Connector terminal fixing structure and method
By using a vertically connected fixed cavity design within the alloy housing and a modular layout of the insulator, the problems of low space utilization and insufficient reliability of traditional automotive connectors are solved, resulting in a highly efficient and reliable connector structure suitable for modern automotive electronic equipment.
Patent Information
- Application Number
- CN202511521817.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-23
- Publication Date
- 2025-12-12
AI Technical Summary
Traditional automotive connectors suffer from low space utilization, large overall size, complex assembly process, and insufficient reliability under vibration and shock environments, making it difficult to meet the high-density integration and miniaturization requirements of modern automotive electronic devices. They also have low production efficiency and insufficient electrical performance and mechanical stability.
The design employs a vertically connected fixed cavity within an alloy housing, combined with a modular, partitioned layout of insulators, plug-in terminals, and wiring terminals. Through plug-in sleeves and sealing structures, it achieves a stable connection and multi-level sealing, simplifying the assembly process and improving reliability.
It optimizes space utilization, improves assembly efficiency and precision, ensures positional stability and mechanical reliability in vibration environments, reduces contact resistance and signal attenuation, and has high environmental adaptability and high-frequency signal transmission capabilities, meeting the high performance and long life requirements of the automotive electronics field.
Smart Images
Figure CN121123676A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of electrical connection technology, and in particular to a connector terminal fixing structure and method. Background Technology
[0002] With the rapid development of automotive electronics technology, especially the widespread adoption of intelligent driving, vehicle networking, and in-vehicle infotainment systems, automotive connectors, as key components for signal and power transmission, face increasingly stringent performance requirements. Traditional automotive connectors, particularly those used for radio frequency signal transmission, often employ direct crimping of coaxial cables or simple single-cavity insulation structures. These structures generally suffer from low space utilization, large overall size, and complex assembly processes, making them ill-suited to the high-density integration and miniaturization trends of modern automotive electronic devices. In the frequently vibrating and impact-prone automotive environment, the terminal fixation reliability of traditional structures is insufficient, easily leading to poor contact and increased resistance due to long-term micro-movements, affecting signal transmission stability and connection lifespan. Furthermore, the assembly process often relies on manual operation and complex alignment, resulting in low production efficiency, difficulty in ensuring consistency, and increased manufacturing costs. In addition, with the continuous increase in data transmission rates and current loads, higher requirements are placed on the electrical performance, electromagnetic shielding, and mechanical strength of connectors.
[0003] Therefore, the industry urgently needs an innovative connector structure design that can achieve more efficient terminal layout and fixation within a limited space, improve the level of assembly automation, and ensure excellent electrical continuity, mechanical stability and anti-interference capabilities under harsh operating conditions, so as to meet the urgent needs of the next generation of intelligent connected vehicles for high-performance and high-reliability connection solutions. Summary of the Invention
[0004] To address the aforementioned issues, this invention provides a connector terminal fixing structure and method with high environmental adaptability, capable of meeting the stringent requirements of the automotive electronics field for high performance, high reliability, and long lifespan of connectors.
[0005] The technical solution adopted in this invention is: a connector terminal fixing structure, including an alloy shell, a first insulator, a second insulator, a plug-in terminal, a wiring terminal, and a connecting wire. The alloy shell is provided with a first fixing cavity and a second fixing cavity, which are perpendicularly connected. One end of the first fixing cavity is provided with a plug-in cavity. The first insulator is provided in the first fixing cavity, with one end extending into the plug-in cavity and the other end extending into the second fixing cavity. The second insulator is provided in the second fixing cavity and has a power receiving cavity. The wiring terminal is provided in the power receiving cavity. The plug-in terminal is provided in the first insulator, with one end extending into the power receiving cavity and connected to the wiring terminal. The connecting wire is connected to one end of the wiring terminal.
[0006] A further improvement to the above scheme is that the alloy shell is provided with a plug-in sleeve and a wiring part, the plug-in sleeve and the wiring part are vertically connected, the plug-in cavity and the first fixing cavity are sequentially arranged in the plug-in sleeve, and the second fixing cavity is arranged in the wiring part; the connecting wire is arranged in the wiring part and connected to the wiring terminal; the wiring terminal is inserted from the bottom of the wiring part into the second fixing cavity of the second insulator.
[0007] A further improvement to the above solution is that the insertion sleeve is provided with a sealing mounting groove outside the insertion cavity, a first sealing ring is installed on the sealing mounting groove, and multiple sealing lips are provided on the outer periphery of the first sealing ring.
[0008] A further improvement to the above scheme is that an electrical connection sleeve is provided on the insertion cavity, and an electrical connection end and an electrical connection plug end are respectively provided at both ends of the electrical connection sleeve. The electrical connection end is provided on the first insulator, and the electrical connection plug end extends to the port of the first fixed cavity.
[0009] A further improvement to the above scheme is that the power connection end is provided with a limiting inner ring, and the first insulator is provided with a backstop step. The limiting inner ring is used to abut against the backstop step to prevent the power connection sleeve from retracting.
[0010] A further improvement to the above solution is that the inner circumference of the electrical connection end is provided with an electrical contact spring, which is used to make contact with the connector to conduct electricity and generate friction.
[0011] A further improvement to the above scheme is that the alloy shell is provided with an assembly groove at the top of the second fixing cavity, one end of the second fixing cavity is connected to the assembly groove, and the second insulator is inserted into the second fixing cavity from the assembly groove.
[0012] A further improvement to the above solution is that a sealing groove is provided on the outer periphery of the second fixing cavity for the assembly groove, a second sealing ring is installed in the sealing groove, and a sealing cover plate is installed on the assembly groove. The sealing cover plate is used to cooperate with the second sealing ring to seal the assembly groove.
[0013] A further improvement to the above scheme is that the second insulator has an assembly plane on the side facing the first fixing cavity, the assembly plane has an assembly slot, one end of the first insulator is inserted into the assembly slot and extends to the electrical connection cavity.
[0014] A further improvement to the above scheme is that the two ends of the plug-in terminal are respectively provided with a mating part and a power receiving part, the mating part extends into the plug-in cavity, and the power receiving part extends into the power receiving cavity and is connected to the wiring terminal.
[0015] A further improvement to the above scheme is that the mating part is provided with a mating hole and a groove, the groove being used to cut the mating hole into two halves to generate tension during mating; the electrical connection part is provided with electrical connection clips, two of which are arranged opposite each other, forming a mating groove between the two electrical connection clips; the terminal is provided with an insertion end, the insertion end being inserted into the mating groove.
[0016] A connector terminal fixing method for a connector terminal fixing structure includes the following steps: Step S1, Pre-assembly of insulator and terminals: Insert the plug terminals into the corresponding channels of the first insulator to form the first sub-assembly; insert the wiring terminals into the contact cavity of the second insulator to form the second sub-assembly; Step S2, Vertical insertion and internal electrical connection: The first sub-assembly is inserted axially into the first fixed cavity from one end of the insertion sleeve of the alloy shell, and continues to be pushed until one end of the first insulator is inserted and fixed in the assembly slot of the second insulator; during this process, the contact part of the insertion terminal is simultaneously inserted into the contact cavity of the second insulator, and the contact clip on it is used to generate an interference fit and elastic clamping with the insertion end of the wiring terminal in the second sub-assembly to realize the internal vertical electrical connection; Step S3, housing sealing and external interface forming: press the first sealing ring into the sealing mounting groove on the outer periphery of the plug sleeve to complete the forming of the sealing structure on the plug side; fix the conductor of the external connection wire to the tail of the terminal block. Step S4, Top Encapsulation and Final Sealing: The assembly consisting of the second insulator and the terminal block, which has completed internal connections, is inserted vertically into the second fixing cavity from the mounting groove on the top of the alloy housing; then, the second sealing ring is placed in the sealing groove, and finally the sealing cover is installed into the mounting groove and tightened to achieve a bidirectional seal on the top opening of the connector.
[0017] A further improvement to the above scheme is that, in step S1, when the plug terminal is inserted into the first insulator, the mating portion on it is pre-constrained; in the final assembly position of step S2, the front end of the mating portion extends into the plug cavity, and the limiting structure at its rear end is limited by the anti-retraction step or internal structure of the first insulator, thereby achieving dual fixation of the plug terminal in the axial and radial directions, preventing it from loosening or retracting when plugging and unplugging the mating connector.
[0018] A further improvement to the above scheme is that, in step S2, the connection between the plug-in terminal and the wiring terminal is achieved through the elastic deformation of the electrical clamp; during the insertion process, the electrical clamp is opened by the insertion end of the wiring terminal, and the continuous rebound force generated by it forms a stable contact pressure, ensuring low impedance and high reliability of the electrical connection. At the same time, this elastic connection also compensates for the manufacturing tolerance of the parts and the effect of thermal expansion and contraction.
[0019] The beneficial effects of this invention are: Compared to existing connector terminal fixing structures, this invention achieves a three-dimensional, modular, and partitioned layout of the plug-in terminals, wiring terminals, and connecting wires by setting up a first and second fixing cavity that are perpendicularly connected inside the alloy housing. This optimizes the internal space utilization efficiency, reduces the overall size and weight of the connector, and perfectly meets the stringent requirements of modern automotive electronic systems for high-density integration and miniaturization. A first insulator penetrates the first fixing cavity and extends to the plug-in cavity and the second fixing cavity. A second insulator is precisely installed in the second fixing cavity and has a pre-set electrical contact cavity. This layered guiding structure greatly simplifies the assembly process, improves assembly accuracy and production efficiency, and ensures the positional stability and mechanical reliability of each component under vibration. The plug-in terminals are fixed to the first insulator and extend to the electrical contact cavity to achieve a stable connection with the wiring terminals. The wiring terminals are located in the electrical contact cavity and reliably connected to external connecting wires. This effectively shortens the current transmission path, reduces contact resistance and signal attenuation, and ensures high current carrying capacity and high-fidelity, low-loss transmission of high-frequency signals. It is particularly suitable for RF signal connection scenarios such as automotive FAKRA. The alloy housing itself provides excellent mechanical strength, vibration resistance, shock resistance, and electromagnetic shielding, effectively resisting external mechanical stress and electromagnetic interference. The insulating assembly provides reliable insulation protection and support for internal conductive components, preventing short-circuit risks and ensuring safe operation. The overall structure has high environmental adaptability, meeting the stringent requirements of the automotive electronics industry for high performance, high reliability, and long lifespan of connectors.
[0020] This invention discloses a connector terminal fixing method for fixing connector terminals. Through a rational process flow design, the complex assembly process is broken down into multiple modular and sequential operation steps, improving the assembly efficiency, consistency, and reliability of connector products. In step S1, the first insulator and the plug terminal, and the second insulator and the wiring terminal are pre-assembled to form two independent sub-components. This pre-assembly method facilitates automated operation, reduces the overall assembly difficulty, and avoids potential damage or improper installation caused by directly operating the tiny terminals within a narrow housing, thus improving the assembly accuracy and yield rate of components. In step S2, the first sub-component is axially inserted and pushed forward, utilizing the pre-set assembly slots on the first and second insulators for precise alignment and mechanical interlocking, achieving a stable connection between the two components. Simultaneously, the contact portion of the plug terminal automatically and accurately inserts into the contact cavity, and uses elastic contact clips to form an interference fit and durable, reliable elastic contact with the wiring terminal. This process completes mechanical fixing and electrical connection in one step, simplifying the process and ensuring low resistance and high stability of the internal electrical connection interface, which is beneficial for high-frequency signal transmission. Steps S3 and S4 complete the multi-layered sealing structure of the connector from the mating side and the top, respectively. The first sealing ring at the mating sleeve effectively prevents moisture and contaminants from entering through the mating interface, while the top, through the cooperation of the second sealing ring and the sealing cover, achieves bidirectional compression sealing of the assembly groove, forming another robust protective barrier. This multi-stage sealing design greatly enhances the connector's sealing performance, weather resistance, and long-term reliability in harsh automotive environments (such as high temperature, high humidity, oil contamination, and vibration). The entire process is clear and the steps are seamlessly connected, ensuring a high degree of consistency in product performance and fully meeting the stringent requirements of the automotive industry for high-quality, high-efficiency, and low-cost manufacturing of components. Attached Figure Description
[0021] Figure 1 This is a three-dimensional schematic diagram of the connector terminal fixing structure of the present invention; Figure 2 for Figure 1 Exploded view of the connector terminal fixing structure; Figure 3 for Figure 1 An exploded view of the connector terminal fixing structure from another perspective; Figure 4 for Figure 1 Front view schematic diagram of the connector terminal fixing structure; Figure 5 for Figure 4 Sectional view of AA; Figure 6 This is a schematic diagram of the connection between the plug-in terminal and the wiring terminal in this invention.
[0022] Explanation of reference numerals in the attached drawings: Alloy housing 1, First fixing cavity 11, Second fixing cavity 12, Insertion cavity 13, Insertion sleeve 14, First sealing ring 141, Sealing outer lip 142, Wiring part 15, Electrical sleeve 16, Electrical connection end 161, Electrical plug-in end 162, Limiting inner ring 163, Electrical contact spring 164, Assembly groove 17, Sealing groove 171, Second sealing ring 172, Sealing cover plate 173, First insulator 2, Anti-retraction step 21, Second insulator 3, Electrical cavity 31, Assembly plane 32, Assembly slot 33, Insertion terminal 4, Plug-in part 41, Plug-in hole 411, Groove 412, Electrical part 42, Electrical clamp 421, Wiring terminal 5, Insertion end 51, Connecting wire 6. Detailed Implementation
[0023] To facilitate understanding of the present invention, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of the invention are shown in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a thorough and complete understanding of the disclosure of the invention.
[0024] It should be noted that when a component is said to be "fixed to" another component, it can be directly on the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component.
[0025] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. Figures 1-6As shown, in one embodiment of the present invention, a connector terminal fixing structure is provided, including an alloy housing 1, a first insulator 2, a second insulator 3, a plug-in terminal 4, a wiring terminal 5, and a connecting wire 6. The alloy housing 1 is provided with a first fixing cavity 11 and a second fixing cavity 12, which are perpendicularly connected. One end of the first fixing cavity 11 is provided with a plug-in cavity 13. The first insulator 2 is provided in the first fixing cavity 11, with one end extending to the plug-in cavity 13 and the other end extending to the second fixing cavity 12. The second insulator 3 is provided in the second fixing cavity 12 and has a power receiving cavity 31. The wiring terminal 5 is provided in the power receiving cavity 31. The plug-in terminal 4 is provided in the first insulator 2, with one end extending to the power receiving cavity 31 and connected to the wiring terminal 5. The connecting wire 6 is connected to one end of the wiring terminal 5. This invention achieves a three-dimensional, modular, and partitioned layout of the plug-in terminal 4, wiring terminal 5, and connecting wire 6 by setting a first fixed cavity 11 and a second fixed cavity 12 that are perpendicularly connected inside the alloy housing 1. This optimizes the internal space utilization efficiency, reduces the overall size and weight of the connector, and perfectly meets the stringent requirements of modern automotive electronic systems for high-density integration and miniaturization. The first insulator 2 penetrates the first fixed cavity 11 and extends to the plug-in cavity 13 and the second fixed cavity 12. The second insulator 3 is precisely installed in the second fixed cavity 12 and has a pre-set electrical connection cavity 31. This layered guiding structure greatly simplifies the assembly process, improves assembly accuracy and production efficiency, and ensures the positional stability and mechanical reliability of each component under vibration. The plug-in terminal 4 is fixed to the first insulator 2 and extends to the electrical connection cavity 31 to achieve a stable connection with the wiring terminal 5. The wiring terminal 5 is located in the electrical connection cavity 31 and reliably connected to the external connecting wire 6. This effectively shortens the current transmission path, reduces contact resistance and signal attenuation, and ensures high current carrying capacity and high-fidelity, low-loss transmission of high-frequency signals. It is particularly suitable for RF signal connection scenarios such as automotive FAKRA. The alloy housing 1 itself provides excellent mechanical strength, vibration resistance, shock resistance, and electromagnetic shielding, effectively resisting external mechanical stress and electromagnetic interference. The insulating assembly provides reliable insulation protection and support for the internal conductive components, preventing short-circuit risks and ensuring safe operation. The overall structure has high environmental adaptability and can meet the stringent requirements of the automotive electronics field for high performance, high reliability, and long lifespan of connectors.
[0026] The alloy housing 1 is provided with a plug-in sleeve 14 and a wiring portion 15. The plug-in sleeve 14 and the wiring portion 15 are vertically connected. The plug-in cavity 13 and the first fixing cavity 11 are sequentially arranged in the plug-in sleeve 14, and the second fixing cavity 12 is arranged in the wiring portion 15. The connecting wire 6 is arranged in the wiring portion 15 and connected to the terminal block 5. The terminal block 5 is inserted from the bottom of the wiring portion 15 into the second fixing cavity 12 of the second insulator 3. In this embodiment, by designing the alloy housing 1 to include a vertically connected plug-in sleeve 14 and a wiring portion 15, and setting the first fixing cavity 11 and the second fixing cavity 12 that are interconnected in both, a clear and reasonable functional partition and spatial layout are formed. This makes the insertion direction of the plug-in terminal 4 and the exit direction of the connecting wire 6 perpendicularly distributed, which greatly optimizes the adaptability and installation convenience of the connector in a small space, effectively avoids excessive bending of the cable, and reduces installation stress. At the same time, the wiring terminal 5 is inserted from the bottom of the wiring portion 15 upwards, which simplifies the wire connection operation and improves assembly efficiency and maintainability. It enhances the overall mechanical strength and electromagnetic interference resistance, and provides a solid structural foundation for the orderly installation, reliable fixation and multi-level sealing of internal components, significantly improving the structural stability and durability of the connector in complex vehicle environments.
[0027] The insertion sleeve 14 is provided with a sealing mounting groove on the outside of the insertion cavity 13. A first sealing ring 141 is installed on the sealing mounting groove, and multiple sealing lips 142 are provided on the outer periphery of the first sealing ring 141. In this embodiment, the design of multiple sealing lips 142 significantly increases the sealing contact area and forms multiple elastic contact barriers with the mating connector housing during the insertion process, effectively improving the tolerance and fault tolerance of the sealing interface, and reliably preventing external moisture, dust and other contaminants from entering the insertion cavity 13. This structure has good adaptability to housing machining tolerances and installation alignment deviations. Even under the condition of structural micro-movement caused by vibration or temperature changes, it can still maintain a stable and lasting sealing pressure, ensuring that the connector maintains a high level of sealing protection for a long time in harsh environments such as humid and dusty environments.
[0028] A power-connecting sleeve 16 is provided on the insertion cavity 13. The two ends of the power-connecting sleeve 16 are respectively provided with a power-connecting connection end 161 and a power-connecting mating end 162. The power-connecting connection end 161 is located on the first insulator 2, and the power-connecting mating end 162 extends to the port of the first fixed cavity 11. In this embodiment, it is ensured that the insertion terminal 4 can be smoothly inserted into the power-connecting sleeve 16 along a predetermined axis during insertion, effectively avoiding poor contact and mechanical damage caused by misalignment or displacement. The power-connecting connection end 161 is fixed to the first insulator 2, enhancing the structural stability of the power-connecting sleeve 16, preventing displacement or deformation during insertion and removal, and ensuring the long-term alignment of the contact interface. Simultaneously, the power-connecting mating end 162 extends to the port to form a guiding structure, reducing the difficulty of insertion operations and improving assembly efficiency and connection reliability. This design optimizes the current transmission path, reduces contact resistance, and improves the overall mechanical durability and electrical performance consistency of the connector through precise positioning and support of key conductive components.
[0029] The electrical connection end 161 is provided with a limiting inner ring 163, and the first insulator 2 is provided with a backstop step 21. The limiting inner ring 163 is used to abut against the backstop step 21 to prevent the electrical sleeve 16 from retracting. Specifically, the inner circumference of the electrical connection mating end 162 is provided with an electrical contact spring 164, which is used to make contact with the connector for conduction and to generate friction. In this embodiment, the axial movement or detachment of the electrical sleeve 16 is effectively prevented during insertion, removal or vibration, ensuring the stability and consistency of the electrical connection interface and avoiding increased contact resistance or instantaneous power failure caused by component displacement. The electrical contact spring 164 protruding from the inner circumference of the electrical connection mating end 162 forms elastic contact with the mating terminal during insertion, which not only provides self-locking force through friction, enhancing the firmness of the mechanical connection, but also increases the effective contact area, reduces contact resistance, and improves current conduction efficiency and resistance to fretting wear. The elastic deformation design of the spring can compensate for tolerance fluctuations and thermal expansion and contraction, maintaining a long-lasting and stable contact pressure, thereby comprehensively improving the electrical reliability and mechanical life of the connector under harsh conditions such as vibration and high temperature.
[0030] An assembly groove 17 is provided at the top of the alloy housing 1, located at the second fixing cavity 12. One end of the second fixing cavity 12 is connected to the assembly groove 17, and the second insulator 3 is inserted into the second fixing cavity 12 from the assembly groove 17. In this embodiment, a clear assembly path and guiding reference are provided, reducing the risk of insulator misalignment, jamming, or displacement during installation and improving production assembly efficiency and consistency. The assembly groove 17 serves as an axial guide structure, ensuring that the second insulator 3 can be smoothly inserted into the second fixing cavity 12 along a preset direction, avoiding component damage or sealing structure destruction caused by forced assembly. It enhances the positioning stability of the second insulator 3 within the cavity, preventing axial displacement or rotation under vibration or impact environments, and ensuring the geometric accuracy and electrical reliability of the internal terminal connections. By optimizing the assembly process, the manufacturing cost and failure rate of complex connectors are significantly reduced, making it particularly suitable for industrial or automotive electrical systems with high density and high reliability requirements.
[0031] A sealing groove 171 is provided on the outer periphery of the second fixed cavity 12, and a second sealing ring 172 is installed in the sealing groove 171. A sealing cover plate 173 is installed in the assembly groove 17, and the sealing cover plate 173 is used to seal the assembly groove 17 in conjunction with the second sealing ring 172. In this embodiment, the second sealing ring 172 is compressed and deformed in the sealing groove 171 to form a continuous and stable annular sealing interface, which effectively prevents external contaminants such as moisture, dust, and oil from entering the interior of the second fixed cavity 12, thereby improving the protection level of the connector in harsh environments such as humid, dusty, or oily conditions. The synergistic effect of the sealing cover plate 173 and the second sealing ring 172 not only enhances the reliability of the axial seal, but also prevents the sealing ring from creeping or shifting during long-term use through structural constraints, maintaining the durability of the seal. No additional complex processes are required during assembly; the sealing cover plate 173 can be press-fitted to achieve a uniform sealing pressure distribution, which improves production efficiency and avoids damage to the sealing ring caused by excessive compression.
[0032] The second insulator 3 has an assembly plane 32 on the side facing the first fixed cavity 11. The assembly plane 32 has an assembly slot 33. One end of the first insulator 2 is inserted into the assembly slot 33 and extends to the contact cavity 31. In this embodiment, a clear axial assembly reference and radial limit are provided to ensure that the first insulator 2 and the second insulator 3 maintain coaxiality and relative positional accuracy during the docking process, avoiding terminal misalignment or poor contact caused by misalignment. The guiding effect of the assembly slot 33 significantly simplifies the assembly process, improves production efficiency and consistency, and reduces manual assembly errors. The design extending to the contact cavity 31 ensures stable overhang positioning of the terminals of the first insulator 2, creating ideal conditions for reliable mating with the contact sleeve 16. The planar mating structure enhances the mechanical stability of the overall insulation assembly, effectively disperses vibration and impact stress, and prevents fretting wear or loosening between insulators, thereby improving the electrical continuity and long-term reliability of the connector in high-temperature and high-vibration environments. This design is particularly suitable for high-density multi-core connectors, achieving the integration and reliable isolation of complex functions within a limited space.
[0033] The two ends of the plug-in terminal 4 are respectively provided with a mating portion 41 and a connecting portion 42. The mating portion 41 extends into the plug-in cavity 13, and the connecting portion 42 extends into the connecting cavity 31 and connects to the terminal 5. Specifically, the mating portion 41 is provided with a mating hole 411 and a groove 412, which is used to cut the mating hole 411 into two halves to generate tension during mating. The connecting portion 42 is provided with two connecting clips 421, which are arranged opposite each other and form a plug-in groove between the two connecting clips 421. The terminal 5 is provided with an insertion end 51, which is inserted into the plug-in groove. In this embodiment, the mating hole 411 is divided into two halves by setting the groove 412 to form an elastic tension structure. During mating, this design utilizes the elasticity of the material to generate radial tension force, ensuring continuous and stable contact pressure with the mating terminal, effectively reducing contact resistance and improving conductivity reliability. The elastic deformation structure can compensate for mating tolerances, withstand vibration and insertion / removal wear, and extend the mechanical life of the connector. The dual-clamp type electrical clamp 421 design forms symmetrical insertion slots, creating surface contact rather than point contact with the insertion end 51 of the terminal 5. The guiding design of the insertion slots simplifies the wiring assembly process, enabling rapid crimping without additional tools, balancing production efficiency and connection reliability. The mating part 41 and the electrical connection part 42 have clearly defined functions, optimizing the mechanical and electrical characteristics of the mating connection and the wire connection respectively. This allows a single terminal to simultaneously meet the requirements of high-frequency insertion / removal and high-load power delivery, making it particularly suitable for fields with stringent connector performance requirements, such as new energy vehicles and industrial equipment.
[0034] A connector terminal fixing method for a connector terminal fixing structure includes the following steps: Step S1, Pre-assembly of insulator and terminal: Insert the plug terminal 4 into the corresponding channel of the first insulator 2 to form the first sub-assembly; insert the wiring terminal 5 into the receiving cavity 31 of the second insulator 3 to form the second sub-assembly; Step S2, vertical insertion and internal electrical connection: The first sub-assembly is inserted axially into the first fixed cavity 11 from one end of the insertion sleeve 14 of the alloy housing 1, and continues to be pushed until one end of the first insulator 2 is inserted and fixed in the assembly slot 33 of the second insulator 3; during this process, the contact part 42 of the insertion terminal 4 is simultaneously inserted into the contact cavity 31 of the second insulator 3, and the contact clip 421 on it is used to form an interference fit and elastic clamping with the insertion end 51 of the wiring terminal 5 in the second sub-assembly to realize the internal vertical electrical connection; Step S3, housing sealing and external interface forming: press the first sealing ring 141 into the sealing mounting groove on the outer periphery of the plug sleeve 14 to complete the forming of the sealing structure on the plug side; fix the conductor of the external connecting wire 6 to the tail of the terminal 5. Step S4, top encapsulation and final sealing: The assembly consisting of the second insulator 3 and the terminal 5, which has completed internal connection, is inserted vertically into the second fixing cavity 12 from the mounting groove 17 on the top of the alloy housing 1; then, the second sealing ring 172 is placed in the sealing groove 171, and finally the sealing cover plate 173 is installed into the mounting groove 17 and tightened to achieve bidirectional sealing of the top opening of the connector.
[0035] This embodiment, through a reasonable process flow design, decomposes the complex assembly process into multiple modular and sequential operation steps, improving the assembly efficiency, consistency, and reliability of connector products. In step S1, the first insulator 2 and the plug terminal 4, and the second insulator 3 and the wiring terminal 5 are pre-assembled to form two independent sub-components. This pre-assembly method facilitates automated operation, reduces the overall assembly difficulty, and avoids potential damage or improper installation caused by directly operating the tiny terminals within the narrow housing, thus improving the assembly accuracy and yield of components. In step S2, by axially inserting and pushing the first sub-component, precise alignment and mechanical interlocking are achieved using the pre-set assembly slots 33 on the first insulator 2 and the second insulator 3, realizing a stable connection between the two components. At the same time, the contact part 42 of the plug terminal 4 automatically and accurately inserts into the contact cavity 31, and forms an interference fit and durable and reliable elastic contact with the wiring terminal 5 using the elastic contact clip 421. This process completes mechanical fixing and electrical connection in one step, simplifying the process, ensuring low resistance and high stability of the internal electrical connection interface, which is beneficial for the transmission of high-frequency signals. Steps S3 and S4 complete the multi-layer sealing structure of the connector from the mating side and the top, respectively. The first sealing ring 141 at the mating sleeve 14 effectively prevents moisture and contaminants from entering through the mating interface, while the top, through the cooperation of the second sealing ring 172 and the sealing cover plate 173, achieves bidirectional compression sealing of the assembly groove 17, forming another robust protective barrier. The multi-stage sealing design greatly enhances the connector's sealing performance, weather resistance, and long-term reliability in harsh automotive environments (such as high temperature, high humidity, oil contamination, and vibration). The entire process is clear, and the steps are seamlessly connected, ensuring not only a high degree of consistency in product performance but also fully meeting the stringent requirements of the automotive industry for high-quality, high-efficiency, and low-cost manufacturing of components.
[0036] In step S1, when the plug terminal 4 is inserted into the first insulator 2, its mating portion 41 is pre-constrained. In the final assembly position in step S2, the front end of the mating portion 41 extends into the plug cavity 13, and its rear end limiting structure is limited by the anti-retraction step 21 or internal structure of the first insulator 2, thereby achieving dual fixation of the plug terminal 4 in the axial and radial directions, preventing it from loosening or retracting when plugging and unplugging the mating connector. In this embodiment, by pre-constraining the mating portion 41 of the plug terminal 4 during the pre-assembly process in step S1, and by using the anti-retraction step 21 or its internal limiting structure of the first insulator 2 to reliably limit the limiting structure of the rear end of the plug terminal 4 after the final assembly in step S2, the plug terminal 4 is dually and firmly fixed in the axial and radial directions. This effectively limits the axial displacement or radial movement of the plug terminal 4 caused by external insertion and extraction forces, mechanical vibration, or cable stress during subsequent use, greatly improving the mechanical holding force and positional stability of the terminal. On the one hand, it ensures the alignment and contact reliability of the plug terminal 4 when it is mated with the external connector, avoiding poor contact, signal interruption, or electrical performance fluctuations caused by terminal retraction. On the other hand, it enhances the vibration resistance and durability of the entire connector in the high-frequency vibration environment of the vehicle, preventing terminal loosening, wear, or failure due to long-term vibration. This embodiment is ingeniously designed, requiring no additional fasteners, simplifying the assembly process, improving production efficiency, and ensuring that the connector maintains durable and stable electrical connection performance under harsh operating conditions, fully meeting the technical requirements of automotive electronics for high-reliability connectors.
[0037] In step S2, the connection between the plug-in terminal 4 and the wiring terminal 5 is achieved through the elastic deformation of the contact clip 421. During insertion, the contact clip 421 is opened by the insertion end 51 of the wiring terminal 5, and the resulting continuous rebound force forms a stable contact pressure, ensuring low impedance and high reliability of the electrical connection. Simultaneously, this elastic connection compensates for manufacturing tolerances and thermal expansion and contraction effects. In this embodiment, by utilizing the elastic interference fit between the contact clip 421 of the plug-in terminal 4 and the insertion end 51 of the wiring terminal 5 in step S2, a highly reliable internal electrical connection is achieved. During insertion, the contact clip 421 undergoes elastic deformation under the mechanical action of the insertion end 51 of the wiring terminal 5. The continuous rebound force generated by this deformation forms a stable and controllable contact pressure at the contact interface, ensuring that the electrical connection has extremely low contact resistance and excellent conductivity, which is beneficial for high-current transmission and low-loss communication of high-frequency signals. The flexible connection structure possesses excellent tolerance adaptability, effectively compensating for unavoidable dimensional deviations in component processing and assembly, thereby improving production yield and assembly efficiency. When the temperature in the automotive environment changes, the flexible contact design can adapt to minor dimensional changes caused by thermal expansion and contraction, avoiding problems such as decreased contact pressure or even connection failure due to material expansion and contraction. This enhances the electrical stability and mechanical durability of the connector under wide temperature range conditions.
[0038] The above embodiments merely illustrate several implementation methods of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this patent should be determined by the appended claims.
Claims
1. A connector terminal fixing structure, characterized in that: The device includes an alloy housing, a first insulator, a second insulator, a plug-in terminal, a wiring terminal, and a connecting wire. The alloy housing has a first fixed cavity and a second fixed cavity, which are perpendicularly connected. One end of the first fixed cavity has a plug-in cavity. The first insulator is disposed in the first fixed cavity, with one end extending into the plug-in cavity and the other end extending into the second fixed cavity. The second insulator is disposed in the second fixed cavity and has a power-connecting cavity. The wiring terminal is disposed in the power-connecting cavity. The plug-in terminal is disposed in the first insulator, with one end extending into the power-connecting cavity and connected to the wiring terminal. The connecting wire is connected to one end of the wiring terminal.
2. The connector terminal fixing structure according to claim 1, characterized in that: The alloy housing is provided with a plug-in sleeve and a wiring part. The plug-in sleeve and the wiring part are vertically connected. The plug-in cavity and the first fixed cavity are sequentially arranged in the plug-in sleeve, and the second fixed cavity is arranged in the wiring part. The connecting wire is arranged in the wiring part and connected to the wiring terminal. The wiring terminal is inserted into the second fixed cavity of the second insulator from the bottom of the wiring part. The insertion sleeve is provided with a sealing mounting groove outside the insertion cavity, and a first sealing ring is installed on the sealing mounting groove. Multiple sealing lips are provided on the outer periphery of the first sealing ring.
3. The connector terminal fixing structure according to claim 1, characterized in that: The insertion cavity is provided with an electrical connection sleeve, and the two ends of the electrical connection sleeve are respectively provided with an electrical connection end and an electrical connection plug end. The electrical connection end is provided on the first insulator, and the electrical connection plug end extends to the port of the first fixed cavity.
4. The connector terminal fixing structure according to claim 3, characterized in that: The power connection end is provided with a limiting inner ring, and the first insulator is provided with a backstop step. The limiting inner ring is used to abut against the backstop step and to prevent the power connection sleeve from retracting. The inner circumference of the electrical connection end is provided with an electrical contact spring, which is used to make contact with the connector to conduct electricity and generate friction.
5. The connector terminal fixing structure according to claim 1, characterized in that: The alloy shell is provided with an assembly groove at the top of the second fixing cavity. One end of the second fixing cavity is connected to the assembly groove, and the second insulator is inserted into the second fixing cavity from the assembly groove.
6. The connector terminal fixing structure according to claim 5, characterized in that: The assembly groove is provided with a sealing groove on the outer periphery of the second fixing cavity. A second sealing ring is installed in the sealing groove. A sealing cover plate is installed in the assembly groove. The sealing cover plate is used to cooperate with the second sealing ring to seal the assembly groove.
7. The connector terminal fixing structure according to claim 1, characterized in that: The second insulator has an assembly plane on the side facing the first fixing cavity, and the assembly plane has an assembly slot. One end of the first insulator is inserted into the assembly slot and extends to the electrical connection cavity.
8. The connector terminal fixing structure according to claim 1, characterized in that: The two ends of the plug terminal are respectively provided with a mating part and a power receiving part. The mating part extends into the plug cavity, and the power receiving part extends into the power receiving cavity and is connected to the wiring terminal.
9. The connector terminal fixing structure according to claim 8, characterized in that: The mating part is provided with a mating hole and a groove. The groove is used to cut the mating hole into two halves so as to generate tension force when mating. The electrical connection part is provided with electrical connection clips. Two electrical connection clips are arranged opposite each other and a mating groove is formed between the two electrical connection clips. The terminal is provided with an insertion end, which is inserted into the mating groove.
10. A method for fixing connector terminals, characterized in that: The connector terminal fixing structure according to any one of claims 1 to 9 includes the following steps: Step S1, Pre-assembly of insulator and terminals: Insert the plug terminals into the corresponding channels of the first insulator to form the first sub-assembly; insert the wiring terminals into the contact cavity of the second insulator to form the second sub-assembly; Step S2, Vertical insertion and internal electrical connection: The first sub-assembly is inserted axially into the first fixed cavity from one end of the insertion sleeve of the alloy shell, and continues to be pushed until one end of the first insulator is inserted and fixed in the assembly slot of the second insulator; during this process, the contact part of the insertion terminal is simultaneously inserted into the contact cavity of the second insulator, and the contact clip on it is used to generate an interference fit and elastic clamping with the insertion end of the wiring terminal in the second sub-assembly to realize the internal vertical electrical connection; Step S3, housing sealing and external interface forming: press the first sealing ring into the sealing mounting groove on the outer periphery of the plug sleeve to complete the forming of the sealing structure on the plug side; fix the conductor of the external connection wire to the tail of the terminal block. Step S4, Top Encapsulation and Final Sealing: The assembly consisting of the second insulator and the terminal block, which has completed the internal connection, is inserted vertically into the second fixing cavity from the mounting groove on the top of the alloy housing; then, the second sealing ring is placed in the sealing groove, and finally the sealing cover is installed into the mounting groove and tightened to achieve a bidirectional seal on the top opening of the connector. In step S1, when the plug terminal is inserted into the first insulator, the mating portion on it is pre-constrained; in the final assembly position of step S2, the front end of the mating portion extends into the plug cavity, and the limiting structure at its rear end is limited by the anti-retraction step or internal structure of the first insulator, thereby achieving double fixation of the plug terminal in the axial and radial directions, preventing it from loosening or retracting when plugging and unplugging the mating connector. In step S2, the connection between the plug-in terminal and the wiring terminal is achieved through the elastic deformation of the electrical clamp. During the insertion process, the electrical clamp is opened by the insertion end of the wiring terminal, and the continuous rebound force generated by it forms a stable contact pressure, ensuring low impedance and high reliability of the electrical connection. At the same time, this elastic connection also compensates for the manufacturing tolerance of the parts and the effect of thermal expansion and contraction.