CN117728218A - An integrated new energy low-voltage connector and its manufacturing process - Google Patents

Abstract

The application relates to the technical field of connectors, in particular to an integrated new energy low-voltage connector and a manufacturing process thereof. In a first aspect, the present application provides an integrated new energy low voltage connector comprising a body, a conductive line, a terminal, and an electrical component; the main body is integrally formed; the conductive circuit is arranged inside the main body; the terminals and the electrical components are connected to the conductive traces and are secured to the body. The integrated new energy low-voltage connector has the advantages of low cost and high stability. In another aspect, the present application provides a manufacturing process of an integrated new energy low-voltage connector, including the steps of: processing the conductive circuit; assembling; injection molding the main body, forming the main body on the conductive circuit by injection molding based on the conductive circuit, and positioning the conductive circuit inside the main body; and (5) welding. The manufacturing process of the integrated new energy low-voltage connector has the advantages of being low in processing cost and high in processing efficiency.

Description

An integrated new energy low-voltage connector and its manufacturing process

Technical field

This application relates to the technical field of connectors, and in particular to an integrated new energy low-voltage connector and its manufacturing process.

Background technique

Common low-voltage connectors generally include a shell, metal terminals and a PCB board. Electrical components such as resistors are welded on the PCB board. The PCB board with electrical components is then installed into the shell as a whole. The terminals also need to be installed on the shell, and the The terminals are fixed on the PCB board.

With current technical means, the process of assembling the PCB board and terminals to the housing usually requires assembly line manual work and is fixed with screws or welding. The assembly process is complex and the manufacturing cost is high. Moreover, due to the electrical components and terminals of low-voltage connectors, The quantity is large and it relies on manual work on the assembly line, which will lead to low production efficiency. Moreover, the assembled low-voltage connector has poor integrity and a high defective rate.

Contents of the invention

This application provides an integrated new energy low-voltage connector and its manufacturing process.

In the first aspect, this application provides an integrated new energy low-voltage connector that adopts the following technical solution:

An integrated new energy low-voltage connector, including a main body, conductive lines, terminals and electrical components;

The main body is integrally formed; the conductive circuit is provided inside the main body; the terminals and electrical components are connected to the conductive circuit and fixed on the main body.

By adopting the above technical solution, electrical components and plugs can be fixed on the conductive circuit in advance, and the main body is injection molded on the outside of the conductive circuit. This can not only reduce the number of parts such as low-voltage connector shells, but also help Simplify the processing process and improve processing efficiency. At the same time, the integral injection molding of the main body makes the low-voltage connector more integrated, which can help improve the yield rate and save production costs.

Preferably, the electrical component is covered with glue on the outside, the main body is provided with an embedding groove, and the electrical component is embedded and fixed in the embedding groove.

By adopting the above technical solution, thermally conductive adhesive can be used for the encapsulation, so as to improve the heat dissipation effect of the electrical components, and on the other hand, the electrical components can be fixed on the main body.

Preferably, the main body is also provided with welding holes; the conductive lines extend to the welding holes, and the electrical components are connected to the conductive lines through the welding holes;

A communication groove is provided between the embedding groove and the welding hole.

By adopting the above technical solution, the electrical components can be welded to the conductive lines through the welding holes, thereby realizing the connection between the electrical components and the conductive lines; the pins of the electrical components can be placed in the communication slots for protection.

Preferably, it also includes an insulating frame, and the conductive lines are fixed on the insulating frame; both the insulating frame and the conductive lines are arranged inside the main body.

By adopting the above technical solution, the insulating frame can provide support for the conductive lines and facilitate the injection molding work of the main body.

On the other hand, this application provides a manufacturing process for an integrated new energy low-voltage connector, including the following steps:

Process conductive lines and use metal conductive materials to make conductive lines;

Assembling and fixing terminals on conductive wires;

The main body is injection molded based on conductive lines. The conductive lines are injection molded into the main body, and the conductive lines are located inside the main body; the terminals extend to the outside of the main body; welding holes are reserved on the main body, and the conductive lines are located in the welding holes;

Welding, welding electrical components to conductive lines through welding holes.

By adopting the above technical solution, conductive lines and terminals can be installed inside the main body when the main body is injection molded. And the main body is made of injection molding, which has high integration, good shock resistance and durability. And it can eliminate the steps of assembling ordinary low-voltage connector shells, improve processing efficiency, reduce the number of parts, and solve processing costs.

Preferably, the conductive circuit is made by punching a metal plate; the conductive circuit is arranged on the inside of the metal plate, and a positioning plate is formed at the edge of the metal plate;

During injection molding, the conductive circuit is placed in the injection mold cavity, and the positioning plate is connected to the injection mold to realize the positioning of the conductive circuit.

By adopting the above technical solution, metal plate blanking has the advantages of simple processing and high efficiency. The use of positioning plates to position conductive lines can improve the quality of injection molding, thus ensuring the quality of integrated new energy low-voltage connectors.

Preferably, it also includes cutting; after the injection molding of the main body is completed, cutting the part of the metal plate located outside the main body;

It also includes secondary injection molding, which is based on the main body molded by the first injection molding, and performs secondary injection molding at the cutting place of the conductive circuit, so that the main body after the second injection molding completely covers the conductive circuit.

By adopting the above technical solution and secondary injection molding, the conductive lines can be completely sealed inside the main body to avoid short circuits and improve the processing quality of the integrated new energy low-voltage connector.

Preferably, when the main body is injection molded, an insulating frame is used to fix the conductive line at the center of the insulating frame, and the edge of the insulating frame is the positioning portion;

The conductive circuit is placed in the injection mold cavity, and the positioning part is connected to the injection mold to realize the positioning of the conductive circuit;

After the main body is injection molded, the part of the insulating frame located outside the main body is cut.

By adopting the above technical solution, on the one hand, the insulating frame can support the conductive lines and ensure the position accuracy of the conductive lines. On the other hand, after cutting, it can ensure that the conductive lines are completely placed inside the main body without the need for secondary injection molding. Helps simplify processing steps and reduce processing costs.

Preferably, the material of the insulating frame is the same as the material of the main body; the surface of the insulating frame is roughened and has burrs on the surface.

By adopting the above technical solution, during the injection molding process, the molten plastic in the mold has a higher temperature, which can melt the burrs on the insulating frame, so that the insulating frame and the main body are combined and formed as a whole, so the integrated structure can be effectively improved. Integration of new energy low voltage connectors. Since the insulating frame is made of the same material as the main body, it can be recycled twice and used for injection molding of the main body, thus reducing costs.

To sum up, the present invention includes at least one of the following beneficial technical effects:

1. Electrical components and plugs can be fixed on the conductive lines in advance, and the main body is injection molded on the outside of the conductive lines. This can not only reduce the number of parts such as low-voltage connector shells, but also help simplify the processing process and improve processing. efficiency. At the same time, the integral injection molding of the main body makes the low-voltage connector more integrated, which can help improve the yield rate and save production costs;

2. The main body is injection molded, with high integration, good shock resistance and durability, thus effectively improving the integrated new energy low-voltage connector;

3. During injection molding, an insulating frame is used to support the conductive lines, and the insulating frame is injection molded into the main body. Therefore, it is ensured that the conductive lines are completely placed inside the main body, avoiding short circuits caused by exposed conductive lines, and no secondary injection molding is required. Requires only insulating frame;

4. The material of the insulating frame is the same as that of the main body, so the insulating frame can be recycled twice after cutting, and can be used for injection molding of the main body, reducing costs.

Description of the drawings

Figure 1 is a schematic diagram of the overall structure of the integrated new energy low-voltage connector in Embodiment 1 of the present application;

Figure 2 is a schematic diagram of the exploded structure of the integrated new energy low-voltage connector in Embodiment 1 of the present application;

Figure 3 is a schematic structural diagram of a conductive circuit in Embodiment 3 of the present application;

Figure 4 is a schematic diagram of the connection relationship between the integrated new energy low-voltage connector and the metal plate after the main body is injection molded and before cutting in Embodiment 3 of the present application.

Markings in the drawings: 1. Main body; 11. Embedding groove; 12. Welding hole; 13. Communication groove; 2. Conductive line; 3. Terminal; 4. Electrical component; 5. Metal plate; 51. Positioning plate; 6. Insulating frame; 61. Positioning part.

Detailed ways

The present invention will be further described in detail below with reference to the accompanying drawings 1-4.

The embodiment of the present application discloses an integrated new energy low-voltage connector, which can be applied to electric equipment such as car charging guns and power socket plugs. Referring to Figures 1 and 2, the integrated new energy low-voltage connector includes a main body 1, conductive lines 2, terminals 3 and electrical components 4. The main body 1 is made of insulating plastic material and is made of one-piece injection molding. The conductive circuit 2 is punched out of a metal plate 5 and is arranged inside the main body 1 . The terminals 3 and the electrical components 4 are both connected to the conductive lines 2 and fixed on the main body 1 .

Therefore, in the embodiment of the present application, the terminals 3 and the electrical components 4 can be welded to the temporary conductive line 2 first, and then the body 1 is injection molded and the terminals 3 and the electrical components 4 are disposed inside the body 1 .

For electrical components 4 that require higher heat dissipation, the electrical components 4 can be installed on the surface of the main body 1 . The main body 1 is provided with an embedding groove 11 , the electrical components 4 are covered with glue on the outside, and the electrical components 4 are embedded and fixed in the embedding groove 11 . Thermal conductive glue can be used for the encapsulation to facilitate the improvement of the heat dissipation effect of the electrical component 4, and on the other hand, it can also fix the electrical component 4 on the main body 1.

In order to realize the connection between the electrical component 4 and the conductive line 2, the main body 1 is also provided with a welding hole 12, the conductive line 2 extends to the welding hole 12, and the electrical component 4 can be welded to the conductive line 2 through the welding hole 12. A communication groove 13 is also provided between the embedding groove 11 and the welding hole 12 . The pins of the electrical components 4 can be placed in the communication slots 13 for protection.

The implementation principle of the integrated new energy low-voltage connector in the embodiment of this application is: the electrical component 4 and the plug can be fixed on the conductive line 2 in advance, and the main body 1 is injection molded on the outside of the conductive line 2. From this, it can Reducing the number of parts such as low-voltage connector shells can also help simplify the processing process and improve processing efficiency. At the same time, the integral injection molding of the main body 1 makes the low-voltage connector more integrated, which can help improve the yield rate and save production costs.

Example 2

The embodiment of the present application discloses an integrated new energy low-voltage connector, which is different from Embodiment 1 in that it also includes an insulating frame 6, which is also made of insulating plastic. The conductive line 2 is made of metal wire and fixed on the insulating frame 6. The fixing method can be bonding or the like. The insulating frame 6 is arranged inside the main body 1 together with the conductive lines 2 .

The implementation principle of the integrated new energy low-voltage connector in the embodiment of this application is: the insulating frame 6 can provide support for the conductive line 2 to facilitate the injection molding work of the main body 1 .

Example 3

The embodiment of this application discloses a manufacturing process for an integrated new energy low-voltage connector, which is intended to process the integrated new energy low-voltage connector disclosed in Embodiment 1. Specifically, the manufacturing process of an integrated new energy low-voltage connector includes the following steps:

S1, processing conductive lines 2.

Referring to FIG. 3 , the conductive circuit 2 is made by punching the metal plate 5 , that is, the conductive circuit 2 of the required shape is punched at the center of the entire metal plate 5 , and a positioning plate 51 is formed at the edge of the metal plate 5 .

S2, assembled. Secure terminal 3 to conductive trace 2. For some electrical components 4 with low heat dissipation requirements, they can also be directly welded to the conductive lines 2 in this step.

S2, main body 1 is injection molded.

Referring to Figure 4, during injection molding, the conductive circuit 2 is placed in the injection mold cavity, and the positioning plate 51 is connected to the injection mold to realize the positioning of the conductive circuit 2, and then the injection molding work is performed.

After the injection molding is completed, the conductive lines 2 are covered with the main body 1. At this time, the conductive lines 2 and the electrical components 4 with low heat dissipation requirements are located inside the main body 1. The terminal 3 is also fixed on the main body 1 and extends from the inside of the main body 1 to the outside of the main body 1 .

Reserve on the main body 1 and make the conductive lines 2 located in the welding holes 12 to facilitate the subsequent welding holes 12 of the electrical components 4;

S4, crop. After the injection molding of the main body 1 is completed, the part of the metal plate 5 located outside the main body 1 is cut;

S5, secondary injection molding, also includes secondary injection molding. Based on the main body 1 molded in the first injection molding, secondary injection molding is performed at the cutting place of the conductive line 2, so that the main body 1 after the second injection molding completely covers the conductive line 2. Through secondary injection molding, the conductive circuit 2 can be completely sealed inside the main body 1 to avoid short circuit and improve the processing quality of the integrated new energy low-voltage connector.

S6, welding. For some electrical components 4 with high heat dissipation requirements, they cannot be placed inside the main body 1. Therefore, the electrical components 4 need to be fixed on the main body 1, and the electrical components 4 are connected to the conductive parts through the welding holes 12. Line 2 is soldered.

In the embodiment of the present application, the purpose of step S5 is that step S5 can be omitted according to actual production requirements.

Example 4

The embodiment of this application discloses a manufacturing process for an integrated new energy low-voltage connector. The difference from Embodiment 2 is that the conductive line 2 is made of metal wire. The metal wire can be made of copper, gold and other metals, which can effectively improve the The conductive efficiency of the conductive line 2.

Since in Embodiment 1, the conductive lines 2 are made by punching the metal plate 5 as a whole, and the metal plate 5 needs to be cut later, metal scraps will be formed, and these scraps are difficult to reuse. In this embodiment, the conductive lines 2 are made of metal wires, which can effectively reduce the generation of metal scraps and save costs.

Specifically, the manufacturing process of integrated new energy low-voltage connectors includes the following steps:

S1, processing conductive lines 2. The conductive line 2 is wound by metal wire. An insulating frame 6 is used, and the material of the insulating frame 6 is the same as that of the main body 1 . The conductive line 2 is fixed at the center of the insulating frame 6 , and the positioning portion 61 is located at the edge of the insulating frame 6 .

S2, assembled. Secure terminal 3 to conductive trace 2. For some electrical components 4 with low heat dissipation requirements, they can also be directly welded to the conductive lines 2 in this step.

S2, main body 1 is injection molded. First, the surface of the insulating frame 6 needs to be roughened and burred. Then, the conductive line 2 is placed in the injection mold cavity, and the positioning part 61 is connected to the injection mold to realize the positioning of the conductive line 2 .

During the injection molding process, the molten plastic in the mold has a high temperature, which can cause the burrs on the insulating frame 6 to melt, so that the insulating frame 6 and the main body 1 are combined and formed into a whole.

After the injection molding is completed, the conductive circuit 2 will be completely placed inside the main body 1, and the electrical components 4 with low heat dissipation requirements are also located inside the main body 1. The terminal 3 is also fixed on the main body 1 and extends from the inside of the main body 1 to the outside of the main body 1 .

Reserve on the main body 1 and make the conductive lines 2 located in the welding holes 12 to facilitate the subsequent welding holes 12 of the electrical components 4 .

S3, crop. After the injection molding of the main body 1 is completed, the part of the insulating frame 6 located outside the main body 1 is cut. Since the insulating frame 6 is made of the same material as the main body 1, it can be recycled twice and can be used for injection molding of the main body 1, so the cost can be reduced.

S4, welding. For some electrical components 4 with high heat dissipation requirements, they cannot be placed inside the main body 1. Therefore, the electrical components 4 need to be fixed on the main body 1, and the electrical components 4 are connected to the conductive parts through the welding holes 12. Line 2 is soldered.

In the embodiment of the present application, since the insulating frame 6 is integrated with the main body 1 and the conductive lines 2 will be completely placed inside the main body 1, there is no need to perform secondary injection molding after cutting the part of the insulating frame 6 located outside the main body 1. .

The examples of this specific implementation mode are all preferred embodiments of the present invention, and do not limit the scope of protection of the present invention. Therefore, all equivalent changes made based on the structure, shape, and principle of the present invention should be covered by within the protection scope of the present invention.

Claims (9)

1. An integrated new energy low-voltage connector, characterized by: including a main body (1), conductive lines (2), terminals (3) and electrical components (4); The main body (1) is integrally formed; the conductive circuit (2) is provided inside the main body (1); the terminal (3) and the electrical component (4) are both connected to the conductive circuit (2) and fixed on the main body (1) 1) Up. 2. The integrated new energy low-voltage connector according to claim 1, characterized in that: the electrical component (4) is provided with rubber coating on the outside, the main body (1) is provided with an embedded groove (11), and The electrical component (4) is embedded and fixed in the embedding groove (11). 3. The integrated new energy low-voltage connector according to claim 2, characterized in that: the main body (1) is also provided with a welding hole (12); the conductive line (2) extends to the welding hole (12) ), the electrical component (4) is connected to the conductive line (2) through the welding hole (12); A communication groove (13) is provided between the embedding groove (11) and the welding hole (12). 4. The integrated new energy low-voltage connector according to claim 1, characterized in that: it also includes an insulating frame (6), the conductive line (2) is fixed on the insulating frame (6); the insulating frame (6) 6) and the conductive circuit (2) are both arranged inside the main body (1). 5. A manufacturing process for an integrated new energy low-voltage connector, which is characterized by including the following steps: Process conductive lines (2) and use metal conductive materials to make conductive lines (2); Assemble and fix the terminal (3) on the conductive circuit (2); The main body (1) is injection molded based on the conductive circuit (2), and the conductive circuit (2) is injection molded into the main body (1), and the conductive circuit (2) is located inside the main body (1); the terminal (3) extends to Outside the main body (1); a welding hole (12) is reserved on the main body (1), and the conductive line (2) is located in the welding hole (12); For welding, the electrical components (4) are welded to the conductive lines (2) through the welding holes (12). 6. The manufacturing process of an integrated new energy low-voltage connector according to claim 5, characterized in that: the conductive line (2) is made by punching a metal plate (5); the conductive line (2) Set inside the metal plate (5), a positioning plate (51) is formed at the edge of the metal plate (5); During injection molding, the conductive circuit (2) is placed in the injection mold cavity, and the positioning plate (51) is connected to the injection mold to realize the positioning of the conductive circuit (2). 7. The manufacturing process of the integrated new energy low-voltage connector according to claim 6, characterized in that: it also includes cutting; after the injection molding of the main body (1) is completed, the metal plate (5) located outside the main body (1) is Partially cropped; It also includes secondary injection molding. Based on the main body (1) molded in the first injection molding, secondary injection molding is performed at the cutting place of the conductive line (2), so that the main body (1) after the second injection molding completely covers the conductive line (2). ). 8. The manufacturing process of integrated new energy low-voltage connector according to claim 5, characterized in that: when the main body (1) is injection molded, an insulating frame (6) is used to fix the conductive line (2) on the insulating frame. (6) The center position, and the edge position of the insulation frame (6) is the positioning part (61); The conductive line (2) is placed in the injection mold cavity, and the positioning part (61) is connected to the injection mold to realize the positioning of the conductive line (2); After the main body (1) is injection molded, the part of the insulating frame (6) located outside the main body (1) is cut. 9. The manufacturing process of integrated new energy low-voltage connector according to claim 8, characterized in that: the material of the insulating frame (6) is the same as the material of the main body (1); the surface of the insulating frame (6) Roughen the surface of the insulation frame (6) with burrs.