Modular connector and method of making the same

Abstract

The application discloses a modular connector and a manufacturing method thereof, and relates to the technical field of connectors. The connector comprises an insulator, a shielding shell and a terminal assembly arranged in the insulator, the terminal assembly is split into a first module along a plugging direction and a second module connected perpendicularly, each terminal section is fixed by a fixing member; the shielding shell is provided with a limiting block, a positioning sheet and a reinforcing part, which can effectively prevent the end feet from being laterally expanded. The manufacturing method comprises the following steps: stamping, electroplating and injection molding the first module and the second module respectively, forming the terminal assembly by means of spot welding process, integrally injection molding an L-shaped insulator, and then assembling the inner shielding shell and the outer shielding shell in sequence. The application adopts a split modular design, solves the defects that long terminals of a traditional cushioning connector are prone to bending deformation and the shielding shell is expanded, improves the terminal positioning precision and the product structure stability, simplifies the manufacturing process, reduces the production failure rate, is suitable for large-scale production, and significantly improves the production yield and use reliability of the cushioning connector.

Description

Technical Field

[0001] This invention relates to the field of connector technology, and in particular to a modular connector and its manufacturing method. Background Technology

[0002] Electrical connectors for 3C terminal devices are widely compatible with mobile devices such as smartphones and computers. They primarily enable data transmission, audio signal transmission, and power conduction between devices, serving as the core foundational components for electrical connections in 3C terminal devices. With the diversification of structural designs in 3C terminal devices, the market has placed higher demands on the structural adaptability, process stability, and ease of assembly of these connectors. In particular, connector structural designs for specially elevated usage scenarios have become a key research and development focus within the industry.

[0003] In existing technologies, electrical connectors used in 3C terminal devices require increased overall structural height to meet the needs of elevated assembly in some devices, especially in the automotive industry. However, due to limitations in traditional structural design, technical defects exist in actual production and application. Traditional high-rise connectors typically have integrally molded conductive terminals. To accommodate the height requirements, the terminals must be designed as long cantilever structures with bending sections, increasing the overall length of the terminal with the height increase. In the manufacturing process, these terminals must first be bent and then undergo overall injection molding. The slender terminals after bending have residual structural stress, and the suspended cantilever sections lack effective support, making them highly susceptible to the high-pressure impact of molten plastic during injection molding. This can lead to misalignment at the bend and overall bending deformation. Furthermore, in the earlier stamping and electroplating processes, the long terminals are also prone to deformation due to external forces during mounting and transport, ultimately resulting in a significant reduction in product yield and a substantial increase in manufacturing costs. Summary of the Invention

[0004] In view of the shortcomings of the prior art, the technical problem to be solved by the present invention is to provide a modular connector and its manufacturing method, which can effectively solve the problems of easy deformation of conductive terminals and easy deformation of shielding shell after the raised design, thereby improving product process yield and structural stability.

[0005] To solve the above-mentioned technical problems, one technical solution adopted by the present invention is to provide a modular connector, including an insulator and a shielding shell disposed outside the insulator, and further including a terminal assembly disposed inside the insulator. The terminal assembly includes a first module and a second module. The first module is disposed along the insertion direction, and the second module is perpendicularly connected to the rear end of the first module. The first module and the second module are interconnected to form an integral unit and realize electrical connection.

[0006] Furthermore, the terminal assembly includes a plurality of terminals and a fixing component. Each terminal includes a separate first segment and a second segment. The first segment extends along the insertion direction, and the second segment is perpendicular to the first segment and connected to its rear end. The fixing component includes a first fixing member and a second fixing member. The first fixing member is used to fix a plurality of the first segments together to form the first module, and the second fixing member is used to fix the second segments together to form the second module.

[0007] Furthermore, the outer periphery of the first fixing member is provided with a plurality of first protrusions and a first groove, and the outer periphery of the second fixing member is provided with a plurality of second protrusions and a second groove.

[0008] Furthermore, the inner circumferential wall of the shielding shell is provided with limiting blocks along the insertion direction, and the insulator is provided with a limiting groove at the position corresponding to the limiting block to engage with the limiting block.

[0009] Furthermore, the insulator has a base along the insertion direction and an extension perpendicular to the insertion direction, the first module is embedded in the base, the second module is embedded in the extension, and a positioning component is provided between the shielding shell and the extension.

[0010] Furthermore, the positioning component includes two positioning grooves formed in the extension and two positioning pieces disposed on the shielding shell. The two positioning pieces are respectively located on the two lateral ends of the shielding shell, and the two positioning pieces are respectively engaged with the two positioning grooves to prevent the lateral shape of the ends of the shielding shell from deforming.

[0011] Furthermore, the positioning piece is integrally formed with the shielding shell.

[0012] Furthermore, the front sides of the two end feet of the shielding shell are bent towards the middle of the shielding shell to form a reinforcing section.

[0013] A method for manufacturing a modular connector, comprising the following steps: S100, Preparation of the first module: Take a plate and stamp it to form a number of first blanks, electroplate the number of first blanks to form a number of first segments, and use an insulating material to at least partially cover the number of first segments through an injection molding process to form the first module. S200, Second module preparation; take a plate and stamp it to form a number of second blanks, electroplate the number of second blanks to form a number of second segments, and use an insulating material to at least partially cover the number of second segments through an injection molding process to form the second module; S300, Terminal assembly connection: The second module is vertically aligned with the rear end of the first module, and the rear ends of several first sections are connected one-to-one with the front ends of several second sections to form an integral terminal assembly. S400, Insulator Injection Molding: The terminal assembly is integrally injection molded using insulating material to form an L-shaped insulator; S500, Shielding shell assembly: The shielding shell is assembled on the outside of the insulator.

[0014] Furthermore, in step S300, the rear ends of several first sections and the front ends of several second sections are welded and fixed one-to-one by spot welding to achieve electrical connection.

[0015] The modular connector and its manufacturing method of the present invention have at least the following beneficial effects: The terminal assembly is divided into a first module along the insertion direction and a second module connected vertically, and each module segment is covered and fixed by a fastener, effectively avoiding the bending and injection molding offset problems caused by excessively long terminals in traditional raised connectors, and significantly improving the positioning stability of the terminals within the insulator; simultaneously, the present invention provides a limiting block, positioning piece, and reinforcing structure on the shielding shell, which prevents the shielding shell end from deforming outwards, making the engagement between the shielding shell and the insulator tighter; the synergistic effect of the above structures not only significantly improves the overall structural stability and durability of the connector, but also enhances the damping effect during mating, making the connector more reliable; The process of segmented preparation and modular assembly firstly uses injection-molded fasteners to pre-fix and precisely position the first and second segments, forming a stable first and second module. This avoids bending and misalignment of slender terminals during processing. Then, the two modules are vertically aligned and spot-welded together to ensure accurate and reliable terminal connection. Finally, the terminal assembly is integrally encapsulated and fixed through overall injection molding. This process completely eliminates the defective process of bending long terminals before overall injection molding in traditional processes, effectively improving terminal positioning accuracy and process stability, and significantly reducing the production defect rate. At the same time, each module can be processed independently and prepared simultaneously, simplifying complex assembly procedures and making it more suitable for efficient large-scale mass production, significantly optimizing production efficiency and manufacturing costs. Attached Figure Description

[0016] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings: Figure 1 This is a schematic diagram of the structure of an embodiment of the modular connector and its manufacturing method according to the present invention. Figure 1 ; Figure 2 This is a schematic diagram of the structure of an embodiment of the modular connector and its manufacturing method according to the present invention. Figure 2 ; Figure 3 This is a schematic diagram of the structure of the first segment and the second segment in one embodiment of the modular connector and its manufacturing method of the present invention; Figure 4 This is a schematic diagram of the terminal assembly in one embodiment of the modular connector and its manufacturing method of the present invention; Figure 5 This is a schematic diagram of the structure of an embodiment of the modular connector and its manufacturing method according to the present invention. Figure 3 ; Figure 6 This is a schematic diagram of the insulator, inner shielding shell, and second section in one embodiment of the modular connector and its manufacturing method of the present invention. Figure 7 This is a schematic diagram of the structure of an embodiment of the modular connector and its manufacturing method according to the present invention. Figure 4 .

[0017] The meanings of the labels in the attached diagram are as follows: Insulator 1, base 11, extension 12, stepped surface 13, first limiting groove 14, second limiting groove 15, positioning groove 16; Shielding shell 2, inner shielding shell 21, first limiting block 211, second limiting block 212, pressure plate 213, outer shielding shell 22, positioning plate 221, reinforcing part 222; Terminal assembly 3, first module 31, first section 311, first grounding terminal section 3111, first power terminal section 3112, first signal terminal section 3113, metal sheet 3114, first fixing member 312, first protrusion 313, first groove 314, second module 32, second section 321, second grounding terminal section 3211, second power terminal section 3212, second signal terminal section 3213, second fixing member 322, second protrusion 323, second groove 324. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below in conjunction with specific embodiments and corresponding drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0019] The following disclosure provides various embodiments or examples for implementing different features of the invention. Specific examples of components and arrangements will be described below to simplify the invention. Of course, these are merely examples and are not intended to limit the invention. For example, in the following description, forming a first component above or on a second component may include embodiments where the first and second components are in direct contact, or embodiments where other components may be formed between the first and second components such that the first and second components are not in direct contact. Furthermore, reference numerals and / or characters may be repeated in various instances of the invention. Such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or configurations.

[0020] Furthermore, spatial relation terms such as "below," "under," "below," "above," and "above" may be used herein to readily describe the relationship between one element or component and another element (or component) or component (or component) as shown in the figure. In addition to the orientations shown in the figure, spatial relation terms will encompass various different orientations of the device in use or operation. The device may be positioned in other ways (rotated 90 degrees or in other orientations) and will be interpreted accordingly through the spatial relation descriptors used herein.

[0021] Furthermore, the technical parts described in this invention and the appended claims are primarily the improved technical parts of this invention, and do not limit the object protected by this invention to only having these technical parts. Other known essential components (structures and / or methods) and / or non-essential components of the object protected, besides the technical parts described in this invention and the appended claims, are not included in this invention and the appended claims because they do not fall within the scope of improvements of this invention; however, this does not mean that the object protected by this invention does not possess these known components.

[0022] The invention will now be further described with reference to the accompanying drawings.

[0023] Please refer to Figure 1 and Figure 2 The modular connector of the present invention includes an insulator 1, a shielding shell 2 disposed outside the insulator 1, and a terminal assembly 3 disposed inside the insulator 1. The terminal assembly 3 includes a first module 31 and a second module 32. The first module 31 is disposed along the insertion direction, and the second module 32 is perpendicularly connected to the rear end of the first module 31. The first module 31 and the second module 32 are interconnected to form a whole and achieve electrical connection.

[0024] Please refer to Figure 3 and Figure 4The terminal assembly 3 includes a plurality of terminals and a fixing assembly for fixing the terminals. Each terminal includes a first segment 311 and a second segment 321. The plurality of first segments 311 extend along the insertion direction, and the second segment 321 is connected to the rear end of the first segment 311 and perpendicular to the first segment 311. The plurality of first segments 311 are arranged in two rows, and each row of first segments 311 includes a first ground terminal segment 3111 located on the outermost two sides laterally, a first power terminal segment 3112 disposed inside the two first ground terminal segments 3111, and a plurality of first signal terminal segments 3113 arranged between the two first power terminal segments 3112. The rear ends of the two rows of first ground terminal segments 3111, first power terminal segments 3112, and first signal terminal segments 3113 converge into one row for soldering to the plurality of second segments 321. When the components are connected, two first grounding terminal segments 3111 on the same side are arranged side by side close to each other on one horizontal side, and two first power terminal segments 3112 on the same side are arranged side by side close to each other on one horizontal side and located inside the first grounding terminal segments 3111 on the same side. A plurality of first signal terminal segments 3113 are arranged side by side in the middle of the first power terminal segments 3112 on both sides. A metal reinforcing member is also provided between the two rows of first segments 311. In this embodiment, the metal reinforcing member is a metal sheet 3114. The metal sheet 3114 is disposed between the two rows of first segments 311. Specifically, it is disposed between two first grounding terminal segments 3111 distributed vertically, and is in contact with both the upper and lower first grounding terminal segments 3111 for common grounding. Each row of first grounding terminal segments 3111 has two distributed on both sides, therefore the metal sheet 3114 also has two distributed on both sides. Since the metal plate 3114 is grounded by contacting the first grounding terminal section 3111 at its front end, it does not need to extend outwards from the insulator 1 to form solder feet for grounding, as is the case with metal reinforcements in other connectors. This design of the metal plate 3114 simplifies the structure, avoids assembly interference, better adapts to modular assembly requirements, reduces product size, shortens the grounding path, and improves grounding stability and anti-interference effect.

[0025] The second sections 321 include a second grounding terminal section 3211, a second power supply terminal section 3212, and a second signal terminal section 3213. The second grounding terminal section 3211, the second power supply terminal section 3212, and the second signal terminal section 3213 are respectively used for soldering to the first grounding terminal section 3111, the first power supply terminal section 3112, and the first signal terminal section 3113 in a one-to-one correspondence. Two of the four second grounding terminal sections 3211 are arranged side-by-side close to each other on one side of the lateral direction to be soldered to the two first grounding terminal sections 3111 arranged on the same side; the other two second grounding terminal sections 3211 are arranged in the same manner on the other side of the lateral direction. Two of the four second power terminal sections 3212 are arranged side-by-side close to each other on one side of the lateral direction, and are located inside the two second ground terminal sections 3211 on the same side, so as to be welded to the two first power terminal sections 3112 arranged on the same side; the other two second power terminal sections 3212 are arranged in the same manner on the other side of the lateral direction. In this way, a number of second signal terminal sections 3213 are all concentrated in the middle of the second section 321, which not only makes the arrangement more neat, but also keeps the second signal terminal sections 3213 away from electromagnetic interference from edge interference sources, making the signal transmission more stable.

[0026] The fixing assembly includes a first fixing member 312 and a second fixing member 322. The first fixing member 312 is made of insulating material and is used to fix several first segments 311 together to form the first module 31. Specifically, the first fixing member 312 is a fixing block formed by injection molding of insulating material. The first fixing member 312 covers at least a portion of several first segments 311 to form the first module 31. In this embodiment, the first fixing member 312 covers the middle portion of several first segments 311 and exposes both ends of the first segments 311. The front end is used for electrical connection with the docking connector, and the rear end is used for connection with the second segment 321. In other embodiments, the first fixing member 312 may cover more or less of the first segments 311, as long as it can meet the requirements of fixing the first segments 311 and the connection requirements of the first segments 311 with the docking connector and the second segment 321. The outer periphery of the first fixing member 312 is provided with a plurality of first protrusions 313 and first grooves 314. The first protrusions 313 and the first grooves 314 are used to increase the contact area with the insulator 1, so that the two are fixed more stably.

[0027] The second fixing member 322 is also made of insulating material and is used to fix several second segments 321 together to form the second module 32. Specifically, the second fixing member 322 is a fixing block formed by injection molding of insulating material. The second fixing member 322 covers at least a portion of several second segments 321 to form the second module 32. In this embodiment, the second fixing member 322 covers the middle portion of several second segments 321 and exposes both the upper and lower ends of the second segments 321. The upper end is used to connect to the rear end of the first segment 311, and the lower end is used to connect to the wire. In other embodiments, the covering of the second fixing member 322 on the second segments 321 can be more or less, as long as it can meet the requirements of fixing the second segments 321 and the connection requirements of the second segments 321 with the first segment 311 and the wire. The outer periphery of the second fixing member 322 is provided with a plurality of second protrusions 323 and second grooves 324. The second protrusions 323 and the second grooves 324 are used to increase the contact area with the insulator 1, so that the two are fixed more stably.

[0028] Please refer to Figure 5 The insulator 1 covers the exterior of the terminal assembly 3. The insulator 1 has a base 11 along the insertion direction and an extension 12 perpendicular to the insertion direction. The first module 31 is embedded in the base 11, and the second module 32 is embedded in the extension 12. The base 11 includes a first portion connected to the extension 12 and a second portion located at the front end of the first portion. The outer diameter of the second portion is smaller than the outer diameter of the first portion to form a stepped surface 13 between the second and first portions.

[0029] Please refer to Figure 6The shielding shell 2 is disposed around the outer periphery of the insulator 1, and includes an inner shielding shell 21 and an outer shielding shell 22. The inner shielding shell 21 extends through the front and rear and surrounds the outer periphery of the base 11. An insertion space is formed between the inner shielding shell 21 and the base 11, and the insertion space is for the insertion of a mating connector. A first limiting block 211 and a second limiting block 212 are distributed circumferentially along the insertion direction of the inner shielding shell 21. The first limiting block 211 is formed by an inwardly recessed inner wall of the inner shielding shell 21, and the stepped surface 13 is recessed rearward to form a first limiting groove 14 for cooperating with the first limiting block 211. The rear wall of the first limiting groove 14 forms a first abutting wall that abuts against the first limiting block 211. The inner shielding shell 21 has two sets of first limiting blocks 211 arranged symmetrically on the left and right sides, forming a group. The two sets of first limiting blocks 211 are located on the upper and lower sides inside the inner shielding shell 21. The first limiting groove 14 has four corresponding to the first limiting blocks 211. The second limiting block 21 is formed by punching and laterally bending the rear end of the inner shielding shell 21. The rear end of the base 11 is recessed forward to form a second limiting groove 15. The front wall of the second limiting groove 15 forms a second abutting wall that abuts against the second limiting block 212. There are two second limiting blocks 212 arranged symmetrically on the left and right sides, and two second limiting grooves 15 are also symmetrically opened on the left and right sides. The inner shielding shell 21 is also provided with a pressure plate 213. The pressure plate 213 is integral with the inner shielding shell 21 and is inclined from front to back from high to low. When the mating connector is inserted, the lower part of the pressure plate 213 contacts the mating connector. The pressure plate 213 is used to provide a tight friction force for the mating connector to be inserted, thereby enhancing the damping insertion effect.

[0030] Please refer to Figure 7The outer shielding shell 22 is disposed around the insulator 1 and the outer periphery of the inner shielding shell 21, with the upper end of the outer shielding shell 22 matching and covering the outer periphery of the inner shielding shell 21. The left and right sides of the outer shielding shell 22 extend downward to form end feet and fit against the outer wall of the insulator 1. A positioning assembly is provided between the shielding shell 2 and the extension 12. The positioning assembly includes two positioning grooves 16 formed in the extension 12 and two positioning pieces 221 disposed on the shielding shell 2. The two positioning pieces 221 are respectively located on the two lateral end feet of the shielding shell 2. The two positioning pieces 221 are both vertically arranged and inclined from front to back and from outside to inside. The two positioning grooves 16 are both formed on the front side of the extension 12 to allow the corresponding positioning pieces 221 to be engaged. The engagement of the positioning pieces 221 with the positioning grooves 16 can prevent the end feet from deforming laterally. Furthermore, the positioning piece 221 is integrally formed with the outer shielding shell 22, which makes the connection strength between the positioning piece 221 and the outer shielding shell 22 higher and eliminates splicing gaps. The positioning piece 221 is not easy to fall off and can be stably engaged with the positioning groove 16 for a long time to limit the outward expansion of the end feet, ensuring the structural stability of the shielding shell 2. At the same time, there is no need to add additional assembly and welding processes for the positioning piece 221, simplifying the processing process and reducing the production defect rate. The front sides of the two end feet of the shielding shell 2 are bent towards the middle of the shielding shell 2 to form a reinforcing part 222. The reinforcing part 222 is used to improve the structural rigidity and deformation resistance of the outer shielding shell 22, further suppressing the lateral outward expansion of the end feet, forming a double anti-outward expansion protection with the positioning piece 221. At the same time, the reinforcing part 222 can also distribute the force on the end feet and improve the structural durability of the outer shielding shell 22.

[0031] Compared with the prior art, the modular connector of the present invention splits the terminal assembly 3 into a first module 31 along the insertion direction and a second module 32 connected vertically, and uses fasteners to cover and fix each module section, effectively avoiding the bending and injection molding offset problems caused by excessively long terminals in traditional raised connectors, and greatly improving the positioning stability of the terminals in the insulator 1. At the same time, the present invention provides a limiting block, a positioning piece 221 and a reinforcing part 222 structure on the shielding shell 2, which can prevent the end of the shielding shell 2 from deforming outward, and make the engagement between the shielding shell 2 and the insulator 1 tighter. The synergistic effect of the above structures not only significantly improves the overall structural stability and durability of the connector, but also enhances the damping effect during docking, making the connector more reliable.

[0032] The method for manufacturing the modular connector of the present invention is used to efficiently produce the above-mentioned modular connector, and the method includes the following steps: S100, Preparation of the first module 31: Take a plate and stamp it to form a number of first blanks, electroplate the number of first blanks to form a number of first segments 311, and use an insulating material to at least partially cover the number of first segments 311 through an injection molding process to form the first module 31. In this step, several first blanks formed by stamping are respectively matched with the first grounding terminal section 3111, the first power terminal section 3112, the first signal terminal section 3113, and the metal sheet 3114. The several first sections 311 formed by electroplating of the several first blanks are arranged in the manner described above. The several first sections 311 arranged in place are placed into the injection mold. The first fixing member 312 is integrally formed in the middle position of the several first sections 311 using an insulating material through an injection molding process. The first fixing member 312 covers and fixes the middle of the several first sections 311, so that each first section 311 maintains a stable arrangement spacing and relative position. At the same time, the insertion front end and connection rear end of the first section 311 are exposed to meet the assembly requirements of docking and connection with the second section 321, respectively. Finally, the first module 31 with a stable structure is formed.

[0033] S200, Preparation of the second module 32: Take a plate and stamp it to form a number of straight second blanks, electroplate the number of second blanks to form a number of second segments 321, and use an insulating material to at least partially cover the number of second segments 321 through injection molding process to form the second module 32. In this step, several second blanks formed by stamping are respectively matched with the second grounding terminal section 3211, the second power terminal section 3212, and the second signal terminal section 3213. Several second blanks and electroplated second sections 321 are arranged in the manner described above. When arranging them, care should be taken to ensure that the spacing is the same as that of several first sections 311 to facilitate interconnection in subsequent steps. The several second sections 321 arranged in place are placed into an injection mold. Using an insulating material, the second fixing member 322 is integrally formed at the middle position of several second sections 321 through injection molding. The second fixing member 322 covers and fixes the middle of several second sections 321, so that each second section 321 maintains a stable arrangement spacing and relative position. At the same time, the upper and lower ends of the second sections 321 are exposed to meet the assembly requirements of electrical connection with the rear end of the first section 311 and electrical connection with external circuits or wires, respectively. Finally, a structurally stable second module 32 is formed.

[0034] In this embodiment, the first and second blanks can also be processed in two other ways: firstly, the first and second blanks are arranged and injection molded, and then the exposed parts after injection molding are electroplated; secondly, the predetermined exposed areas of the first and second blanks are electroplated first, and then the electroplated first section 311 and second section 321 are injection molded. Both of the above methods are conventional electroplating injection molding processes in the art.

[0035] S300, Terminal assembly 3 connection: The second module 32 is vertically aligned with the rear end of the first module 31, and the rear ends of a plurality of first sections 311 are connected one by one with the front ends of a plurality of second sections 321 to form the integrated terminal assembly 3. In this step, the processed first module 31 and second module 32 are kept perpendicular to each other, and the rear ends of several first sections 311 and the front ends of several second sections 321 are welded one by one using a spot welding process, so that the first section 311 and the second section 321 are firmly mechanically connected and electrically connected, ultimately forming the integrated terminal assembly 3.

[0036] S400, Insulator 1 injection molding: The terminal assembly 3 is integrally injection molded using insulating material to form an L-shaped insulator 1; In this step, the terminal assembly 3 is placed in an injection mold, and the terminal assembly 3 is encapsulated and injection molded using an insulating material. After injection molding, the first module 31 is embedded in the base 11, and the wall surface of the first section 311 is exposed outside the base 11 for electrical connection with the terminal of the mating connector; the second module 32 is embedded in the extension 12, and the lower end of the second section 321 is exposed outside the extension 12 for connection with the wire.

[0037] S500, Assembly of shielding shell 2: Assemble the shielding shell 2 on the outside of the insulator 1.

[0038] In this step, a metal sheet is stamped and bent to form a continuous annular body. The mating ends of the annular body are closed and fixed by welding to form a closed-loop inner shielding shell 21. Another metal sheet is precisely bent and integrally formed into an outer shielding shell 22 according to the external fitting structure of the inner shielding shell 21 and the insulator 1. First, the inner shielding shell 21 is fitted onto the outer periphery of the base 11 of the insulator 1 from front to back along the insertion direction, so that the inner shielding shell 21 surrounds the outside of the base 11 to form an insertion space. Then, the outer shielding shell 22 is fitted onto the outside of the integral body composed of the inner shielding shell 21 and the insulator 1 from front to back along the insertion direction, so that the outer shielding shell 22 and the extension 12 of the insulator 1 cooperate with each other, and the limiting structure of the shielding shell 2 engages with the insulator 1, finally completing the overall assembly of the shielding shell 2.

[0039] It should be noted that the injection molds used in this invention are all conventional existing molds used for encapsulation and fixation in the connector field, and fall within the scope of common knowledge in the field. Those skilled in the art, based on existing technology and common knowledge, can select suitable standard injection molds to implement the above processes without creative effort, and there is no need to elaborate on the specific structure and cavity design of the injection molds in this specification. The core improvement of this invention lies in the modular disassembly, segmented preparation, and assembly connection process of the terminal components, not in the structural improvement of the injection mold itself. Therefore, the disclosure in this specification fully complies with the statutory requirements of the Patent Law regarding sufficient disclosure.

[0040] Compared with existing technologies, the modular connector manufacturing method of this invention adopts a segmented preparation and modular assembly process. First, the first and second segments are pre-fixed and precisely positioned by injection molding fasteners to form a stable first and second module, avoiding bending and displacement of slender terminals during processing. Then, the two modules are vertically aligned and spot-welded to ensure accurate and reliable terminal docking. Finally, the terminal assembly is integrally encapsulated and fixed by injection molding. This process completely eliminates the defective process of bending long terminals before integral injection molding in traditional processes, effectively improving terminal positioning accuracy and process stability, and significantly reducing the production defect rate. At the same time, each module can be processed independently and prepared synchronously, simplifying complex assembly procedures and making it more suitable for efficient large-scale mass production, significantly optimizing production efficiency and manufacturing costs.

[0041] The above embodiments merely illustrate preferred implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the 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 invention should be determined by the appended claims.

Claims

1. A modular connector, comprising an insulator and a shielding shell disposed outside the insulator, characterized in that: It also includes a terminal assembly disposed within the insulator, the terminal assembly comprising a first module and a second module, the first module being disposed along the insertion direction, the second module being perpendicularly connected to the rear end of the first module, the first module and the second module being interconnected to form an integral unit and achieve electrical connection.

2. The modular connector as described in claim 1, characterized in that: The terminal assembly includes a plurality of terminals and a fixing component. Each terminal includes a separate first section and a second section. The first section extends along the insertion direction, and the second section is perpendicular to the first section and connected to its rear end. The fixing component includes a first fixing member and a second fixing member. The first fixing member is used to fix a plurality of the first sections together to form the first module, and the second fixing member is used to fix the second sections together to form the second module.

3. The modular connector as described in claim 2, characterized in that: The outer periphery of the first fixing member is provided with a plurality of first protrusions and a first groove, and the outer periphery of the second fixing member is provided with a plurality of second protrusions and a second groove.

4. The modular connector as described in claim 1, characterized in that: The shielding shell has limit blocks distributed along the insertion direction on its circumferential inner wall, and the insulator has a limit groove at the position corresponding to the limit block that engages with the limit block.

5. The modular connector as described in claim 1, characterized in that: The insulator has a base along the insertion direction and an extension perpendicular to the insertion direction. The first module is embedded in the base, the second module is embedded in the extension, and a positioning component is provided between the shield and the extension.

6. The modular connector as described in claim 5, characterized in that: The positioning component includes two positioning slots formed in the extension and two positioning pieces disposed on the shielding shell. The two positioning pieces are respectively located on the two lateral ends of the shielding shell, and the two positioning pieces are respectively engaged with the two positioning slots to prevent the lateral shape of the ends of the shielding shell from deforming.

7. The modular connector as described in claim 6, characterized in that: The positioning piece is integrally formed with the shielding shell.

8. The modular connector as described in claim 7, characterized in that: The two front ends of the shielding shell are bent toward the middle of the shielding shell to form a reinforcing section.

9. A method for manufacturing a modular connector, used to prepare a modular connector as described in any one of claims 2 to 8, characterized in that: The method includes the following steps: S100, Preparation of the first module: Take a plate and stamp it to form a number of first blanks, electroplate the number of first blanks to form a number of first segments, and use an insulating material to at least partially cover the number of first segments through an injection molding process to form the first module. S200, Second module preparation; take a plate and stamp it to form a number of second blanks, electroplate the number of second blanks to form a number of second segments, and use an insulating material to at least partially cover the number of second segments through an injection molding process to form the second module; S300, Terminal assembly connection: The second module is vertically aligned with the rear end of the first module, and the rear ends of several first sections are connected one-to-one with the front ends of several second sections to form an integral terminal assembly. S400, Insulator Injection Molding: The terminal assembly is integrally injection molded using insulating material to form an L-shaped insulator; S500, Shielding shell assembly: The shielding shell is assembled on the outside of the insulator.

10. The method for manufacturing a modular connector as described in claim 9, characterized in that: In step S300, the rear ends of a plurality of the first sections and the front ends of a plurality of the second sections are welded and fixed one-to-one by spot welding to achieve electrical connection.

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