Encapsulated terminal

Abstract

The application relates to the technical field of electric connectors, in particular to a rubber-coated terminal which comprises a terminal body, a containing cavity formed by stamping and curling, a pre-sealing structure arranged at a curling contact position of the terminal body, a first sealing element contained in the containing cavity, and a second sealing element sleeved on the terminal body and forming an integrated structure with the first sealing element. Compared with the terminal provided by the prior art, the rubber-coated terminal provided by the application forms an injection molding cavity by cooperation of the first sealing element, the terminal body and an injection molding mold, the setting of the redundant notch is cancelled, the cross-sectional area of the terminal body is increased, and the current-carrying capacity of the rubber-coated terminal is improved; the pre-sealing structure is arranged to hinder the flow of injection molding glue, the overflow phenomenon of the inner wall of the containing cavity is reduced, and the processing cost is reduced; and the contradiction between the overflow phenomenon and the current-carrying of the terminal is improved.

Description

[Technical Field]

[0001] This application relates to the field of electrical connector technology, and more particularly to an overmolded terminal. [Background Technology]

[0002] New energy vehicles refer to automobiles that use unconventional vehicle fuels as their power source (or use conventional vehicle fuels and adopt new on-board power devices), integrating advanced technologies in vehicle power control and drive, resulting in vehicles with advanced technical principles and new technologies and structures. Compared to conventional vehicles, new energy vehicles have more complex electrical circuits and higher requirements for the sealing of high-voltage wiring harnesses.

[0003] Coated components are composite structures formed by covering the surface of rigid substrates such as metal and plastic with an elastomer (such as rubber or silicone) through a special process. Some coated terminals provided by related technologies have metal contacts formed into receiving cavities by stamping and rolling. The rolled joints (welds) on the inner wall of the receiving cavity are prone to glue overflow. The cured glue overflow will interfere with the mating and assembly of the terminal with other electrical connectors. Figure 1 The illustration shows the actual structure of a coated terminal provided by related technology without the removal of excess adhesive. Obvious excess adhesive (W) is observed at the rolled joint of the inner wall of the receiving cavity, resulting in unsatisfactory processing. Furthermore, removing the excess adhesive (W) in subsequent processes is difficult and costly.

[0004] To reduce adhesive overflow, the metal contacts need to have radial notches to allow the injection mold to enter. These notches reduce the cross-sectional area of ​​the contacts, resulting in poor current carrying capacity, which cannot meet the high current requirements of high-voltage wiring harnesses in new energy vehicles.

[0005] Therefore, how to improve the contradiction between the current carrying capacity and adhesive overflow of the overmolded terminal is a problem that urgently needs to be solved by those skilled in the art. [Utility Model Content]

[0006] To address the aforementioned problems, this application provides an insulated terminal.

[0007] This application provides an overmolded terminal, comprising: a terminal body, which is formed into a receiving cavity by stamping and rolling, and a pre-sealing structure is provided at the rolling joint of the terminal body; a first sealing member, which is received in the receiving cavity; and a second sealing member, which is sleeved on the terminal body and forms an integral structure with the first sealing member.

[0008] In some embodiments, the first seal includes a connecting portion and two opposing sealing portions, the sealing portions being fixedly connected as an integral structure via the connecting portion, the size of the connecting portion being smaller than the size of the sealing portions.

[0009] In some embodiments, the outer surface of the sealing portion is provided with ribs, and the ribs are interference-fitted with the inner wall of the receiving cavity.

[0010] In some embodiments, the rolled joint includes a first contact surface and a second contact surface, the first contact surface being provided with the pre-sealing structure, the pre-sealing structure being serrated.

[0011] In some embodiments, the root end of the pre-sealed structure is fixedly connected to the first contact surface, and the tip end of the pre-sealed structure extends toward the second contact surface.

[0012] In some embodiments, several limiting blocks are also included, which are disposed on the inner wall of the receiving cavity.

[0013] In some embodiments, the limiting block includes a first sidewall and a second sidewall disposed opposite to each other, the first sidewall being inclined to the inner wall of the receiving cavity, and the second sidewall being perpendicular to the inner wall of the receiving cavity.

[0014] In some embodiments, the first seal is made of silicone.

[0015] In some embodiments, the second seal is made of silicone.

[0016] In some embodiments, the first seal and the second seal are formed into an integral structure by injection molding.

[0017] Compared to terminals provided by related technologies, the overmolded terminal provided in this application forms an injection cavity through the cooperation of a first sealing element, a terminal body, and an injection mold. This eliminates unnecessary notches, increases the cross-sectional area of ​​the terminal body, and improves the current carrying capacity of the overmolded terminal. The pre-sealing structure hinders the flow of injection molding material, reduces overflow from the inner wall of the cavity, and lowers processing costs. It also synergistically improves the contradiction between reducing overflow and terminal current carrying capacity. [Attached Image Description]

[0018] Figure 1 This image shows a coated terminal without the process of removing excess material, which is provided for related technologies.

[0019] Figure 2 for Figure 1 The diagram shows a three-dimensional structure of the contact element of the rubber-coated terminal.

[0020] Figure 3 for Figure 2 The diagram shows a partial cross-sectional view of the contact element and the injection mold.

[0021] Figure 4 This is a three-dimensional structural diagram of a rubber-coated terminal provided in this application.

[0022] Figure 5 for Figure 4 The diagram shown is an exploded three-dimensional representation of the insulated terminal.

[0023] Figure 6 for Figure 4 The enlarged structural diagram of the rolled joint shown.

[0024] Figure 7 for Figure 4 The diagram shows a three-dimensional structure of the first seal.

[0025] Figure 8 for Figure 4 The diagram shows a cross-sectional view of the insulated terminal.

[0026] Figure 9 for Figure 4 The diagram shows a flow chart of the injection molding method for the overmolded terminal.

Detailed Implementation Methods

[0027] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments.

[0028] In the description of the embodiments of this application, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0029] Furthermore, if the embodiments of this application involve descriptions such as "first" or "second," such descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features.

[0030] Please see Figure 2 , Figure 2 The illustration shows a three-dimensional structure of a contact element for a coated terminal. The coated terminal includes a contact element 11 and an insulating sealant covering the contact element 11. The contact element 11 is formed by stamping and rolling a metal sheet, and the contact element 11 has a receiving cavity 111. The insulating sealant is formed by an injection molding process, such as... Figure 1As shown, excess adhesive appeared at the rolled joint on the inner wall of the receiving cavity 111. The solidified excess adhesive hindered the engagement or insertion of the coated terminal 1 with other electrical connectors, resulting in a sharp increase in insertion and extraction force or incomplete insertion. This is because traditional rolled joints are flat interlocking surfaces, which rely on elastic compression and welding for fixation. Therefore, the rolled joint is prone to instantaneous elastic separation under high injection pressure, and the flowing injection molding material can quickly penetrate along the flat interlocking surface.

[0031] In addition, refer to Figure 3 , Figure 3 The diagram illustrates a partial assembly relationship between an injection mold and a contact element provided by the related technology. The related technology employs an injection mold with a protrusion 231 for injection molding. The injection mold includes a first mold core 21 and a second mold core 23, with the protrusion 231 located on the second mold core 23 near the first mold core 21. The contact element 11 has radially formed notches 113 and 115, with notch 113 facing the first mold core 21 and notch 115 facing the second mold core 23. Notch 113 is located within a molding area 117, the area where the insulating seal 13 is formed, and notch 115 is located at two opposite ends of the molding area 117. Both notches 113 and 115 communicate with the receiving cavity 111. Injection molding material flows into the receiving cavity 111 through notch 113. The protrusion 231 enters the receiving cavity 111 through notch 115 and abuts against the inner wall of the receiving cavity 111. The protrusion 231 obstructs the axial flow of injection molding material from the molding area 117 to other locations within the receiving cavity. The notch 115 and the protrusion 231 are fitted together, resulting in a significant reduction in the cross-sectional area of ​​the contact 11 and a decrease in the terminal current-carrying capacity.

[0032] In summary, the overmolded terminals provided by the relevant technologies cannot reconcile the contradiction between adhesive overflow and terminal current carrying capacity.

[0033] Based on this, this application provides a rubber-coated terminal that eliminates the multi-notch design of the contact element, improves the current carrying capacity of the terminal, and at the same time adjusts the injection molding method to improve the contradiction between glue overflow and terminal current carrying capacity.

[0034] The following embodiments of this application provide an overmolded terminal.

[0035] Please refer to the following: Figure 4 and Figure 5 , Figure 4 This is a three-dimensional structural diagram of a rubber-coated terminal provided in this application. Figure 5 for Figure 4The diagram shows an exploded view of the three-dimensional structure of the insulated terminal. The insulated terminal 3 is used to conduct large currents; specifically, it can be installed in electrical connectors used in new energy vehicles, or in charging guns for new energy vehicles.

[0036] The overmolded terminal 3 includes a terminal body 31, a first sealing element 3333, and a second sealing element 3535. The terminal body 31 is formed into a receiving cavity 311 by stamping and rolling. The first sealing element 33 is received in the receiving cavity 311 and is interference-fitted with the inner wall of the receiving cavity 311. The second sealing element 35 is sleeved on the outer surface of the terminal body 31, corresponding to the position of the first sealing element 33. The first sealing element 33 and the second sealing element 35 are integrally formed by injection molding to improve the airtightness of the overmolded terminal 3.

[0037] Specifically, one end of the terminal body 31 is a plug-in end 313, which is the end where the insulated terminal 3 is plugged in and mated with other electrical components (such as sockets or plugs). The other end of the terminal body 31, relative to the plug-in end 313, is a wiring end 315, which is the end where the insulated terminal 3 is crimped with a wire. The direction from the plug-in end 313 to the wiring end 315 is defined as the first direction D. Near the plug-in end 313, the receiving cavity 311 communicates with the external space through a first opening 3131, the centerline of which is parallel to the first direction D; near the wiring end 315, the receiving cavity 311 communicates with the external space through a second opening 3151, the centerline of which is parallel to the first direction D.

[0038] The combination of the first sealing element 33 and the second sealing element 35 is fixedly installed in the injection molding area 317 of the terminal body 31, where the injection molding area 317 is the area where the first sealing element 33 is injection molded. The terminal body 31 has a radially formed injection hole 319, which is pill-shaped. The center line of the injection hole 319 perpendicular to the first direction D and the center line of the injection molding area 317 perpendicular to the first direction D overlap. The size of the injection hole 319 is matched to the injection mold 4 so that the inner wall of the injection hole 319 abuts against the injection mold 4.

[0039] Please see Figure 6 , Figure 6 for Figure 4The diagram shows an enlarged view of the rolled joint. The receiving cavity 311 is formed by stamping and rolling a conductive metal plate. Normally, the injection molding material flows and permeates along direction V, then cools to form overflow. The rolled joint 312 includes a first joint surface 3121 and a second joint surface 3123. The first joint surface 3121 and the second joint surface 3123 are first elastically pressed together through a rolling process, and then fixedly connected by welding. The first joint surface 3121 has a pre-sealing structure 3125, which is triangularly serrated. The root end of the pre-sealing structure 3125 is fixedly connected to the first joint surface 3121, and the tip of the pre-sealing structure 3125 extends towards the second joint surface 3123. The pre-sealing structure 3125 deforms under the pressure F of the rolling process. The uneven interlocking surface significantly increases the flow path of the injection molding material, hindering its flow. Furthermore, the strong compressive deformation of the pre-sealed structure 3125 increases the dislocation density of the metal material, and the rolled joint portion 312 undergoes work hardening, which can resist the penetration pressure of the injection molding material and enhance the sealing effect.

[0040] Please see Figure 7 , Figure 7 for Figure 4 The diagram shows a three-dimensional structural schematic of the first sealing element. The first sealing element 33 is made of a waterproof soft material, specifically, in this embodiment, it can be made of silicone. The first sealing element 33 is a blind-plug structure, specifically, in this embodiment, it is a dumbbell-shaped blind-plug structure, including a connecting part 331 and two opposing sealing parts 333. The sealing parts 333 are fixedly connected to each other as an integral structure through the connecting part 331, and the size of the connecting part 331 is smaller than the size of the sealing part 333. The outer surface of the sealing part 333 is provided with ribs 3331, and the ribs 3331 are arc-shaped and protrude outwards. The ribs 3331 can strengthen the connection between the first sealing element 33 and the inner wall of the receiving cavity 311, and prevent deformation or relative displacement at the contact point between the two.

[0041] Please refer to the following: Figure 4 , Figure 5 and Figure 8 , Figure 8 for Figure 4 The diagram shows a cross-sectional view of the overmolded terminal and the injection mold assembly. The sealing part 333 is interference-fitted with the inner wall of the receiving cavity 311, and the sealing part 333, the connecting part 331, and the inner wall of the receiving cavity 311 cooperate to form a receiving groove 3111. The receiving groove 3111 communicates with the external space through the injection hole 319.

[0042] To facilitate the assembly of the terminal body 31 with the first sealing member 33, the rubber-coated terminal 3 further includes several limiting blocks 37, which are disposed on the inner wall of the receiving cavity, such as... Figure 8 As shown. Taking plane A, perpendicular to the first direction D and containing the centerline of the injection hole 319, as the boundary, the inner walls of the receiving cavity 311 on both opposite sides of plane A are provided with limiting blocks 37. The first sidewall 371 of the limiting block 37, away from plane A, is inclined to the inner wall of the receiving cavity. Thus, when the first sealing member 33 enters the receiving cavity 311 from the first opening 3131 or the second opening 3151, the first sidewall 371 induces deformation in the first sealing member 33, facilitating its installation. Simultaneously, the second sidewall 373 of the limiting block 37, opposite to the first sidewall 371, is perpendicular to the inner wall of the receiving cavity. Thus, the second sidewall 373 prevents the first sealing member 33 from exiting the receiving cavity 311 from the first opening 3131 or the second opening 3151.

[0043] Please refer to the following: Figure 8 and Figure 9 , Figure 9 for Figure 4 The diagram shows a flow chart of the injection molding method for the overmolded terminal. The second seal 35 is integrally formed with the first seal 33 through injection molding. Specifically, ejector pins are used as auxiliary assembly tools. These ejector pins abut against the sealing portion 333 of the first seal 33 to maintain the positional correspondence between the receiving groove 3111 and the injection hole 319. The assembly of the terminal body 31 and the first seal 33 is loaded into the injection mold 4. After the injection mold 4 is closed, the inner wall of the injection hole 319 abuts against the injection mold 4. Thus, the receiving groove 3111 and the injection mold 4 cooperate to form a closed injection cavity. High-temperature injection molding material fills the injection cavity, cools to form the second seal 35, and the second seal 35 is sleeved on the outer surface of the terminal body 31 and fixedly connected to the first seal 33. At this time, the ejector pins are removed. The first sealing element 33 and the second sealing element 35 are formed into an integral structure through injection molding, which completely blocks the exchange of aerosols between the wiring terminal and the plug terminal with the plane A as the boundary, thus achieving a good sealing effect.

[0044] The second sealing element 35 is made of a waterproof soft material. In this embodiment, the second sealing element 35 can be made of silicone. The second sealing element 35 can be integrally formed with the first sealing element 33 through liquid injection molding (LIM). The outer surface of the second sealing element 35 is also provided with reinforcing ribs 351, which are arc-shaped and protrude outwards. The reinforcing ribs 351 can enhance the sealing fit between the second sealing element 35 and other electrical connectors, preventing deformation or relative displacement at the contact points, and ensuring good airtightness of the assembly of the insulated terminal 3 and other electrical connectors.

[0045] Understandably, due to the pre-sealing structure 3125, it is difficult for adhesive to overflow from the rolled joint 312 of the receiving cavity 311. Therefore, the injection molding material may overflow from the contact point between the injection mold and the injection hole 319. Even if a small amount of adhesive overflow appears on the outer surface of the terminal body 31, it can be easily removed through subsequent processes, eliminating the need for complex processing to remove internal adhesive overflow as described in related technologies, thus saving processing costs.

[0046] The injection molding method for the overmolded terminal 3 includes the following steps:

[0047] S501, a terminal body with a receiving cavity is formed by stamping and rolling a metal plate. A serrated pre-sealing structure is formed at the rolled joint of the terminal body. An injection hole is opened in the radial direction of the terminal body.

[0048] S502, a first sealing element is installed on the terminal body. The first sealing element cooperates with the inner wall of the receiving cavity to form a receiving groove. The receiving groove is connected to the external space through the glue injection hole.

[0049] S503, the assembly of the terminal body and the first seal is loaded into the injection mold. After the injection mold is closed, the inner wall of the injection hole abuts against the injection mold, and the receiving groove cooperates with the injection mold to form a closed injection cavity.

[0050] S504, a second sealing element is formed by injection molding process, the second sealing element is sleeved on the surface of the terminal body and forms an integral structure with the first sealing element.

[0051] In summary, the overmolded terminal provided in this application forms an injection cavity through the cooperation of a first sealing element, a terminal body, and an injection mold. This eliminates unnecessary notches, increases the cross-sectional area of ​​the terminal body, and improves the current-carrying capacity of the overmolded terminal. The pre-sealing structure hinders the flow of injection molding material, reduces overflow from the inner wall of the cavity, and lowers processing costs. It also synergistically improves the contradiction between reducing overflow and terminal current carrying capacity.

[0052] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A type of insulated terminal, characterized in that, include: The terminal body is formed into a receiving cavity by stamping and rolling, and the rolled joint of the terminal body is provided with a pre-sealing structure; A first sealing element is housed within the receiving cavity; and The second sealing element is sleeved on the terminal body and forms an integral structure with the first sealing element.

2. The insulated terminal according to claim 1, characterized in that, The first sealing element includes a connecting portion and two opposing sealing portions, which are fixedly connected as an integral structure by the connecting portion, and the size of the connecting portion is smaller than the size of the sealing portion.

3. The insulated terminal according to claim 2, characterized in that, The outer surface of the sealing part is provided with ribs, and the ribs are interference-fitted with the inner wall of the receiving cavity.

4. The insulated terminal according to claim 1, characterized in that, The rolled joint includes a first contact surface and a second contact surface. The first contact surface is provided with the pre-sealing structure, which is serrated.

5. The insulated terminal according to claim 4, characterized in that, The root end of the pre-sealed structure is fixedly connected to the first contact surface, and the tip of the pre-sealed structure extends toward the second contact surface.

6. The insulated terminal according to claim 1, characterized in that, It also includes several limiting blocks, which are disposed on the inner wall of the receiving cavity.

7. The insulated terminal according to claim 6, characterized in that, The limiting block includes a first sidewall and a second sidewall disposed opposite to each other. The first sidewall is inclined to the inner wall of the receiving cavity, and the second sidewall is perpendicular to the inner wall of the receiving cavity.

8. The insulated terminal according to claim 1, characterized in that, The first seal is made of silicone.

9. The insulated terminal according to claim 1, characterized in that, The second seal is made of silicone.

10. The insulated terminal according to claim 1, characterized in that, The first seal and the second seal are formed into an integral structure through injection molding.

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