A welding type fuse terminal and manufacturing process

Abstract

This invention discloses a welded fuse terminal and its manufacturing process. The terminal includes an integrally formed terminal body, which has a main side plate, a right-angle bend formed by bending the bottom end of the main side plate, and a weldable male connector formed at the bottom of the right-angle bend and protruding downward. During manufacturing, copper blanks are first continuously pre-formed into copper profiles with a main side plate blank, a right-angle bend blank, and a male connector blank. Then, the cross-sectional dimensions are controlled by precision drawing or shaping. Subsequently, the profiles are stamped and cut to form individual terminals. This structure allows the male connector to be partially supported by the bend, and the main side plate can be relatively thinned. This process avoids mechanically cutting the male connector piece by piece, reduces the amount of copper used, and improves the efficiency of mass production.

Description

Technical Field

[0001] This invention mainly relates to the field of fuse manufacturing technology, specifically a welded fuse terminal and its manufacturing process. Background Technology

[0002] As a circuit protection element, a fuse typically needs to be electrically connected to an external conductive workpiece, circuit board, busbar, or mounting base via terminals. For fuse terminals used in welding, the terminals not only need to conduct electricity, but also need to form a pre-positioning fit between the male end and the hole on the workpiece to be welded before welding. This ensures that the terminal maintains a stable position during welding, thereby guaranteeing the reliability of the weld point position, weld gap, and post-weld electrical connection.

[0003] like Figure 6 As shown, in some similar welded fuse terminals that the applicant is aware of, when the welding male head requires high insertion dimensional accuracy, some products use a partial cutting method on a thick copper part to obtain the male head, so that the male head can meet the insertion dimensions and positioning accuracy of the workpiece hole. The reason for this method is that the terminal body needs to have a certain assembly rigidity, while the male head is relatively thin and has strict dimensional tolerance requirements. If the male head is directly formed on a thick copper part by conventional forging or stamping methods, it is easy to have unstable male head thickness, local burrs or dimensional deviations, making it difficult to consistently meet the welding assembly requirements.

[0004] However, the machining method itself does not change the terminal structure's reliance on thick copper material. To produce thinner male connectors, thicker terminal material needs to be prepared first, followed by the removal of some material. For pure copper or highly conductive copper, this process increases the amount of copper used per unit terminal and consumes a significant amount of processing time in milling, cutting, and dimensional correction. When products enter mass production applications, this process directly manifests as high material costs, slow processing cycles, and limited production capacity.

[0005] Improving solely by reducing material thickness introduces new challenges. For instance, while thinning the terminal body can save copper, the soldering male connector still needs sufficient insertion dimensions, root strength, and positional accuracy. If the male connector is formed directly on the bottom of the thinned flat plate, insufficient effective support at the root can easily lead to bending deformation or fluctuations in the insertion surface dimensions during stamping.

[0006] Therefore, the real limitation of existing technology is not whether the terminals can be made thinner, but how to form male connectors that meet the requirements of plug-in soldering in a way that is suitable for mass production after the terminal body is thinned.

[0007] Based on the aforementioned contradictions, a new terminal structure and manufacturing process are needed to eliminate the reliance on subsequent cutting of thick copper parts for the male connector. Instead, the required local shape of the male connector can be pre-formed within the bending structure at the bottom of the terminal. This approach reduces the overall copper consumption while maintaining the structural strength and dimensional accuracy required for male connector insertion and positioning. Furthermore, it shifts the processing method from inefficient single-piece mechanical cutting to continuous pre-forming and stamping slitting. Summary of the Invention

[0008] This invention addresses the problem of overly simplistic solutions in existing technologies by providing a significantly different approach. It primarily offers a welded fuse terminal and its manufacturing process. This addresses the limitations of existing welded fuse terminals mentioned in the background section, which require thicker copper material and mechanical cutting to obtain the male connector, resulting in high material consumption and low processing efficiency. Furthermore, simply thinning the terminal body makes it difficult to guarantee the male connector's insertion dimensions, root strength, and post-stamping stability.

[0009] The technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows: A weldable fuse terminal includes an integrally formed terminal body, the terminal body including a main body side plate for being disposed on the side of the fuse end, a right-angle bend portion formed by bending the bottom end of the main body side plate, and a weldable plug-in male formed at the bottom of the right-angle bend portion. The welding plug protrusion protrudes downward from the outer bottom surface of the right-angle bend and is used to be inserted into the positioning hole of the workpiece to be welded before welding. The main body side plate, the right-angle bend and the welding plug protrusion are an integral structure formed by stamping and cutting a continuous preformed copper profile.

[0010] Furthermore, the right-angle bend includes a bottom receiving section extending outward from the bottom end of the main body side plate and a corner transition section connecting the main body side plate and the bottom receiving section. The welding plug male is disposed on the lower surface of the bottom receiving section, and the root of the welding plug male is integrally connected with the bottom receiving section.

[0011] Furthermore, at least one side of the welding plug-in male is offset from the corner transition section in the terminal thickness direction, so that the insertion thickness of the welding plug-in male is determined by the cross-sectional shape of the continuous preformed copper profile, rather than by the thickness of the main body side plate alone.

[0012] Furthermore, the welding connector is formed by the bottom receiving section protruding downwards; In the thickness direction of the main body side plate, the welding plug is located between the two support parts on both sides of the bottom receiving section, so that when the welding plug is inserted into the plug hole of the workpiece to be welded, the support parts on both sides jointly bear the insertion reaction force. In the thickness direction of the main body side plate, the welding plug male is not completely misaligned with the main body side plate to suppress the shearing effect on the bottom receiving section caused by the misaligned arrangement of the welding plug male and the main body side plate.

[0013] Furthermore, the welding plug-in male head is a strip-shaped protrusion, a block-shaped protrusion, or a plug-in boss formed by stamping and cutting a strip-shaped protrusion extending along the width direction of the main body side plate.

[0014] Furthermore, the main body side plate is provided with mounting holes for assembly with the fuse end, and there are multiple mounting holes distributed in the corner areas of the main body side plate.

[0015] Furthermore, the main body side plate is also provided with a functional window, which is located between the plurality of mounting holes, and the functional window and the welding plug are arranged at intervals in the height direction.

[0016] Furthermore, the terminal body is a pure copper terminal body, an oxygen-free copper terminal body, or a copper terminal body plated with a conductive protective layer.

[0017] This invention also discloses a manufacturing process for a welded fuse terminal, comprising the following steps: S1. Provide copper billets; S2. The copper billet is continuously preformed to form a preformed copper profile that extends continuously along the length direction. The cross section of the preformed copper profile includes a main side plate blank, a right-angle bent blank formed by bending the bottom end of the main side plate blank, and a male blank located at the bottom of the right-angle bent blank. S3. Perform precision drawing or shaping calibration on the preformed copper profile so that the cross-sectional dimensions of the main body side plate blank, the right-angle bent blank, and the male blank reach the predetermined tolerance. S4. The pre-formed copper profile, after precision drawing or shaping and calibration, is stamped and cut to form a single terminal body, and the male blank is retained on the single terminal body as a welding plug-in male.

[0018] Furthermore, in step S2, the preformed copper profile is formed by extrusion molding, continuous rolling molding, or extrusion followed by rolling shaping, so that the male blank extends continuously in the length direction; In step S4, the continuously extending male head blank segments are retained as welding plug-in male heads corresponding to individual terminals by stamping and cutting.

[0019] Furthermore, in step S3, a drawing die with a contoured cavity is used to perform precision drawing on the preformed copper profile. The contoured cavity simultaneously constrains the main body side plate blank, the right-angle bent blank, and the male head blank so that the insertion dimension of the welding plug-in male head achieves a processing accuracy of ±0.02mm.

[0020] Further, in step S4, the stamping die used includes a side plate support surface for supporting the main body side plate blank, a bending support surface for supporting the right-angle bent blank, and a male head relief groove for accommodating the male head blank. During stamping and cutting, the side plate support surface, the bending support surface, and the male end relief groove cooperate to perform contour positioning of the preformed copper profile, so as to suppress the deformation of the right-angle bent blank and the male end blank during stamping and cutting.

[0021] Furthermore, the stamping die also includes a lateral positioning block and a pressure plate. The lateral positioning block abuts against the side of the main body side plate blank, and the pressure plate presses the upper side of the right-angle bent blank to maintain the relative position of the male blank and the right-angle bent blank during punching, trimming and cutting.

[0022] Furthermore, step S4 includes completing at least two of the following in the same continuous stamping process: punching mounting holes, punching functional windows, trimming the outline, cutting adjacent terminals, and shaping the end of the welding plug male connector.

[0023] Furthermore, after step S4, at least one of the following is included: deburring, corner rounding, cleaning, and surface conductive protection treatment.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) The present invention sets the welding plug male head at the bottom of the right angle bend, so that the thickness of the welding plug male head no longer depends solely on the thickness of the main body side plate. The right angle bend forms a local reinforcement at the root of the welding plug male head, so that the terminal body can use thinner copper material or thinner main body side plate. While meeting the requirements of conductivity and assembly strength, the amount of copper material used is reduced, and the welding plug male head can still retain the effective thickness and support strength required for plug positioning. However, existing terminals are limited by their male head structure design and the requirements for the strength and dimensional accuracy of the male head. It is difficult to process the male head structure that meets the strength and accuracy requirements of the terminal body bottom with a relatively small thickness using conventional stamping and forging methods. Therefore, the male head is processed one by one by milling at the bottom after the terminal body is formed. The problems of this are large copper material consumption, low production efficiency, which is not conducive to mass production and makes it difficult to achieve cost reduction and efficiency improvement. (2) By limiting the welding plug male in the thickness direction of the main body side plate between the support parts on both sides of the bottom receiving section, the welding plug male is inserted into the plug hole of the workpiece to be welded, and the support parts on both sides bear the insertion reaction force together. Moreover, the welding plug male is not completely misaligned with the main body side plate, thereby reducing the shearing effect of the welding plug male and the main body side plate on the bottom receiving section. Compared with the prior art, the structural strength of the male is guaranteed while reducing the material used in the main body side plate. (3) The manufacturing process of the present invention adopts a combination of continuous preforming, precision drawing or shaping calibration and stamping slitting. After precision drawing or shaping calibration, the preformed copper profile is stamped and slitting to form a single terminal body with a welding plug male head. This can transform the original piece-by-piece mechanical cutting into continuous and molded production, improve the production cycle, and is suitable for mass supply of products. (4) The male head blank of the present invention is continuously formed in the length direction of the continuous preformed copper profile, and then cut by stamping to retain a single terminal welding plug male head. Compared with the direct formation of multiple broken male head blanks in the continuous forming stage of the preformed copper profile, the continuously formed male head blank is less prone to deformation in the subsequent fine drawing or shaping calibration stage, which is conducive to ensuring the processing accuracy of the welding plug male head and reducing the processing difficulty. (5) The present invention can further correct the cross-sectional dimensions of the main body side plate blank, the right angle bending blank and the male head blank after preforming by fine drawing or shaping calibration, so that the male head insertion dimension is jointly controlled by the stamping die cavity and the drawing amount. Compared with ordinary profiles that are used directly after extrusion, the present invention can more stably meet the higher dimensional tolerance requirements. (6) The present invention uses a contour support structure in the stamping die, consisting of a main body side plate blank, a right-angle bent blank, a bent support surface, a male end relief groove, a side positioning block and a pressure plate, to support and avoid the right-angle bent part and the male end blank respectively, thereby reducing the risk of male end skewing, root deformation and bending collapse during stamping and cutting, and enabling continuous punching, trimming and cutting to be coordinated with the male end precision requirements.

[0025] The present invention will be explained in detail below with reference to the accompanying drawings and specific embodiments. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall structure of the fuse of the present invention; Figure 2 This is a schematic diagram of the structure of the terminal body of the present invention; Figure 3 This is a schematic diagram of the right-angle bend portion of the present invention; Figure 4 This is a schematic diagram of the preformed copper material of the present invention; Figure 5This is a schematic diagram of the stamping die of the present invention; Figure 6 This is a schematic diagram of the structure of existing similar fuse terminals.

[0027] Reference numerals: 1. Terminal body; 11. Main body side plate; 12. Right angle bend; 121. Bottom receiving section; 122. Corner transition section; 13. Welding plug male connector; 14. Mounting hole; 15. Functional window; 2. Pre-formed copper profile; 21. Main body side plate blank; 22. Right-angle bent blank; 23. Male end blank; 3. Stamping die; 31. Side plate support surface; 32. Bending support surface; 33. Male end clearance groove; 34. Lateral positioning block; 35. Pressure plate. Detailed Implementation

[0028] To facilitate understanding of the present invention, a more comprehensive description of the present invention will be given below with reference to the accompanying drawings, which illustrate several embodiments of the present invention. However, the present invention can be implemented in different forms and is not limited to the embodiments described in the text. Rather, these embodiments are provided to make the disclosure of the present invention more thorough and complete.

[0029] It should be noted that when an element is said to be fixed to another element, it can be directly on the other element or there may be an intermediate element. When an element is said to be connected to another element, it can be directly connected to the other element or there may be an intermediate element at the same time. The terms vertical, horizontal, left, right and similar expressions used in this article are for illustrative purposes only.

[0030] 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 specification of this invention is for the purpose of describing particular embodiments only and is not intended to limit the invention. The terminology used herein includes and / or includes any and all combinations of one or more of the associated listed items.

[0031] like Figures 1 to 3 As shown, this embodiment provides a weldable fuse terminal, which is used to be installed at the end of a fuse and is welded after being positioned by inserting a welding male connector 13 at the bottom into a hole on an external workpiece. The terminal body 1 can be made of pure copper, oxygen-free copper, or other highly conductive copper alloys. In order to balance welding conductivity and oxidation resistance, the terminal body 1 can also be tin-plated, nickel-plated, or subjected to other conductive protection treatments after forming.

[0032] The terminal body 1 includes a main side plate 11, a right-angle bend 12, and a welding plug-in male connector 13. The main side plate 11 is generally plate-shaped and is used to abut or mount against the side of the fuse end. Multiple mounting holes 14 can be provided on the main side plate 11, distributed in the corner areas of the main side plate 11, for mating with the fuse housing end, end cap, or fasteners. A functional window 15 can also be provided in the middle of the main side plate 11. This functional window 15 can be used to avoid the fuse end structure, reduce local weight, or meet assembly identification requirements.

[0033] A right-angle bend 12 is formed at the bottom end of the main body side plate 11. The right-angle bend 12 includes a bottom receiving section 121 and a corner transition section 122. The bottom receiving section 121 extends outward from the bottom end of the main body side plate 11, and the corner transition section 122 is located between the main body side plate 11 and the bottom receiving section 121, forming an approximately right-angle connection between the main body side plate 11 and the bottom receiving section 121. The right angle here does not require an absolute 90° in a mathematical sense; it can also be set to an angle close to 90° based on molding springback and assembly space.

[0034] The welding connector 13 is formed at the bottom of the right-angle bend 12, specifically protruding downwards from the outer bottom surface of the bottom receiving section 121. The welding connector 13 is used to insert into the positioning hole of an external workpiece, so that the fuse terminals have a defined positional relationship before welding. Unlike the conventional method of mechanically cutting the male connector at the bottom of a thick copper terminal, the welding connector 13 in this embodiment is not directly cut within the thickness range of the main body side plate 11, but rather forms part of the pre-formed cross-section together with the right-angle bend 12.

[0035] Because the male connector 13 is located at the bottom of the right-angle bend 12, the root of the male connector 13 can be supported by both the bottom receiving section 121 and the corner transition section 122. In this way, the thickness of the main body side plate 11 can be determined according to the terminal conductivity and installation strength, without having to use excessively thick copper material for the male connector machining. In other words, the connector's insertion size and root strength are borne by the local bending section, allowing the main body side plate 11 to be relatively thinner, thereby reducing copper consumption per unit terminal.

[0036] In a preferred embodiment, the welding connector 13 protrudes downward from the bottom receiving section 121. Furthermore, in the thickness direction of the main body side plate 11, the welding connector 13 is located between the two supporting portions on either side of the bottom receiving section 121, so that when the welding connector 13 is inserted into the insertion hole of the workpiece to be welded, the supporting portions on both sides jointly bear the insertion reaction force. Further, in the thickness direction of the main body side plate 11, the welding connector 13 is not completely misaligned with the main body side plate 11. The purpose of this design is that when the fuse is subjected to an impact force from the welding male connector 13 in the direction of insertion into the workpiece to be welded, the non-complete misalignment design of the welding male connector 13 and the main body side plate 11 (i.e., the projections of the two on the lower horizontal plane coincide in the thickness direction of the main body side plate 11) can effectively reduce the shearing effect on the bottom receiving section 121, thereby effectively suppressing the deformation of the bottom receiving section 121 under shearing force caused by the impact force and shock force pointing towards the mounting surface during the installation and use of the fuse.

[0037] The welding connector 13 can be a strip-shaped protrusion or a block-shaped protrusion. When manufactured using a continuous preformed copper profile 2, the male connector blank 23 preferably extends continuously in the length direction of the profile first, and then the welding connector 13 of the corresponding length is formed on a single terminal body 1 by stamping and cutting. In this way, the cross-sectional dimensions of the welding connector 13 are determined by the preformed die and the precision drawing die, while the length and end shape of the welding connector 13 on a single terminal body 1 are determined by the stamping and cutting process.

[0038] like Figure 4 and Figure 5 As shown, this embodiment also provides a manufacturing process for the above-mentioned welded fuse terminal. The basic idea of ​​this process is not to cut the male end piece by piece on the thick copper terminal, but to first manufacture a continuous preformed copper profile 2 with a male end blank 23, and then cut the continuous preformed copper profile 2 into individual terminals. Since the main body side plate blank 21, the right-angle bent blank 22 and the male end blank 23 in the terminal cross-section have already determined their positions in the preform stage, the subsequent stamping mainly undertakes the planar shape processing and segmentation function, thus significantly reducing the amount of mechanical cutting.

[0039] Specifically, the manufacturing process may include the following steps.

[0040] S1. Material Preparation: Select pure copper, oxygen-free copper, or high-conductivity copper alloy as the copper billet. Depending on the forming method, the copper billet can be a copper rod, copper strip, copper busbar, or pre-rolled copper material. To reduce the resistance to deformation during subsequent preforming, annealing can be performed before preforming; for copper billets that already possess suitable plasticity, they can also directly proceed to the preforming process.

[0041] S2. Continuous Preforming: Copper billets are processed into preformed copper profiles 2 that extend continuously along the length direction through extrusion molding, continuous rolling molding, or extrusion followed by rolling shaping. The cross-section of the preformed copper profile 2 includes a main body side plate blank 21, a right-angle bent blank 22, and a male blank 23. The main body side plate blank 21 corresponds to the main body side plate 11 of the subsequent terminal body 1; the right-angle bent blank 22 corresponds to the right-angle bent portion 12 of the subsequent terminal body 1; and the male blank 23 is located at the outer bottom of the right-angle bent blank 22 and extends continuously along the length direction of the profile.

[0042] In this step, the male blank portion 23 is formed as part of the preformed copper profile 2, rather than being formed by mechanical cutting after the terminal is cut. Since the male blank portion 23 and the right-angle bent blank portion 22 are formed simultaneously, the root of the male blank portion 23 is naturally connected to the bottom receiving section 121, which can form a more stable local reinforcement area.

[0043] S3. Fine Drawing or Shaping Calibration: Although ordinary extruded or rolled profiles can form a basic cross-section, dimensional fluctuations may still exist for structures such as the welded male connector 13 that require mating with holes. Therefore, in this embodiment, a fine drawing or shaping calibration process is preferably added after continuous preforming. The fine drawing die is equipped with a contoured cavity that matches the preformed copper profile 2. This contoured cavity simultaneously constrains the main body side blank 21, the right-angle bent blank 22, and the male connector blank 23. When the preformed copper profile 2 passes through this contoured cavity, the cross-sectional dimensions are further corrected, making the mating dimensions of the male connector blank 23, the thickness of the bottom receiving section 121, and the plate thickness of the main body side blank 21 tend to be stable.

[0044] When high dimensional requirements are needed, multi-pass precision drawing can be used, with intermediate annealing or straightening steps between adjacent drawing passes. This method allows for control of the critical interlocking dimensions of the welded male connector 13 to a high precision range, such as achieving a machining accuracy of ±0.02mm, thus meeting higher assembly tolerance requirements than conventional profile extrusion.

[0045] S4. Straightening and Length Feeding: The pre-formed copper profile 2, after precision drawing or shaping calibration, enters the straightening mechanism to eliminate bending and twisting in the length direction; then, it is fed into the continuous stamping die by the feeding mechanism at a preset step distance. The feeding positioning can rely on the outer reference edge of the profile, or it can be positioned by guide pins after the positioning holes are formed in the previous station.

[0046] S5. Stamping and Cutting: The stamping die 3 punches holes, cuts functional windows, trims the outer shape, cuts adjacent terminals, and shapes the male end of the pre-formed copper profile 2. After stamping, the main body side plate blank 21 forms the main body side plate 11, the right-angle bent blank 22 forms the right-angle bent part 12, and the male end blank 23 is retained on a single terminal body 1 as a welding plug-in male end 13.

[0047] Since the preformed copper profile 2 is not a single flat plate, but has a right-angled bent blank 22 and a downwardly convex male blank 23, the stamping die 3 needs to adopt a contour-following support structure. Specifically, the stamping die 3 may include a side plate support surface 31, a bending support surface 32, and a male blank clearance groove 33. The side plate support surface 31 is used to support the main body side plate blank 21, the bending support surface 32 is used to support the right-angled bent blank 22, and the male blank clearance groove 33 is used to accommodate the male blank 23, so that the male blank 23 will not be flattened or squeezed out of place during the stamping process.

[0048] Furthermore, compared to integrally forming multiple discontinuously distributed male blanks 23 on the pre-formed copper profile 2, it is preferable to integrally form a single male blank 23 on the pre-formed copper profile 2, and then stamp and slit the main body side plate blank 21, the right-angle bent blank 22, and the male blank 23 after finishing. While the former can further reduce copper material usage and lower costs, on the one hand, the design of the stamping die 3 is more complex, and during subsequent finishing, the right-angle bent blank 22 and the male blank 23 suffer from dimensional and shape instability due to compression and pulling along their length. Conversely, although the latter has a higher copper material cost compared to the former, it avoids the problems of high processing difficulty, high processing requirements, and low yield associated with the former.

[0049] Furthermore, the stamping die 3 can also be equipped with a lateral positioning block 34 and a pressure plate 35. The lateral positioning block 34 abuts against the side edge of the main body side plate blank 21 to limit the position of the profile in the width direction; the pressure plate 35 presses the upper side of the right-angle bent blank 22 to prevent the bent part from lifting up during trimming or cutting. Through the coordinated positioning of the side plate support surface 31, the bent support surface 32, the male end relief groove 33, the lateral positioning block 34 and the pressure plate 35, the male end blank 23 can be prevented from tilting forward and backward, tearing at the root, or being misaligned relative to the main body side plate blank 21 during stamping and cutting.

[0050] During continuous stamping, mounting holes 14 and functional windows 15 can be punched first, according to the terminal structure, followed by trimming, and finally cutting off adjacent terminals. Alternatively, punching, trimming, and cutting can be arranged in multiple progressive stations according to the mold layout. For products where the male end requires rounded or chamfered corners, the end of the welding plug male 13 can be rounded, chamfered, or shaped in the last one or more stations to reduce scratches and jamming when inserted into the hole of the workpiece to be welded.

[0051] S6. Post-processing: After stamping and slitting, the individual terminal bodies 1 can undergo deburring, corner rounding, cleaning, drying, and surface conductive protection. If a plating process is used, the terminal bodies 1 can be tin-plated, nickel-plated, or subjected to other surface treatments suitable for soldering and conductivity after cleaning.

[0052] S7. Inspection: Inspect the insertion dimensions of the welding male connector 13, the thickness of the terminal body plate, the diameter and spacing of the mounting holes 14, the angle of the right-angle bend 12, and the overall shape of the terminal. Since the key dimensions of the welding male connector 13 are already defined by the cross-section mold during the pre-forming and precision drawing stages, the stamping stage mainly changes the length and contour of the terminal. Therefore, compared with the piece-by-piece mechanical cutting method, it is easier to maintain dimensional consistency in mass production.

[0053] Through the aforementioned structure and process, this embodiment establishes a continuous relationship from material reduction in structure to process efficiency improvement. First, the male terminal is positioned at the bottom of the right-angle bend, eliminating the need for overall thickening of the main body side plate due to the male terminal requirement. Second, continuous preforming allows the male terminal blank to be formed in one step during the profile stage, avoiding the mechanical cutting of individual male terminal pieces. Third, precision drawing or shaping calibration compensates for the insufficient forming accuracy of ordinary profiles. Finally, the contour-supporting stamping die ensures that the profile with the bend and convex male terminal can be stably cut into individual terminals. Therefore, this invention can improve the production efficiency and dimensional stability of welded fuse terminals while reducing copper consumption.

[0054] The present invention has been described by way of example in conjunction with the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvement made by adopting the inventive concept and technical solution of the present invention, or the direct application of the inventive concept and technical solution of the present invention to other occasions without modification, shall be within the protection scope of the present invention.

Claims

1. A welded fuse terminal, characterized in that, The terminal body (1) is integrally formed. The terminal body (1) includes a main body side plate (11) for being disposed on the side of the fuse end, a right-angle bend (12) formed by bending the bottom end of the main body side plate (11), and a welding plug male (13) formed at the bottom of the right-angle bend (12). The welding plug male (13) protrudes downward from the outer bottom surface of the right-angle bend (12) and is used to be inserted into the positioning hole of the workpiece to be welded before welding. The main body side plate (11), the right-angle bend (12) and the welding plug male (13) are an integral structure formed by stamping and cutting of continuous preformed copper profile (2).

2. The welded fuse terminal according to claim 1, characterized in that, The right-angle bend (12) includes a bottom receiving section (121) extending outward from the bottom end of the main body side plate (11) and a corner transition section (122) connecting the main body side plate (11) and the bottom receiving section (121). The welding plug (13) is disposed on the lower surface of the bottom receiving section (121). The root of the welding plug (13) is integrated with the bottom receiving section (121), and the connection between the two forms a rounded transition part or a support shoulder, so as to reduce the stress concentration generated at the root of the welding plug (13) when the welding plug (13) is inserted into the positioning hole of the workpiece to be welded.

3. The welded fuse terminal according to claim 2, characterized in that, At least one side of the welding plug (13) is offset from the corner transition section (122) in the terminal thickness direction, so that the insertion thickness of the welding plug (13) is determined by the cross-sectional shape of the preformed copper profile (2) rather than by the thickness of the main body side plate (11).

4. The welded fuse terminal according to claim 2, characterized in that, The welding connector (13) is formed by the bottom receiving section (121) protruding downwards; In the thickness direction of the main body side plate (11), the welding plug male (13) is located between the two support portions on both sides of the bottom receiving section (121), so that when the welding plug male (13) is inserted into the plug hole of the workpiece to be welded, the support portions on both sides jointly bear the plugging reaction force. In the thickness direction of the main body side plate (11), at least a portion of the thickness of the welding plug male (13) is located within the thickness projection range of the main body side plate (11), so that the welding plug male (13) and the main body side plate (11) are not completely misaligned, so as to suppress the shearing effect on the bottom receiving section (121) caused by the misaligned arrangement of the welding plug male (13) and the main body side plate (11).

5. The welded fuse terminal according to claim 1, characterized in that, The welding plug-in male head (13) is a strip-shaped protrusion, a block-shaped protrusion, or a plug-in boss formed by stamping and cutting a strip-shaped protrusion extending along the width direction of the main body side plate (11).

6. The welded fuse terminal according to claim 1, characterized in that, The main body side plate (11) is provided with mounting holes (14) for assembling with the fuse end. There are multiple mounting holes (14) distributed in the corner areas of the main body side plate (11).

7. The welded fuse terminal according to claim 6, characterized in that, The main body side plate (11) is also provided with a functional window (15), which is located between a plurality of mounting holes (14), and the functional window (15) and the welding plug male head (13) are arranged at intervals in the height direction.

8. The welded fuse terminal according to any one of claims 1 to 7, characterized in that, The terminal body (1) is a pure copper terminal body (1), an oxygen-free copper terminal body (1), or a copper terminal body (1) plated with a conductive protective layer.

9. A manufacturing process for a welded fuse terminal, characterized in that, For manufacturing the welded fuse terminal according to any one of claims 1 to 8, the manufacturing process includes the following steps: S1. Provide copper billets; S2. The copper blank is continuously preformed to form a preformed copper profile (2) that extends continuously along the length direction. The cross section of the preformed copper profile (2) includes a main body side plate blank (21), a right-angle bent blank (22) formed by bending the bottom end of the main body side plate blank (21), and a male blank (23) located at the bottom of the right-angle bent blank (22). The male blank (23) extends continuously along the length direction of the preformed copper profile (2). S3. Perform fine drawing or shaping calibration on the preformed copper profile (2) so that the cross-sectional dimensions of the main body side plate blank (21), the right angle bent blank (22) and the male blank (23) reach the predetermined tolerance, and limit the bottom position of the male blank (23) relative to the right angle bent blank (22); S4. Using a stamping die (3) that matches the cross-section of the preformed copper profile (2), the preformed copper profile (2) after fine drawing or shaping is stamped and cut to form a single terminal body (1), and the continuously extending male head blank (23) is segmented on the single terminal body (1) and retained as a welding plug male head (13). The stamping die (3) includes a side plate support surface (31) for supporting the main body side plate blank (21), a bending support surface (32) for supporting the right-angle bent blank (22), and a male head relief groove (33) for accommodating the male head blank (23). During stamping and cutting, the side plate support surface (31), the bending support surface (32), and the male head relief groove (33) cooperate to perform contour positioning on the preformed copper profile (2) to suppress the deformation of the right-angle bent blank (22) and the male head blank (23) during stamping and cutting.

10. The manufacturing process according to claim 9, characterized in that, In step S2, the preformed copper profile (2) is formed by extrusion molding, continuous rolling molding, or extrusion followed by rolling shaping, so that the main body side plate blank (21), the right-angle bent blank (22), and the male head blank (23) are continuously formed in the same cross section.

11. The manufacturing process according to claim 9, characterized in that, In step S3, the preformed copper profile (2) is finely drawn using a drawing die with a contoured cavity. The contoured cavity simultaneously constrains the main body side plate blank (21), the right-angle bent blank (22), and the male blank (23) so that the insertion dimensions of the welded plug-in male head (13) formed by the male blank (23) reach the predetermined processing accuracy. The predetermined machining accuracy is ±0.02mm.

12. The manufacturing process according to claim 9, characterized in that, In step S4, the stamping die (3) used includes a side plate support surface (31) for supporting the main body side plate blank (21), a bending support surface (32) for supporting the right angle bent blank (22), and a male head relief groove (33) for accommodating the male head blank (23). During stamping and cutting, the side plate support surface (31), the bending support surface (32) and the male end relief groove (33) cooperate to perform contour positioning on the preformed copper profile (2) to suppress the deformation of the right-angle bent blank (22) and the male end blank (23) during stamping and cutting.

13. The manufacturing process according to claim 12, characterized in that, The stamping die (3) further includes a lateral positioning block (34) and a pressure plate (35). The lateral positioning block (34) abuts against the side of the main body side blank (21), and the pressure plate (35) presses the upper side of the right-angle bent blank (22) to maintain the relative position of the male blank (23) and the right-angle bent blank (22) during punching, trimming and cutting.

14. The manufacturing process according to claim 9, characterized in that, Step S4 includes completing at least two of the following in the same continuous stamping process: punching the mounting hole (14), punching the functional window (15), trimming the outline, cutting off adjacent terminals, and shaping the end of the soldering male connector (13).

15. The manufacturing process according to claim 9, characterized in that, After step S4, at least one of the following is included: deburring, corner rounding, cleaning, and surface conductive protection treatment.

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