Automobile connector terminal and manufacturing process thereof

Abstract

The application discloses a kind of automobile connector terminal and manufacturing process thereof, it is related to automobile terminal production technical field, including terminal main body, the middle part of terminal main body is equipped with terminal injection face, the top surface and bottom surface of terminal injection face are all set with first etching groove, the front and back of terminal injection face are all set with second etching groove, the outer wall of terminal injection face of terminal main body is fixedly connected with injection block, the inner wall of injection block and the first etching groove of terminal injection face corresponding position are all set with injection large face, the application is processed by hardware, increase the close combination between hardware and injection, under the condition of microcosmic, increase the bonding area of terminal and plastic, and form the tortuous of wave crest and wave trough, increase the rough of airway, under the power working environment of new energy automobile, automobile connector can satisfy closed requirement.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile terminal production, and in particular to an automobile connector terminal and a manufacturing process thereof. Background Art

[0002] Connectors bridge blocked or isolated circuits within a circuit, facilitating the flow of current and enabling the circuit to function as intended. Connector forms and structures vary widely, with various types of connectors being used depending on the application, frequency, power, and environment. The rise of new energy vehicles in recent years has led to an increasing number of specialized connector requirements.

[0003] Conventional automotive connectors typically use a smooth surface for direct injection molding. In the power operating environment of new energy vehicles, automotive connectors cannot meet the sealing requirements, affecting the electrical connection stability of new energy vehicles. Therefore, the present invention provides an automotive connector terminal and its manufacturing process. Summary of the Invention

[0004] In view of the above existing problems, the present invention is proposed.

[0005] In order to achieve the above object, the present invention provides the following technical solutions:

[0006] An automotive connector terminal includes a terminal body, a terminal injection molding surface is provided in the middle of the terminal body, a first etching groove is provided on the top and bottom surfaces of the terminal injection molding surface, a second etching groove is provided on the front and back surfaces of the terminal injection molding surface, an injection molding block is fixedly connected to the outer wall of the terminal injection molding surface of the terminal body, a large injection molding surface is provided at the inner wall of the injection molding block corresponding to the first etching groove of the terminal injection molding surface, and a small injection molding surface is provided at the position of the injection molding block corresponding to the second etching groove.

[0007] A manufacturing process for automobile connector terminals includes the following:

[0008] S1. First, select a metal strip that meets the terminal production standards, electrolytically clean it at a current density of 3-5A / dm² and a temperature of 40-60°C, and then transport it to the stamping equipment. When the metal strip is fed into a mold that meets the terminal body, stamping is performed to stamp out a primary terminal with a terminal bending shape;

[0009] S2. After the stamping, the primary terminals need to be sheared. After shearing, burrs need to be removed. After the burrs are removed, the terminals need to be drilled to form connection holes for car connection. After drilling, the terminals need to be cleaned, degreased, and then dried to ensure that they have a neat appearance without burrs and oil stains.

[0010] S3, film coating operation is performed on the primary terminal surface which has been processed, after the film coating operation, the area which needs to be injection molded is specially treated, that is, in the film coating area, one-time spray film coating is performed, that is, rough film coating, to ensure that the primary terminal injection molding area has a film coating area of 40-60%, when the spray film coating is performed, the non-injection molding area is also coated, the film coating of the non-coating area is full coverage, after the film coating is completed, etching operation is performed at this time;

[0011] S4, when the etching operation is performed, first of all, ensure that the etching liquid sprays the etching liquid on the rough film coating area of the primary terminal, etches the non-coating area of the injection molding area, uses continuous spraying method, controls the spraying time of each surface to be the same to ensure that the etching process is the same;

[0012] S5, after the etching is completed, film removal operation is performed, after the film removal is completed, the etched terminal is obtained, and then injection molding operation is performed at this time;

[0013] S6, when the injection molding is performed, first of all, the pressure and injection speed of the injection molding machine are determined, the etched terminal is placed into the injection mold, the injection molding machine is started to inject plastic material into the mold, the injection speed is controlled to be slow to prevent the etched structure of the terminal surface from being damaged due to fast injection speed, and the flowability of the plastic material in the injection molding machine is controlled to be improved, after the improvement, the injection molding is performed to ensure that the injection molding material can flow into the first etching groove and the second etching groove of the etched terminal surface, after the injection molding is completed, solidification treatment is performed;

[0014] S7, after the solidification treatment is completed, deburring operation is performed to remove the burrs on the surface of the injection molding block, and the finished product of the terminal body is obtained.

[0015] Further, the metal strip is made of copper alloy.

[0016] Further, the etching liquid is FeCl3 solution, and the mass concentration of the solution is 20%-28%.

[0017] Further, the film coating is epoxy resin-based ink, and the film removal operation uses DMAC for soaking treatment.

[0018] Further, when the injection molding operation is performed, the initial injection speed is as low as 30-50% of the rated value, after the etching groove is blocked, the speed is increased to the rated value for injection molding, and the injection molding material is appropriately heated to improve the flowability of the injection molding material.

[0019] In the above technical solution, the technical effects and advantages provided by the present application are as follows:

[0020] 1、The application increases the close combination between hardware and injection molding through the processing of hardware, increases the bonding area of the terminal and plastic under the microcosmic condition, forms the tortuousness of the wave crest and trough, increases the unevenness of the air channel, and enables the automobile connector to still meet the closed requirement under the power working environment of the new energy automobile.

[0021] 2、The application can greatly control the injection molding to the etching groove during the injection molding, can prevent the melt jetting line, air inclusion and etching structure destruction, and can also improve the process length under the rated speed, ensure the thin wall area, fully fill, and reduce the shrinkage hole.

[0022] 3、The application can avoid the sharp burr by using the etching structure, and reduce the risk of the high voltage breakdown terminal of the new energy automobile.

[0023] 4、The application realizes the comprehensive goal of high performance, low cost and high reliability of the connector terminal by the material selection, etching microstructure design, stage injection control and environmental protection process chain integration, and is especially suitable for the harsh scene of the new energy automobile high voltage connector. BRIEF DESCRIPTION OF DRAWINGS

[0024] In order to more clearly illustrate the technical scheme in the embodiments of the present application or the prior art, the drawings needed to be used in the embodiments will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments described in the present application, and other drawings can also be obtained by those skilled in the art according to these drawings.

[0025] Figure 1 It is the overall structure schematic diagram of the present application;

[0026] Figure 2 It is the overall structure exploded schematic diagram of the present application;

[0027] Figure 3 It is the injection block cross section structure schematic diagram of the present application;

[0028] Figure 4 It is the traditional terminal metal part structure schematic diagram of the present application;

[0029] Figure 5 It is the traditional terminal overall structure schematic diagram of the present application;

[0030] Figure 6 It is the etching groove structure schematic diagram of the present application;

[0031] Figure 7 It is the etching groove injection schematic diagram of the present application.

[0032] Explanation of reference signs:

[0033] 1, terminal body; 101, terminal injection surface; 1011, first etching groove; 102, second etching groove; 2, injection block; 201, injection large surface; 202, injection small surface. DETAILED DESCRIPTION

[0034] In order to make the technical personnel in the art better understand the technical solutions of the present application, the present application will be further described in detail below in conjunction with the drawings.

[0035] The embodiment of the application discloses a kind of automobile connector terminal and manufacturing process thereof.

[0036] The application provides a kind of automobile connector terminal as shown in Figures 1-7 The automobile connector terminal includes a terminal body 1, the middle part of the terminal body 1 is provided with a terminal injection surface 101, the top surface and the bottom surface of the terminal injection surface 101 are both provided with a first etching groove 1011, the front surface and the back surface of the terminal injection surface 101 are both provided with a second etching groove 102, the outer wall of the terminal injection surface 101 of the terminal body 1 is fixedly connected with an injection block 2, the inner wall of the injection block 2 and the corresponding position of the first etching groove 1011 of the terminal injection surface 101 are both provided with an injection large surface 201, and the injection block 2 and the second etching groove 102 are both provided with an injection small surface 202 at the corresponding position.

[0037] An automobile connector terminal and manufacturing process thereof include the following contents:

[0038] S1, first select the metal strip that meets the terminal manufacturing standard, electrolytic cleaning is carried out under the condition of current density 3-5A / dm² and temperature 40-60℃, and then it is conveyed to the stamping equipment, according to the metal strip is sent into the mold that meets the terminal body 1, stamping is carried out, so that the metal strip is stamped into a primary terminal with terminal bending shape;

[0039] S2, after the primary terminal after stamping, the terminal needs to be sheared, after shearing, burr removal is needed, after burr removal, the terminal needs to be drilled, and a connecting hole for automobile connection is drilled, after drilling, the terminal needs to be cleaned, and oil treatment is completed, then drying is carried out, to ensure that its appearance is neat, burr-free and oil-free;

[0040] S3, film coating operation is performed on the primary terminal surface that has been processed, after the film coating operation, the area that needs to be injection molded is specially treated, that is, in the film coating area, one-time spray film coating is performed, that is, rough film coating, to ensure that the primary terminal injection molding area has a film coating area of 40-60%, and at the same time of the spray film coating, the non-injection molding area is also coated, the film coating of the non-injection molding area is full coverage, after the film coating is completed, etching operation is performed, the epoxy resin-based ink film coating is divided into non-injection molding area full coverage + injection molding area partial coverage, accurately protecting the non-etching area, ensuring that etching only acts on the target area, and improving the consistency of the bonding surface;

[0041] S4, when performing etching operation, first ensure that the etching liquid sprays etching liquid on the rough film coating area of the primary terminal, etches the non-film coating area of the injection molding area, and uses continuous spraying method, controls the spraying time of each surface to be the same to ensure that the etching process is the same, and the etching structure avoids sharp burrs and reduces the risk of high voltage breakdown;

[0042] S5, after the etching is completed, film removal operation is performed, after the film removal is completed, the etched terminal is obtained, and then injection molding operation is performed;

[0043] S6, when performing injection molding, first determine the pressure and injection speed of the injection molding machine, place the etched terminal into the injection mold, start the injection molding machine to inject plastic material into the mold, control the injection speed to prevent the terminal surface etching structure from being damaged due to fast injection speed, and control the flowability of the plastic material in the injection molding machine to be improved, after the improvement, injection molding is performed to ensure that the injection molding material can flow into the first etching groove 1011 and the second etching groove 102 of the etched terminal surface, after the injection molding is completed, solidification treatment is performed to form a wave-shaped fold, increase the roughness of the airway, and make the automobile connector still meet the sealing requirement in the power working environment of the new energy automobile, the injection molding block 2 formed after the injection molding naturally produces the injection molding large surface 201 and the injection molding small surface 202 corresponding to the first etching groove 1011 and the second etching groove 102;

[0044] S7, after the solidification treatment is completed, deburring operation is performed to remove the burrs on the surface of the injection molding block 2, and the finished product of the terminal main body 1 is obtained.

[0045] Further, the metal strip is made of copper alloy.

[0046] Further, the etching liquid is FeCl3 solution, and the mass concentration of the solution is 20%-28%.

[0047] Further, the film adopts an epoxy resin-based ink, and the film removing operation adopts DMAC for soaking treatment. Through the treatment of the hardware, the area of the bonding surface of the hardware and the plastic is increased, the air passage distance is prolonged and becomes more complex, and the bonding force of the plastic and the hardware is enhanced, so that good bonding is achieved, and the requirement of gas sealing is met.

[0048] Further, during the injection molding operation, the initial injection speed is as low as 30-50% of the rated value, and after the etching groove is blocked, the speed is increased to the rated value for injection molding. According to the injection molding material, appropriate heating is performed to improve the flowability of the injection molding material. Through the high flowability of the plastic by heating, two-stage injection speed is adopted to fully fill the etching groove, and the risk of air bubbles and material shortage is reduced.

[0049] Experiment 1:

[0050] Control group 1: adopt the traditional hardware terminal injection molding mode;

[0051] Control group 2: adopt the two-stage injection molding traditional hardware terminal in the application;

[0052] Experimental group 1: adopt the etching wave crest and wave trough in the application, but not adopt two-stage injection molding;

[0053] Experimental group 2: adopt the etching wave crest and wave trough in the application, and adopt two-stage injection molding;

[0054] The data is tested at a test pressure of 250KPa, according to a holding time of 30 seconds, a test time of 10 seconds, a monitoring leakage amount, a determination of air tightness strength, a fusion strength, a thermal shock environment of-40℃~85℃, and a fusion strength retention rate after 200 cycles of testing are compared:

[0055] Category Leakage (Pa) Weld strength (MPa) Strength retention rate (%) Control group 1 80 30 85 Control group 2 76 32 86 Experimental group 1 40 44 95 Experimental group 2 28 50 98

[0056] As can be seen from the above, compared with the etching microstructure design, stage injection control and environmental protection process chain integration in the traditional hardware terminal, the application realizes the comprehensive goal of high performance, low cost and high reliability of the connector terminal, and is especially suitable for harsh scenes such as new energy vehicle high-voltage connectors.

[0057] Experiment 2:

[0058] The primary terminal surface that has been treated is subjected to a film coating operation. After the film coating operation, the area that needs to be injection molded is subjected to special treatment. In the film coating area, a one-time spray film coating, i.e., a rough film coating, is performed to ensure that the primary terminal injection molding area has a film coating area in the range of 40-60%. When performing the spray film coating, the non-injection molding area is also subjected to film coating. The film coating used for the non-injection molding area is full coverage. After the film coating is completed, etching is performed. The epoxy resin-based ink film coating is divided into full coverage in the non-injection molding area and partial coverage in the injection molding area. The purpose of the spray coating is to create a rough film coating area with some areas that are not coated, which facilitates subsequent etching of the uncoated areas. The purpose of protecting the film coating area from etching is to precisely protect the non-etching area and ensure that etching only occurs in the target area, thereby improving the consistency of the bonding surface.

[0059] The following experiments were conducted:

[0060] Control group 1: The surface of the traditional hardware terminal is not treated and serves as the control group.

[0061] Control group 2: The primary terminal injection molding area has a film coating in the range of 40%.

[0062] Experimental group 1: The primary terminal injection molding area has a film coating in the range of 50%.

[0063] Experimental group 2: The primary terminal injection molding area has a film coating in the range of 60%.

[0064] The test pressure is 250 KPa. The holding time is 30 seconds, and the test time is 10 seconds. The leakage is monitored to determine the gas tightness strength, the fusion strength, and the fusion strength retention rate after 200 cycles of thermal shock environment -40°C to 85°C.

[0065] Category Leakage (Pa) Weld strength (MPa) Strength retention rate (%) Control group 1 80 30 85 Control group 2 36 45 92 Experimental group 1 28 50 98 Experimental group 2 24 46 91

[0066] The above results show that a film coating in the range of 50% leads to the highest fusion strength. This is because the injection molding block 2 and the first etching groove 1011 and the second etching groove 102 form a similar proportion of wave peaks and troughs, increasing the roughness of the airway and the fusion strength and gas tightness strength between the injection molding block 2 and the first etching groove 1011 and the second etching groove 102, greatly improving the gas tightness of the new energy vehicle in use.

[0067] The foregoing merely illustrates some exemplary embodiments of the application, and it will be appreciated that those skilled in the art will be able to devise various modifications without departing from the spirit and scope of the application. The appended drawings and description are illustrative only, and are not intended to be limiting.

Claims

1. A manufacturing process for automobile connector terminals, characterized in that: The following steps are included: S1. First, a metal strip is selected and electrolytically cleaned at a current density of 3-5A / dm² and a temperature of 40-60°C. The metal strip is then fed into a die of a stamping machine for stamping, so that a primary terminal having a bent terminal shape is stamped out of the metal strip. S2. Shearing the stamped primary terminal; after shearing, deburring; after deburring, drilling the primary terminal to form a connection hole for vehicle connection; after drilling, cleaning, degreasing, and drying the primary terminal; S3. Laminating the treated surface of the primary terminal. In the injection molding area, perform a spray lamination, i.e., rough lamination, to ensure that 40%-60% of the injection molding area of ​​the primary terminal is covered with film. At the same time, spray lamination is also performed on the non-injection molding area. The non-injection molding area is fully covered with film. S4. After the lamination is completed, an etching operation is performed. The rough lamination area of ​​the primary terminal is sprayed with an etching solution for etching. The unlaminated area in the injection molding area is sprayed using a continuous spraying method. The spraying time on each side of the primary terminal is controlled to be the same to ensure the same etching process. S5. After etching is completed, a film stripping operation is performed to obtain an etched terminal, and then an injection molding operation is performed; S6. During injection molding, first determine the pressure and injection speed of the injection molding machine, place the etched terminal in the injection mold, start the injection molding machine to inject the plastic material into the mold, control the injection speed to prevent the injection speed from being too fast and damaging the etched structure on the surface of the etched terminal, and simultaneously control and improve the fluidity of the plastic material in the injection molding machine to ensure that the plastic material can flow into the first etched groove and the second etched groove on the surface of the etched terminal. After the injection molding is completed, perform a curing process; S7. After taking out the injection molded part, perform a deburring operation to obtain a finished automotive connector terminal.

2. The manufacturing process of the automobile connector terminal according to claim 1, characterized in that: The metal strip is made of copper alloy.

3. The manufacturing process of the automobile connector terminal according to claim 1, characterized in that: The etching solution used is FeCl3 solution, and the mass concentration of the solution is 20%-28%.

4. The manufacturing process of the automobile connector terminal according to claim 1, characterized in that: The lamination operation uses epoxy resin-based ink, and the delamination operation uses DMAC.

5. The manufacturing process of the automobile connector terminal according to claim 1, characterized in that: During the injection molding operation, the initial injection speed is 30%-50% of the rated value. After the first etching groove and the second etching groove are blocked, the speed is increased to the rated value for injection molding. At the same time, the temperature is increased according to the plastic material to improve the fluidity of the plastic material.

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