Terminal structure of high-speed connector and preparation process thereof

Abstract

The invention discloses a terminal structure of a high-speed connector and a preparation process thereof, and the preparation process comprises the following steps: selecting a conductive core material, carrying out wire drawing treatment to obtain a uniform conductive wire, and carrying out surface treatment on the conductive wire through an electroplating process to form a metal coating; combining in a twisting or parallel winding manner to obtain a conductive wire core, and uniformly wrapping the conductive wire core with a composite material to form an inner insulating layer; then feeding the terminal into a mold, rolling the terminal into an initial structure of the U-shaped terminal by adjusting the mold and the pressure, and forming self-locking structures on two sides of the terminal; micro-structure textures are formed on the surface of the steel plate through laser engraving, and then an anti-corrosion coating is sprayed on the outer layer through a micro-spraying technology; the U-shaped terminal is uniformly wrapped with an elastic protection layer material through an extrusion injection molding process to form a protective sheath layer, and the U-shaped crimping terminal is manufactured; by optimizing the electrical connection performance, durability and adaptability, the connector is suitable for various high-requirement application scenes.

Description

Technical Field

[0001] The present invention relates to the field of connection terminals, and particularly to a terminal structure of a high-speed connector and its manufacturing process. Background Art

[0002] With the rapid development of modern industry and technology, electrical connectors play a crucial role in various devices and systems. As a commonly used connection component, connector terminals are widely used in power transmission, communication equipment, automotive electronics, aerospace and other fields. Especially in the environment of high-current transmission and frequent vibration, reliable and stable electrical connection is of vital importance. These application scenarios require that the connector can not only withstand high-current loads, but also possess the properties of high temperature resistance, corrosion resistance and mechanical vibration resistance to ensure the safety and reliability of the system.

[0003] Currently, the manufacturing of traditional connector terminals mainly adopts processes such as stamping, bending or casting. Although these processes are mature, there are some deficiencies in applications with high-performance requirements. First of all, the contact area of the terminals manufactured by such processes is limited, which cannot meet the requirements of high-current transmission, easily leads to an increase in contact resistance and generates overheating. Secondly, in the environment of frequent vibration, the mechanical strength and self-locking performance of traditional terminals are insufficient, and there may be a risk of loosening or falling off. In addition, the materials of traditional terminals usually have poor high-temperature resistance and corrosion resistance, and it is difficult to operate reliably for a long time in a harsh environment. These disadvantages limit the performance of the terminals in high-demand applications and cannot fully meet the high reliability and high-performance requirements of modern industry for connection devices.

[0004] In view of this, it is necessary to improve the manufacturing process of connector terminals in the prior art to solve the problem that it cannot meet the high-performance and stability requirements in complex environments. Summary of the Invention

[0005] The purpose of the present invention is to provide a terminal structure of a high-speed connector and its manufacturing process to solve the above technical problems.

[0006] To achieve this purpose, the present invention adopts the following technical solutions: A manufacturing process of a terminal structure of a high-speed connector, comprising: Step S1, select copper wire or aluminum wire suitable for high-current transmission as the conductive core material, and use wire drawing equipment to perform wire drawing treatment on the conductive core material to obtain uniform conductive wire, and perform surface treatment on the conductive wire through electroplating process to form a metal coating; Step S2, combine the treated conductive wires by means of stranding or parallel winding to obtain a conductive wire core, and uniformly wrap a composite material of polyimide or fluoroplastic on the outside of the conductive wire core through an extrusion process to form an inner insulating layer; Step S3: Feed the wire core wrapped with the inner insulating layer into the mold using a rolling machine, and roll it into the preliminary structure of a U-shaped terminal by adjusting the mold and pressure, and form a self-locking structure on both sides of the terminal. Step S4: On the surface of the U-shaped terminal after rolling and forming, form microstructural textures by laser engraving, and then spray a corrosion-resistant coating on the outer layer using microspray technology. Step S5: Provide an elastic protective layer material, and evenly wrap the elastic protective layer material around the U-shaped terminal through an extrusion and injection process to form a protective sheath layer, and then cure the elastic protective layer by heat treatment or UV curing to obtain a U-shaped crimp terminal.

[0007] Optionally, step S1 specifically includes: Step S11: Select the conductive core material: According to the high-current transmission requirements, select a material suitable for good electrical conductivity as the conductive core material, and select copper wire or aluminum wire. Step S12: Clean the raw material: Perform surface cleaning on the selected conductive core material to remove impurities such as surface oxide layers and oil stains, and then perform a drying process. Step S13: Wire drawing process: Use wire drawing equipment to perform wire drawing on the cleaned conductive core material to achieve the required diameter of the conductive wire. During the wire drawing process, the wire drawing machine gradually reduces the size of the wire drawing die hole. Step S14: Surface plating: Perform surface treatment on the conductive wire using an electroplating process to form a uniform metal coating; among them, the thickness range of the metal coating is set within 310 μm, the electroplating current density is set between 0.53 A / dm 2 and the plating solution temperature is maintained within the range of 50-70 °C.

[0008] Optionally, after step S14, it further includes: Step S15: Heat treatment: The electroplated conductive wire needs to be heat-treated, the heat treatment temperature is set between 150 °C and 200 °C, and the heat treatment time is 15-30 minutes. Step S16: Cooling and surface inspection: After the heat treatment is completed, cool the conductive wire to room temperature, and the cooled conductive wire needs to be surface-inspected, including the uniformity of the coating thickness, conductivity test, and surface defect inspection.

[0009] Optionally, step S2 specifically includes: Step S21: According to the design requirements, select stranding or parallel winding as the combination method of the wire core, and set the number of strands and stranding density corresponding to the stranding method, and the number of winding wires and winding angle corresponding to the parallel winding method. Step S22, if the stranding method is selected, a stranding machine is used to combine multiple conductive wires with a preset number of stranding lines and stranding density; If the parallel winding method is selected, a winding machine is used to arrange the conductive wires in accordance with the set winding method, which is set to a 90° angle winding method; Step S23, after the combination of the conductive wire cores is completed, stretching treatment is carried out to improve the uniformity of its overall structure and electrical performance.

[0010] Optionally, after the step S23, the following steps are further included: Step S24, according to the performance requirements of the conductive wire core, a suitable composite material is selected, specifically composed of a mixture or a single material of polyimide and fluoroplastics; Step S25, the composite material is heated and melted by an extruder and evenly wrapped outside the conductive wire core. The screw speed of the extruder is set to 20~50 rpm, the temperature is controlled between 180°C and 250°C, and the thickness of the inner insulating layer is controlled between 0.05mm and 0.2mm; Step S26, the extruded conductive wire core and its inner insulating layer are subjected to a curing treatment, and then a surface smoothing treatment is carried out. The curing process adopts thermal curing, the thermal curing temperature is 180°C to 220°C, and the curing time is 30 to 60 minutes; Optionally, the step S3 specifically includes: Step S31, a rolling machine and a special mold are selected. The special mold is designed to form the shape of a U-shaped terminal and is equipped with an adjustable pressure regulating device and a forming component; Step S32, the conductive wire core wrapped with the inner insulating layer is led out from the pay-off reel, passed through the guiding device, and fed into the inlet of the rolling machine. The guiding device is provided with a tension control system, and the tension control range is 5N to 15N; Step S33, start the rolling machine, the rolling speed is set to 10 to 20 meters per minute. Under the action of the rolling machine, the conductive wire core is gradually bent and rolled into a preliminary structure of a U-shaped terminal through the forming component of the special mold; Step S34, on both sides of the terminal, a self-locking structure is formed through the self-locking structure forming component in the mold. The self-locking structure is specifically an inner buckling groove and an outer convex buckle formed on both sides of the U-shaped terminal respectively. The size of the inner buckling groove is designed to be a width of 0.5mm to 1mm and a depth of 0.3mm to 0.7mm; the size of the outer convex buckle is a width of 0.4mm to 0.9mm and a height of 0.2mm to 0.6mm; Optionally, the step S4 specifically includes: Step S41, cleaning the surface of the U-shaped terminal after roll forming, setting the parameters of the laser engraving equipment according to the microstructure texture design to be formed, setting the laser power to 5W to 15W, the pulse frequency to 50kHz to 200kHz, the scanning speed to 100mm / s to 500mm / s, and positioning the focus position on the terminal surface; Step S42, fixing the dried U-shaped terminal on the working platform of the laser engraving equipment, aligning the terminal using the positioning system, starting the laser engraving equipment, and laser engraving the terminal surface according to a preset texture pattern to form a microstructure texture; Step S43, after the laser engraving is completed, the terminal surface is cleaned again to remove particles and residues generated during the engraving process; Step S44, preparation of anti-corrosion coating material: selecting an anti-corrosion coating material such as a fluorocarbon coating, an epoxy resin coating or a polyurethane coating, adding a conductive filler to the coating, wherein the conductive filler is graphene, carbon nanotubes or metal nanoparticles, and mixing the coating material and the conductive filler according to the formula requirements, and adjusting the viscosity to 10-50 mPa·s; Step S45, fixing the cleaned and dried U-shaped terminal on the workbench of the micro-spraying equipment, starting the spraying program, and micro-spraying the terminal surface according to the set parameters, and controlling the coating thickness to be between 5 μm and 15 μm; Step S46, after the spraying is completed, the terminal is subjected to a coating heat curing treatment, the curing temperature is set to 80° C. to 150° C., and the curing time is 30 minutes to 2 hours.

[0011] Optionally, the step S5 specifically includes: Step S51, selecting a suitable elastic protective layer material according to the use environment and performance requirements of the U-shaped terminal, the elastic protective layer material being silicone rubber, thermoplastic elastomer or polyurethane material; Step S52, selecting a twin-screw extruder, setting the parameters of the extruder, arranging the U-shaped terminals on a conveyor belt, and feeding the U-shaped terminals into the extruder one by one through a positioning device; Step S53, start the extruder, extrude the molten elastic protective layer material through the die head, and evenly wrap it around the outside of the U-shaped terminal. The extrusion speed is controlled at 5 mm / s to 20 mm / s, and the thickness of the protective layer is generally controlled at 0.5 mm to 2 mm. Step S54, after extrusion and wrapping, the U-shaped terminal together with the elastic protective layer enters the cooling system, and the cooling method can be water cooling, air cooling or cooling plate cooling, the cooling temperature is generally maintained between 10°C and 25°C, and the cooling time is 1 to 3 minutes; Step S55: Curing the cooled and shaped elastic protective layer, and then performing surface treatment on the surface of the cured elastic protective layer; Step S56: Terminal performance test: Perform performance tests on the manufactured U-shaped crimp terminals to verify whether they meet the design requirements; The performance tests include mechanical strength, insulation resistance, withstand voltage performance, and environmental resistance.

[0012] The present invention also provides a terminal structure for a high-speed connector, which is manufactured by using the preparation process of the terminal structure of the high-speed connector as described above. The U-shaped crimp terminal includes: A conductive core component, including a wire core with a metal coating and an inner insulating layer, for providing electrical performance; A mechanical connection structure, including a U-shaped terminal body and self-locking structures on both sides, for providing mechanical and electrical connections; A functional surface layer, including microstructural textures formed by laser engraving and an anti-corrosion coating, for improving coating adhesion and anti-corrosion ability; An elastic protective layer, for providing outer protection, insulation, and protection functions.

[0013] Compared with the prior art, the present invention has the following beneficial effects: First, copper wires or aluminum wires suitable for high-current transmission are selected and drawn, and at the same time, the conductive performance is improved through electroplating surface treatment. In step S2, the conductive core wires are combined by stranding or parallel winding, and a high-performance composite material is wrapped around the wire core through an extrusion process to form an inner insulating layer; The wire core wrapped with the inner insulating layer is rolled into a preliminary structure of a U-shaped terminal by a rolling machine and a mold, and self-locking structures are formed on both sides of the terminal to ensure firm fixation of the terminal during the crimping process. Microstructural textures are formed by laser engraving, and an anti-corrosion layer is coated by microspraying technology to improve the electrical connection stability and environmental adaptability of the terminal. Then, the elastic protective layer material is wrapped through an injection molding process, and the protective layer is cured by heat treatment or UV curing to ensure that the terminal has good durability and seismic resistance; This solution optimizes the electrical connection performance, durability, and adaptability, and is suitable for various high-requirement application scenarios. Description of the Drawings

[0014] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the following drawings are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0015] The structures, proportions, sizes, etc. depicted in the drawings of this specification are only used to cooperate with the content disclosed in the specification for those familiar with this technology to understand and read, and are not used to limit the conditions for the implementation of the present invention. Therefore, they do not have substantial technical significance. Any modification of the structure, change in the proportional relationship, or adjustment of the size, without affecting the efficacy that the present invention can produce and the purpose that can be achieved, should still fall within the scope that can be covered by the technical content disclosed in the present invention.

[0016] Figure 1 It is one of the process schematic diagrams of the preparation process of the terminal structure of the high-speed connector in the first embodiment; Figure 2 It is the second of the process schematic diagrams of the preparation process of the terminal structure of the high-speed connector in the first embodiment. Detailed implementation manners

[0017] In order to make the invention objectives, features, and advantages of the present invention more obvious and understandable, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the embodiments described below are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without making creative efforts belong to the scope of protection of the present invention.

[0018] In the description of the present invention, it should be understood that the orientation or positional relationships indicated by the terms "upper", "lower", "top", "bottom", "inner", "outer", etc. are based on the orientation or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be construed as a limitation of the present invention. It should be noted that when a component is considered to be "connected" to another component, it may be directly connected to the other component or there may be intermediate components present simultaneously.

[0019] The technical solutions of the present invention will be further described below in conjunction with the drawings and through specific implementation manners.

[0020] First embodiment: Combined with Figures 1 to 2 As shown, the embodiments of the present invention provide a preparation process for the terminal structure of a high-speed connector, including: Step S1, select copper wire or aluminum wire suitable for high-current transmission as the conductive core material, and use wire drawing equipment to perform wire drawing on the conductive core material to obtain uniform conductive wires, and perform surface treatment on the conductive wires through electroplating process to form a metal coating.

[0021] Step S2: Combine the processed conductive wires by stranding or parallel winding to obtain a conductive wire core, and evenly wrap a composite material of polyimide or fluoroplastic around the conductive wire core through an extrusion process to form an inner insulating layer.

[0022] Step S3: Use a rolling machine to feed the conductive wire core wrapped with the inner insulating layer into a mold, and roll it into a preliminary structure of a U-shaped terminal by adjusting the mold and pressure, and form a self-locking structure on both sides of the terminal; enable the terminal to be firmly locked during the crimping process.

[0023] Step S4: On the surface of the U-shaped terminal after rolling and forming, form microstructural textures by laser engraving, and then spray a corrosion-resistant coating on the outer layer using a micro-spraying technique; the microstructural textures are used to increase the contact area and improve the stability of electrical connection, and at the same time apply a high-temperature resistant and corrosion-resistant coating to enhance the environmental adaptability of the terminal; Step S5: Provide an elastic protective layer material, evenly wrap the elastic protective layer material around the U-shaped terminal through an extrusion and injection molding process to form a protective sheath layer, and then cure the elastic protective layer by heat treatment or UV curing to obtain a U-shaped crimping terminal. Ensure that the terminal provides good shock resistance and abrasion resistance under high-frequency vibration and external force.

[0024] The working principle of the present invention is as follows: First, select copper wires or aluminum wires suitable for high-current transmission and perform wire drawing treatment, and at the same time improve the electrical conductivity through electroplating surface treatment. In step S2, the conductive core wires are combined by stranding or parallel winding, and a high-performance composite material is wrapped around the conductive wire core through an extrusion process to form an inner insulating layer; the conductive wire core wrapped with the inner insulating layer is rolled into a preliminary structure of a U-shaped terminal by a rolling machine and a mold, and a self-locking structure is formed on both sides of the terminal to ensure that the terminal is firmly fixed during the crimping process. Microstructural textures are formed by laser engraving, and a corrosion-resistant layer is coated using a micro-spraying technique to improve the electrical connection stability and environmental adaptability of the terminal. Then, an elastic protective layer material is wrapped through an injection molding process, and the protective layer is cured by heat treatment or UV curing to ensure that the terminal has good durability and earthquake resistance; this solution optimizes the electrical connection performance, durability and adaptability, and is applicable to a variety of high-demand application scenarios.

[0025] In this embodiment, specifically, step S1 specifically includes: Step S11, Select the conductive core material: According to the high-current transmission requirements, select a material suitable for good electrical conductivity as the conductive core material, such as copper wire or aluminum wire. Copper wire has a lower resistivity and higher electrical conductivity, so it is usually used in applications that require higher current transmission. Aluminum wire can also be used as the conductive core material in some specific situations due to its light weight and cost-effectiveness. Select the appropriate material according to the specific application scenario (such as high-frequency, high-current transmission, etc.) to ensure that the terminal working requirements are met.

[0026] Step S12, Clean the raw materials: Conduct surface cleaning treatment on the selected conductive core material to remove impurities such as surface oxide layers and oil stains, and then perform drying treatment. This step can use methods such as chemical cleaning, ultrasonic cleaning, or plasma cleaning. After cleaning, perform drying treatment to ensure that there is no residual liquid and contaminants on the surface, and prepare to enter the next processing step.

[0027] Step S13, Wire drawing treatment: Use wire drawing equipment to perform wire drawing treatment on the cleaned conductive core material to achieve the required diameter of the conductive wire. During the wire drawing process, the wire drawing machine gradually reduces the size of the wire drawing die hole, making the material gradually thinner while maintaining a certain strength and toughness. The process parameters of wire drawing include drawing rate, drawing temperature, and the size of the wire drawing die. The common range of drawing temperature is 20°C to 80°C, and the specific temperature is adjusted according to the material characteristics. The drawing rate is generally set to several meters to more than ten meters per minute to ensure that the metal wire does not break or have other defects during the wire drawing process.

[0028] Step S14, Surface plating: Use electroplating technology to perform surface treatment on the conductive wire to form a uniform metal coating. Among them, the thickness range of the metal coating is set within 310μm, and the electroplating current density is set between 0.53 A / dm 2 The plating solution temperature is maintained within the range of 50 - 70°C.

[0029] The plating metal is usually selected as silver plating, tin plating, or gold plating. The specific material selection is based on factors such as electrical conductivity requirements, environmental adaptability, and cost. Through the electroplating process, the thickness of the coating can be precisely controlled. Usually, the coating thickness range is 310μm to ensure excellent electrical conductivity and antioxidant ability. The control of the current density, temperature, and time of the coating is crucial. Usually, the electroplating current density is set between 0.53 A / dm 2 The plating solution temperature is maintained within the range of 50 - 70°C to ensure uniform coating deposition.

[0030] Step S15, Heat treatment: The conductive wire after electroplating needs to be heat-treated. The heat treatment temperature is set between 150°C and 200°C, and the heat treatment time is 15 - 30 minutes. To improve the adhesion and conductivity of the coating, the heat treatment temperature is usually set between 150°C and 200°C, and the time is appropriately adjusted according to the metal type of the coating and the requirements of the wire, generally 15 - 30 minutes. Heat treatment can eliminate the internal stress that may be generated during the electroplating process, and further enhance the adhesion and durability of the metal layer.

[0031] Step S16, Cooling and Surface Inspection: After the heat treatment is completed, cool the conductive wire to room temperature, and the cooled conductive wire needs to be subjected to surface inspection, including coating thickness uniformity, conductivity test, and surface defect inspection.

[0032] The cooling process can adopt natural cooling or air cooling methods to ensure that the surface of the conductive wire is not damaged. The cooled conductive wire needs to be subjected to surface inspection, including coating thickness uniformity, conductivity test, and surface defect inspection, to ensure that the coating is complete and free of defects such as cracks and bubbles.

[0033] Stretching and Annealing Treatment (Optional): If it is necessary to further improve the mechanical and electrical properties of the conductive wire, the cooled conductive wire can be subjected to stretching or annealing treatment. The annealing temperature is generally 200°C to 300°C, and the annealing time is 30 to 60 minutes. This step can effectively improve the conductivity and ductility of the wire, and make the coating more uniform and flat.

[0034] In this embodiment, specifically, step S2 specifically includes: Step S21, According to the design requirements, select stranding or parallel winding as the combination method of the conductive wire core, and set the number of strands and stranding density corresponding to the stranding method, and the number of winding wires and winding angle corresponding to the parallel winding method; Select the combination method of the conductive wire core: Select a suitable combination method of the conductive wire core, preferably combine the processed conductive wires into a conductive wire core by stranding or parallel winding. The stranding process is suitable for improving the flexibility and tensile strength of the wire core, and is suitable for occasions that require high toughness and durability; the parallel winding process is suitable for improving the current-carrying capacity and signal stability of the conductive wire core, and is suitable for applications with high current transmission. Adjust the number of strands or windings, stranding density, and winding angle according to actual needs.

[0035] Step S22, If the stranding method is selected, use a stranding machine to combine multiple conductive wires with a preset number of strands and stranding density; The stranding method ensures that the combined conductive wire core has a uniform structure and excellent mechanical strength. The stranding density is usually controlled between 30 and 40 strands per meter, and the specific density is adjusted according to actual needs.

[0036] If the parallel winding method is selected, use a winding machine to arrange the conductive wires according to the set winding method, and set it as a 90° angle winding method; Ensuring the parallel arrangement of the wire cores can provide more stable current transmission and signal stability.

[0037] Step S23, after the combination of the conductive wire cores is completed, improve the uniformity and electrical performance of its overall structure through stretching. During the stretching process, precisely control the stretching rate (usually several meters per minute) and stretching temperature (common range is 20°C to 80°C) to ensure that the conductive wire cores do not break or have non-uniform structures. After stretching, the conductive wire cores need to be inspected for appearance and electrical performance, including diameter uniformity, mechanical strength, conductivity, etc., to ensure meeting the design requirements.

[0038] Step S24, select a suitable composite material according to the performance requirements of the conductive wire cores, specifically composed of a mixture of polyimide and fluoroplastics or a single material; Preparation of the inner insulation layer composite material: Select a suitable high-performance material (such as polyimide, fluoroplastics, etc.) as the composite material for the inner insulation layer according to the performance requirements of the conductive wire cores. According to actual needs, the composite material can be composed of a mixture of polyimide and fluoroplastics or a single material. Polyimide has excellent high-temperature resistance, while fluoroplastics have good corrosion resistance and electrical insulation properties. The selected composite material needs to meet the requirements of temperature resistance, voltage resistance, and environmental adaptability, and the common material specific gravity range is 1.3~1.6 g / cm³.

[0039] Step S25, heat and melt the composite material through an extruder and evenly wrap it outside the conductive wire cores. The screw speed of the extruder is set to 20~50 rpm, the temperature is controlled between 180°C and 250°C, and the thickness of the inner insulation layer is controlled between 0.05mm and 0.2mm; Extrusion process of the composite material: Heat and melt the composite material through an extruder and evenly wrap it outside the conductive wire cores. The screw speed of the extruder is usually set to 20~50 rpm, and the temperature is controlled between 180°C and 250°C to ensure the fluidity and uniform coverage of the composite material. During the extrusion process, precisely control the material flow rate to ensure the uniform thickness of the inner insulation layer. The thickness of the inner insulation layer is generally controlled between 0.05mm and 0.2mm, and the specific thickness is adjusted according to the usage requirements of the conductive wire cores and the conditions of the external environment.

[0040] Step S26, the extruded conductive wire cores and their inner insulation layers are subjected to a curing process, and then surface smoothing treatment is carried out. The curing process uses thermal curing, the thermal curing temperature is 180°C to 220°C, and the curing time is 30~60 minutes; Inner Insulation Layer Curing and Cooling: The extruded conductor core and its inner insulation layer are cured to improve the stability and durability of the insulation layer. The curing process usually adopts thermal curing or ultraviolet (UV) curing. The thermal curing temperature is usually 180°C to 220°C, and the curing time is 30 - 60 minutes. After curing, the conductor core and its inner insulation layer are gradually cooled to room temperature through a cooling system to ensure the sealing performance and anti-current leakage ability of the inner insulation layer.

[0041] Meanwhile, to ensure that the final conductor core has a good appearance and touch, the cured inner insulation layer needs to be surface-smooth treated. The surface of the insulation layer can be polished smooth through mechanical polishing, sanding or chemical polishing processes to eliminate any surface unevenness or roughness. The smooth surface can reduce the contact resistance, improve the conductivity, and make the inner insulation layer not easily worn or damaged during subsequent processing and use.

[0042] In this embodiment, specifically, step S3 specifically includes: Step S31, select a winding machine and a special mold. The special mold is designed to form the shape of a U-shaped terminal and is equipped with an adjustable pressure regulating device and a forming component; Prepare the winding equipment and the mold: Select a precision winding machine and a special mold. The mold is designed to form the shape of a U-shaped terminal and is equipped with an adjustable pressure regulating device and a forming component. The mold material is preferably high-strength alloy steel, which has good wear resistance and high-temperature resistance. Check the working status of the winding machine and the mold to ensure the normal operation of the equipment.

[0043] Step S32, lead out the conductor core wrapped with the inner insulation layer from the pay-off reel, pass it through the guiding device, and send it into the inlet of the winding machine. The guiding device is equipped with a tension control system, and the tension control range is 5N to 15N; Conductor Core Conveying and Positioning: Lead out the conductor core wrapped with the inner insulation layer from the pay-off reel, pass it through the guiding device, and smoothly send it into the inlet of the winding machine. The guiding device is equipped with a tension control system, and the tension control range is 5N to 15N to ensure the stability of the conductor core during the conveying process. The position of the conductor core is monitored in real time through an optoelectronic sensor to ensure its accurate entry into the designated position of the mold.

[0044] Among them, the setting and adjustment of the mold parameters: According to the diameter of the conductor core and the thickness of the inner insulation layer, set the opening size and winding angle of the mold. The opening size of the mold should be slightly larger than the diameter of the conductor core plus twice the thickness of the inner insulation layer to ensure that the conductor core can pass through smoothly. The winding angle is generally set to 180° to form a standard U-shaped structure. Adjust the pressure regulating device to control the winding pressure between 50MPa and 80MPa, and the specific pressure depends on the material properties and forming requirements.

[0045] Step S33: Start the coiling machine and set the coiling speed to 10 to 20 meters per minute. Under the action of the coiling machine, the conductive wire core is gradually bent and coiled into the preliminary structure of the U-shaped terminal through the forming part of the special mold. Coiling and forming process: Start the coiling machine and set the coiling speed to 10 to 20 meters per minute. Under the action of the coiling machine, the conductive wire core is gradually bent and coiled into the preliminary structure of the U-shaped terminal through the forming part of the mold. During the coiling process, ensure the stability of the coiling speed, pressure, and temperature. The temperature is generally controlled between room temperature and 50°C to avoid damage to the inner insulating layer due to overheating.

[0046] Step S34: On both sides of the terminal, form a self-locking structure through the self-locking structure forming part inside the mold. The self-locking structure specifically forms an inner buckling groove and an outer convex buckle on both sides of the U-shaped terminal respectively. The size of the inner buckling groove is designed with a width of 0.5 mm to 1 mm and a depth of 0.3 mm to 0.7 mm; the size of the outer convex buckle is a width of 0.4 mm to 0.9 mm and a height of 0.2 mm to 0.6 mm. Through precise machining of the mold, the groove and the buckle are formed synchronously during the coiling process, and the self-locking structure can achieve reliable mechanical locking during crimping.

[0047] After coiling and forming, the U-shaped terminal undergoes a sizing and shape correction process. Use an on-line measuring device to detect the key dimensions of the terminal, including the U-shaped radius, opening width, position and size of the self-locking structure, etc. If any deviation is found, adjust the parameters of the coiling machine and the mold in real time to ensure that the dimensional accuracy of the terminal is controlled within ±0.02 mm.

[0048] In this embodiment, specifically, step S4 specifically includes: Step S41: Clean the surface of the coiled and formed U-shaped terminal. According to the designed microstructure texture to be formed, set the parameters of the laser engraving equipment. Set the laser power to 5 W to 15 W, the pulse frequency to 50 kHz to 200 kHz, the scanning speed to 100 mm / s to 500 mm / s, and position the focus on the terminal surface. Surface cleaning treatment: Remove the residual oil, oxides, and fine particles during the processing. The cleaning method can adopt ultrasonic cleaning, plasma cleaning, or chemical cleaning, and the cleaning medium is a neutral cleaning agent or deionized water. Control the cleaning temperature at 25°C to 35°C and the cleaning time at 5 to 15 minutes. After cleaning, use a hot air dryer or a vacuum drying device to completely dry the terminal surface to ensure that there is no moisture and impurity residue, and prepare for the subsequent laser engraving.

[0049] Laser engraving parameter setting: According to the depth and precision requirements of the texture, adjust the number of repetitions and energy density of the laser to ensure that the size and shape of the microstructure texture meet the design requirements.

[0050] Step S42, fixing the dried U-shaped terminal on the working platform of the laser engraving equipment, aligning the terminal using the positioning system, starting the laser engraving equipment, and laser engraving the terminal surface according to a preset texture pattern to form a microstructure texture; The texture of the microstructure texture can be in the form of stripes, grids, grooves or other geometric patterns, the depth of the texture is controlled between 1μm and 10μm, and the texture spacing is 5μm to 20μm. The formation of the microstructure texture increases the surface area of ​​the terminal, which helps to improve the adhesion of the coating and the anti-oxidation performance of the terminal.

[0051] Step S43, after the laser engraving is completed, the terminal surface is cleaned again to remove particles and residues generated during the engraving process; Cleaning after engraving ensures that there is no residue in the microstructure texture, ensuring the uniformity and adhesion of the coating. After cleaning, drying is carried out in preparation for the coating process.

[0052] Step S44, preparation of anti-corrosion coating material: selecting an anti-corrosion coating material such as a fluorocarbon coating, an epoxy resin coating or a polyurethane coating, adding a conductive filler to the coating, wherein the conductive filler is graphene, carbon nanotubes or metal nanoparticles, and mixing the coating material and the conductive filler according to the formula requirements, and adjusting the viscosity to 10-50 mPa·s; The coating material should have excellent corrosion resistance, wear resistance and good electrical properties. If necessary, conductive fillers such as graphene, carbon nanotubes or metal nanoparticles can be added to the coating to improve the conductivity and oxidation resistance of the terminal. The coating material is formulated according to the formula requirements and the viscosity is adjusted to 10~50 mPa·s to ensure that it is suitable for the micro-spraying process.

[0053] Micro-spraying parameter setting: Use micro-spraying equipment to set the spraying process parameters. Select an appropriate nozzle diameter (generally 50μm to 150μm), set the spraying pressure to 0.05 MPa to 0.3 MPa, the spraying distance to 10 mm to 30 mm, and keep the spraying angle perpendicular to the terminal surface. Adjust the spraying speed to 50 mm / s to 200 mm / s to ensure that the coating evenly covers the terminal surface. Control the temperature of the spraying environment to 20℃ to 25℃ and the humidity to 40% to 60% to avoid defects in the coating caused by environmental influences.

[0054] Step S45: Fix the cleaned and dried U-shaped terminals on the workbench of the microspraying equipment, start the spraying program, and perform microspray coating on the terminal surface according to the set parameters, with the coating thickness controlled between 5 μm and 15 μm. Implement the microspraying process: During the spraying process, the stability and uniformity of the nozzle should be maintained to avoid uneven coating thickness or sagging. The coating thickness is controlled between 5 μm and 15 μm and adjusted according to the anti-corrosion performance requirements. To achieve better coating effects, multiple spraying methods can be used, and short-term flash drying is performed after each spraying.

[0055] Step S46: After spraying, perform thermal curing treatment on the terminals. The curing temperature is set between 80 °C and 150 °C, and the curing time is 30 minutes to 2 hours. During the curing process, it should be ensured that the terminals are evenly heated or illuminated to avoid cracking or peeling of the coating due to uneven heating.

[0056] After curing, perform appropriate surface treatment on the coating surface to improve the density and smoothness of the coating. Plasma treatment or polishing processes can be used to remove surface microdefects, enhance the physical properties and aesthetics of the coating. After treatment, perform final cleaning and drying on the terminals to ensure that there are no impurities and contaminants on the surface.

[0057] In this embodiment, specifically, step S5 specifically includes: Step S51: Select a suitable elastic protective layer material according to the usage environment and performance requirements of the U-shaped terminals. The elastic protective layer material is silicone rubber, thermoplastic elastomer, or polyurethane material. Perform pretreatment on the selected material, including processes such as drying, mixing, and adding color masterbatch. The drying temperature is generally set between 70 °C and 90 °C, and the drying time is 2 to 4 hours to remove moisture in the material and prevent bubbles or holes from appearing during the extrusion process.

[0058] Step S52: Select a twin-screw extruder, set the parameters of the extruder, arrange the U-shaped terminals on the conveyor belt, and send the U-shaped terminals into the extruder one by one through the positioning device; the parameters include screw speed, temperature range, and pressure. The screw speed is usually set between 20 rpm and 60 rpm, and the temperature range increases sequentially from the feeding section to the head section, generally controlled between 150 °C and 220 °C. The injection pressure is set between 50 MPa and 150 MPa to ensure that the material fully fills the mold and achieves uniform wrapping.

[0059] Step S53: Start the extruder, and the molten elastic protective layer material is extruded through the head and evenly wraps around the outside of the U-shaped terminals. The extrusion speed is controlled between 5 mm / s and 20 mm / s, and the thickness of the protective layer is generally controlled between 0.5 mm and 2 mm. The extrusion and wrapping molding of the elastic protective layer ensures that the material fully covers the surface of the terminal and has a uniform thickness. The mold design should consider the shape and size of the terminal, and a split mold structure is adopted for easy molding and demolding.

[0060] Step S54, after the extrusion and wrapping molding, the U-shaped terminal together with the elastic protective layer enters the cooling system. The cooling method can be water cooling, air cooling or cooling plate cooling. The cooling temperature generally remains between 10°C and 25°C, and the cooling time is 1 to 3 minutes. Cooling and shaping of the protective layer. During the cooling process, it is necessary to ensure that the protective layer material shrinks evenly to prevent internal stress and deformation, and to ensure the dimensional stability and surface smoothness of the protective layer.

[0061] Step S55, the elastic protective layer after cooling and shaping is subjected to a curing treatment, and then the surface of the cured elastic protective layer is subjected to a surface treatment. Curing treatment of the protective layer: to improve its mechanical properties and environmental resistance. According to the characteristics of the materials used, heat treatment or ultraviolet (UV) curing methods are selected. For materials that require heat curing, such as silicone rubber, the curing temperature is set at 150°C to 200°C, and the curing time is 30 minutes to 2 hours; for materials that can be UV cured, such as special polyurethane, a UV light source with a wavelength of 320 nm to 400 nm is used, and the irradiation time is 5 to 15 minutes. During the curing process, ensure uniform temperature or light to prevent the protective layer from aging or performance degradation.

[0062] There may be small burrs or unevenness on the surface of the cured elastic protective layer, which requires surface treatment. Methods such as polishing, deburring or plasma surface treatment can be used. Polishing can use fine sandpaper or a polishing machine to remove surface defects and improve the smoothness. Plasma treatment can improve the adhesion and wear resistance of the protective layer surface, and the treatment time is generally 30 seconds to 2 minutes.

[0063] Step S56, terminal performance testing: The prepared U-shaped crimp terminal is subjected to performance testing to verify whether it meets the design requirements; the performance testing includes mechanical strength, insulation resistance, withstand voltage performance and environmental resistance.

[0064] The mechanical strength test can use a tensile testing machine to detect the tensile strength and bending performance of the terminal. The insulation resistance test requires a resistance value of more than 10^12 Ω, the withstand voltage test voltage is set at 1 kV to 5 kV, and the duration is 1 minute without breakdown. The environmental resistance test includes high and low temperature cycling, salt spray corrosion and damp heat tests to ensure that the terminal maintains stable performance in harsh environments.

[0065] Example Two: The present invention also provides a terminal structure for a high-speed connector, which is obtained by using the preparation process of the terminal structure of the high-speed connector in the first embodiment. The U-shaped crimp terminal includes: A conductive core component, including a wire core with a metal coating and an inner insulating layer, which is used to achieve electrical performance.

[0066] A mechanical connection structure, including a U-shaped terminal body and self-locking structures on both sides, which is used to provide mechanical and electrical connections.

[0067] A functional surface layer, including laser-engraved microstructural textures and an anti-corrosion coating, which is used to improve the coating adhesion and anti-corrosion ability.

[0068] An elastic protective layer, which is used to provide outer protection, insulation, and protection functions.

[0069] As mentioned above, the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that: they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements on some of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A process for preparing a terminal structure of a high-speed connector, characterized in that: include: Step S1, selecting copper wire or aluminum wire suitable for high current transmission as a conductive core material, and using a wire drawing device to draw the conductive core material to obtain a uniform conductive wire, and performing surface treatment on the conductive wire through an electroplating process to form a metal coating; Step S2, combining the treated conductive wires by twisting or parallel winding to obtain a conductive wire core, and uniformly wrapping the composite material of polyimide or fluoroplastic on the outside of the conductive wire core by an extrusion process to form an inner insulating layer; Step S3, using a rolling machine to feed the conductive wire core wrapped with the inner insulating layer into a mold, and by adjusting the mold and pressure, rolling it into a preliminary structure of a U-shaped terminal, and forming a self-locking structure on both sides of the terminal; Step S4, forming a microstructure texture on the surface of the U-shaped terminal after rolling by laser engraving, and then spraying a layer of anti-corrosion coating on the outer layer by micro-spraying technology; Step S5, providing an elastic protective layer material, and uniformly wrapping the elastic protective layer material on the outside of the U-shaped terminal through an extrusion injection molding process to form a protective sheath layer, and then curing the elastic protective layer through heat treatment or UV curing to obtain a U-shaped crimping terminal.

2. The process for preparing the terminal structure of the high-speed connector according to claim 1, characterized in that: The step S1 specifically includes: Step S11, selecting a conductive core material: according to the high current transmission requirement, selecting a material with good conductive properties as the conductive core material, such as copper wire or aluminum wire; Step S12, raw material cleaning: cleaning the surface of the selected conductive core material to remove the surface oxide layer and oil impurities, and then drying it; Step S13, wire drawing: using a wire drawing device to perform wire drawing on the cleaned conductive core material to achieve a desired conductive wire diameter. During the wire drawing process, the wire drawing machine gradually reduces the size of the wire drawing die hole; Step S14, surface coating: the conductive wire is surface treated by electroplating process to form a uniform metal coating; wherein the thickness range of the metal coating is set within 310 μm, and the electroplating current density is set at 0.53 A / dm 2 The plating solution temperature is maintained in the range of 50~70℃.

3. The process for preparing the terminal structure of the high-speed connector according to claim 2, characterized in that: After step S14, the following steps are also included: Step S15, heat treatment: the conductive wire after electroplating needs to be heat treated, the heat treatment temperature is set between 150° C. and 200° C., and the heat treatment time is 15 to 30 minutes; Step S16, cooling and surface inspection: After the heat treatment is completed, the conductive wire is cooled to room temperature, and the cooled conductive wire needs to be subjected to surface inspection, including coating thickness uniformity, conductivity test and surface defect inspection.

4. The process for preparing the terminal structure of the high-speed connector according to claim 1, characterized in that: The step S2 specifically includes: Step S21, according to the design requirements, select twisting or parallel winding as the conductive wire core combination mode, and set the number of twisted wires and twisting density corresponding to the twisting mode, and the number of winding wires and winding angle corresponding to the parallel winding mode; Step S22, if the twisting method is selected, a twisting machine is used to combine the plurality of conductive wires with a preset number of twisted wires and twisting density; If the parallel winding method is selected, the conductive wire is arranged according to the set winding method using a winding machine, and the winding method is set to a 90° angle; Step S23, after the conductive cores are assembled, a stretching process is performed to improve the uniformity of the overall structure and the electrical performance.

5. The process for preparing the terminal structure of the high-speed connector according to claim 4, characterized in that: After step S23, the following steps are also included: Step S24, selecting a suitable composite material according to the performance requirements of the conductive core, specifically a mixture of polyimide and fluoroplastic or a single material; Step S25, heating and melting the composite material through an extruder, and evenly wrapping it around the outside of the conductive core, the screw speed of the extruder is set to 20-50 rpm, the temperature is controlled between 180° C. and 250° C., and the thickness of the inner insulating layer is controlled between 0.05 mm and 0.2 mm; Step S26, the extruded conductive core and its inner insulating layer are cured and then surface-smoothed. The curing process uses thermal curing at a temperature of 180° C. to 220° C. for 30 to 60 minutes.

6. The process for preparing the terminal structure of the high-speed connector according to claim 1, characterized in that: The step S3 specifically includes: Step S31, selecting a rolling machine and a special mold, wherein the special mold is designed to form a U-shaped terminal and is equipped with an adjustable pressure regulating device and a molding component; Step S32, leading the conductive wire core wrapped with the inner insulation layer from the pay-off frame, passing through the guide device, and feeding it into the wire inlet of the winding machine, wherein the guide device is provided with a tension control system, and the tension control range is 5N to 15N; Step S33, starting the rolling machine, setting the rolling speed to 10 to 20 m / min, the conductive wire core is gradually bent and rolled into a preliminary structure of a U-shaped terminal through a forming component of a special mold under the action of the rolling machine; Step S34, on both sides of the terminal, a self-locking structure is formed by the self-locking structure molding components arranged in the mold. Specifically, the self-locking structure is to form an inner snap-in slot and an outer convex snap-in on both sides of the U-shaped terminal. The size of the inner snap-in slot is designed to be 0.5mm to 1mm in width and 0.3mm to 0.7mm in depth; the size of the outer convex snap-in is 0.4mm to 0.9mm in width and 0.2mm to 0.6mm in height.

7. The process for preparing the terminal structure of the high-speed connector according to claim 1, characterized in that: The step S4 specifically includes: Step S41, cleaning the surface of the U-shaped terminal after roll forming, setting the parameters of the laser engraving equipment according to the microstructure texture design to be formed, setting the laser power to 5W to 15W, the pulse frequency to 50kHz to 200kHz, the scanning speed to 100mm / s to 500mm / s, and positioning the focus position on the terminal surface; Step S42, fixing the dried U-shaped terminal on the working platform of the laser engraving equipment, aligning the terminal using the positioning system, starting the laser engraving equipment, and laser engraving the terminal surface according to a preset texture pattern to form a microstructure texture; Step S43, after the laser engraving is completed, the terminal surface is cleaned again to remove particles and residues generated during the engraving process; Step S44, preparation of anti-corrosion coating material: selecting an anti-corrosion coating material such as a fluorocarbon coating, an epoxy resin coating or a polyurethane coating, adding a conductive filler to the coating, wherein the conductive filler is graphene, carbon nanotubes or metal nanoparticles, and mixing the coating material and the conductive filler according to the formula requirements, and adjusting the viscosity to 10-50 mPa·s; Step S45, fixing the cleaned and dried U-shaped terminal on the workbench of the micro-spraying equipment, starting the spraying program, and micro-spraying the terminal surface according to the set parameters, and controlling the coating thickness to be between 5 μm and 15 μm; Step S46, after spraying is completed, the terminal is subjected to thermal curing treatment of the coating, the curing temperature is set to 80° C. to 150° C., and the curing time is 30 minutes to 2 hours.

8. The process for preparing the terminal structure of the high-speed connector according to claim 1, characterized in that: The step S5 specifically includes: Step S51, selecting a suitable elastic protective layer material according to the use environment and performance requirements of the U-shaped terminal, the elastic protective layer material being silicone rubber, thermoplastic elastomer or polyurethane material; Step S52, selecting a twin-screw extruder, setting the parameters of the extruder, arranging the U-shaped terminals on a conveyor belt, and feeding the U-shaped terminals into the extruder one by one through a positioning device; Step S53, start the extruder, extrude the molten elastic protective layer material through the die head, and evenly wrap it around the outside of the U-shaped terminal. The extrusion speed is controlled at 5 mm / s to 20 mm / s, and the thickness of the protective layer is generally controlled at 0.5 mm to 2 mm. Step S54, after extrusion and wrapping, the U-shaped terminal together with the elastic protective layer enters the cooling system, and the cooling method can be water cooling, air cooling or cooling plate cooling, the cooling temperature is generally maintained between 10°C and 25°C, and the cooling time is 1 to 3 minutes; Step S55, curing the elastic protective layer after cooling and setting, and then performing surface treatment on the surface of the cured elastic protective layer; Step S56, terminal performance test: perform a performance test on the prepared U-shaped crimping terminal to verify whether it meets the design requirements; the performance test includes mechanical strength, insulation resistance, voltage resistance and environmental resistance.

9. A terminal structure of a high-speed connector, characterized in that: The U-shaped crimping terminal is manufactured by adopting the manufacturing process of the terminal structure of the high-speed connector according to any one of claims 1 to 8, wherein the U-shaped crimping terminal comprises: Conductive core components, including a conductive core with a metal coating and an inner insulating layer, are used to perform electrical performance; A mechanical connection structure, including a U-shaped terminal body and self-locking structures on both sides, for providing mechanical and electrical connection; Functional surface layers, including laser-engraved microstructure textures and anti-corrosion coatings, for improved coating adhesion and corrosion resistance; Elastic protective layer used to provide outer protection, insulation and protection functions.

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