 1 and the female terminal 2, it can be in closer contact with the male terminal 1 and the female terminal 2, thereby increasing the contact area between the curved elastic conductor 31 and the male terminal 1 and the female terminal 2. Through a number of curved elastic conductors 31, as many elastic points as possible can be connected, thereby improving the heat dissipation efficiency, conducting more heat generated by high current, further enhancing the current carrying capacity, and being more convenient and diverse.

[0064] Among them, the elastic base sleeve 32 is made of elastic material with insulating effect, such as silicone, polypropylene, polyurethane or rubber. When the elastic base sleeve 32 is made of silicone, the insulating sleeve 310 made of silicone can have better shrinkage, seal the gap more tightly, is easier to manufacture, and is not easy to cause pollution during manufacture.

[0065] The elastic base sleeve 32 is made of polypropylene. The elastic base sleeve 32 made of polypropylene can be more easily shaped and is relatively cheap. It has high flexural strength, a relatively smooth surface, is easy to install, and has good chemical corrosion resistance and impact resistance, thereby increasing the service life of the elastic base sleeve 32.

[0066] The elastic base sleeve 32 is made of polyurethane. The elastic base sleeve 32 made of polyurethane has excellent elasticity, elongation, compression strength and softness, as well as good chemical stability, which makes it easy to install and further improves the service life of the elastic base sleeve 32.

[0067] The elastic base sleeve 32 is made of rubber. The elastic base sleeve 32 made of rubber is easier to manufacture and the raw materials are cheaper, thereby saving manufacturing costs.

[0068] The present application provides a plurality of assembly through holes 33 on the elastic base sleeve 32, and correspondingly fixes a plurality of curved elastic conductors 31 on the assembly through holes 33 to form a plug connector 3. The middle portion of the curved elastic conductor 31 is installed on the elastic base sleeve 32 through the assembly through holes 33, so that when the curved elastic conductor 31 is installed between the male terminal 1 and the female terminal 2, the elastic pressure of the two ends of the curved elastic conductor 31 on the male terminal 1 and the female terminal 2 is more uniform, and the contact area is closer, which can reduce the current loss, enhance the current carrying capacity, improve the heat dissipation efficiency, and conduct more heat generated by high current. At the same time, the assembly through holes 33 can make the connection between the curved elastic conductor 31 and the elastic base sleeve 32 tighter, making installation more convenient and improving work efficiency.

[0069] In some embodiments, please refer to Figure 2 , step S1 comprises:

[0070] S11: forming the metal substrate into a metal wire; the diameter of the metal wire is equivalent to the diameter of the assembly through hole 33;

[0071] S12: cutting the metal wire into a plurality of metal wire segments of equal length;

[0072] S13: rolling the two ends of each metal wire segment into a flat head 311; the diameter of the flat head 311 is larger than the diameter of the assembly through hole 33;

[0073] S14: bending the middle portion of each metal wire segment to obtain a curved elastic conductor 31;

[0074] S15: The curved elastic conductor 31 obtained in step S14 is subjected to surface gold plating.

[0075] The present application can make processing easier by stretching or pressing a metal substrate into a metal wire, and can make storage and transportation easier by winding the metal wire into bundles. The bundled metal wires are then placed in an automatic cutting device, and the metal wires are drawn and stretched using the automatic cutting device. The stretched metal wires are then cut into segments, and the metal wires are cut into a number of metal wire segments of equal length. The two ends of the metal wire segments are then rolled into flat heads 311 using a forming machine through a mechanical pressing head. By rolling the two ends of the metal wire segments into flat heads 311, the contact area between the male terminal 1 and the female terminal 2 can be increased, and the mutual contact is more stable and not easily deformed, thereby further enhancing the current carrying capacity, improving the heat dissipation efficiency, and conducting more heat generated by high current to dissipate.

[0076] The present application prevents separation between the bent elastic conductor 31 and the elastic base sleeve 32 by setting the diameter of the rolled flat head 311 to be larger than the diameter of the assembly through hole 33, thereby further improving stability, making the connector 3 more stable during operation, dissipating heat more evenly, and extending its service life.

[0077] The present application obtains a bent elastic conductor 31 by bending the middle part of each metal wire segment. The forming machine bends the middle part of the metal wire segment through a mechanical press. The bent metal wire segment itself will generate elasticity, further enhancing the elasticity of the metal wire segment and having a better rebound effect. The flat heads 311 at both ends of the bent elastic conductor 31 can be closely contacted with the male terminal 1 and the female terminal 2 through the superposition of its own shape elasticity and material elasticity, further enhancing the stability between the male terminal 1 and the female terminal 2, and also improving the heat dissipation efficiency and the current carrying capacity, and conducting more heat generated by high current. The bent bent elastic conductor 31 can also apply pressure to the male terminal 1 and the female terminal 2 through the elasticity generated, so that the connector 3 acts more closely between the male terminal 1 and the female terminal 2, making it difficult for the male terminal 1 and the female terminal 2 to loosen, thereby making the operation more stable, the adaptability stronger, and the use environment more diverse.

[0078] The present application performs gold plating on the surface of the obtained curved elastic conductor 31 to enhance the conductivity of the curved elastic conductor 31 and improve the conductive effect between the male terminal 1 and the female terminal 2 , making the operation faster and more sensitive, and easier to operate.

[0079] Among them, step S13 and step S14 are performed sequentially or synchronously. When step S13 and step S14 are performed sequentially, each process can be made more stable, the error in the processing process can be reduced, and the yield rate is higher.

[0080] When step S13 and step S14 are performed simultaneously, the curved elastic conductor 31 can be manufactured more quickly, and the transportation and personnel involvement can be reduced, thereby improving work efficiency.

[0081] In some embodiments, please refer to Figure 3 , step S2 comprises:

[0082] S21: heating and melting the base material of the elastic base sleeve 32, and injecting it into the mold;

[0083] S22: After the base material of the elastic base sleeve 32 is solidified in the mold, the elastic base sleeve 32 blank is taken out from the mold;

[0084] S23: removing the burrs of the elastic base sleeve 32 blank and cleaning it to obtain the elastic base sleeve 32.

[0085] Among them, the base material of the elastic base sleeve 32 injected into the mold after heating and melting can change with the shape of the mold, so that it is convenient to produce elastic base sleeves 32 of different shapes, such as polygonal, elliptical or circular, and the size of the elastic base sleeve 32 can be changed with the size of the mold, so that the elastic base sleeve 32 can be produced following the shape between the male terminal 1 and the female terminal 2, and can be suitable for different models of male terminals 1 and female terminals 2, so that it is more diverse, suitable for different usage environments, and easier to produce.

[0086] In some embodiments, please refer to Figure 3 , step S2 further includes:

[0087] S24: Fixing the elastic base sleeve 32 on the fixture;

[0088] S25: punching a plurality of through holes in the middle of the elastic base sleeve 32 to form an assembly through hole 33;

[0089] or,

[0090] The mold is a top-bottom split mold structure and is provided with a plurality of smooth ejector pins. In step S21, when the base material of the elastic base sleeve 32 is injected into the mold, a plurality of assembly through holes 33 are formed at the positions of the smooth ejector pins.

[0091] The present application fixes the elastic base sleeve 32 on the fixture and punches a plurality of through holes in the middle of the elastic base sleeve 32 to form an assembly through hole 33. The punched plurality of assembly through holes 33 can reduce the gap between the curved elastic conductor 31 and the elastic base sleeve 32, making the connection between the curved elastic conductor 31 and the elastic base sleeve 32 tighter, reducing the use of adhesives, and reducing manufacturing costs.

[0092] The present application sets the mold as an upper and lower split mold structure and sets a plurality of smooth ejector pins on the mold; in step S21, when the base material of the elastic base sleeve 32 is injected into the mold, a plurality of assembly through holes 33 are formed at the position of the smooth ejector pins, and then after demolding, the elastic base sleeve 32 will have a plurality of assembly through holes 33, thereby reducing the processing steps and improving the manufacturing efficiency.

[0093] In some embodiments please see Figure 4 , step S3 comprises:

[0094] S31: Put the elastic base sleeve 32 on the positioning assembly fixture 4;

[0095] S32: Assemble the curved elastic conductor 31 into the corresponding assembly through hole 33 of the elastic base sleeve 32;

[0096] S33: Adding an adhesive made of the same material as the base material of the elastic base sleeve 32 at the joint between each curved elastic conductor 31 and the assembly through hole 33 of the elastic base sleeve 32;

[0097] S34: After the adhesive is cured, the elastic base sleeve 32 is removed from the positioning and assembly jig 4 to obtain the connector 3.

[0098] The present application sets the elastic base sleeve 32 on the positioning assembly jig 4, and uses the positioning assembly jig 4 to facilitate the elastic base sleeve 32 to be stretched, thereby improving the installation efficiency. Then, the curved elastic conductor 31 is assembled into the corresponding assembly through hole 33 of the elastic base sleeve 32. During the assembly process, the elasticity of the elastic base sleeve 32 is used to insert the flat head 311 at one end of the curved elastic conductor 31 into the assembly through hole 33, and then the inserted flat head 311 passes through the assembly through hole 33 and contacts the outer wall of the positioning assembly jig 4. After all the curved elastic conductors 31 are assembled in the corresponding assembly through holes 33, a material of the same material as the base material of the elastic base sleeve 32 is added at the joint between each curved elastic conductor 31 and the assembly through hole 33 of the elastic base sleeve 32. The adhesive of the same material as the base material of the elastic base sleeve 32 can be integrated with the elastic base sleeve 32 after curing, and then the curved elastic conductor 31 and the elastic base sleeve 32 can be connected more tightly through the adhesive. After the adhesive is cured, the gap between the curved elastic conductor 31 and the elastic base sleeve 32 can be blocked to prevent dust from entering the male terminal 1 and the female terminal 2 to cause dust pollution, further improving the service life and operation stability. After waiting for the adhesive to cure, the elastic base sleeve 32 is removed from the positioning and assembly jig 4 to obtain the connector 3. The curved elastic conductor 31 can be more conveniently assembled on the elastic base sleeve 32 through the positioning and assembly jig 4, thereby improving the assembly efficiency and the yield rate, and the operation is more convenient.

[0099] In some embodiments please see Figure 5-Figure 7 The positioning assembly jig 4 is provided with an assembly step 5. In step S31, when the elastic base sleeve 32 is sleeved on the periphery of the positioning assembly jig 4, a positioning gap is formed between the outer wall of the positioning assembly jig 4 and the inner wall of the elastic base sleeve 32. In step S32, the curved elastic conductor 31 is inserted into the assembly through hole 33 until the end surface of the insertion end of the curved elastic conductor 31 abuts against the outer wall of the positioning assembly jig 4. The radial dimension of the positioning gap is equivalent to the thickness of the flat head 311 of the curved elastic conductor 31, so that the flat head 311 of the insertion end of the curved elastic conductor 31 can be accommodated in the positioning gap, so that the curved elastic conductor 31 can be accurately positioned and installed.

[0100] The present application can open the elastic base sleeve 32 through the assembly step 5 provided on the positioning assembly jig 4, so that a positioning gap is formed between the outer wall of the positioning assembly jig 4 and the inner wall of the elastic base sleeve 32. The positioning gap can assist the assembler in assembling the curved elastic conductor 31. The assembly step 5 can enable the assembler to more accurately fit the elastic base sleeve 32 on the reference position of the positioning assembly jig 4, thereby facilitating the installation of a plurality of curved elastic conductors 31 into the assembly through holes 33, further improving work efficiency, making operation more convenient, and reducing the labor intensity of the assembler.

[0101] In the present application, in step S32, the curved elastic conductor 31 is installed into the assembly through hole 33 until the end face of the insertion end of the curved elastic conductor 31 abuts against the outer wall of the positioning assembly fixture 4, and the outer wall of the positioning assembly fixture 4 is used to limit the curved elastic conductor 31, so that the inner and outer ends of the curved elastic conductor 31 on the elastic base sleeve 32 have the same length, the elasticity between the inner and outer ends of the curved elastic conductor 31 is balanced, the pressure between the male terminal 1 and the female terminal 2 is more uniform, the current carrying capacity is further enhanced, the heat dissipation efficiency is improved, and more heat generated by high current is conducted and dissipated.

[0102] In some embodiments please see Figure 5-Figure 7 , the positioning and assembly jig 4 also includes a positioning ring 6 arranged at its insertion end;

[0103] In step S31 , the elastic base sleeve 32 is positioned by the positioning ring 6 and is sleeved on the position of the positioning assembly fixture 4 , and is retained in the elastic base sleeve 32 .

[0104] The present application can facilitate propping up the elastic base sleeve 32 by means of the positioning ring 6 mounted on the positioning assembly jig 4. The positioning ring 6 can also be used to further perform assembly positioning when the elastic base sleeve 32 is mounted in the positioning assembly jig 4, and the position of the elastic base sleeve 32 mounted on the positioning assembly jig 4 can be further calibrated to improve the yield rate.

[0105] In the present application, by leaving the positioning ring 6 in the elastic base sleeve 32, when the male terminal 1 and the female terminal 2 are plugged in, the positioning ring 6 can provide positioning for the insertion of the male terminal 1, so that the pressure between the various positions of the elastic base sleeve 32 wrapped around the outside of the male terminal 1 is the same, the elastic pressure of each contact point of the curved elastic conductor 31 on the elastic base sleeve 32 is basically the same, the contact resistance is almost the same, the power and current distribution are almost the same, and the error of the shape of the male terminal 1 and the female terminal 2 is less affected, the evenly distributed power and current are small, so the reliability is better and more stable under high-power and high-current working conditions for a long time and in harsh working environments.

[0106] See also Figure 5-Figure 10The present invention also provides a method for manufacturing a connector, which can be used for conductive connection between a male terminal 1 and a female terminal 2. The connector 3 includes an elastic base sleeve 32 arranged between the male terminal 1 and the female terminal 2, and a plurality of curved elastic conductors 31 are glued onto the elastic base sleeve 32. When the male terminal 1 and the female terminal 2 are plugged in, the conductive connection is achieved by compressing the curved elastic conductors 31.

[0107] The present application glues a plurality of curved elastic conductors 31 on an elastic base sleeve 32. When the male terminal 1 and the female terminal 2 are plugged in, the conductive connection is achieved by compressing the curved elastic conductors 31. Since the elastic base sleeve 32 is flexible, it can change along with the shapes of the male terminal 1 and the female terminal 2. The elasticity of the elastic base sleeve 32 can fully wrap around the male terminal 1. Through the plurality of curved elastic conductors 31 glued on the elastic base sleeve 32, the elastic pressure of each curved elastic conductor 31 in the elastic base sleeve 32 is basically the same, the contact resistance is almost the same, the power and current distribution are almost the same, and the error of the shape of the male terminal 1 and the female terminal 2 is less affected. As many flexible and reliable elastic point connections as possible can be provided between the male terminal 1 and the female terminal 2. Therefore, the equivalent total contact resistance can be reduced as much as possible, the power distribution is uniform, the heat dissipation efficiency is improved, and the heat generated by the high current is more conducted and dissipated. The reliability is better under high current working conditions and harsh working environments.

[0108] In some embodiments please see Figure 8 A detachable positioning block 34 is installed inside one end of the elastic base sleeve 32.

[0109] In the present application, a detachable positioning block 34 is installed inside one end of the elastic base sleeve 32. The detachable positioning block 34 can replace the positioning ring 6 on the positioning assembly fixture 4. The positioning block 34 changes according to the shape change of the male terminal 1 and the female terminal 2. When the shape of the male terminal 1 and the female terminal 2 is a polygon, the internal shape of the positioning block 34 is also changed into a polygon. Through the mutual cooperation between the positioning block 34 and the positioning assembly fixture 4, a positioning gap can be formed between the inner wall of the elastic base sleeve 32, which is convenient for installing the curved elastic conductor 31. The positioning block 34 can facilitate the installation of the elastic base sleeve 32 on the male terminal 1. When the elastic base sleeve 32 shakes on the male terminal 1, the elastic base sleeve 32 can be re-evenly wrapped on the male terminal 1 by replacing the detachable positioning block 34, thereby saving costs.

[0110] In some embodiments please see Figure 8 A positioning block 34 is integrally formed inside one end of the elastic base sleeve 32. The positioning block 34 integrally formed with the elastic base sleeve 32 can be more stable when installed on the male terminal 1, with a smaller gap. The positioning block 34 increases the connection area of ​​the end of the elastic base sleeve 32. After multiple plug-ins, the end of the elastic base sleeve 32 is not easily damaged, thereby extending the service life.

[0111] In some embodiments please see Fig. 9 and Fig.10 The curved elastic conductor 31 includes a cylindrical middle section 312 and flat heads 311 arranged at both ends of the middle section 312. The cylindrical curved elastic conductor 31 in the middle section 312 can generate greater elasticity. During multiple plug-ins, the middle of the curved elastic conductor 31 is not easily deformed. It can still have good elasticity after multiple plug-ins, and the connection between the male terminal 1 and the female terminal 2 is more stable. The flat heads 311 arranged at both ends of the middle section 312 can increase the contact area between the curved elastic conductor 31 and the male terminal 1 and the female terminal 2, which can further reduce the equivalent total contact resistance, evenly distribute power, improve heat dissipation efficiency, conduct more heat generated by high current, and have better reliability under strong current working conditions and harsh working environments.

[0112] In some embodiments please see Fig. 9 and Fig.10 The diameter of the flat head 311 is larger than the diameter of the middle section 312. After multiple plug-ins, the larger flat head 311 can be more wear-resistant, making the male terminal 1 and the female terminal 2 connected thereto more stable and extending their service life.

[0113] In some embodiments please see Fig. 9 and Fig.10 The curved elastic conductor 31 can be in the shape of an arc-shaped sheet. The curved elastic conductor 31 in the shape of an arc-shaped sheet has better elasticity, is easier to manufacture and assemble, and has a lower manufacturing cost.

[0114] In some embodiments please see Fig. 9 and Fig.10 The cross section of the bent elastic conductor 31 perpendicular to the male terminal 1 is an I-shape with a bent middle portion. The I-shape bent in the middle portion can generate elasticity by itself, and both ends of the I-shaped bent elastic conductor 31 can better contact with the male terminal 1 and the female terminal 2, thereby conducting more heat generated by high current and dissipating more heat, thereby achieving better reliability under high current working conditions and harsh working environments.

[0115] In some embodiments please see Figure 6 and Figure 7 The curved elastic conductors 31 are arranged in an array along the circumference of the axis of the male terminal 1 on the elastic base sleeve 32 at intervals. The curved elastic conductors 31 arranged circumferentially on the elastic base sleeve 32 can increase the conductive contact points between the curved elastic conductors 31 and the male terminal 1 and the female terminal 2, and further make the conductivity and heat dissipation efficiency between the male terminal 1 and the female terminal 2 higher.

[0116] In some embodiments please see Figure 6 and Figure 7 The curved elastic conductor 31 is arranged in a spiral pattern and spaced apart on the elastic base sleeve 32. When the male terminal 1 is plugged in or out, the elastic base sleeve 32 can be rotated while the male terminal 1 is inserted or pulled out, so that the user can pull out the male terminal 1 or insert the female terminal 2 with less effort, and the operation is more convenient.

[0117] In some embodiments please see Figure 5 and Figure 6 The shape of the elastic base sleeve 32 corresponds to the shape of the gap between the male terminal 1 and the female terminal 2. The shape of the elastic base sleeve 32 corresponds to the shape of the gap between the male terminal 1 and the female terminal 2, which can reduce the deformation of the elastic base sleeve 32, so that the elastic base sleeve 32 fits the male terminal 1 and the female terminal 2 more closely, and the elastic base sleeve 32 can seal the gap more tightly, further reducing the entry of dust, making the male terminal 1 and the female terminal 2 more stable during operation, and extending the service life.

[0118] In some embodiments please see Fig.11 The middle section 312 of the curved elastic conductor 31 can be made into a spiral shape by a wire winding machine. The spiral middle section 312 can produce more lasting elasticity. After multiple plugging and unplugging of the male terminal 1 and the female terminal 2, the spiral middle section 312 can still maintain good elasticity, so that the two ends of the curved elastic conductor 31 are still in contact with the male terminal 1 and the female terminal 2, thereby being more stable under long-term operation, having a longer service life, and having better reliability under strong current working conditions and harsh working environments.

[0119] In some embodiments please see Fig.11 The flat head 311 of the curved elastic conductor 31 can be formed into a flat end with a dome by a pressing machine. The flat head 311 with a dome can reduce the wear between the male terminal 1 and the female terminal 2. After multiple plugging and unplugging, the flat head 311 with a dome can still be in close contact with the male terminal 1 and the female terminal 2. At the same time, the dome has a guiding function, which makes it easier and more convenient for operators to plug and unplug the male terminal 1 and the female terminal 2. It is more stable under long-term operation, has a longer service life, and has better reliability under strong current working conditions and harsh working environments.

[0120] In some embodiments please see Fig.11, when the spirally rolled middle section 312 and the curved elastic conductor 31 with the dome flat head 311 are installed into the assembly through hole 33 of the elastic base sleeve 32, similarly, the elastic base sleeve 32 is first mounted on the positioning assembly fixture 4, and then the curved elastic conductor 31 with the dome flat head 311 is passed through the assembly through hole 33, so that the spirally rolled middle section 312 is restored to a state without elastic compression, and the dome flat head 311 contacts the outer wall of the positioning assembly fixture 4, and then an adhesive of the same material as the base material of the elastic base sleeve 32 is added to the joint. The adhesive has a slow flowability and fills The gap between the spirally rolled middle section 312 and the elastic base sleeve 32 is filled, and then the manufactured connector 3 is removed from the positioning and assembly jig 4 after the adhesive is cured. The spirally rolled middle section 312 can increase the connection area with the elastic base sleeve 32, so that the bent elastic conductor 31 can be more firmly glued to the elastic base sleeve 32. After multiple plugging and unplugging, the bent elastic conductor 31 will not shake, thereby extending the service life and being suitable for more severe use environments. The direct conductive connection between the male terminal 1 and the female terminal 2 is more stable, more adaptable, and has a more diverse use environment.

[0121] It can be understood that the above embodiments only express the preferred implementation modes of the present invention, and the description thereof is relatively specific and detailed, but it cannot be understood as limiting the patent scope of the present invention. It should be pointed out that, for ordinary technicians in this field, without departing from the concept of the present invention, the above technical features can be freely combined, and several deformations and improvements can be made, which all belong to the protection scope of the present invention. Therefore, all equivalent changes and modifications made to the scope of the claims of the present invention should belong to the scope covered by the claims of the present invention.

Claims

1. A method for manufacturing a connector, characterized in that: The steps include: S1: manufacturing a plurality of curved elastic conductors (31); S2: manufacturing an elastic base sleeve (32); and providing a plurality of assembly through holes (33) on the elastic base sleeve (32); S3: a plurality of the curved elastic conductors (31) are fixedly arranged correspondingly on the assembly through holes (33) to form the plug connector (3).

2. The method for manufacturing the connector according to claim 1, characterized in that: The step S1 comprises: S11: making the metal substrate into a metal wire; the diameter of the metal wire is equivalent to the diameter of the assembly through hole (33); S12: cutting the metal wire into a plurality of metal wire segments of equal length; S13: rolling the two ends of each of the metal wire segments into a flat head (311); the diameter of the flat head (311) is larger than the diameter of the assembly through hole (33); S14: bending the middle portion of each of the metal wire segments to obtain the curved elastic conductor (31).

3. The method for manufacturing the connector according to claim 2, characterized in that: The step S1 further comprises: S15: performing a gold plating process on the surface of the curved elastic conductor (31) obtained in step S14; Wherein, the step S13 and the step S14 are performed sequentially or synchronously.

4. The method for manufacturing the connector according to claim 1, characterized in that: The step S2 comprises: S21: heating and melting the base material of the elastic base sleeve (32), and injecting it into the mold; S22: After the base material of the elastic base sleeve (32) is solidified in the mold, the elastic base sleeve (32) blank is taken out from the mold; S23: removing the burrs of the elastic base sleeve (32) blank and cleaning it to obtain the elastic base sleeve (32).

5. The method for manufacturing the connector according to claim 4, characterized in that: The step S2 further comprises: S24: fixing the elastic base sleeve (32) on a fixture; S25: punching a plurality of through holes in the middle of the elastic base sleeve (32) to form the assembly through hole (33); or, The mold is a top-bottom split mold structure and is provided with a plurality of smooth ejector pins; in the step S21, when the base material of the elastic base sleeve (32) is injected into the mold, a plurality of assembly through holes (33) are formed at the positions of the smooth ejector pins.

6. The method for manufacturing the connector according to claim 1, characterized in that: The step S3 comprises: S31: putting the elastic base sleeve (32) onto the positioning and assembly jig (4); S32: assembling the curved elastic conductor (31) into the corresponding assembly through hole (33) of the elastic base sleeve (32); S33: adding an adhesive made of the same material as the base material of the elastic base sleeve (32) to the joint between each of the curved elastic conductors (31) and the assembly through hole (33) of the elastic base sleeve (32); S34: After the adhesive is cured, the elastic base sleeve (32) is removed from the positioning and assembly jig (4) to obtain the connector (3).

7. The method for manufacturing a plug connector according to claim 6, characterized in that: The positioning assembly jig (4) is provided with an assembly step (5), and in the step S31, when the elastic base sleeve (32) is sleeved on the periphery of the positioning assembly jig (4), a positioning gap is formed between the outer wall of the positioning assembly jig (4) and the inner wall of the elastic base sleeve (32); In the step S32, the curved elastic conductor (31) is inserted into the assembly through hole (33) until the end surface of the insertion end of the curved elastic conductor (31) abuts against the outer wall of the positioning assembly fixture (4).

8. The method for manufacturing a plug connector according to claim 6 or 7, characterized in that: The positioning and assembly jig (4) further comprises a positioning ring (6) arranged at its insertion end; In the step S31, the elastic base sleeve (32) is positioned by the positioning ring (6) so as to be sleeved on the position of the positioning and assembly fixture (4) and retained in the elastic base sleeve (32).

9. A connector manufactured according to the method for manufacturing a connector according to any one of claims 1 to 7, which can be used for conductive connection between a male terminal (1) and a female terminal (2), characterized in that: The plug connector (3) comprises an elastic base sleeve (32) arranged between a male terminal (1) and a female terminal (2), wherein a plurality of curved elastic conductors (31) are arranged on the elastic base sleeve (32), and when the male terminal (1) and the female terminal (2) are plugged in, the curved elastic conductors (31) are compressed to achieve conductive connection.

10. The connector manufactured by the method for manufacturing a connector according to claim 7, characterized in that: A detachable positioning block (34) is installed inside one end of the elastic base sleeve (32); or a positioning block (34) is integrally formed inside one end of the elastic base sleeve (32); The curved elastic conductor (31) comprises a cylindrical middle section (312) and flat heads (311) arranged at both ends of the middle section (312); the diameter of the flat head (311) is greater than the diameter of the middle section (312).

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