A method for manufacturing an electric connection terminal for a waterproof connector

Abstract

The application relates to the technical field of terminal manufacturing, and discloses a manufacturing method of an electric connection terminal for a waterproof connector. A continuous metal strip is used to form a continuous terminal blank, and a processing area for forming different connection modes is reserved at a plug-in end; a corresponding forming mode is selected according to a target structure, the plug-in cavity type terminal is subjected to side wall plastic deformation, end turning and overall shape correction to form a plug-in cavity and a plug-in connection part, the sheet-shaped plug-in type terminal is subjected to contour processing, double-sided pressure correction and reference straightening to form a sheet-shaped plug-in part, and the formed terminal blank is positioned and fixed with a corresponding metal cover. The method concentrates the structural changes between different plug-in modes in the plug-in end forming stage, completes the manufacturing of different products while maintaining the basic processing relationship of the terminal body, reduces the synchronous adjustment of multiple related processing stations during product switching, narrows the process range involved in the switching, and reduces the workload of mold re-matching and trial production adjustment.

Description

Technical Field

[0001] This application relates to the field of terminal manufacturing technology, and more specifically, to a method for manufacturing electrical connection terminals for waterproof connectors. Background Technology

[0002] Waterproof connectors typically consist of a connector housing, a sealing structure, and electrical connection terminals located inside the connector. These electrical connection terminals are used to achieve conductive connections and mechanical mating. Depending on the connection object, installation space, and interface type, the mating ends of the electrical connection terminals can have different shapes and spatial structures. Since the mating ends are a crucial part of the terminal's connection function, changes in their structure directly affect the forming state and assembly relationships during the terminal manufacturing process. Therefore, different mating forms usually require processing conditions adapted to their structures.

[0003] In existing technologies, electrical connection terminals with different plug-in forms are typically manufactured through separate processing routes based on their final structures, and the corresponding products are manufactured by adjusting stamping dies, forming stations, and assembly fixtures. When the structure of the product's plug-in terminal changes, the intermediate state formed in the previous processing stage also changes accordingly. Since the processing stages in terminal manufacturing have a continuous relationship, changes in the intermediate state will continue to affect the workpiece's posture, stress position, and assembly reference when it enters the next processing position, making it difficult to directly use the original coordination relationship between stations.

[0004] In this situation, existing manufacturing methods, if aiming to reduce the scope of adjustments during product switchovers, typically retain some common equipment or continue using some existing processing parameters. However, due to differences in intermediate processing states corresponding to different plug-in forms, the retained processing conditions are prone to mismatch with the new workpiece state, necessitating readjustment of relevant workstations and the establishment of stable process connections through trial production. Therefore, the existing manufacturing method for electrical connection terminals of waterproof connectors presents a significant technical challenge: multiple related processing steps need to be adjusted in tandem when switching between products with different plug-in forms, and the process scope involved in the changeover is substantial. Summary of the Invention

[0005] The main purpose of this application is to solve the technical problem that existing waterproof connector electrical connection terminal manufacturing methods require adjustments to multiple related processing steps and involve a large range of processes when switching between products with different plug-in forms.

[0006] To address the aforementioned problems, this application proposes a method for manufacturing an electrical connection terminal for a waterproof connector, comprising: S1. A continuous metal strip is formed into a blank, and a continuous arrangement of terminal blanks is formed on the strip carrier. The terminal blanks include a terminal body section and a plug-in end forming section. S2. According to the target insertion shape, an insertion cavity forming area or a sheet-like insertion forming area is provided in the forming section of the insertion end, and the corresponding forming sequence is matched. S3. When the target insertion shape is a cavity type, the cavity forming area is subjected to sidewall bending, bending transition and shaping to form a first insertion shape with a cavity and a connection part; when the target insertion shape is a sheet type, the sheet forming area is subjected to contour forming, double-sided pressing and reference straightening to form a second insertion shape with a sheet type connection part. S4. Position, assemble and fix the terminal blanks that form the first or second plug-in configuration to the corresponding metal jacket.

[0007] Beneficial effects: This application first forms a continuous arrangement of terminal blanks from a continuous metal strip under a uniform feeding and load-bearing state, so that the terminals have a stable main processing foundation before forming a specific insertion structure. This way, when the product insertion shape changes, it is not necessary to rebuild the entire manufacturing relationship from the strip processing stage. On this basis, the structural changes between different products are concentrated in the insertion end area of ​​the terminal blank, and the corresponding forming sequence is adopted according to the target insertion shape, so that the material deformation of the insertion end is completed within a limited area, avoiding the structural changes of the insertion end from continuing to affect the blank state of the terminal body.

[0008] For plug-in cavity structures, the sidewall spatial morphology is gradually established and the transitions and shaping are completed, transforming the original planar material into a spatial plug-in structure that meets the requirements of this type of interface. For sheet-like plug-in structures, the sheet-like area is shaped to meet the requirements of this type of interface through shape formation, surface pressing, and extension direction correction. Both types of plug-in ends are positioned and connected to the corresponding metal jacket after their respective forming relationships are established, creating a clear process connection between the shape changes of the plug-in ends and the connection of the metal jacket.

[0009] In summary, this application limits the manufacturing differences between different plug-in forms mainly to the forming range of the plug end, reducing the need for simultaneous adjustments to multiple related workstations other than the front-end forming when switching products, thereby narrowing the process range involved in the changeover and reducing the workload of mold re-matching and trial production adjustments. Attached Figure Description

[0010] Figure 1 This is a schematic flowchart of a method for manufacturing an electrical connection terminal for a waterproof connector according to an embodiment of this application; Figure 2 This is a schematic diagram of the overall structure of the electrical connection terminal for the waterproof connector in one embodiment of this application; Figure 3 This is a schematic diagram of the first insertion configuration of the electrical connection terminal for a waterproof connector in one embodiment of this application; Figure 4 This is a schematic diagram of the second insertion configuration of the electrical connection terminal for a waterproof connector in one embodiment of this application; Figure 5 This is a schematic diagram of the plug-in terminal structure of the second plug-in form of the electrical connection terminal for the waterproof connector in one embodiment of this application.

[0011] The attached figures are labeled as follows: 1. Terminal body section; 2. Insertion end forming section; 21. Insertion cavity forming area; 211. First side wall forming part; 212. Second side wall forming part; 213. Bending transition part; 214. Insertion connection part; 215. Insertion cavity; 22. Sheet-shaped insertion forming area; 221. Main body insertion section; 222. Root transition section; 223. Lead-in section; 3. Metal jacket.

[0012] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0013] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0014] Those skilled in the art will understand that, unless explicitly stated otherwise, the singular forms “a,” “an,” “the,” and “the” used herein may also include the plural forms. It should be further understood that the term “comprising” as used in the specification of this application means the presence of features, integers, steps, operations, elements, modules, and / or components, but does not exclude the presence or addition of one or more other features, integers, steps, operations, elements, modules, components, and / or groups thereof. It should be understood that when an element is referred to as “connected” or “coupled” to another element, it may be directly connected or coupled to the other element, or there may be intermediate elements. Furthermore, “connected” or “coupled” as used herein may include wireless connections or wireless coupling. The term “and / or” as used herein includes all or any modules and all combinations thereof of one or more associated listed items.

[0015] Those skilled in the art will understand that, unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains. It should also be understood that terms such as those defined in general dictionaries should be understood to have the same meaning as in the context of the prior art, and should not be interpreted in an idealized or overly formal sense unless specifically defined as herein.

[0016] refer to Figure 1-5This application provides a method for manufacturing electrical connection terminals for waterproof connectors, including: S1. A continuous metal strip is formed into a blank, and a continuous arrangement of terminal blanks is formed on the strip carrier. The terminal blanks include a terminal body section and a plug-in end forming section.

[0017] In step S1, a continuous metal strip is selected based on the material thickness, overall contour, and continuous feeding direction of the electrical connection terminals for the waterproof connector to be manufactured. The continuous metal strip is then fed into the blank forming area according to the arrangement pitch of the terminals on the metal strip. During processing, a material area extending continuously along the feeding direction is reserved on one side of the metal strip as a material carrier, and each terminal blank is kept connected to the material carrier at a set interval, allowing the terminal blanks to pass through each processing position sequentially with the material carrier. The terminal blanks are divided into a terminal body section and a plug-in forming section according to their functional areas. The terminal body section serves as the basic part of the overall terminal structure, while the plug-in forming section retains the material range required to form different target plug-in shapes. The blank forming stage mainly establishes the basic outer contour of the terminal and the material base required for plug-in forming, ensuring that the continuously arranged terminal blanks maintain a relatively uniform feeding state and processing benchmark. The plug-in forming section does not form the final plug-in shape in this stage, allowing it to enter the corresponding plug-in forming process according to the target product.

[0018] S2. According to the target insertion shape, an insertion cavity forming area or a sheet-like insertion forming area is set in the forming section of the insertion end, and the corresponding forming sequence is matched.

[0019] In step S2, based on the product model and plug-in structure of the electrical connection terminals for the waterproof connector to be manufactured, the plug-in forming section of the terminal blank is mapped to the corresponding processing area according to the target shape. When the target product adopts a plug-in structure with an internal cavity, the plug-in forming section is placed in a forming station that matches the plug-in cavity structure, and the processing positions are configured according to the material deformation relationship required for the structure to transform from an unfolded state to a spatial structure. When the target product adopts a sheet-like plug-in structure, the plug-in forming section is placed in a processing station that matches the sheet-like structure, and the processing sequence is configured according to the contour forming, surface condition adjustment, and extension direction correction relationship of the sheet-like structure. Different plug-in shapes are all processed based on the terminal blank obtained in step S1, so that the structural changes between products are concentrated within the plug-in forming section, without changing the basic processing state already established for the main terminal section.

[0020] S3. When the target insertion shape is a cavity type, the cavity forming area is subjected to sidewall bending, bending transition and shaping to form a first insertion shape with a cavity and a connection part; when the target insertion shape is a sheet type, the sheet forming area is subjected to contour forming, double-sided pressing and reference straightening to form a second insertion shape with a sheet type connection part.

[0021] In step S3, when manufacturing the first insertion form, the insertion cavity forming area first forms an initial bend in the corresponding sidewall material area, so that the material originally in an unfolded state gradually transforms into the spatial sidewall constituting the insertion cavity. Then, the material located between the insertion connection forming area and the sidewall area is bent, so that the insertion connection forms a prescribed spatial turning relationship relative to the insertion cavity body. After the main bending relationships are formed, the spatial state of the insertion cavity and the insertion connection is restricted by the shaping working surface that matches the first insertion form, so that the aforementioned areas form a stable relative positional relationship, and the first insertion form is obtained. When manufacturing the second insertion form, the insertion end forming section is first contoured according to the design shape of the sheet-like insertion part, so that the main insertion area, the area connected to the terminal body, and the insertion end area form the corresponding shape. Then, the relative surfaces of the sheet-like area are pressed in the thickness direction to reduce warping caused by punching and material release. Subsequently, the overall extension state of the sheet-like insertion part is corrected with the terminal length direction as a reference, so that it forms the second insertion form. The first and second plug-in forms correspond to their respective external connection objects, and are used independently as electrical connection terminal plug-in structures for different types of waterproof connectors.

[0022] S4. Position, assemble and fix the terminal blanks that form the first or second plug-in configuration to the corresponding metal jacket.

[0023] In step S4, a metal sleeve corresponding to the structure of the terminal blank is selected based on the already formed insertion shape, and the metal sleeve is brought close to the terminal blank according to the set assembly direction. During assembly, the relatively stable geometric position on the main body of the terminal is used as an assembly reference, and the metal sleeve is moved to the connection area along the predetermined direction. Before the fixed connection, the relative state of the metal sleeve and the terminal blank in the length direction, width direction, and rotation direction is checked. When the two reach the specified assembly position, a locking effect is applied to the connection area to form a stable connection between the metal sleeve and the terminal blank. For the first insertion shape and the second insertion shape, metal sleeves and assembly states that match their respective structures are used respectively, so that the insertion end forming process and the metal sleeve connection process form a clear process connection relationship.

[0024] In summary, this application uses continuous metal strip as the basis for terminal manufacturing. First, a terminal blank with a main body segment and a plug-in end forming segment is formed under continuous feeding conditions. This ensures that different target plug-in shapes have a relatively consistent blank foundation and feeding relationship before entering the specific plug-in end forming stage. Since the main body segment has already formed a stable basic outline at this stage, when the target plug-in structure changes, it is not necessary to simultaneously change the basic feeding method of the continuous metal strip and the basic processing relationship of the main body segment. Instead, the structural differences between products are concentrated within the plug-in end forming segment. During specific manufacturing, the plug-in end forming segment enters a forming process that matches the target plug-in shape. When the target structure requires the formation of a plug-in cavity, bending, turning, and shaping are performed on the corresponding material areas to gradually form a structure with a spatial cavity and plug-in connection relationship from the original unfolded state of the metal material. When the target structure requires the formation of a sheet-like plug-in portion, contour forming, surface pressing, and extension direction correction are used to maintain the required shape and posture of the sheet-like structure at the plug-in end. Since the structural changes of different plug-in forms are mainly completed during the plug-in end forming stage, the main body of the terminal and its preceding processing relationships are not synchronously reconstructed with the change of the plug-in end shape. Therefore, the adjustments required during product switching are mainly focused on the forming conditions directly related to the target plug-in form. After the plug-in end forms the specified shape, a metal jacket is selected according to the corresponding product for positioning, assembly, and fixed connection, so that the plug-in end shape and the metal jacket connection form a relatively clear process connection relationship.

[0025] Through the above processing relationships, the manufacturing differences between different plug-in forms can be concentrated in a smaller local forming range, thereby reducing the need for multiple processing stations to be rematched due to changes in the plug-in end structure, reducing the range of processes that need to be adjusted when changing product models, and reducing the workload of mold readjustment and trial production verification. This solves the problem that multiple related processing links need to be adjusted in a coordinated manner when switching between different plug-in forms in the manufacturing process of electrical connection terminals for existing waterproof connectors.

[0026] It is worth noting that the housing, sealing ring / sealing structure, waterproof interface, etc. of the waterproof connector described in this application can all be implemented with existing technology. Those skilled in the art can complete the assembly of the remaining parts according to the product design requirements and existing mature technology to obtain a finished waterproof connector that meets the requirements.

[0027] In one embodiment, when forming a continuous metal strip into terminal blanks on a strip carrier, the continuous metal strip first enters the punching area according to a set pitch, and positioning holes spaced apart along the feeding direction are formed in the material area serving as the strip carrier. After the positioning holes are formed, they can cooperate with positioning components in the mold at the end of each step feeding to restrict the metal strip from moving along the feeding direction and laterally. Subsequently, excess material is removed from the periphery according to the unfolded contour of the terminal blank, while retaining the material connection between the terminal blank and the strip carrier, so that each terminal blank can maintain a continuous arrangement with the strip carrier. After the terminal blank is formed, its main body area is machined to form a basic contour that adapts to the product structure, and the direction in which the terminal main body extends from the root to the insertion end is used as the longitudinal reference. When pre-cutting the contour in the insertion end area, corresponding cutting edges or local slits are set according to the movement direction of the insertion end material during the forming process, so that the material areas that need to undergo plastic deformation in different directions can move relatively independently, while retaining the material required to form the target insertion structure, thereby forming the insertion end forming section. After the above processing, each terminal blank is still continuously conveyed by the material belt carrier and can enter the plug-in forming area in sequence according to the feeding position established by the positioning hole.

[0028] In one embodiment, when an insertion cavity forming area or a sheet-like insertion forming area is provided in the forming section of the insertion end according to the target insertion shape, if the target product is an insertion cavity structure, the insertion cavity forming area includes a first sidewall forming part, a second sidewall forming part, a bending transition part, and an insertion connection part forming area. The first and second sidewall forming parts are material regions used to form the corresponding sidewalls of the insertion cavity in the unfolded state. After bending, the two sidewall forming parts together form the sidewall structure of the insertion cavity body. The insertion connection part forming area is located on one side of the insertion end and is used to form an end structure that establishes an insertion connection with the corresponding external structure. The bending transition part is located at the junction of the sidewall forming part and the insertion connection part forming area, allowing the insertion connection part to form a spatial transition relative to the insertion cavity body. When the target product is a sheet-like plug-in structure, the sheet-like plug-in forming area sequentially forms a root transition section, a main plug-in section, and an inlet section along the length of the terminal. The main plug-in section performs the primary plug-in function, the root transition section continuously connects the main plug-in section to the terminal body section, and the inlet section is located at the insertion end of the main plug-in section to form an end profile suitable for entering the corresponding external interface. The two types of forming areas enter their respective workstations according to their material deformation characteristics, gradually forming the plug-in cavity structure according to the sidewall spatial morphology, end folding relationship, and overall shape, and gradually forming the sheet-like plug-in structure according to its outer contour, surface condition, and length direction orientation.

[0029] In one embodiment, when the target insertion shape is a cavity type, the first and second sidewall forming portions are pre-bent, causing the two sidewall material areas, originally in an unfolded state, to detach from their original planes. During pre-bending, a support surface matching the root of the sidewall is used to restrict the position of the terminal blank body, and a bending action is applied to the sidewall forming portions by forming members, establishing an initial bending trend. After pre-bending, the terminal blank is sent to the angle-increasing bending position, and while maintaining the support at the root of the sidewall, the bending degree of the two sidewall forming portions is further increased, so that the two sidewalls gradually form the spatial relationship required for the insertion cavity. The termination position of the angle-increasing bending can be adjusted according to the actual sidewall state after the prototype terminal is unloaded, so that the material is still within the range that allows for continued forming after springback. After the two sidewalls form a basic cavity structure, a bending action is applied to the bending transition portion, causing the insertion connection forming area on the other side of the bending transition portion to change its original extension direction and form a predetermined turn relative to the insertion cavity body. After the main bending relationships are formed, the insertion cavity and the forming area of ​​the insertion connection are placed in the pressure correction area that is adapted to the first insertion shape. The cumulative offset generated by each forming area during the continuous bending process is corrected by local restriction and pressure correction, thereby forming the first insertion shape.

[0030] In one embodiment, when bending the bending transition portion, a pre-bending is first performed on the bending transition portion, causing the forming area of ​​the insertion connection portion to change direction from a state of basically continuous extension with the sidewall forming portion. The deformation amount in the pre-bending stage is less than the total deformation amount required for the bending transition portion to form the final fold shape, so that the material first forms a continuous bending state at the bending position, and reduces the impact of a large directional change in the forming area of ​​the insertion connection portion on the already formed sidewall state. After the pre-bending is completed, the bending transition portion continues to be bent a second time. By increasing the stroke of the bending member, the forming area of ​​the insertion connection portion is further deviated from the extension direction of the sidewall forming portion, and a fold relationship corresponding to the first insertion shape is formed. During the second bending process, the bending state of the bending transition portion and the spatial position of the forming area of ​​the insertion connection portion relative to the insertion cavity are used as the basis for judging the processing state. When springback occurs after the material is unloaded, the termination position of the bending member can be adjusted according to the actual fold state of the prototype. After the second bending is completed, the bending transition section is pressed and straightened to ensure that the bending section maintains a continuous turning shape along its width direction, and to correct any local warping or uneven bending, so that the forming area of ​​the plug-in connection section can enter the pressing and straightening process in the prescribed posture.

[0031] Taking the first sidewall forming part of the first insertion form undergoing angle-increasing bending as an example, after pre-bending, the first sidewall forming part continues to be pressured by the bending member and gradually forms the bending state required for the sidewall of the insertion cavity. Assuming that according to product structure requirements, the first sidewall forming part needs to form a 90° bend relative to its initial unfolding direction after forming, when the bending member immediately withdraws after pressing the first sidewall forming part to 90°, due to the elastic deformation of the metal material during bending, the first sidewall forming part may spring back towards its original unfolding direction after the external force is released, causing the actual bending angle to become 87° or 88°, thus causing the sidewall to deviate outward relative to the designed position. To compensate for this springback, the angle change after material unloading can be measured during the trial production process, and the stroke of the bending member can be appropriately increased according to this change, for example, to make the bending angle under pressure reach 92° or 93°. When the bending member withdraws and the material springs back, the first sidewall forming part returns to the target state close to 90°. The second sidewall forming section can also be adjusted in the same way, so that the two sidewalls maintain a spatial relationship matching the insertion cavity structure after the external force is released. The above angles are only used to illustrate the unloading springback and compensation principle. The actual bending angle and compensation amount can be set according to the material type, thickness, bending radius of the metal strip, and the actual springback state after trial production. The same phenomenon may occur when the bending transition section is pre-bent and secondary bent, so the termination position of the corresponding forming component can also be adjusted according to the actual bending state after unloading.

[0032] In one embodiment, when calibrating the forming area of ​​the insertion cavity and the insertion connection portion, the terminal blank, which has already undergone sidewall bending and bending transition, is fed into a shaping area adapted to the first insertion shape, and the corresponding position of the insertion cavity mates with the inner limiting member. After the inner limiting member enters the insertion cavity, it provides support for the internal space of the cavity. At the same time, calibrating members corresponding to the two side walls are provided on the outside of the insertion cavity, so that the external force is applied towards the inner limiting member, thereby correcting the skew, local outward expansion, or asymmetry of the two side walls formed during the aforementioned bending process. When the inner limiting member and the outer calibrating member are in sync, the termination position of the calibrating member is set according to the cavity contour of the first insertion shape, so that the two side walls are calibrated while maintaining the basic space of the insertion cavity. After the insertion cavity is shaped, local pressure is applied to the forming area of ​​the insertion connection to create a predetermined insertion connection outline. Then, the connection position between the bent transition section and the insertion connection is adjusted overall to ensure the insertion connection maintains a specified folding state relative to the insertion cavity and to prevent reverse offset of the bent transition section caused by local pressure adjustment. After completing the above processing, the insertion cavity, bent transition section, and insertion connection form a first insertion configuration that interconnects with each other.

[0033] In one embodiment, when the target insertion form is a sheet-like insertion type, the insertion end forming section is fed into the sheet-like insertion forming area, and the sheet-like insertion forming area is contour-processed according to the outer contour of the second insertion form. During processing, a root transition section, a main insertion section, and a guide section are gradually formed from the terminal body section towards the insertion end. The root transition section is used to create a continuous width transition between the terminal body section and the main insertion section. The main insertion section extends along the length direction of the terminal and forms the main insertion area. The guide section is located at the free end of the main insertion section, and its outer contour gradually contracts towards the insertion direction to accommodate the insertion process of the corresponding interface structure. After contour processing, the main insertion section is placed between oppositely arranged pressing members, and the two pressing members move towards each other along the thickness direction of the main insertion section, applying pressure to the two opposite surfaces of the main insertion section simultaneously, thereby reducing punching release, material internal stress, and warping caused by contour processing. After double-sided pressing is completed, the extension state of the main body insertion section is checked using the length direction of the terminal body section as the longitudinal reference, and the area that deviates from the longitudinal reference is straightened so that the plate insertion part maintains a stable length direction extension relationship from the root transition section to the lead section, forming the second insertion form.

[0034] In one embodiment, when straightening the main body connector segment using a longitudinal reference, a longitudinal reference is first established along the center extension direction of the terminal main body segment, and the lateral state of the root position and free end position of the main body connector segment relative to the longitudinal reference is detected respectively. When the root position or free end position shifts to one side of the terminal width direction, a support is set at the position corresponding to the shift direction, and a correction action is applied to the main body connector segment from the opposite direction, so that the root and free end re-enter the position range matching the longitudinal reference. After the root and free end positions are corrected, the overall direction of the main body connector segment is checked according to the extension relationship between them; when the main body connector segment tilts from the root to the free end, the corresponding area is corrected to make the extension direction of the main body connector segment tend to be consistent with the longitudinal reference. For local bends in the main body connector segment along the length direction, instead of correcting by a large overall bend, a pressing correction area is set according to the bend position, and the local protrusions or concave bends are pressed correction in segments, and the length direction state is re-checked after each pressing correction. After the lateral position, overall extension direction and local bending of the main insertion segment are corrected, the planar state of its two opposite surfaces is checked. When a local area is slightly raised due to the straightening action, a small amount of shaping is performed on the area to keep the main insertion segment in a continuous sheet-like shape, thereby forming the second insertion shape.

[0035] In one embodiment, when positioning and assembling a terminal blank forming a first or second plug-in configuration with a corresponding metal sleeve, a metal sleeve corresponding to the current product specifications of the terminal blank is selected, and the terminal blank is held in the feeding posture established by the strip carrier before entering the assembly area. During assembly, the insertion direction of the metal sleeve is matched with the length direction of the terminal blank, and the metal sleeve is moved along a predetermined direction to the connection area on the terminal body segment. After the metal sleeve moves to the assembly position, its free movement relative to the terminal blank is restricted by an assembly fixture, and the position of the metal sleeve in the length direction of the terminal and its offset relative to the width direction of the terminal blank are checked. Simultaneously, it is checked whether the metal sleeve tilts or rotates relative to the terminal blank. For the first and second plug-in configurations, the stable main body area in their respective terminal structures is used as the assembly reference, ensuring that the assembly position of the metal sleeve does not lose its positioning basis due to differences in the specific shape of the plug-in end. When the assembly state between the metal sleeve and the terminal blank enters a specified range, they are held in their current relative position, allowing the corresponding connection area to enter a fixed connection station.

[0036] In one embodiment, when fixing the connection area between the metal jacket and the terminal blank, pre-compression members are first arranged oppositely in the connection area, and the pre-compression members are moved toward the outer surface of the metal jacket to apply a pre-compression force to the metal jacket that is less than the amount of deformation required for formal locking. After pre-compression, the metal jacket partially adheres to the terminal blank, making it less prone to axial slippage, lateral movement, or angular changes when entering the locking process. After the pre-compression positioning state is stable, the stroke of the pressing member is further increased, causing plastic deformation in the connection area of ​​the metal jacket and forming a mechanical lock with the corresponding position of the terminal blank. The pressing and locking action is concentrated in the connection area between the metal jacket and the terminal blank, and the pressing termination position is set according to the thickness of the metal jacket material, the thickness of the terminal blank connection position, and the shape after locking, so that the movement of the metal jacket relative to the terminal blank is restricted after locking. After the connection is completed, the axial, lateral, and angular positions of the metal sleeve relative to the terminal blank are checked. The axial position is used to determine if the metal sleeve has shifted along the length of the terminal; the lateral position is used to determine if the center of the metal sleeve has shifted laterally relative to the terminal blank; and the angular position is used to determine if tilting occurs during the locking process. If the above positional relationships exceed the set deviation range, a local correction is applied to the connection area or an adjustable position adjacent to the connection area according to the actual offset direction. After correction, the assembly state between the metal sleeve and the terminal blank is checked again until they maintain the specified relative positions.

[0037] In one embodiment, reference Figure 2-4The metal part of the electrical connection terminal of the waterproof connector includes a terminal body section 1 and a plug-in end forming section 2 connected to the terminal body section 1. The terminal body section 1 is used to form the basic bearing structure of the terminal, and the plug-in end forming section 2 is used to perform corresponding plastic processing according to the plug-in shape to be formed. When the first insertion form needs to be formed, the insertion end forming section 2 is correspondingly set as the insertion cavity forming area 21. The insertion cavity forming area 21 includes a first sidewall forming part 211, a second sidewall forming part 212, a bending transition part 213, and an insertion connecting part 214. The first sidewall forming part 211 and the second sidewall forming part 212 are respectively located in the corresponding material areas of the insertion end forming section 2 in the unfolded state. After pre-bending and angle-increasing bending, they form relatively arranged sidewalls and form an insertion cavity 215 between the two sidewalls. The bending transition part 213 is located between the sidewall and the insertion connecting part 214. By gradually bending the bending transition part 213, the insertion connecting part 214 forms a spatial turning relationship with the target interface relative to the insertion cavity 215. Then, the insertion cavity 215, the bending transition part 213, and the insertion connecting part 214 are adjusted to form the first insertion form shown in the figure. When a second insertion configuration is required, the insertion end forming section 2 is correspondingly configured as a sheet-like insertion forming area 22. The sheet-like insertion forming area 22 includes a main insertion section 221, a root transition section 222, and an inlet section 223. The root transition section 222 connects the terminal main body section 1 and the main insertion section 221. The main insertion section 221 extends along the length of the terminal, and the inlet section 223 is located at the free end of the main insertion section 221. By contouring the sheet-like insertion forming area 22, the above sections form corresponding shapes. Then, the main insertion section 221 is double-sided pressed and its extension direction straightened to form the second insertion configuration shown in the figure. The first and second insertion configurations are used to insert with their respective corresponding external connection structures, not to insert with each other. After the corresponding insertion configuration is formed, the corresponding metal jacket 3 is assembled to the connection position of the terminal main body section 1 and positioned and fixed to ensure a stable assembly relationship between the insertion end structure and the metal jacket 3.

[0038] It is worth noting that the manufacturing method described in this application is not limited to the specific shape of the plug-in end shown in the attached drawings, and can also be adapted to other plugs, sockets or connecting components with corresponding interface structures according to actual needs. Specifically, when the processing relationship of the main body segment of the terminal and the continuous strip meets the usage requirements, the local forming position of the forming segment of the plug-in end can be adjusted according to the interface contour, insertion direction and spatial arrangement of the structure to be connected. For example, one or more bending positions can be set on the forming segment of the plug-in end, and the bending direction, bending angle, bending level and the interval between adjacent bending positions can be changed according to the actual interface structure, so that the plug-in connection part extends towards the target connection direction; for interfaces that need to form offset, turning or multi-segment turning relationships, different bending positions can be plastically deformed along the width direction, thickness direction or corresponding oblique direction of the terminal, and the plug-in end can be formed into a spatial posture that matches the corresponding connection structure through graded bending and shaping; for sheet-like plug-in structures, the width, length, inlet end contour and extension direction of the main body plug-in segment can also be changed according to the target interface, and it can be pressed and straightened to meet the corresponding plug-in requirements. Therefore, the bending position and bending direction in this application can be adapted to the actual mating structure. It is not required that all products adopt the same fixed bending position or fixed bending direction. As long as the forming section of the plug end can form the corresponding plug-in shape according to the target interface structure and complete the assembly connection with the corresponding metal jacket, the manufacturing concept described in this application can be adopted.

[0039] The above description is only a preferred embodiment of this application and does not limit the patent scope of this application. Any equivalent structural or procedural changes made based on the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.

Claims

1. A method for manufacturing electrical connection terminals for a waterproof connector, characterized in that, include: S1. A continuous metal strip is formed into a blank, and a continuous arrangement of terminal blanks is formed on the strip carrier. The terminal blanks include a terminal body section and a plug-in end forming section. S2. According to the target insertion shape, an insertion cavity forming area or a sheet-like insertion forming area is provided in the forming section of the insertion end, and the corresponding forming sequence is matched. S3. When the target insertion shape is a cavity type, the cavity forming area is subjected to sidewall bending, bending transition and shaping to form a first insertion shape with a cavity and a connection part; when the target insertion shape is a sheet type, the sheet forming area is subjected to contour forming, double-sided pressing and reference straightening to form a second insertion shape with a sheet type connection part. S4. Position, assemble and fix the terminal blanks that form the first or second plug-in configuration to the corresponding metal jacket.

2. The method for manufacturing electrical connection terminals for waterproof connectors according to claim 1, characterized in that, The step of forming a continuous metal strip into a blank, thereby forming a continuously arranged array of terminal blanks on the strip carrier, includes: A strip carrier and a terminal blank connected to the strip carrier are formed on the continuous metal strip, and positioning holes are formed on the strip carrier. The terminal blank is formed by outer contour shaping to form the terminal body segment, and the length direction of the terminal body segment is used as the longitudinal reference. The insertion end area of ​​the terminal blank is pre-cut to form the insertion end forming section.

3. The method for manufacturing electrical connection terminals for waterproof connectors according to claim 1, characterized in that, The step of setting a cavity forming area or a sheet-like insertion forming area in the forming section of the insertion end according to the target insertion shape, and matching the corresponding forming sequence, includes: When the target insertion form is a insertion cavity type, the insertion cavity forming area includes a first sidewall forming part, a second sidewall forming part, a bending transition part, and an insertion connection part forming area, wherein the bending transition part is disposed between the sidewall forming part and the insertion connection part forming area; When the target insertion form is a sheet-like insertion type, the sheet-like insertion forming area includes a main insertion section, a root transition section, and an introduction section; The insertion cavity forming area is formed in the order of sidewall bending, bending transition and shaping, and the sheet-like insertion forming area is formed in the order of contour forming, double-sided pressing and reference straightening.

4. The method for manufacturing electrical connection terminals for waterproof connectors according to claim 3, characterized in that, When the target insertion shape is a cavity type, the step of bending the sidewalls, bending transition, and shaping the cavity forming area to form a first insertion shape with a cavity and a connection part includes: The first and second sidewall forming parts are pre-bent and angle-increasing bends are performed to form the two sidewalls of the insertion cavity; The bending transition portion is bent so that the forming area of ​​the plug-in connection portion forms a turn relative to the side wall forming portion; The insertion cavity and the forming area of ​​the insertion connection are pressed and aligned to form the first insertion shape.

5. The method for manufacturing electrical connection terminals for waterproof connectors according to claim 4, characterized in that, The step of bending the bending transition portion to form a bend in the forming area of ​​the insertion connection portion relative to the sidewall forming portion includes: The bending transition portion is pre-bent so that the forming area of ​​the plug connection portion deviates from the extension direction of the side wall forming portion; The pre-bent transition section is bent a second time to form a folded shape in the forming area of ​​the plug-in connection section; The bending transition section is pressed and adjusted to correct the bending state.

6. The method for manufacturing electrical connection terminals for waterproof connectors according to claim 4, characterized in that, The step of pressing and aligning the forming area of ​​the insertion cavity and the insertion connection portion to form the first insertion shape includes: The insertion cavity is shaped by a combination of inner limiting and outer pressing. The forming area of ​​the plug-in connection part is pressed and straightened to form the plug-in connection part, and the bending transition part and the plug-in connection part are straightened as a whole.

7. The method for manufacturing electrical connection terminals for waterproof connectors according to claim 3, characterized in that, When the target insertion shape is a sheet-like insertion type, the step of contouring, double-sided pressing, and benchmark straightening of the sheet-like insertion forming area to form a second insertion shape with a sheet-like insertion portion includes: The sheet-like insertion forming area is contoured to form a main insertion section, a root transition section, and an inlet section; Double-sided pressing is performed on the opposing surfaces of the main body insertion section along the thickness direction; The main body insertion section is straightened using a longitudinal reference to form the second insertion shape.

8. The method for manufacturing electrical connection terminals for waterproof connectors according to claim 7, characterized in that, The step of straightening the main body insertion segment using a longitudinal reference to form the second insertion shape includes: The lateral position of the root and free end of the main body insertion section in the terminal width direction is corrected using the longitudinal reference. Correct the angular deviation of the direction in which the main body insert segment extends from the root to the free end relative to the longitudinal reference. The local bending positions of the main body insertion section along the length direction are segmented and pressed to make the extension direction of the main body insertion section match the longitudinal reference. The planar state of the main plug-in section after compression calibration is checked and locally shaped to form the second plug-in form.

9. The method for manufacturing electrical connection terminals for waterproof connectors according to claim 1, characterized in that, The step of positioning, assembling, and fixing the terminal blank forming the first or second insertion shape to the corresponding metal sleeve includes: Position and assemble the corresponding metal jacket with the terminal blank that forms the first or second plug-in shape; Correct the assembly position between the metal jacket and the first or second insertion configuration; The metal jacket and the terminal blank are fixedly connected.

10. The method for manufacturing electrical connection terminals for waterproof connectors according to claim 9, characterized in that, The step of fixing the metal jacket to the connection area of ​​the terminal blank includes: The connection area is pre-pressed and positioned to limit the relative displacement between the metal jacket and the terminal blank; Press and lock the pre-positioned connection area to form a fixed connection between the metal jacket and the terminal blank; The axial, lateral, and angular positions between the fixedly connected metal jacket and the terminal blank are verified. Local adjustments are made to connection positions that exceed the set deviation range to ensure that the metal jacket and terminal blank maintain the set assembly state.

Images