Injection molding type wire harness connector

Abstract

An injection molding type wire harness connector comprises a wire harness and a plug, the plug comprises a three-fork type terminal and an open type welding clamp, the three-fork type terminal is a terminal which is gradually divided into three branches from a branch point at the tail end to the middle front end direction, the middle front part of the three-fork type terminal is provided with a support beam which is perpendicular to the three branches and is communicated with the three branches, and in addition, the open type welding clamp is arranged on the support beam. The top ends of the three branches of the trident terminal are all of a double-fork structure. The wire harness comprises a columnar wire body, the wire body is composed of a plurality of wire cores, the plurality of wire cores are all wrapped in a columnar insulating layer, and the wire cores are all welded at the tail part of the trident terminal; the tail part of the three-fork type terminal is provided with three open type welding hoops, and each open type welding hoop is clamped with one branch of the three-fork type terminal; and the three wire cores of the wire body are respectively welded on the three open welding hoops at the tail part of the trident terminal. The production process is improved by simplifying the product structure, automatic production is realized, the rejection rate and the cost are reduced, and the production efficiency is improved.

Description

Technical Field

[0001] The utility model relates to the field of automobile ignition coils, in particular to a wiring harness connector of an ignition coil. Background Art

[0002] The ignition coil device of a gasoline vehicle uses a spark plug connected to an ignition coil, and the spark plug discharges under the drive of the ignition coil.

[0003] Currently, commercially available wiring harness connectors often require complex components and assembly processes to manufacture. First, ignition coils are often sealed by inserting a sealing ring through the wire body or snapping it into the housing. This requires an interference fit between the two components, requiring precise dimensions and good sealing. Increasing component precision not only complicates the manufacturing process but also reduces production efficiency and increases maintenance costs. Furthermore, interference fits are prone to rebound due to the interaction of forces. Once this occurs, the ignition coil components deform and become scrapped, compromising component stability and significantly reducing the lifespan of the ignition coil. Second, the wire core and terminals need to be electrically connected. Therefore, the wire core and terminals are typically introduced into the coil and then welded together inside the coil. However, this ignition coil structure and production process creates very limited space for assembly and welding of the wire core and terminals, requiring specialized personnel to perform the welding, making automation difficult. Furthermore, assembly is time-consuming and labor-intensive, making it unsuitable for mass production. Third, after the wiring harness connector and coil body are assembled, the corresponding cavities must be sealed by casting. However, the cavity of the coils on the market is deeper than that of the wiring harness connector, which makes the resin casting uneven, resulting in an uneven casting surface and thus scrapping the product. This not only requires a high level of casting technology, but also has a high scrap rate.

[0004] Therefore, an ignition coil is urgently needed to solve the above problems, improve the production process by simplifying the product structure, realize automated production, thereby reducing the scrap rate and cost, and improving production efficiency. Utility Model Content

[0005] The purpose of the utility model is to provide an injection-molded wiring harness connector, which improves the production process by simplifying the product structure to achieve automated production, thereby reducing the scrap rate and cost and improving production efficiency.

[0006] To achieve the above-mentioned purpose, the utility model provides an injection-molded wiring harness connector, including a wiring harness and a plug. The plug includes a three-pronged terminal and an open welding clamp. The three-pronged terminal is a terminal that gradually divides into three branches starting from the branch point at the tail end toward the middle and front end. The middle front part of the three-pronged terminal has a support beam that is perpendicular to the three branches and connects the three branches. In addition, the tops of the three branches of the three-pronged terminal are all double-pronged structures. The wiring harness includes a columnar wire body. In addition, the wire body is composed of multiple wire cores, and the multiple wire cores are all wrapped in a cylindrical insulation layer. The wire cores are all welded to the tail of the three-pronged terminal. Three open welding clamps are provided at the tail of the three-pronged terminal, and each open welding clamp clamps a branch of the three-pronged terminal. The three wire cores of the wire body are respectively welded to the three open welding clamps at the tail of the three-pronged terminal.

[0007] As a preferred embodiment, the open welding clamp is a metal clamp.

[0008] As a preferred embodiment, the plug also includes a shell. In addition, the shell includes a wiring harness connection structure surrounding the tail of the three-pronged terminal. The wiring harness connection structure includes a terminal cavity for positioning and fixing the tail of the three-pronged terminal and a wiring harness cavity for positioning and fixing the wiring harness. The terminal cavity is a U-shaped shell structure, and the three-pronged terminal is fixed in the terminal cavity. The wiring harness cavity is a cylindrical shell structure. The wiring harness cavity is embedded in and connected to the bottom of the terminal cavity. The wire core of the wire body extends into the terminal cavity through the wiring harness cavity and is welded to the tail of the three-pronged terminal.

[0009] As a preferred embodiment, the terminal cavity is filled with engineering plastic.

[0010] As a preferred embodiment, a plurality of positioning protrusions are provided on the side surface of the terminal cavity.

[0011] As a preferred embodiment, a positioning keel cover is provided on the top of the terminal cavity, and the positioning keel cover is larger than the top surface of the terminal cavity, so that the positioning keel cover is used to close the terminal cavity and position the three-pronged terminal in the socket slot of the ignition coil.

[0012] Preferably, the housing further comprises a terminal bifurcation support structure surrounding the middle portion of the three-pronged terminal. The terminal bifurcation support structure is a flat cylindrical cavity structure that encloses the three branches in the middle portion of the three-pronged terminal, and its bottom is embedded in the positioning keel at the front portion of the wiring harness connection structure.

[0013] As a preferred embodiment, the front of the flat column cavity structure is connected to three flat branch cavities, each of which encloses a branch of the three-pronged terminal. The front branches of the three-pronged terminal extend from each flat branch cavity, and the tips of the branches of the three-pronged terminal are bent upward.

[0014] As a preferred embodiment, a rectangular through hole is provided in the middle of the flat column cavity structure along a direction perpendicular to the horizontal plane.

[0015] As a preferred embodiment, the wiring harness further comprises a connector for fixing the core of the connecting wire body.

[0016] Compared to the prior art, the present invention aims to provide an injection-molded wiring harness connector that simplifies the product structure and improves the production process to achieve automated production, thereby reducing scrap rates and costs and increasing production efficiency. First, by improving the housing seal structure and eliminating the sealing ring, defects caused by interference fit are avoided, significantly improving production efficiency and reducing maintenance costs, ensuring component stability and significantly extending the service life of the ignition coil. Second, the wire core and terminal are welded open-type instead of being welded inside the coil. This provides ample assembly and welding space for the wire core and terminal. The wire core and terminal can be connected using welding processes such as soldering, riveting, and spot welding, effectively improving welding quality and facilitating automation. Assembly is time-saving and labor-saving, making it suitable for mass production. Third, the injection-molded engineering plastic fills the original wiring harness connector cavity, eliminating the wiring harness connector cavity and retaining only the coil cavity. This avoids the problem of uneven resin casting caused by cavity height differences, resulting in a smooth casting surface and significantly reducing product scrap rates. Fourthly, the welded parts are loaded into the mold for injection molding. When the mold is closed during injection molding, the connected terminals will be separated by the mold. The finished product can be used immediately. This simple casting process is easy to automate, saves time and labor, and has high yield and productivity, making it suitable for mass production. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is a schematic diagram of the plug-in connection of the present utility model.

[0018] Figure 2 This is a schematic diagram of an unmolded part of the present invention.

[0019] Figure 3 This is a schematic diagram of an injection molded finished product of the present invention.

[0020] Figure 4 This is a schematic diagram before plugging in the prior art.

[0021] Figure 5 It is a schematic diagram after plugging in the prior art.

[0022] Figure 6 Schematic diagram of a wiring harness connector in the prior art. DETAILED DESCRIPTION

[0023] Hereinafter, embodiments of the injection-molded wiring harness connector of the present invention will be described with reference to the accompanying drawings.

[0024] The embodiments described herein are specific embodiments of the present invention and are used to illustrate the concept of the present invention. They are illustrative and exemplary and should not be construed as limiting the embodiments and scope of the present invention. In addition to the embodiments described herein, those skilled in the art can also adopt other obvious technical solutions based on the claims and the disclosure of the specification of this application, including technical solutions that adopt any obvious replacements and modifications to the embodiments described herein.

[0025] The drawings in this specification are schematic diagrams, which assist in explaining the concept of the present invention and schematically show the shapes of various parts and their mutual relationships.

[0026] Figure 2 Shown is an unmolded part of the present invention, such as Figure 2 As shown, an injection-molded wiring harness connector of the present invention includes a wiring harness 2 and a plug 1. The plug 1 includes a terminal 11 and an open welding clamp 113. The terminal 11 is a three-pronged terminal. The three-pronged terminal, the wiring harness 2, and the open clamp together constitute the unmolded part of the injection-molded wiring harness connector. The three-pronged terminal is a terminal 11 that gradually divides into three branches starting from the branch point 114 at the tail end toward the middle and front end. The middle front part of the three-pronged terminal has a support beam 112 that is perpendicular to the three branches and connects the three branches. In addition, the tops of the three branches of the three-pronged terminal are all double-pronged structures 111. The wiring harness 2 includes a columnar wire body 21. In addition, the wire body 21 is composed of multiple wire cores, and the multiple wire cores are all wrapped in a cylindrical insulation layer. The wire cores are all welded to the tail of the three-pronged terminal. Three open welding clamps 113 are provided at the tail of the three-pronged terminal, and each open welding clamp 113 engages with a branch of the three-pronged terminal. The three cores of the wire body 21 are welded to three open welding clamps 113 at the end of the three-pronged terminal. The corresponding core and terminal 11 are clamped together within the open welding clamps 113. The intersection of the clamping points is the core welding point 12, and welding at this point establishes the electrical connection between the core and terminal 11. The open welding clamps 113 ensure sufficient welding space and precision, allowing the welding of the core and terminal 11 to be automated.

[0027] Furthermore, the open welding clamp 113 is a metal clamp, which has good elasticity, strong clamping force, wear resistance, and electrical conductivity.

[0028] This embodiment is further preferably: Figure 3 The injection molded finished product of the present invention is shown in FIG. Figure 3As shown, the plug 1 also includes a shell 13. The shell 13 is injection molded onto the unmolded part above through an injection molding process, thereby forming a wiring harness connector of the injection molded finished part. In addition, the shell 13 includes a wiring harness connection structure surrounding the tail of the three-pronged terminal. The wiring harness connection structure includes a terminal cavity 132 for positioning and fixing the tail of the three-pronged terminal and a wiring harness cavity 131 for positioning and fixing the wiring harness 2. The terminal cavity 132 is a U-shaped shell structure, and the three-pronged terminal is fixed in the terminal cavity 132. The wiring harness cavity 131 is a cylindrical shell structure. The wiring harness cavity 131 is embedded in and connected to the bottom of the terminal cavity 132. The wire core of the wire body 21 passes through the wiring harness cavity 131 and extends into the terminal cavity 132 and is welded to the tail of the three-pronged terminal. On the one hand, the shell 13 provides support and shaping for the terminal 11, and strengthens the connection between the wiring harness 2 and the terminal 11 so that it does not shake. On the other hand, the housing 13 also serves to position the wiring harness connector when it is plugged in, so that it can be tightly plugged into the ignition coil 3.

[0029] Furthermore, the terminal cavity 132 is filled with engineering plastics, which can simplify the injection molding process and eliminate the need to completely seal the terminal cavity 132.

[0030] Furthermore, a plurality of positioning protrusions 136 are provided on the side of the terminal cavity 132. The positioning protrusions 136 can locate the position of the wiring harness connector when plugged in, so that it can be tightly plugged into the ignition coil 3.

[0031] Furthermore, Figure 1 It shows how the injection molded finished product of the present invention is plugged into the ignition coil 3 body, as shown in FIG. Figure 1 As shown, a positioning keel cover plate 133 is installed at the top of the terminal cavity 132. This keel cover plate 133 is larger than the top surface of the terminal cavity 132, allowing it to seal the terminal cavity 132 and position the three-pronged terminal in the socket of the ignition coil 3. Keel cover plate 133 simplifies the injection molding process by eliminating the need to completely seal the terminal cavity 132. Furthermore, keel cover plate 133 helps position the wiring harness connector during insertion, ensuring a tight fit on the ignition coil 3.

[0032] In this embodiment, the housing 13 further preferably includes a terminal bifurcation support structure surrounding the middle portion of the three-pronged terminal. The terminal bifurcation support structure is a flat cylindrical cavity structure 134 that encloses the three branches in the middle portion of the three-pronged terminal, and its bottom is embedded in the positioning keel at the front of the wiring harness connection structure.

[0033] Furthermore, the front of the flat columnar cavity structure 134 connects to three flat branch cavities, each of which encloses a branch of the three-pronged terminal. Each branch of the three-pronged terminal extends from a corresponding flat branch cavity, with the tip of each branch curving upward. The flat columnar cavity structure 134 and the flat branch cavities simplify the injection molding process and support the structure of the terminal 11.

[0034] Furthermore, a rectangular through hole 135 is provided in the middle of the flat columnar cavity structure 134 along a direction perpendicular to the horizontal plane. The rectangular through hole 135 can facilitate injection molding and demoulding.

[0035] Furthermore, the wiring harness 2 further includes a connector 22 for fixing the core of the connecting wire body 21. The connector 22 can firmly connect the core.

[0036] Figure 4-6 The figure shows the wiring harness connector and its plug-in means of the prior art. Figure 4 As shown, the wiring harness connectors currently on the market often require complex accessories and assembly processes to produce.

[0037] First, as Figure 6 As shown, the ignition coil 3 is often sealed on the market by inserting a sealing ring 14 into the wire body 21 or snapping the sealing ring 14 into the housing 13. This requires an interference fit between the two components, which requires precise dimensions and good sealing of the small components. Increasing the precision of the components not only complicates the manufacturing process but also leads to low production efficiency and high maintenance costs. Furthermore, the interference fit of the components is prone to rebound due to the interaction of forces. Once rebound occurs, the components of the ignition coil 3 are deformed and directly scrapped, making the components unstable and significantly reducing the service life of the ignition coil 3.

[0038] Second, if Figure 5 As shown, the wire core and terminal 11 need to be electrically connected. Therefore, the common method on the market is to guide the wire core and terminal 11 into the coil 3 and then weld them to the corresponding wire core welding points 12 inside the coil 3. However, this ignition coil 3 structure and production process results in very limited space for assembling and welding the wire core and terminal 11, requiring dedicated personnel to perform the welding, making automation difficult. Furthermore, assembly is time-consuming and labor-intensive, making it unsuitable for mass production.

[0039] Third, if Figure 5 As shown, after the wiring harness connector and coil 3 body are assembled, the corresponding cavities need to be sealed by casting. However, the cavity of the coil 3 on the market is deeper than that of the wiring harness connector, which can easily lead to uneven resin casting, resulting in an uneven casting surface and thus product failure. This not only places high demands on the casting process, but also increases the product scrap rate.

[0040] Compared with the prior art, the purpose of the present invention is to provide an injection-molded wiring harness connector, which improves the production process by simplifying the product structure to achieve automated production, thereby reducing scrap rate and cost and improving production efficiency.

[0041] First, by improving the sealing structure of the housing 13 and removing the sealing ring 14, defects caused by interference fit are avoided, production efficiency is greatly improved, and maintenance costs are reduced, so that the stability of the parts is guaranteed and the service life of the ignition coil 3 is greatly improved.

[0042] Secondly, the wire core and the terminal 11 are welded in an open manner instead of being welded inside the coil 3, which makes the assembly space and welding space of the wire core and the terminal 11 very ample. The wire core and the terminal 11 can be connected by welding processes such as soldering, riveting, and spot welding, which effectively improves the welding quality and is easy to automate. The assembly is time-saving and labor-saving, and is suitable for mass production.

[0043] Third, the injection-molded engineering plastic fills the original wiring harness connector cavity, eliminating the wiring harness connector cavity and retaining only the coil 3 cavity, thereby avoiding the problem of uneven resin casting caused by cavity height difference. In this way, the casting surface is flat and the product scrap rate is greatly reduced.

[0044] Fourthly, the welded parts are loaded into the mold for injection molding. When the mold is closed during injection molding, the connected terminal 11 will be separated by the mold. The finished product can be used immediately. This simple casting process is easy to automate, saves time and effort, and has high yield and productivity, making it suitable for mass production.

[0045] The above description of the implementation of the injection-molded wiring harness connector of the present invention is for the purpose of explaining the spirit of the present invention. Please note that those skilled in the art can modify and combine the features of the above-mentioned implementations without departing from the spirit of the present invention. Therefore, the present invention is not limited to the above-mentioned implementations. The specific features of the injection-molded wiring harness connector, such as shape, size and position, can be specifically designed based on the effects of the features disclosed above, and these designs are all achievable by those skilled in the art. Moreover, the technical features disclosed above are not limited to the combination with other features disclosed. Those skilled in the art can also make other combinations between the technical features according to the purpose of the utility model, so as to achieve the purpose of the utility model.

Claims

1. An injection-molded wiring harness connector, characterized in that: Comprising a wiring harness and a plug; wherein the plug comprises a three-pronged terminal and an open welding clamp; wherein, The three-pronged terminal is a terminal that gradually splits into three branches from the branch point at the tail end toward the middle and front end. The middle front portion of the three-pronged terminal has a support beam that is perpendicular to and connects the three branches. Moreover, the top ends of the three branches of the three-pronged terminal are all double-pronged structures. The wiring harness includes a cylindrical wire body; and The wire body is composed of multiple wire cores, and the multiple wire cores are all wrapped in a cylindrical insulation layer; the wire cores are all welded to the tail of the three-pronged terminal; The tail of the three-pronged terminal is provided with three open welding clamps, each of which clamps one branch of the three-pronged terminal; The three wire cores of the wire body are respectively welded to the three open welding clamps at the tail of the three-pronged terminal.

2. The injection-molded wiring harness connector according to claim 1, wherein: The open welding clamp is a metal clamp.

3. The injection-molded wiring harness connector according to claim 1, wherein: The plug further includes a housing; and the housing includes a wiring harness connection structure surrounding the tail of the three-pronged terminal; wherein the wiring harness connection structure includes a terminal cavity for positioning and fixing the tail of the three-pronged terminal and a wiring harness cavity for positioning and fixing the wiring harness; The terminal cavity is a U-shaped shell structure, and the three-pronged terminal is fixed in the terminal cavity; The wiring harness cavity is a cylindrical shell structure; The wiring harness cavity is embedded in and communicates with the bottom of the terminal cavity; The wire core of the wire body passes through the wire harness cavity, extends into the terminal cavity and is welded to the tail of the three-pronged terminal.

4. The injection-molded wiring harness connector according to claim 3, characterized in that: The terminal cavity is filled with engineering plastic.

5. The injection-molded wiring harness connector according to claim 3, wherein: A plurality of positioning protrusions are provided on the side surface of the terminal cavity.

6. The injection-molded wiring harness connector according to any one of claims 3 to 5, characterized in that: A positioning keel cover is provided on the top of the terminal cavity, and the positioning keel cover is larger than the top surface of the terminal cavity, so that the positioning keel cover is used to close the terminal cavity and position the three-pronged terminal in the plug-in slot of the ignition coil.

7. The injection-molded wiring harness connector according to claim 6, wherein: The housing further includes a terminal bifurcation support structure surrounding a middle portion of the three-pronged terminal; The terminal bifurcation support structure is a flat columnar cavity structure, which wraps the three branches in the middle of the three-pronged terminal, and its bottom is embedded in the positioning keel at the front of the wire harness connection structure.

8. The injection-molded wiring harness connector according to claim 7, wherein: The front portion of the flat column cavity structure is connected to three flat branch cavities, each of which encloses a branch of the three-pronged terminal; Each branch of the front portion of the three-pronged terminal extends from each flat branch cavity, and the tip of each branch of the three-pronged terminal bends upward.

9. The injection-molded wiring harness connector according to claim 7, wherein: A rectangular through hole is provided in the middle of the flat column cavity structure along a direction perpendicular to the horizontal plane.

10. The injection-molded wiring harness connector according to any one of claims 1 to 5, characterized in that: The wiring harness further comprises a connector for fixedly connecting the wire cores of the wire bodies.

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