Electrical connector and method of manufacturing the same

Abstract

The application discloses an electric connector and a manufacturing method thereof. The electric connector comprises an insulating body and a terminal module. The terminal module is arranged at least partially in the insulating body. The terminal module comprises a plurality of conductive terminals and an insulating block for holding the conductive terminals. The conductive terminal comprises a main body, an elastic mating structure connected to one end of the main body, and a tail connected to the other end of the main body. The elastic mating structure is configured to mate with a mating connector and has a mating state and a natural state. In the mating state, the elastic mating structure forms a closed circumferential structure. In the natural state, the elastic mating structure is in a non-closed form. In this way, the current can be uniformly distributed to avoid local heating, and the contact can be kept stable in a vibration environment to reduce resistance fluctuation.

Description

Technical Field

[0001] This application relates to an electrical connector and its manufacturing method, belonging to the field of connector technology. Background Technology

[0002] Electrical connectors with Pogo terminals are widely used in various fields for data transmission and / or power connection. A Pogo terminal typically includes a body, a spring mounted in the body, and a contact portion that mates with the spring. The spring provides contact force when the contact portion abuts against the mating terminals of the connector.

[0003] However, Pogo terminals in the prior art often generate localized heating due to uneven current distribution. Summary of the Invention

[0004] The purpose of one embodiment of this application is to provide an electrical connector and a method for manufacturing the same, which enables uniform current distribution to avoid localized heating and maintains stable contact in a vibrating environment to reduce resistance fluctuations.

[0005] In one embodiment of this application: An electrical connector, comprising: Insulating body, and A terminal module, at least partially disposed within the insulating body, includes a plurality of conductive terminals and an insulating block holding the plurality of conductive terminals. Each conductive terminal includes a main body, an elastic mating structure connected to one end of the main body, and a tail connected to the other end of the main body. The elastic mating structure is configured to mate with a mating connector and has a mating state and a natural state. In the mating state, the elastic mating structure forms a closed circumferential structure, and in the natural state, it is in a non-closed form.

[0006] As a further improved technical solution of the embodiments of this application, the elastic docking structure includes a curved part connected to the main body, a rotating part connected to the curved part, and a docking part connected to the rotating part. The docking part includes a first contact part and a second contact part. The first contact part is opposite to the curved part and configured to abut against the docking connector. In the docking state, the second contact part abuts against the curved part.

[0007] As a further improved technical solution of the embodiments of this application, the docking part includes a first arm, a second arm, and an extension. The first arm includes a first end and a second end, and the second arm includes a third end and a fourth end. The first end is connected to the rotating part, the second end is connected to one end of the first contact part, the third end is connected to one end of the second contact part, the fourth end is connected to the other end of the first contact part, and the extension is connected to the other end of the second contact part and extends away from the first arm. The distance between the first end and the third end is greater than the distance between the second end and the fourth end.

[0008] As a further improved technical solution of the embodiments of this application, the main body and the first arm are arranged at a first angle, the first arm and the second arm are arranged at a second angle, and the second arm and the extension are arranged at a third angle, wherein the first angle is smaller than the second angle, the second angle is smaller than the third angle, and the difference between the second angle and the first angle is greater than the difference between the third angle and the second angle.

[0009] As a further improved technical solution of the embodiments of this application, the bending part, the rotating part and the first contact part are all arc-shaped structures. The arc radius of the bending part is greater than the arc radius of the first contact part, the arc radius of the first contact part is greater than the arc radius of the rotating part, and the difference between the arc radius of the bending part and the arc radius of the first contact part is greater than the difference between the arc radius of the first contact part and the arc radius of the rotating part.

[0010] As a further improved technical solution of the embodiments of this application, the plurality of conductive terminals include grounding terminals, signal terminals and power terminals, the electrical connector includes a shielding component, the shielding component includes a shielding body and a bent portion connected to the shielding body and bent relative to the shielding body, the shielding body covers the insulating block, the insulating block has a through hole, and the bent portion passes through the through hole and is connected to the main body of the grounding terminal.

[0011] As a further improved technical solution of the embodiments of this application, the bending portion includes a first segment perpendicularly connected to the shielding body and a second segment perpendicularly connected to the first segment, the second segment being connected to the main body of the grounding terminal.

[0012] As a further improved technical solution of the embodiments of this application, the shielding body is provided with the bending portion on both sides, and the main body of the same grounding terminal is connected to the two bending portions.

[0013] As a further improvement of the technical solution in the embodiments of this application, the electrical connector includes a housing, the housing covers the insulating body, and the housing is a magnetic attraction element; The insulating block has an opening slot, at least a portion of the tail portion is exposed within the opening slot, and is configured to connect to a cable; the electrical connector further includes an adhesive layer formed by curing adhesive filled within the opening slot and covering the tail portion.

[0014] In one embodiment of this application: A method for manufacturing an electrical connector, comprising: The first molding process is performed to mold the insulating block onto a plurality of the conductive terminals; A shielding component is provided, the shielding component including a shielding body and a bent portion connected to the shielding body and bent relative to the shielding body, a plurality of conductive terminals including grounding terminals, an insulating block having a through hole, the bent portion passing through the through hole and connected to the main body of the grounding terminal, and the shielding body covering the insulating block; A second molding process is performed to form the insulating body onto the insulating block and the shielding component.

[0015] Compared with the prior art, the electrical connector provided in one embodiment of this application has the following beneficial effects: the conductive terminals are provided with an elastic mating structure to mate with the mating connector, forming a closed circumferential structure in the mating state, so that the current forms a loop. On the one hand, the current is evenly distributed on the conductive terminals, avoiding local concentration, thereby effectively reducing the risk of heat generation; on the other hand, it can maintain contact stability in a vibration environment, reduce contact resistance fluctuations, and optimize impedance matching, thereby improving signal transmission quality. In addition, its structure also has higher mechanical strength and deformation resistance. Attached Figure Description

[0016] Figure 1 This is a perspective view of an electrical connector provided in an embodiment of this application; Figure 2 yes Figure 1 Top view of the electrical connector shown; Figure 3 It is along Figure 2 Schematic diagram of the cross section of line AA in the middle; Figure 4 yes Figure 1 A schematic diagram of the decomposition process; Figure 5 yes Figure 4 Exploded view of the intermediate terminal module and shielding component; Figure 6 yes Figure 1 A three-dimensional diagram from another angle; Figure 7 yes Figure 6 A schematic diagram of the decomposition process; Figure 8 yes Figure 7 Exploded view of the intermediate terminal module and shielding component; Figure 9 yes Figure 7 A three-dimensional schematic diagram of the conductive terminal and shielding component; Figure 10 yes Figure 9 A three-dimensional schematic diagram of the conductive terminal in the middle; Figure 11 yes Figure 10 A diagram from another angle; Figure 12 yes Figure 10 A diagram from another angle; Figure 13 yes Figure 12 Diagram showing the docking status of the conductive terminals.

[0017] Those skilled in the art should understand that the accompanying drawings provided herein are for the purpose of illustrating specific embodiments of this application, and the scale shown in the drawings is only for illustrative embodiments; other embodiments are not necessarily implemented to scale. Detailed Implementation

[0018] The exemplary embodiments of this application will now be described in detail with reference to the accompanying drawings. If several embodiments exist, features in these embodiments may be combined with each other without conflict. When the description refers to the drawings, unless otherwise stated, the same numbers in different drawings represent the same or similar elements. The descriptions in the following exemplary embodiments do not represent all embodiments consistent with this application; rather, they are merely examples of apparatuses, products, and / or methods consistent with some aspects of this application as set forth in the claims.

[0019] The terminology used in this application is for the purpose of describing particular embodiments only and is not intended to limit the scope of protection of this application. The singular forms “a,” “the,” or “the” used in the description and claims of this application are also intended to include the plural forms unless the context clearly indicates otherwise.

[0020] It should be understood that the terms "first," "second," and similar words used in the specification and claims of this application do not indicate any order, quantity, or importance, but are merely used to distinguish features. Similarly, the terms "an" or "a" and similar words do not indicate a quantity limitation, but rather indicate the presence of at least one. Unless otherwise stated, the terms "before," "after," "above," "below," and similar words appearing in this application are for ease of explanation only and are not limited to a specific location or spatial orientation. The terms "comprising" or "including" and similar words are an open-ended expression, meaning that the element preceding "comprising" or "including" covers the element following "comprising" or "including" and its equivalents, which does not exclude that the element preceding "comprising" or "including" may also include other elements. If "several" appears in this application, it means two or more.

[0021] Please refer to Figures 1 to 12 As shown, one embodiment of this application discloses an electrical connector for mating with a mating connector to transmit data and / or access power. The electrical connector includes an insulating body 1 and a terminal module, the terminal module being at least partially disposed within the insulating body 1. The electrical connector has a first direction BB, a second direction CC, and a third direction DD, wherein the first direction BB, the second direction CC, and the third direction DD are mutually perpendicular.

[0022] Please refer to Figure 4 As shown, the insulating body 1 includes a front end face 11 and a plurality of terminal slots 12 extending through the front end face 11. The plurality of terminal slots 12 are arranged at intervals along the first direction BB. Furthermore, please refer to... Figure 7 As shown, the insulating body 1 further includes a receiving cavity 13, which communicates with the terminal slot 12. In this embodiment, the first direction BB is parallel to the front end face 11.

[0023] Please refer to Figure 4 and Figure 7 As shown, the terminal module includes a plurality of conductive terminals 2 and an insulating block 3 for holding the plurality of conductive terminals 2. The insulating block 3 is housed in the receiving cavity 13, and the conductive terminals 2 are housed in the receiving cavity 13 and respectively pass through the corresponding terminal slots 12.

[0024] In this embodiment, a plurality of conductive terminals 2 are embedded in the insulating block 3 to form a whole for easy assembly. Of course, those skilled in the art will understand that the plurality of conductive terminals 2 can also be fixed to the insulating block 3 by assembly or other means.

[0025] Please refer to Figure 5As shown, the conductive terminal 2 includes a main body 21, an elastic docking structure 22 connected to one end of the main body 21, and a tail 23 connected to the other end of the main body 21. The elastic docking structure 22 is configured to dock with the docking connector and has a docked state and a natural state. In the docked state, the elastic docking structure 22 forms a closed circumferential structure; in the natural state, it is in a non-closed form. By setting the elastic docking structure 22 to dock with the docking connector and forming a closed circumferential structure in the docked state, the current forms a loop. On the one hand, the current is evenly distributed on the conductive terminal 2, avoiding local concentration and effectively reducing the risk of overheating; on the other hand, it can maintain contact stability in a vibration environment, reduce contact resistance fluctuations, and optimize impedance matching to improve signal transmission quality. In addition, its structure also has higher mechanical strength and deformation resistance.

[0026] In this embodiment, please refer to Figure 1 and Figure 9 As shown, the elastic docking structure 22 includes a curved portion 221 connected to the main body 21, a rotating portion 222 connected to the curved portion 221, and a docking portion 223 connected to the rotating portion 222. The docking portion 223 includes a first contact portion 2231 and a second contact portion 2232. The first contact portion 2231 is an arc-shaped structure and is disposed opposite to the curved portion 221, for abutting against the docking connector during docking. The curved portion 221 has elastic deformation capability; therefore, in the docking state, the second contact portion 2232 abuts against the curved portion 221, thereby forming a closed circumferential structure with the curved portion 221, the rotating portion 222, and the docking portion 223. Furthermore, The first contact portion 2231 has a center line, which is the perpendicular bisector of the line connecting the two ends of the first contact portion 2231; the main body portion 21 and the rotating portion 222 are respectively located on both sides of the center line.

[0027] Please refer to Figure 10 As shown, the curved portion 221 is an arc-shaped structure, and the curved portion 221 is connected to the main body portion 21 through an arc-shaped portion 224. The smooth transition of the arc-shaped portion 224 eliminates sharp corners, ensures uniform stress distribution, and further improves structural reliability. The curved portion 221 and the rotating portion 222 are connected through a straight portion 225.

[0028] Please refer to Figure 11As shown, the curved portion 221 includes a first connecting end 2211 connected to the main body portion 21 and a second connecting end 2212 connected to the rotating portion 222. Along the second direction CC, the main body portion 21 is located between the first connecting end 2211 and the second connecting end 2212, allowing the curved portion 221 to extend bidirectionally, increasing the elastic deformation space. In this embodiment, the second direction CC is perpendicular to the direction from the main body portion 21 to the tail portion 23.

[0029] The rotating part 222 has an arc-shaped structure. Please refer to... Figure 12 As shown, the radius R1 of the curved portion 221 is greater than the radius R2 of the first contact portion 2231, the radius R2 of the first contact portion 2231 is greater than the radius R3 of the rotating portion 222, and the difference between the radius R1 of the curved portion 221 and the radius R2 of the first contact portion 2231 is greater than the difference between the radius R2 of the first contact portion 2231 and the radius R3 of the rotating portion 222. The radius R4 of the arc-shaped portion 224 is equal to the radius R1 of the curved portion 221. In this embodiment, the radius R1 of the curved portion 221 is 0.6; the radius R2 of the first contact portion 2231 is 0.3; and the radius R3 of the rotating portion 222 is 0.25. Further, please refer to... Figure 11 As shown, the bent portion 221 includes a first bent segment 221a and a second bent segment 221b. The first bent segment 221a includes the first connecting end 2211, and the second bent segment 221b includes the second connecting end 2212. The radius of curvature of both the first bent segment 221a and the second bent segment 221b is 0.6. When R1 is larger, the stiffness of the bent portion 221 decreases accordingly, making it more prone to elastic deformation under stress. At the same time, the larger radius makes the deformation process smoother, which not only enhances the elastic recovery ability but also effectively avoids plastic buckling or cracking at the bend, thereby significantly improving the durability, load-bearing stability, and overall service life of the elastic deformation portion.

[0030] Please refer to Figure 11As shown, the docking portion 223 includes a first arm portion 2233, a second arm portion 2234, and an extension portion 2235. The first arm portion 2233 includes a first end 22331 and a second end 22332, wherein the first end 22331 is connected to the rotating portion 222, and the second end 22332 is connected to one end of the first contact portion 2231. The second arm portion 2234 includes a third end 22341 and a fourth end 22342, wherein the third end 22341 is connected to one end of the second contact portion 2232, and the fourth end 22342 is connected to the other end of the first contact portion 2231. The extension portion 2235 is connected to the other end of the second contact portion 2232 and extends away from the first arm portion 2233. In this embodiment, the distance d1 between the first end 22331 and the third end 22341 is greater than the distance d2 between the second end 22332 and the fourth end 22342. That is, the first arm portion 2233 and the second arm portion 2234 are arranged in a V-shape. Furthermore, the first arm portion 2233 and the first contact portion 2231 are transitionally connected via a first bending portion 226, and the first bending portion 226 extends outward from the first arm portion 2233. The second arm portion 2234 and the first contact portion 2231 are transitionally connected via a second bending portion 227, and the second bending portion 227 extends outward from the second arm portion 2234. Along the second direction CC, the bent portion 221 is located between the extended portion 2235 and the rotating portion 222.

[0031] Please refer to Figure 12 As shown, the main body 21 and the first arm 2233 are set at a first angle θ1, the first arm 2233 and the second arm 2234 are set at a second angle θ2, and the second arm 2234 and the extension 2235 are set at a third angle θ3. The first angle θ1 is smaller than the second angle θ2, the second angle θ2 is smaller than the third angle θ3, and the difference between the second angle θ2 and the first angle θ1 is greater than the difference between the third angle θ3 and the second angle θ2. In this embodiment, the first angle θ1 is 28°; the second angle θ2 is 55°; and the third angle θ3 is 65°. Please refer to... Figure 13As shown, when the electrical connector mates with the mating connector, the mating portion 223 is compressed, causing the bent portion 221 to undergo elastic deformation. This causes the first contact portion 2231 to retract 0.5mm into the terminal groove 12, and the second contact portion 2232 abuts against the bent portion 221. At this time, the first included angle θ1, the second included angle θ2, and the third included angle θ3 remain almost unchanged. The arc radius of the first bent segment 221a and the arc radius R2 of the first contact portion 2231 remain almost unchanged, while the arc radius of the second bent segment 221b changes from 0.6 to 0.43.

[0032] Please refer to Figure 9 As shown, the conductive terminals 2 include a ground terminal 2a, a signal terminal 2b, and a power terminal 2c. The electrical connector includes a shield 4, which comprises a shield body 41 and a bent portion 42 connected to and bent relative to the shield body 41. (See attached image.) Figure 5 and Figure 8 As shown, the shielding body 41 covers the insulating block 3, the insulating block 3 is provided with a through hole 301, and the bent part 42 passes through the through hole 301 and is connected to the main body part 21 of the grounding terminal 2a.

[0033] Specifically, please refer to Figure 5 As shown, the bending portion 42 includes a first segment 421 perpendicularly connected to the shielding body 41 and a second segment 422 perpendicularly connected to the first segment 421. The second segment 422 is welded and fixed to the main body 21 of the grounding terminal 2a. Furthermore, the shielding body 41 has a narrowing portion 411, the width of which is smaller than the width of the shielding body 41. The first segment 421 is perpendicularly connected to the narrowing portion 411.

[0034] In this embodiment, please refer to Figure 9 As shown, the shielding body 41 has bending portions 42 on both sides, and the main body 21 of the same grounding terminal 2a is connected to two bending portions 42. The terminal module is provided with three grounding terminals 2a, two signal terminals 2b and two power terminals 2c, so the shielding body 41 has six bending portions 42.

[0035] Of course, those skilled in the art will understand that the bending portion 42 may also be provided only on one side of the shielding body 41.

[0036] Please refer to Figure 7As shown, the electrical connector includes a housing 5 that covers the insulating body 1, and the housing 5 is a magnetic element, allowing the electrical connector to engage with the mating connector via magnetic attraction. Specifically, the housing 5 has a limiting step 51 inside, and the front end face 11 of the insulating body 1 abuts against the limiting step 51.

[0037] Please refer to Figure 8 As shown, the insulating block 3 has an opening groove 302, and at least a portion of the tail portion 23 has its surface exposed within the opening groove 302, and is configured to connect with a cable. The electrical connector also includes an adhesive layer 6, which is formed by curing adhesive filled within the opening groove 302, and covers the tail portion 23, achieving sealing, fixation, and insulation protection at the connection point between the tail portion 23 and the cable. In this embodiment, please refer to... Figure 8 As shown, the insulating block 3 has two rows of through holes 301 arranged along the third direction DD. One row of through holes 301 has a through opening 3011 communicating with the opening groove 302, facilitating the welding operation between the bent portion 42 within the through hole 301 and the main body 21. In this embodiment, the third direction DD is perpendicular to the front end face 11.

[0038] This application also discloses a method for manufacturing an electrical connector, the method comprising the following steps: The first molding process involves injection molding the insulating block 3 onto a plurality of the conductive terminals 2; or, the plurality of the conductive terminals 2 are assembled onto the insulating block 3.

[0039] The bent portion 42 of the shield 4 is passed through the through hole 301 and welded to the main body 21 of the grounding terminal 2a, and the shield body 41 covers the insulating block 3.

[0040] The second molding process involves injection molding the insulating body 1 onto the insulating block 3 and the shielding component.

[0041] The outer shell 5 is assembled onto the outside of the insulating body 1.

[0042] The cable is soldered to the tail 23 of the conductive terminal 2, and then adhesive is injected into the opening groove 302, which is then cured to form the adhesive layer 6.

[0043] Before the first molding process, the following steps are also included: stamping to form the conductive terminal 2, and electroplating the stamped conductive terminal 2.

[0044] The manufacturing process of the shielding component 4 is as follows: the shielding component 4 is formed by stamping, and the stamped shielding component 4 is electroplated.

[0045] The above embodiments are only used to illustrate this application and are not intended to limit the technical solutions described in this application. The understanding of this application should be based on those skilled in the art. Although this specification has described this application in detail with reference to the above embodiments, those skilled in the art should understand that they can still make modifications or equivalent substitutions to this application. All technical solutions and improvements that do not depart from the spirit and scope of this application should be covered within the scope of the claims of this application.

Claims

1. An electrical connector, characterized in that, include: Insulating body, and A terminal module, at least partially disposed within the insulating body, includes a plurality of conductive terminals and an insulating block holding the plurality of conductive terminals. Each conductive terminal includes a main body, an elastic mating structure connected to one end of the main body, and a tail connected to the other end of the main body. The elastic mating structure is configured to mate with a mating connector and has a mating state and a natural state. In the mating state, the elastic mating structure forms a closed circumferential structure, and in the natural state, it is in a non-closed form.

2. The electrical connector as claimed in claim 1, characterized in that, The flexible docking structure includes a curved portion connected to the main body, a rotating portion connected to the curved portion, and a docking portion connected to the rotating portion. The docking portion includes a first contact portion and a second contact portion. The first contact portion is opposite to the curved portion and configured to abut against the docking connector. In the docking state, the second contact portion abuts against the curved portion.

3. The electrical connector as described in claim 2, characterized in that, The docking portion includes a first arm, a second arm, and an extension. The first arm includes a first end and a second end, and the second arm includes a third end and a fourth end. The first end is connected to the rotating portion, the second end is connected to one end of the first contact portion, the third end is connected to one end of the second contact portion, and the fourth end is connected to the other end of the first contact portion. The extension is connected to the other end of the second contact portion and extends away from the first arm. The distance between the first end and the third end is greater than the distance between the second end and the fourth end.

4. The electrical connector as described in claim 3, characterized in that, The main body and the first arm are arranged at a first angle, the first arm and the second arm are arranged at a second angle, and the second arm and the extension are arranged at a third angle, wherein the first angle is smaller than the second angle, the second angle is smaller than the third angle, and the difference between the second angle and the first angle is greater than the difference between the third angle and the second angle.

5. The electrical connector as described in any one of claims 2-4, characterized in that, The curved portion, the rotating portion, and the first contact portion are all arc-shaped structures. The radius of the arc of the curved portion is greater than the radius of the arc of the first contact portion, the radius of the arc of the first contact portion is greater than the radius of the arc of the rotating portion, and the difference between the radius of the arc of the curved portion and the radius of the arc of the first contact portion is greater than the difference between the radius of the arc of the first contact portion and the radius of the arc of the rotating portion.

6. The electrical connector as claimed in any one of claims 1-4, characterized in that, The conductive terminals include grounding terminals, signal terminals, and power terminals. The electrical connector includes a shielding component, which includes a shielding body and a bent portion connected to and bent relative to the shielding body. The shielding body covers the insulating block, and the insulating block has a through hole. The bent portion passes through the through hole and is connected to the body portion of the grounding terminal.

7. The electrical connector as claimed in claim 6, characterized in that, The bent portion includes a first segment perpendicularly connected to the shielding body and a second segment perpendicularly connected to the first segment, the second segment being connected to the main body of the grounding terminal.

8. The electrical connector as claimed in claim 6, characterized in that, The shielding body has bending portions on both sides, and the main body of the same grounding terminal is connected to the two bending portions.

9. The electrical connector as claimed in claim 1, characterized in that, The electrical connector includes a housing that covers the insulating body, and the housing is a magnetic element; The insulating block has an opening slot, at least a portion of the tail portion is exposed within the opening slot, and is configured to connect to a cable; the electrical connector further includes an adhesive layer formed by curing adhesive filled within the opening slot and covering the tail portion.

10. A method for manufacturing an electrical connector, characterized in that, The electrical connector is the electrical connector as described in any one of claims 1 to 9, and the manufacturing method includes: The first molding process is performed to mold the insulating block onto a plurality of the conductive terminals; A shielding component is provided, the shielding component including a shielding body and a bent portion connected to the shielding body and bent relative to the shielding body, a plurality of conductive terminals including grounding terminals, an insulating block having a through hole, the bent portion passing through the through hole and connected to the main body of the grounding terminal, and the shielding body covering the insulating block; A second molding process is performed to form the insulating body onto the insulating block and the shielding component.

Images