An electrical connector and method of manufacturing the same

Abstract

The application discloses an electric connector and a manufacturing method thereof, and belongs to the technical field of electric elements. The electric connector comprises an outer shell, a first glass body and at least one first contact piece. The outer shell has a containing cavity; the first glass body is arranged in the containing cavity and is sealed with the outer shell; the first contact piece is inserted into the first glass body and is sealed with the first glass body, the first contact piece has oppositely arranged first and second ends, the first end is located in the containing cavity, and the second end is located outside the outer shell; the material thermal expansion coefficient of the outer shell is greater than the material thermal expansion coefficient of the first glass body, the difference between the material thermal expansion coefficient of the outer shell and the material thermal expansion coefficient of the first glass body is m, the absolute value of the difference between the material thermal expansion coefficient of the first contact piece and the material thermal expansion coefficient of the first glass body is n, and the following conditions are met: n≤1×10 6 / ℃, and m>n.

Description

Technical Field

[0001] This application relates to the field of electrical components technology, and in particular to an electrical connector and a method for manufacturing the same. Background Technology

[0002] Electrical connectors are widely used in electrical connection scenarios between electronic devices, electrical modules, and functional components. For applications requiring a balance of conductive connection, insulation, and sealing performance, a glass-sealed structure is often employed. This involves embedding the contacts within a glass body, which is then sealed to a metal housing. The glass body provides insulation and support for the contacts while simultaneously enabling the transmission of electrical signals or power.

[0003] Glass sealing structures typically require a high-temperature heating process and then cool to form the final structure. However, during the cooling and shrinkage process of the outer shell, glass body, and contacts, residual stress is easily formed inside the glass body and at the interface between the glass body and the outer shell / contacts. In particular, the glass area around the contacts is more prone to generating large local thermal stresses. These local thermal stresses may further induce problems such as glass cracking, delamination around the contacts, decreased insulation performance, and deterioration of sealing performance during subsequent temperature changes or long-term use. Summary of the Invention

[0004] This application provides an electrical connector and its manufacturing method to solve the technical problem in the background art where stress concentration easily occurs in the housing, glass body and contact during the cooling and molding process.

[0005] To achieve the above objectives, according to a first aspect of this application, an electrical connector is provided, comprising: An outer casing having a receiving cavity; A first glass body is disposed within the receiving cavity and sealed to the outer shell; At least one first contact element is inserted into the first glass body and sealed to the first glass body. The first contact element has a first end and a second end that are disposed opposite to each other. The first end is located inside the receiving cavity and the second end is located outside the outer shell. Wherein, the coefficient of thermal expansion of the outer shell material is greater than that of the first glass body material, the difference between the coefficients of thermal expansion of the outer shell material and the first glass body material is m, and the absolute value of the difference between the coefficients of thermal expansion of the first contact material and the first glass body material is n, satisfying: n≤1×10 6 / ℃, and m>n.

[0006] In some embodiments, the outer casing is made of Monel alloy, which has a coefficient of thermal expansion of 13.5 × 10⁻⁶ in the temperature range of 20°C to 300°C. 6 / ℃ to 14.0×10 6 / ℃; The Monel alloy includes at least one of Monel 400 alloy or Monel K-500 alloy.

[0007] In some embodiments, the first glass body is made of sealing glass, the sealing glass comprising at least one of a monolithic glass preform and a thin-walled glass tube; The first glass body is made of iron-sealed glass, which has a coefficient of thermal expansion of 9.3 × 10⁻⁶ in the temperature range of 20°C to 300°C. 6 / ℃ to 10.5×10 6 / ℃.

[0008] In some embodiments, the material of the first contact element comprises an iron-nickel alloy, wherein the coefficient of thermal expansion of the iron-nickel alloy is 9.0 × 10⁻⁶ in the range of 20°C to 300°C. 6 / ℃ to 9.5×10 6 / ℃.

[0009] In some embodiments, a cuprous oxide and nickel oxide composite film is formed on the surface of the outer casing at the junction with the first glass body.

[0010] In some embodiments, the first contact has a composite film of iron oxide and nickel oxide formed on the surface at the connection point with the first glass body.

[0011] In some embodiments, the wall thickness of the outer casing in the sealing region with the first glass body is not less than 0.2 mm; and / or, The first contact includes an insertion section and a sealing section. The sealing section is sealed to the first glass body, and the insertion section is located outside the outer shell. The outer diameter of the sealing section is larger than the outer diameter of the insertion section, and the difference between the outer diameter of the sealing section and the outer diameter of the insertion section is 0.05 mm to 0.1 mm.

[0012] In some embodiments, the electrical connector is a watertight electrical connector, and the electrical connector further includes an internal transmission unit, the internal transmission unit comprising: An inner shell is disposed within the first glass body and sealed to the first glass body; the material of the inner shell is an iron-nickel alloy. A second glass body is disposed within the inner shell and sealed to the inner shell, and the material of the second glass body is the same as that of the first glass body. At least one second contact is inserted into and sealed to the second glass body, and the material of the second contact is the same as that of the first contact.

[0013] In some embodiments, the electrical connector is an airtight electrical connector, and the housing is provided with mounting edges and / or solder rings.

[0014] According to a second aspect of this application, a method for manufacturing an electrical connector is provided, comprising: Provides an outer casing, a first contact element, and a sealing glass; The outer casing and the first contact element are respectively subjected to pre-oxidation treatment; The pre-oxidized outer shell, the pre-oxidized first contact, and the sealing glass are assembled into a mold to form an assembly; The assembly is then heated and sintered. The sintered assembly is cooled to obtain the electrical connector provided in the first aspect of this application.

[0015] In some embodiments, the housing and the first contact are annealed prior to the pre-oxidation treatment; The annealing process is carried out in a vacuum atmosphere or a protective atmosphere, with an annealing temperature of 990°C to 1010°C and a processing time of 20 min to 70 min.

[0016] In some embodiments, the pre-oxidation treatment includes at least one of the following: (a) Using a muffle furnace air oxidation method, the first contact element is oxidized at 690°C to 710°C for 570s to 630s, and the outer shell is oxidized at 500°C to 550°C for 840s to 960s. (b) The first contact is oxidized at 690°C to 710°C for 1620s to 1980s and the outer casing is oxidized at 530°C to 550°C for 2100s to 2700s using a wet nitrogen oxidation method; the purity of the nitrogen gas used in the wet nitrogen oxidation is not less than 99.99% and the dew point is -5°C to 10°C.

[0017] In some embodiments, heating and sintering the assembly includes: holding at 960°C to 980°C for 15 to 20 minutes; and / or, Cooling the sintered assembly includes cooling it to room temperature at a rate of 10°C / min to 20°C / min.

[0018] In the electrical connector of this application embodiment, the coefficient of thermal expansion of the outer shell material is higher than that of the first glass body material, and the difference in the coefficients of thermal expansion between the outer shell and the first glass body is greater than the difference in the coefficients of thermal expansion between the first contact and the first glass body. Therefore, after sealing and cooling, the outer shell can exert a pressing effect on the first glass body, while the first contact and the first glass body maintain a small difference in thermal expansion. This improves the stability of the sealing interface between the outer shell and the first glass body, and reduces localized thermal stress in the glass area around the first contact, minimizing the risks of glass cracking, interface peeling, decreased insulation performance, and deteriorated sealing performance. This improves the sealing reliability, insulation reliability, and long-term stability of the electrical connector.

[0019] Other features and advantages of this application will be described in detail in the following detailed description section. Attached Figure Description To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] To gain a more complete understanding of this application and its beneficial effects, the following description will be provided in conjunction with the accompanying drawings, wherein the same reference numerals in the following description denote the same parts.

[0021] Figure 1 This is a schematic diagram of the overall structure of the electrical connector in some embodiments of this application; Figure 2 This application Figure 1 Side view; Figure 3 This is a schematic diagram of the first glass body provided in some embodiments of this application when it is made of a thin-walled glass tube; Figure 4 This is a schematic diagram of the first glass body provided in some embodiments of this application when it is made from a single glass blank; Figure 5 This is a structural schematic diagram of the electrical connector provided in some embodiments of this application when it is a watertight electrical connector.

[0022] Explanation of reference numerals in the attached figures: 1. Outer shell; 2. First glass body; 3. First contact element; 31. Sealing section; 32. Insertion section; 4. Inner shell; 5. Second glass body; 6. Second contact element. Detailed Implementation

[0023] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the protection scope of this application.

[0024] In the description of this application, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0025] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0026] The following disclosure provides many different embodiments or examples for implementing different structures of this application. To simplify the disclosure, specific examples of components and arrangements are described below. Of course, these are merely examples and are not intended to limit the scope of this application. Furthermore, reference numerals and / or letters may be repeated in different examples; such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed. In addition, various specific examples of processes and materials are provided in this application, but those skilled in the art will recognize the application of other processes and / or the use of other materials.

[0027] Glass sealing structures typically require a high-temperature heating process and then cool to form the final structure. However, during the cooling and shrinkage process of the outer shell, glass body, and contacts, residual stress is easily formed inside the glass body and at the interface between the glass body and the outer shell / contacts. In particular, the glass area around the contacts is more prone to generating large local thermal stresses. These local thermal stresses may further induce problems such as glass cracking, delamination around the contacts, decreased insulation performance, and deterioration of sealing performance during subsequent temperature changes or long-term use.

[0028] In hermetic applications, electrical connectors typically need to operate over a wide temperature range for extended periods, or form a hermetic seal with the housing of the mating device. When significant residual stress exists within the glass housing and at its interfaces, this stress can easily accumulate and be released towards the sealing interface during subsequent temperature cycling, thermal shock, or assembly, leading to a decrease in hermeticity and even degradation of insulation withstand voltage. When the housing of the mating device is an aluminum alloy cavity, the coefficient of thermal expansion of aluminum alloy is generally significantly higher than that of the metal components and glass housing in the glass sealing structure. During assembly and subsequent temperature cycling and thermal shock, additional thermal stress is more likely to be introduced into the connection area between the electrical connector and the aluminum alloy cavity, as well as the glass sealing area.

[0029] In watertight applications, electrical connectors, in addition to their electrical connection function, need to be used in humid, immersion, and even high-pressure liquid environments for extended periods. If there is significant residual stress or localized weak areas at the sealing interface between the glass body and the outer shell, or between the contacts, external water pressure, temperature changes, and long-term exposure to the medium can more easily induce interface damage and propagate, thus affecting the overall watertight performance. Furthermore, insufficient stability of the sealing structure can further reduce the insulation reliability and long-term stability of the electrical connector in complex environments.

[0030] Firstly, this application provides an electrical connector, please refer to [link to relevant documentation]. Figure 1 and Figure 2 The electrical connector includes a housing 1, a first glass body 2, and at least one first contact 3. The housing 1 has a receiving cavity; the first glass body 2 is disposed within the receiving cavity and sealed to the housing 1; the first contact 3 is inserted into the first glass body 2 and sealed to it. The first contact 3 has a first end and a second end disposed opposite to each other, the first end being located within the receiving cavity and the second end being located outside the housing 1. Within a temperature range of 20°C to 300°C, the coefficient of thermal expansion of the material of the housing 1 is greater than that of the material of the first glass body 2. The difference between the coefficients of thermal expansion of the materials of the housing 1 and the first glass body 2 is m, and the absolute value of the difference between the coefficients of thermal expansion of the materials of the first contact 3 and the first glass body 2 is n, satisfying: n ≤ 1 × 10⁻⁶. 6 / ℃, and m>n.

[0031] The thermal expansion coefficient of the outer shell 1 is higher than that of the first glass body 2, and the difference in thermal expansion coefficients between the outer shell 1 and the first glass body 2 is greater than the difference in thermal expansion coefficients between the first contact 3 and the first glass body 2. Therefore, after sealing and cooling, the outer shell 1 can exert a pressing effect on the first glass body 2, while the first contact 3 and the first glass body 2 maintain a small difference in thermal expansion. This benefits both the stability of the sealing interface between the outer shell 1 and the first glass body 2 and the reduction of localized thermal stress in the glass area around the first contact 3, thus reducing the risk of glass cracking, interface peeling, decreased insulation performance, and deterioration of sealing performance. This improves the sealing reliability, insulation reliability, and long-term stability of the electrical connector. Simultaneously, the absolute value n of the difference between the thermal expansion coefficient of the first contact 3 and the sealing glass is no greater than 1 × 10⁻⁶. 6 / ℃, which helps to reduce the interfacial thermal stress between the first contact 3 and the first glass body 2 caused by thermal expansion mismatch.

[0032] In some embodiments, m does not exceed 4.7 × 10 6 / ℃ is preferable. In some stainless steel housing connectors, m is approximately 6.5~7.0×10 6 / ℃, which makes the sealing interface between the shell and the glass body extremely prone to microcracks, while m does not exceed 4.7×10 6 / ℃ helps to avoid excessive residual stress at the sealing interface due to excessive thermal expansion mismatch between the outer shell 1 and the first glass body 2, thereby reducing the risk of cracking, delamination or interface damage of the first glass body 2.

[0033] In some embodiments, the outer casing 1 is made of Monel alloy, which has a coefficient of thermal expansion of 13.5 × 10⁻⁶ in the temperature range of 20°C to 300°C. 6 / ℃ to 14.0×10 6 / ℃. Monel alloy has a moderate coefficient of thermal expansion, low magnetic permeability and high corrosion resistance. When used as the material for the outer shell 1, it is beneficial to balance the reliability of glass sealing, the requirement of low magnetic properties and long-term service stability in complex environments.

[0034] In some specific examples, the Monel alloy includes at least one of Monel 400 alloy or Monel K-500 alloy.

[0035] Monel 400 alloy is a nickel-copper alloy with the following chemical composition: nickel (Ni) ≥ 63.0%, copper (Cu) 28.0% to 34.0%, iron (Fe) ≤ 2.5%, manganese (Mn) ≤ 2.0%, carbon (C) ≤ 0.30%, silicon (Si) ≤ 0.50%, sulfur (S) ≤ 0.024%, and phosphorus (P) ≤ 0.015%. The coefficient of thermal expansion of Monel 400 alloy is approximately 13.9 × 10⁻⁶ °C in the temperature range of 20°C to 300°C. 6 / ℃. Monel 400 alloy exhibits good plasticity in the fully annealed state, thus possessing strong mechanical and thermal stress buffering capabilities. Monel K-500 alloy is a precipitation-hardening Monel alloy formed by adding aluminum and titanium to Monel 400 alloy. Monel K-500 alloy has a nickel content greater than 63%, a copper content of 27% to 33%, an aluminum content of 2.3% to 3.15%, and a titanium content of 0.35% to 0.85%, and is strengthened through the formation of Ni3(Al,Ti) precipitate phases. In the temperature range of 20℃ to 300℃, the coefficient of thermal expansion of Monel K-500 alloy is approximately 13.5 × 10⁻⁶. 6 / ℃. Monel K-500 alloy maintains good corrosion resistance while also possessing high strength and low magnetic permeability.

[0036] In some hermetically sealed applications, the coefficient of thermal expansion of Monel alloy is significantly higher than that of 4J29 Kovar alloy, significantly lower than that of ordinary aluminum alloy, and moderately higher than that of iron-sealed glass and 4J50 alloy. Based on this thermal expansion relationship, Monel alloy can form a compression seal with iron-sealed glass on the one hand, and on the other hand, when connected with an aluminum alloy cavity, it can serve as a thermal expansion transition layer between the glass sealing structure and the aluminum alloy cavity. This helps to buffer and release the thermal stress at the brazing interface, reduce the risk of external structural stress being transmitted to the glass sealing interface, and thus improve the hermetically tight reliability and temperature cycling stability of the electrical connector after assembly with the aluminum alloy cavity.

[0037] In some watertight applications, Monel alloys exhibit excellent resistance to seawater corrosion and chloride ion pitting. They also have a small potential difference with austenitic stainless steel and good potential compatibility with titanium alloys. This helps reduce the risk of galvanic corrosion when electrical connectors come into contact with surrounding metal components in marine environments. For example, the potential difference between Monel alloys and 316L stainless steel is typically only slightly higher than that of 316L stainless steel, below the range corresponding to significant galvanic corrosion. Similarly, the potential difference between Monel K-500 and TC4 titanium alloys is small. Therefore, from a potential compatibility perspective, Monel alloys, as a watertight connector housing material, can balance corrosion resistance and system compatibility. Furthermore, both Monel 400 and Monel K-500 are low-magnetic alloys, with Monel K-500 having even lower permeability, making it more advantageous in underwater applications where low-magnetic environments are required. In addition, Monel alloy has a high melting point, which, when combined with a pre-oxidation process, provides good conditions for the sealing glass to wet the metal surface and reliably bond, thereby facilitating the formation of a stable glass sealing interface and improving the long-term sealing stability of watertight connectors in complex marine environments.

[0038] In some specific examples, the outer casing 1 has a cuprous oxide and nickel oxide composite film formed on at least the surface where it connects to the first glass body 2. The thickness of the cuprous oxide and nickel oxide composite film is from 0.9 μm to 1.5 μm.

[0039] Specifically, the thickness of the cuprous oxide and nickel oxide composite film is within the range of any one or both of 0.9 μm, 1.0 μm, 1.1 μm, 1.2 μm, 1.3 μm, 1.4 μm, and 1.5 μm.

[0040] Oxides such as cuprous oxide and nickel oxide exhibit good chemical affinity with components in the sealing glass, such as silicon oxide and boron oxide, during high-temperature sealing. This facilitates the wetting and spreading of the molten glass on the metal surface, forming a stable sealing transition interface. Metal-oxygen-silicon bonds can form at the interface, enhancing the bonding strength between the glass and the metal. Furthermore, the oxide film on the surface of the outer shell 1 has a dense structure, ensuring high interfacial bonding strength and long-term stability between the glass and the metal.

[0041] In some embodiments, a metal plating layer may be formed on the surface of the outer casing 1, the metal plating layer being located on the side of the cuprous oxide and nickel oxide composite film away from the outer casing 1.

[0042] In some specific examples, the metal plating includes a nickel layer and a gold layer. The nickel layer is located on the side of the cuprous oxide and nickel oxide composite film facing away from the outer casing 1, and the gold layer is located on the side of the nickel layer facing away from the cuprous oxide and nickel oxide composite film. By setting the nickel and gold layers, it is beneficial to improve the corrosion resistance and surface stability of the outer casing 1 surface, as well as the conductivity and environmental adaptability of the outer casing 1 surface.

[0043] It should be noted that the cuprous oxide and nickel oxide composite film on the surface of the outer casing 1 is formed before glass sealing. This composite film covers the sealing surface between the outer casing 1 and the first glass body 2, improving the wettability and interfacial bonding strength between the outer casing 1 and the sealing glass, thereby enhancing the connection reliability between the outer casing 1 and the first glass body 2. The metal plating layer is formed after glass sealing is completed and is applied to the exposed surface of the outer casing 1. In other words, the metal plating layer is not applied at the sealing interface between the outer casing 1 and the first glass body 2.

[0044] In some embodiments, the wall thickness of the outer casing 1 at least in the sealing area where it connects with the first glass body 2 is not less than 0.2 mm. By controlling the wall thickness of the sealing area of ​​the outer casing 1 to not less than 0.2 mm, it is beneficial to ensure that the outer casing 1 has sufficient structural strength and rigidity in the sealing area, reducing the risk of adverse effects on the first glass body 2 due to excessive local deformation during the sealing process and subsequent use; on the other hand, it is also beneficial to enable the outer casing 1 to form a more stable pressing effect on the first glass body 2, reducing local stress concentration in the sealing area, thereby improving the sealing reliability and long-term stability between the first glass body 2 and the outer casing 1.

[0045] In some specific examples, the cross-section of the outer shell 1 can be rectangular, circular, or other shapes to adapt to different assembly structures and application requirements.

[0046] In some embodiments, the glass body refers to an insulating support formed by heating, softening, wetting, and cooling the sealing glass to solidify. The glass body serves both to insulate and fix the contacts, and to provide a sealing and isolation function between the housing and the contacts. Please refer to [link to relevant documentation]. Figure 3 and Figure 4 Sealing glass can be made from at least one of integral glass blanks and thin-walled glass tubes.

[0047] Specifically, when the electrical connector is a circular connector, the sealing glass body can be made of glass powder with added adhesive, which is pressed, debonded, and vitrified to form a monolithic glass blank. Alternatively, it can be prefabricated as a thin-walled glass tube and then sealed at high temperature. Since the sealing area of ​​a circular connector usually has good axial symmetry, the glass body experiences relatively balanced forces in all directions during the heating and sealing process and the cooling and shrinkage process. Therefore, both monolithic glass blanks and thin-walled glass tubes can be used as optional sealing methods.

[0048] Specifically, when the electrical connector is a rectangular connector, because the sealing area of ​​a rectangular connector is usually non-axially symmetrically distributed, and multiple contacts are spaced apart within the rectangular area, when using a whole glass blank for sealing, large local stresses can easily form around the contacts, the rectangular edges, and the corners during the sealing heating and cooling contraction process. To reduce the impact of these local stresses on the glass body and the sealing interface, thin-walled glass tubes can be used for high-temperature sealing, thereby improving sealing reliability.

[0049] In some embodiments, the material of the first glass body 2 includes iron-sealed glass, which is a type of sealing glass. The coefficient of thermal expansion of iron-sealed glass is 9.3 × 10⁻⁶ in the temperature range of 20°C to 300°C. 6 / ℃ to 10.5×10 6 / ℃. The iron-sealed glass can form a relatively suitable sealing system with the contacts and the housing 1, with a sealing temperature of 960℃ to 980℃.

[0050] In some embodiments, the material of the first contact 3 includes an iron-nickel alloy, the iron-nickel alloy having a coefficient of thermal expansion of 9.0 × 10⁻⁶ in the range of 20°C to 300°C. 6 / ℃ to 9.5×10 6 / ℃.

[0051] In some specific examples, the material of the first contact 3 can be 4J50 alloy. 4J50 alloy is a type of iron-nickel constant-expansion alloy, and its coefficient of thermal expansion is well-matched with that of the iron-sealed glass. This helps reduce thermal stress between the first contact 3 and the glass body after high-temperature sealing, reducing the risk of cracks or interface damage in the glass around the contact, and improving the airtightness and structural stability after sealing. 4J50 alloy is an iron-nickel constant-expansion alloy listed in the Chinese national standard GB / T 37797-2019 "Expansion Alloys." Its design purpose is to form a relatively well-matched thermal expansion relationship with specific materials within a predetermined temperature range to meet the requirements of reliable sealing. In the temperature range of 20℃ to 300℃, the average linear expansion coefficient of 4J50 alloy is approximately 9.0 × 10⁻⁶. 6 / ℃ to 9.5×10 6 / ℃, its typical value can be 9.2×10 6 / ℃.

[0052] In some specific examples, the first contact 3 is spaced apart along at least one of the first and second directions. The end of the first contact 3 located inside the receiving cavity has a solder cup structure for soldering leads, while the end located outside the housing 1 has a pin or socket structure for plugging and unplugging with corresponding model parts.

[0053] In some specific examples, the first contact 3 has a composite film of iron oxide and nickel oxide formed on its surface at least at the junction with the first glass body 2. The iron oxide and nickel oxide composite film on the surface of the first contact 3 exhibits good chemical affinity with components such as silicon oxide and boron oxide in the sealing glass during the high-temperature sealing process, thereby facilitating the wetting and spreading of the molten glass on the surface of the first contact 3 and forming a stable sealing transition interface. Furthermore, the oxide film on the surface of the first contact 3 can be controlled to have a dense structure to ensure high interfacial bonding strength and long-term stability between the glass and the metal.

[0054] In some embodiments, a metal plating layer is formed on the surface of the first contact 3.

[0055] In some specific examples, the metal plating on the surface of the first contact 3 includes a copper layer, a nickel layer, and a gold layer. The copper layer is located on the side of the iron oxide and nickel oxide composite film on the surface of the first contact 3 that faces away from the first contact 3; the nickel layer is located on the side of the copper layer that faces away from the composite film; and the gold layer is located on the side of the nickel layer that faces away from the copper layer. By sequentially setting the copper, nickel, and gold layers, it is beneficial to improve the conductivity, corrosion resistance, and contact reliability of the first contact 3.

[0056] It should be noted that the composite film of iron oxide and nickel oxide on the surface of the first contact 3 is formed before glass sealing, and is mainly used to improve the wettability and interfacial bonding strength between the first contact 3 and the sealing glass; the aforementioned metal coating is formed after glass sealing is completed, and is mainly applied to the exposed surface of the first contact 3. Therefore, the aforementioned metal coating is not applied at the sealing interface between the first contact 3 and the first glass body 2.

[0057] In some embodiments, the first contact 3 includes an engagement section 32 and a sealing section 31. The sealing section 31 is sealed to the first glass body 2, and the engagement section 32 is located outside the outer shell 1. The outer diameter of the sealing section 31 is larger than the outer diameter of the engagement section 32, and the difference between the outer diameters of the sealing section 31 and the engagement section 32 is 0.05 mm to 0.10 mm. Specifically, the difference between the outer diameters of the sealing section 31 and the engagement section 32 is within the range of any one or both of 0.05 mm, 0.06 mm, 0.07 mm, 0.08 mm, 0.09 mm, and 0.10 mm.

[0058] In some embodiments, the electrical connector is a watertight electrical connector.

[0059] For some specific examples, please refer to Figure 5 The watertight electrical connector also includes an inner transmission unit, which comprises an inner housing 4, a second glass body 5, and at least one second contact 6. The inner housing 4 is disposed within and sealed to the first glass body 2, and is made of an iron-nickel alloy. The second glass body 5 is disposed within and sealed to the inner housing 4, and is made of the same material as the first glass body 2. The second contact 6 is inserted into and sealed to the second glass body 5, and is made of the same material as the first contact 3. The inner transmission unit transmits two pairs of differential signals, and the first contact 3, located outside the inner transmission unit, transmits ordinary signals and / or power current.

[0060] In some specific examples, the watertight electrical connector has an external sealing structure, which is located on the outer periphery of the housing 1 and at the external sealing surface formed by the watertight electrical connector and the mating part and / or mounting structure. The external sealing structure includes a sealing ring and / or a sealing lubricating medium. Specifically, the sealing ring may be located in an annular groove on the outer periphery of the housing 1, or at the sealing portion where the housing 1 mates with the mating part; the sealing lubricating medium may be located on the surface of the sealing ring, the sealing mating surface of the housing 1, and / or the corresponding sealing mating surface of the mating part. Through the above configuration, the external sealing structure can further form an auxiliary seal at the interface between the electrical connector and the external mating part, in addition to the internal seal formed by the glass sealing.

[0061] In some embodiments, the electrical connector is a hermetically sealed electrical connector that can mate with a docking device housing. The docking device housing is used to house electronic devices or circuit modules and has mounting openings on its walls corresponding to the hermetically sealed electrical connector. The docking device housing may be made of aluminum alloy. The hermetically sealed electrical connector is brazed to the periphery of the mounting opening of the docking device housing via mounting edges and / or solder rings to form a hermetically sealed structure.

[0062] Secondly, embodiments of this application provide a method for manufacturing an electrical connector, comprising: Provides housing 1, first contact 3, and sealing glass; The outer casing 1 and the first contact element 3 are respectively subjected to pre-oxidation treatment; The pre-oxidized outer shell 1, the pre-oxidized first contact 3, and the sealing glass are assembled into a mold to form an assembly. The assembly is heated and sintered; The sintered assembly is cooled to obtain the electrical connector provided in the first aspect of this application.

[0063] Pre-oxidation treatment refers to the controlled oxidation treatment of the metal sealing surface to form a thin and dense oxide film on the metal surface, thereby improving the wettability of the molten glass to the metal surface and the interfacial bonding strength.

[0064] By pre-oxidizing the outer shell 1 and the first contact 3, a thin and dense oxide film is formed on their sealing surfaces. This improves the wettability and spreadability of the molten glass on the metal surface and enhances the interfacial bonding strength between the glass and the metal. After assembling the pre-oxidized outer shell 1, the first contact 3, and the sealing glass, followed by heating and controlled cooling, a stable and stress-controlled glass sealing structure is formed, thereby improving the sealing reliability, sealing reliability, and long-term stability of the electrical connector. The sealing glass forms the first glass body 2 after heating and sintering.

[0065] In some embodiments, the outer shell 1 and the first contact 3 are annealed before the pre-oxidation treatment; Annealing is performed under a vacuum or protective atmosphere at a temperature of 990°C to 1010°C for 20 to 70 minutes.

[0066] Specifically, the annealing temperature is any one or both of the following: 990℃, 995℃, 1000℃, 1005℃, and 1010℃. The annealing time is any one or both of the following: 20 min, 30 min, 40 min, 50 min, 60 min, and 70 min.

[0067] In some specific examples, the outer shell 1 and the first contact 3 are cleaned before annealing to remove surface contaminants and improve the stability of subsequent annealing, pre-oxidation and glass sealing.

[0068] In some embodiments, the pre-oxidation treatment includes: pre-oxidation using a muffle furnace air oxidation method, oxidizing the first contact 3 at 690°C to 710°C for 570s to 630s, and oxidizing the outer casing 1 at 500°C to 550°C for 840s to 960s.

[0069] Through pre-oxidation treatment, a dense oxide film mainly composed of iron oxide and nickel oxide can be formed on the surface of the first contact 3, and a dense oxide film mainly composed of cuprous oxide and nickel oxide can be formed on the surface of the outer shell 1. This helps to improve the wettability of the molten glass to the metal surface and the interfacial bonding strength, thereby improving the sealing reliability, sealing reliability and long-term use stability.

[0070] Specifically, an air oxidation method using a muffle furnace is adopted, and the pre-oxidation temperature of the first contact element 3 is within the range of any one or any two of 690℃, 695℃, 700℃, 705℃, and 710℃; the pre-oxidation time is within the range of any one or any two of 570s, 580s, 590s, 600s, 610s, 620s, and 630s.

[0071] Specifically, an air oxidation method using a muffle furnace is adopted, and the pre-oxidation temperature of the outer shell 1 is within the range of any one or any two of 500℃, 510℃, 520℃, 530℃, 540℃, and 550℃; the pre-oxidation time is within the range of any one or any two of 840s, 860s, 880s, 900s, 920s, 940s, and 960s.

[0072] In other embodiments, the pre-oxidation treatment includes: performing a wet nitrogen oxidation process, oxidizing the first contact 3 at 690°C to 710°C for 1620s to 1980s, and oxidizing the outer casing 1 at 530°C to 550°C for 2100s to 2700s; the nitrogen used in the wet nitrogen oxidation process has a purity of not less than 99.99% and a dew point of -5°C to 10°C. By employing the wet nitrogen oxidation process, the first contact 3 and the outer casing 1 can be pre-oxidized under controlled atmospheric conditions, which is beneficial for forming a more uniform and dense oxide film on their sealing surfaces, improving the wettability of the molten glass to the metal surface and the interfacial bonding ability.

[0073] Specifically, a wet nitrogen oxidation method is adopted, with the pre-oxidation temperature of the first contact 3 being any one or both of 690℃, 695℃, 700℃, 705℃, and 710℃; the pre-oxidation time being any one or both of 1620s, 1700s, 1780s, 1860s, 1940s, and 1980s; and the dew point being any one or both of -5℃, 0℃, 2℃, 4℃, 6℃, 8℃, and 10℃.

[0074] Specifically, a wet nitrogen oxidation method is adopted, with the pre-oxidation temperature of the outer shell 1 being any one or both of 530℃, 535℃, 540℃, 545℃, and 550℃; and the pre-oxidation time being any one or both of 2100s, 2250s, 2400s, 2550s, and 2700s. The dew point is any one or both of -5℃, 0℃, 2℃, 4℃, 6℃, 8℃, and 10℃.

[0075] In some embodiments, heating and sintering the assembly includes holding at 960°C to 980°C for 15 to 20 minutes. By heating to 960°C to 980°C and holding for 15 to 20 minutes, it is beneficial to allow the molten glass to fully wet the sealing surfaces of the outer shell 1 and the first contact 3, thereby completing the sealing bond between the glass and the metal, and improving the bonding strength and sealing integrity of the sealing interface.

[0076] Specifically, the heat preservation temperature is any one or any two of 960℃, 965℃, 970℃, 975℃, and 980℃. The heat preservation time is any one or any two of 15min, 16min, 17min, 18min, 19min, and 20min.

[0077] The heating rate can be selected based on the size or total mass of the assembly. When using the total mass of the assembly as the classification criterion, assemblies with a total mass of no more than 50g can be considered small products, and their heating rate can be 50℃ / min to 100℃ / min. Assemblies with a total mass greater than 50g can be considered large products, and their heating rate can be 20℃ / min to 50℃ / min. Figures 1 to 4 This diagram illustrates a possible structure for a small product. Figure 5 The diagram illustrates a possible structure for a large product. Selecting different heating rates based on the size of the assembly helps to ensure more uniform heating of the entire assembly, reducing the risk of excessive temperature differences between the inside and outside of large-sized products, uneven heating of the glass, or unstable interface conditions caused by excessively rapid heating. For small products, it helps to improve heating efficiency while ensuring sealing quality.

[0078] In some embodiments, cooling the sintered assembly includes cooling it to room temperature at a cooling rate of 10°C / min to 20°C / min. By controlling the cooling rate within the above range, it is beneficial to gradually release the thermal stress in the sealing interface and glass body during the cooling process of the sintered assembly, and to avoid excessive stress concentration between the glass body, the outer shell 1 and the first contact member 3 due to excessively rapid cooling.

[0079] Specifically, the cooling rate is any one or any two of the following: 10℃ / min, 11℃ / min, 12℃ / min, 13℃ / min, 14℃ / min, 15℃ / min, 16℃ / min, 17℃ / min, 18℃ / min, 19℃ / min, and 20℃ / min.

[0080] In some embodiments, when the electrical connector is a watertight connector, the contacts can be subjected to copper / nickel / gold composite electroplating. Specifically, a copper layer, a nickel layer, and a gold layer can be sequentially formed on the contact surface to improve the conductivity, corrosion resistance, and contact reliability of the contacts. Furthermore, a sealing ring can be fitted around the outer periphery of the housing to further form an external sealing structure between the electrical connector and the mating parts, in addition to the internal seal formed by the glass seal, thereby improving the overall sealing reliability and environmental adaptability of the watertight connector.

[0081] It is understandable that, in the case of a watertight electrical connector including an inner transmission unit, the inner housing 4 and the second contact 6 can be annealed, pre-oxidized and / or subsequently sealed simultaneously with the outer housing 1 and the first contact 3, in order to ensure the process consistency and sealing stability of the inner sealing structure and the outer sealing structure.

[0082] In some embodiments, when the electrical connector is a hermetically sealed electrical connector, the entire electrical connector can be nickel / gold plated. Forming nickel and gold layers on the entire surface of the electrical connector helps to improve the corrosion resistance and surface stability of the outer surface.

[0083] The present application will now be described in detail with reference to specific embodiments.

[0084] Example 1 (1) Provide an outer casing 1, a first contact 3, and a sealing glass, wherein the outer casing 1 is made of Monel 400 alloy, the first contact 3 is made of 4J50 alloy, and the sealing glass is made of alloy with a thermal expansion coefficient of 9.8×10⁻⁶. Iron-sealed glass blanks at 6℃; (2) The outer shell 1 and the first contact 3 are cleaned and dried, and then annealed under vacuum at 1000°C for 30 minutes; (3) The outer shell 1 is subjected to muffle furnace pre-oxidation treatment at a temperature of 550°C for 15 minutes, followed by air cooling; the first contact 3 is subjected to pre-oxidation treatment at a temperature of 700°C for 10 minutes, followed by air cooling. (4) Use graphite molds to assemble and position the outer shell 1, the first contact part 3 and the sealing glass; (5) Sealing and forming are carried out in a nitrogen-protected chain furnace. The equipment is set to heat up to 980°C at a heating rate of 20°C / min, and the nitrogen flow rate is 3~5 m³ / min. 3 / h; (6) Set the equipment to cool down to room temperature at a rate of 15℃ / min; (7) The outer shell 1 is protected with electroplated peelable adhesive. The first contact 3 is electroplated with a combination of copper, nickel and gold, wherein the copper thickness is 10 micrometers, the nickel thickness is 3 micrometers and the gold thickness is 0.5 micrometers. After electroplating, the shell is cleaned with ultrasonic-assisted pure water and dried in an oven at 120°C for 2 hours. The peelable adhesive film is then removed by mechanical means.

[0085] Example 2 The difference between this embodiment and Embodiment 1 is that: (1) The sealing glass uses glass with a thermal expansion coefficient of 9.8×10. 6 Iron-sealed thin-walled glass tube at / ℃; (3) The pre-oxidation temperature of the outer shell 1 is 540°C and the pre-oxidation time is 15 minutes; the pre-oxidation temperature of the first contact 3 is still 700°C and the pre-oxidation time is still 10 minutes.

[0086] The remaining preparation steps are the same as in Example 1.

[0087] Example 3 The difference between this embodiment and Embodiment 1 is that: (1) The outer shell 1 is made of Monel K-500 alloy; (3) The pre-oxidation temperature of the outer shell 1 is 540℃ and the pre-oxidation time is 15 minutes.

[0088] The remaining preparation steps are the same as in Example 1.

[0089] Example 4 The difference between this embodiment and Embodiment 1 is that: (1) The outer shell 1 is made of Monel K-500 alloy, and the sealing glass is made of glass with a thermal expansion coefficient of 9.8×10. Iron-sealed thin-walled glass tubes at 6℃; (3) The pre-oxidation temperature of the outer shell 1 is 550℃ and the pre-oxidation time is 15 minutes.

[0090] The remaining preparation steps are the same as in Example 1.

[0091] Example 5 The difference between this embodiment and Embodiment 1 is that: (1) The sealing glass uses glass with a thermal expansion coefficient of 9.8×10. 6 Iron-sealed thin-walled glass tube at / ℃; (3) The outer shell 1 is pre-oxidized in a muffle furnace at a temperature of 550°C for 15 minutes, followed by air cooling; the first contact 3 is pre-oxidized in a wet nitrogen environment, wherein protective nitrogen gas is introduced into the oxidation furnace through pure water to form a wet nitrogen atmosphere, and the first contact 3 is pre-oxidized at 700°C for 30 minutes in this wet nitrogen atmosphere. (5) Seal and form at 970℃ for 15 minutes.

[0092] The remaining preparation steps are the same as in Example 1.

[0093] Example 6 The difference between this embodiment and Embodiment 1 is that: (1) The outer shell 1 is made of Monel K-500 alloy, and the sealing glass is made of glass with a thermal expansion coefficient of 9.8×10. Iron-sealed thin-walled glass tubes at 6℃; (3) Both the outer shell 1 and the first contact 3 are treated by wet nitrogen pre-oxidation. Protective nitrogen gas enters the oxidation furnace through pure water to form a wet nitrogen atmosphere. The outer shell 1 is pre-oxidized at 550°C for 30 minutes under the wet nitrogen atmosphere, and the first contact 3 is pre-oxidized at 700°C for 30 minutes under the wet nitrogen atmosphere. (5) Seal and form at 970℃ for 15 minutes.

[0094] The remaining preparation steps are the same as in Example 1.

[0095] Example 7 (1) Provide an outer casing 1, a first contact 3, and a sealing glass, wherein the outer casing 1 is made of Monel 400 alloy, the first contact 3 is made of 4J50 alloy, and the sealing glass is made of alloy with a thermal expansion coefficient of 9.5×10⁻⁶. 6 Iron-sealed glass thin-walled tube at / ℃; (2) Anneal the outer casing 1 and the first contact 3 under vacuum at 1000°C for 60 minutes; (3) The outer shell 1 is pre-oxidized at a temperature of 550°C for 15 minutes; the first contact 3 is pre-oxidized at a temperature of 700°C for 10 minutes. (4) Assemble and position the outer shell 1, the first contact 3 and the sealing glass using a graphite mold; (5) Sealing and molding are carried out in a nitrogen protective atmosphere. The equipment is set to heat up to 980°C at a heating rate of 20°C / min, and the nitrogen flow rate is 3~5 m³ / min. 3 / h; (7) First, chemically plate the entire electrical connector with medium phosphorus nickel with a plating thickness of 8 micrometers, then perform gold plating with a plating thickness of 0.5 micrometers; then use weak ultrasonic assisted pure water cleaning that does not damage the glass body, then passivate with potassium dichromate solution, then use weak ultrasonic assisted pure water cleaning that does not damage the glass body again, and blow dry the surface moisture; finally, place the electrical connector in a 120℃ oven to dry for 1 hour.

[0096] The remaining preparation steps are the same as in Example 1.

[0097] Example 8 The difference between this embodiment and embodiment 7 is that: (1) The sealing glass uses glass with a thermal expansion coefficient of 9.5×10. 6 Iron-sealed glass blanks at / ℃.

[0098] The remaining preparation steps are the same as in Example 7.

[0099] Example 9 The difference between this embodiment and embodiment 7 is that: (1) The outer shell 1 is made of Monel K-500 alloy.

[0100] The remaining preparation steps are the same as in Example 7.

[0101] Comparative Example 1 The difference between this comparative example and Example 1 is that: (1) The outer casing 1 is made of SUS316L stainless steel; (3) The outer shell 1 is not pre-oxidized, only the first contact 3 is pre-oxidized.

[0102] The remaining conditions are the same as in Example 1.

[0103] Comparative Example 2 The difference between this comparative example and Example 1 is that: (1) The outer shell 1 is made of TC4 titanium alloy. (3) The outer shell 1 is not pre-oxidized, only the first contact 3 is pre-oxidized.

[0104] The remaining conditions are the same as in Example 1.

[0105] Comparative Example 3 The difference between this comparative example and Example 1 is that: (1) The outer shell 1 is made of Monel K-500 alloy; (3) Neither the outer shell 1 nor the first contact 3 is subjected to pre-oxidation treatment.

[0106] The remaining conditions are the same as in Example 1.

[0107] Comparative Example 4 The difference between this comparative example and Example 1 is that: (1) The outer shell 1 is made of Monel K-500 alloy; (3) The first contact 3 and the outer shell 1 are treated by wet nitrogen pre-oxidation, wherein protective nitrogen gas enters the oxidation furnace through pure water to form a wet nitrogen atmosphere, and the first contact 3 and the outer shell 1 are pre-oxidized at 700°C for 30 minutes under the wet nitrogen atmosphere. (5) Seal and form at 970℃.

[0108] The remaining conditions are the same as in Example 1.

[0109] Performance testing (a) Performance testing of sintered products The products obtained after step (6) in Examples 1 to 6 and Comparative Examples 1 to 4 were subjected to air tightness testing, hydrostatic testing and insulation withstand voltage testing.

[0110] The airtightness test was performed using a helium mass spectrometer leak detector under normal temperature and pressure conditions.

[0111] The water pressure test method is as follows: Seal one end of the glass body with a rubber ring and a stainless steel fixture, put the component into the water, pressurize the water and keep it for 24 hours, then take it out, disassemble the stainless steel fixture, and check whether there is water seepage into the glass surface at that end.

[0112] The insulation withstand voltage test method is as follows: the first contact 3 is tested using an insulation and withstand voltage tester and special testing tools; the insulation resistance between any adjacent first contact 3 and between any first contact 3 and the outer casing 1 under DC 100V conditions should not be less than 1000 MΩ; between any adjacent contact and between any contact and the outer casing, it should be able to withstand a test voltage of 250V (50Hz Ac) for 1 minute without breakdown or arcing.

[0113] The test results are as follows: In Example 1, the gas tightness test after sintering was qualified, and the gas leakage rate was no higher than 1×10⁻⁶. -9 Pa·m 3 The water tightness test of 10MPa and the insulation withstand voltage test were both passed.

[0114] In Example 2, the gas tightness test after sintering was qualified, and the gas leakage rate was no higher than 1×10⁻⁶. -9 Pa·m 3 The water tightness test of 20MPa and the insulation withstand voltage test were both passed.

[0115] In Example 3, the gas tightness test after sintering was qualified, and the gas leakage rate was no higher than 1×10⁻⁶. -9 Pa·m 3 The water tightness test of 15MPa and the insulation withstand voltage test were both passed.

[0116] In Example 4, the gas tightness test after sintering was qualified, and the gas leakage rate was no higher than 1×10⁻⁶. -9 Pa·m 3 / s, passed the 80MPa water tightness pressure test, and passed the insulation withstand voltage test.

[0117] In Example 5, the gas tightness test after sintering was qualified, and the gas leakage rate was no higher than 1×10⁻⁶. -9 Pa·m 3 The water tightness test of 20MPa and the insulation withstand voltage test were both passed.

[0118] In Example 6, the gas tightness test after sintering was qualified, and the gas leakage rate was no higher than 1×10⁻⁶. -9 Pa·m 3 / s, passed the 80MPa water tightness pressure test, and passed the insulation withstand voltage test.

[0119] In Comparative Example 1, the air tightness test after sintering was qualified, the 10MPa water tightness pressure test was qualified, and the insulation withstand voltage test was qualified.

[0120] In Comparative Example 2, the sintered glass seals well to the first contact 3, but the wetting of the titanium alloy outer shell 1 is insufficient, resulting in a failure to pass the airtightness test and a gas leakage rate of not less than 1×10⁻⁶. -5 Pa·m 3 The water tightness test at 10MPa per second showed leakage, therefore the insulation withstand voltage test was no longer performed.

[0121] In Comparative Example 3, after sintering, neither the outer shell 1 nor the first contact element 3 was sealed together with the first glass body 2, and no effective sealing interface was formed.

[0122] In Comparative Example 4, the airtightness test after sintering failed, and the gas leakage rate was not less than 1×10⁻⁶. -7 Pa·m 3 / s, 10MPa water tightness pressure test showed leakage.

[0123] (ii) Performance testing of products after electroplating For the electroplated products obtained after step (7) in Examples 1 to 6 and Comparative Example 1, the air tightness test, water pressure test and insulation withstand voltage test methods described above were used for testing.

[0124] The test results are as follows: In Example 1, the airtightness and 10MPa watertightness pressure tests after electroplating were passed, and the insulation withstand voltage test was also passed.

[0125] In Example 2, the airtightness and 20MPa watertightness pressure tests after electroplating were passed, and the insulation withstand voltage test was also passed.

[0126] In Example 3, the airtightness and 15MPa watertightness pressure tests after electroplating were passed, and the insulation withstand voltage test was also passed.

[0127] In Example 4, the airtightness and 80MPa watertightness pressure tests after electroplating were passed, and the insulation withstand voltage test was also passed.

[0128] In Example 5, the airtightness and 20MPa watertightness pressure tests after electroplating were passed, and the insulation withstand voltage test was also passed.

[0129] In Example 6, the airtightness and 80MPa watertightness pressure tests after electroplating were passed, and the insulation withstand voltage test was also passed.

[0130] In Comparative Example 1, the airtightness and 10MPa watertightness pressure tests after electroplating were qualified, but in the DC 100V insulation test, the insulation resistance between some of the first contact 3 and between the first contact 3 and the outer shell 1 was unqualified, with the lowest being only 200 MΩ, which is lower than the design requirement of 1000 MΩ; the 250V (50Hz Ac) 1-minute withstand voltage test was basically qualified.

[0131] (III) Performance testing after temperature cycling After the product in step (7) is subjected to five temperature cycle tests from -40℃ to 125℃, it is then tested according to the above-mentioned methods for air tightness test, water pressure test and insulation withstand voltage test.

[0132] The test results are as follows: In Example 1, the airtightness and 10MPa watertightness pressure tests were passed, and the insulation withstand voltage test was also passed.

[0133] In Example 2, the airtightness and 20MPa watertightness pressure tests were passed, and the insulation withstand voltage test was also passed.

[0134] In Example 3, the airtightness and 15MPa watertightness pressure tests were passed, and the insulation withstand voltage test was also passed.

[0135] In Example 4, the airtightness and 80MPa watertightness pressure tests were passed, and the insulation withstand voltage test was also passed.

[0136] In Example 5, the airtightness and 20MPa watertightness pressure tests were passed, and the insulation withstand voltage test was also passed.

[0137] In Example 6, the airtightness and 80MPa watertightness pressure tests were passed, and the insulation withstand voltage test was also passed.

[0138] In Comparative Example 1, the airtightness and 10MPa watertightness pressure tests passed, but the number of points failing the insulation withstand voltage test increased, with the lowest insulation resistance dropping to 50 MΩ, and breakdown and arcing occurring between some of the first contact elements 3. Observation of the glass surface revealed delamination and even spalling around the first contact elements 3; microcracks were visible on the glass surface around the stainless steel outer casing 1.

[0139] (iv) Salt solution immersion test The products after step (7) in Examples 1 to 6 were soaked in 5% NaCl solution for 180 days.

[0140] The results showed that no visible corrosion pits or gap corrosion were found on the outer surface of any of the embodiments; the airtightness of the connectors was tested after disassembly and all passed the corresponding pressure tests. Specifically, Embodiment 1 corresponds to 10 MPa, Embodiment 2 to 20 MPa, Embodiment 3 to 15 MPa, Embodiment 4 to 80 MPa, Embodiment 5 to 20 MPa, and Embodiment 6 to 80 MPa.

[0141] (v) Performance testing of airtight application examples Performance tests were conducted on Examples 7 to 9 after sintering, after electroplating, and after assembly with the aluminum alloy cavity.

[0142] Among them, the airtightness test is carried out using a helium mass spectrometer leak detector under normal temperature and pressure conditions.

[0143] The insulation withstand voltage test conditions for Example 7 are as follows: the insulation resistance is not less than 1000 MΩ under DC 100V conditions, and there is no breakdown or arcing under 250V (50Hz Ac) conditions for 1 minute.

[0144] The insulation withstand voltage test conditions for Example 9 are: insulation resistance not less than 5000 MΩ, and withstand voltage test at 600V without arcing breakdown.

[0145] The assembly test method is as follows: the qualified components after electroplating are assembled with the nickel-plated and tin-plated aluminum alloy cavity, 63 tin-lead solder paste is applied to the welding interface, and reflow soldering is performed at 250°C. After soldering, the air tightness test is performed; then the temperature cycle test is performed, and the air tightness, insulation and withstand voltage performance are tested again.

[0146] In Example 7, the gas tightness test after sintering was qualified, and the gas leakage rate was no higher than 1×10⁻⁶. -9 Pa·m 3 / s, insulation withstand voltage test passed; air tightness and insulation withstand voltage test passed after electroplating; after 5 cycles of temperature cycling from -55℃ to 200℃, air tightness and insulation withstand voltage test passed. A 48-hour salt spray test was conducted on the electroplated components; no verdigris was observed on the outer casing 1, and a small amount of red rust was present at the sealing root of the first contact 3, but this did not affect functionality. After reflow soldering with the nickel-plated, tin-plated aluminum alloy cavity, air tightness test passed; after 5 cycles of temperature cycling from -55℃ to 200℃, air tightness and insulation withstand voltage test still passed, with a gas leakage rate not exceeding 1×10⁻⁶. -9 Pa·m 3 / s.

[0147] In Example 8, the airtightness and insulation withstand voltage tests were passed after sintering; the airtightness and insulation withstand voltage tests were passed after electroplating; after 5 cycles of temperature cycling from -40℃ to 125℃, the airtightness and insulation withstand voltage tests were passed. After welding with the aluminum alloy cavity, the airtightness test was passed; after 5 cycles of temperature cycling from -55℃ to 200℃, the airtightness, insulation, and withstand voltage tests were passed, and the gas leakage rate was no higher than 1×10⁻⁶. -9 Pa·m 3 / s.

[0148] In Example 9, the test index after sintering was: air tightness less than 1×10⁻⁶. -9 Pa·m 3 / s, insulation resistance not less than 5000 MΩ, withstand voltage test of 600V without arcing breakdown; after electroplating, after 5 cycles of -55℃~200℃ temperature cycle test, and after welding with aluminum alloy cavity and then after 5 cycles of -55℃~200℃ temperature cycle test, the air tightness, insulation and withstand voltage indicators all passed the test.

[0149] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0150] The embodiments, implementation methods, and related technical features of this application can be combined and substituted for each other without conflict.

[0151] The above are merely preferred embodiments of this application and are not intended to limit this application in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of this application without departing from the scope of the technical solution of this application shall still fall within the scope of the technical solution of this application.

Claims

1. An electrical connector, characterized in that, include: The outer shell (1) has a receiving cavity; A first glass body (2) is disposed in the receiving cavity and sealed to the outer shell (1); At least one first contact (3) is inserted into the first glass body (2) and sealed to the first glass body (2). The first contact (3) has a first end and a second end disposed opposite to each other. The first end is located inside the receiving cavity and the second end is located outside the outer shell (1). Wherein, the coefficient of thermal expansion of the material of the outer shell (1) is greater than that of the material of the first glass body (2), the difference between the coefficient of thermal expansion of the material of the outer shell (1) and the coefficient of thermal expansion of the material of the first glass body (2) is m, and the absolute value of the difference between the coefficient of thermal expansion of the material of the first contact (3) and the coefficient of thermal expansion of the material of the first glass body (2) is n, satisfying: n≤1×10 6 / ℃, and m>n.

2. The electrical connector according to claim 1, characterized in that, The outer shell (1) is made of Monel alloy, which has a coefficient of thermal expansion of 13.5 × 10⁻⁶ in the range of 20°C to 300°C. 6 / ℃ to 14.0×10 6 / ℃; The Monel alloy includes at least one of Monel 400 alloy or Monel K-500 alloy.

3. The electrical connector according to claim 1, characterized in that, The first glass body (2) is made of sealed glass, which includes at least one of a monolithic glass blank and a thin-walled glass tube; The first glass body (2) is made of iron-sealed glass, which has a coefficient of thermal expansion of 9.3 × 10⁻⁶ in the range of 20°C to 300°C. 6 / ℃ to 10.5×10 6 / ℃.

4. The electrical connector according to claim 1, characterized in that, The material of the first contact element (3) includes an iron-nickel alloy, wherein the coefficient of thermal expansion of the iron-nickel alloy is 9.0 × 10⁻⁶ in the range of 20°C to 300°C. 6 / ℃ to 9.5×10 6 / ℃.

5. The electrical connector according to claim 1, characterized in that, The outer shell (1) forms a composite film of cuprous oxide and nickel oxide on the surface at the connection with the first glass body (2).

6. The electrical connector according to claim 1, characterized in that, The first contact (3) has a composite film of iron oxide and nickel oxide formed on the surface at the connection with the first glass body (2).

7. The electrical connector according to claim 1, characterized in that, The wall thickness of the outer shell (1) in the sealing area with the first glass body (2) is not less than 0.2 mm; and / or, The first contact (3) includes an insertion section (32) and a sealing section (31). The sealing section (31) is sealed to the first glass body (2). The insertion section (32) is located outside the outer shell (1). The outer diameter of the sealing section (31) is larger than the outer diameter of the insertion section (32). The difference between the outer diameter of the sealing section (31) and the outer diameter of the insertion section (32) is 0.05 mm to 0.1 mm.

8. The electrical connector according to claim 1, characterized in that, The electrical connector is a watertight electrical connector, and the electrical connector further includes an internal transmission unit, which includes: The inner shell (4) is disposed inside the first glass body (2) and sealed to the first glass body (2). The material of the inner shell (4) is an iron-nickel alloy. The second glass body (5) is disposed inside the inner shell (4) and sealed to the inner shell (4). The material of the second glass body (5) is the same as that of the first glass body (2). At least one second contact (6) is inserted into the second glass body (5) and sealed to the second glass body (5), and the material of the second contact (6) is the same as that of the first contact (3).

9. The electrical connector according to claim 1, characterized in that, The electrical connector is an airtight electrical connector, and the housing (1) is provided with mounting edges and / or solder rings.

10. A method for manufacturing an electrical connector, characterized in that, include: Provides an outer casing (1), a first contact (3), and a sealing glass; The outer shell (1) and the first contact (3) are respectively subjected to pre-oxidation treatment; The pre-oxidized outer shell (1), the pre-oxidized first contact (3), and the sealing glass are assembled in a mold to form an assembly; The assembly is then heated and sintered. The sintered assembly is cooled to obtain the electrical connector as described in any one of claims 1 to 9.

11. The method for manufacturing an electrical connector according to claim 10, characterized in that, Before the pre-oxidation treatment, the outer shell (1) and the first contact (3) are annealed; The annealing process is carried out in a vacuum atmosphere or a protective atmosphere, with an annealing temperature of 990°C to 1010°C and a processing time of 20 min to 70 min.

12. The manufacturing method according to claim 10, characterized in that, The pre-oxidation treatment includes at least one of the following: (a) The first contact (3) is oxidized at 690°C to 710°C for 570s to 630s using an air oxidation method, and the outer shell (1) is oxidized at 500°C to 550°C for 840s to 960s. (b) The first contact (3) is oxidized at 690°C to 710°C for 1620s to 1980s and the outer shell (1) is oxidized at 530°C to 550°C for 2100s to 2700s using a wet nitrogen oxidation method; the purity of the nitrogen gas used in the wet nitrogen oxidation is not less than 99.99% and the dew point is -5°C to 10°C.

13. The manufacturing method according to claim 10, characterized in that, The heating and sintering of the assembly includes: holding at 960°C to 980°C for 15 to 20 minutes; and / or, Cooling the sintered assembly includes cooling it to room temperature at a rate of 10°C / min to 20°C / min.

Images