CN104143749A - Power connector forming method - Google Patents

Abstract

The invention relates to a power connector forming method. The power connector forming method comprises the forming steps that a large-diameter terminal round bar material is processed through two or more times of cold drawing machining so that a formed thin round rod material can be obtained, the two ends of the thin round rod material are machined to be butt joint portions and connecting portions of terminals respectively, the thin round rod material is cut into the terminals with the preset length after being embedded in a material strap, and after the machining mode is repeated to form the multiple terminals, the terminals are positioned on the material strap; after the terminals are machined to be shaped, the terminals are first separated from the material strap, and then all the terminals are electroplated; parts of the butt joint portions and the connecting portions of every two adjacent terminals are embedded into a mold cavity of a forming mold and provided with bench insulators through plastic ejection in a coating mode, and after the forming mold is removed, power connectors can be directly formed; or every two terminals and the corresponding bench insulators are assembled in an insulator to form one power connector, and the purposes that structural strength of the multiple terminals is improved, the manufacturing cost is reduced, full electroplating is performed, and machining can be conveniently performed are achieved.

Description

The forming method of power connector

Technical field

The present invention is the forming method of relevant a kind of power connector, espespecially major diameter pole material is passed through to cold-draw stretch process and a plurality of terminals of punch forming, and a plurality of terminals are embedded to material strip to be processed moulding, and by the separated laggard electroplating processing on material strip of each terminal, recycling mould penetrates the Overmolded insulating base that has, and gains in strength, reduces costs, complete plating and object easy to process to reach.

Background technology

Press, supply socket is widely used in electric equipment products, such as portable sound equipment or audio-visual projector (as VCD, DVD etc.), and information products, such as computer, notebook computer, mobile phone etc., supply socket and commercial power socket in order to do be the power line difference intercalation product of plug by two ends, make this product be obtained power supply, for user, operates.

And the inner indispensable assembly of supply socket is at least one metal bolt, traditional metal bolt can be divided into hollow and solid two kinds, as shown in figure 12, hollow metal terminal is at a sheet metal, for example copper coin is gone out the lamellar body of a predetermined appearance, then by its one end curling be columniform contact site A, another end is extended the portion of terminal B of a flat, this contact site A and portion of terminal B are formed in one to make, but not riveting, the shortcoming of this hollow metal terminal is, because it is cans, in the process rolling, the control of strength is quite important, if the application of force is excessive or the application of force is not enough, dual side-edge cannot be in bonding station relative bonding closely, easily cause bow warping or distortion, so that product fraction defective improves, and the structural strength of hollow metal terminal is poor, while pegging graft with relative pattern electric connector, easily cause metal terminal stress deformation, the phenomenon such as distortion or fracture, in addition, the curling latch leading edge inclusion place of sheet can form seam, and have a strong impact on product appearance.

Because the shortcoming of aforementioned hollow metal terminal, relevant dealer proposes a kind of supply socket with solid metal terminal, as shown in figure 13, in the pedestal C of this supply socket, there is solid terminal D and terminal E, solid terminal D is for being arranged in pedestal C, solid terminal D is provided with the baffle ring D1 that is held in pedestal C front side, solid terminal D extend out to pedestal C rear one side and is provided with link D2, terminal E with the link D2 riveted of solid terminal D, allow solid terminal D be fixed in pedestal C, because this solid terminal D is for utilizing turning mode to make, because baffle ring D1 has the large external diameter of more solid terminal D, so metal charge material need at least be equal to the external diameter of baffle ring D1, just can turning form solid terminal D and baffle ring D1, the waste material that turning produces accounts for whole 40%, cause the waste of material, the recycling of waste material is quite inconvenience also, thus, the cost of manufacture of its solid terminal D just can significantly improve, and because need carry out riveted, equipment and the processing cost of riveted have not only been increased, if and the link D2 of solid terminal D and terminal E, because of riveted undercapacity or be subject to outside destroy to make to rivet position when loosening, to cause high temperature, loose contact, the situation that produces spark or come off, and have a strong impact on the use safety of product.

Only, the metal bolt of current power connector inside, no matter be hollow or solid terminal, in manufacturing the process of processing, all must consume the plenty of time in the processing operation of moulding, the structural strength of hollow terminal is poor, flexible, distortion or fracture, and the coiling operation of moulding quite bothers, easily causes the raising of product fraction defective; Solid terminal must carry out turning processing consuming time, that take a lot of work, and produces the difficult processing of many processing waste materials, forms the waste of resource.

Therefore the terminal that how to solve existing power supply connector manufacture add man-hour problem and shortcoming, be the relevant manufacturer that is engaged in the industry and desire most ardently the direction place person that research improves.

Summary of the invention

Therefore, inventor is because above-mentioned problem and shortcoming, be to collect related data, via in many ways assessing and considering, and to engage in the many years of experience of the industry accumulation, via constantly studying and revising, begin to design this kind and can utilize after a plurality of terminals of cold-draw stretch process moulding, and utilize material strip to process moulding rear separation to a plurality of terminals and electroplate processing, then in the patent of invention birth survivor of the forming method of the outside Overmolded power connector that has an insulating base of two-terminal.

Main purpose of the present invention is to be that this major diameter pole material is with secondary or cold-draw stretch process more than secondary, and in one end and appropriate position, rear respectively punch process form docking section and connecting portion, and thin round bar material is embedded at respectively to each locating groove of terminal material belt, cut into again the terminal of predetermined length, pass through above-mentioned steps iterative process and a plurality of terminals of moulding, be embedded at one by one each locating groove of terminal material belt, to being embedded at a plurality of terminals of material strip, first process moulding again in the laggard electroplating processing of separation, fit in again at least two of mould inside or two above die cavitys, with a plastic injection operation, form at least two or two above insulating bases, not only the manufacture process of a plurality of terminals can not produce a large amount of waste materials, and can increase the structural strength of a plurality of terminals and can reduce manufacturing cost, more can accelerate manufacturing speed, reach and shorten man-hour, promote the object of operating efficiency.

Secondary objective of the present invention is to be that the plurality of terminal is embedded at after material strip, first process moulding processing, and by each terminal after separating on material strip, for the loose pin barrel plating mode of all terminal utilizations, electroplate processing again, because terminal integral body all can produce electrodeposited coating, and electrodeposited coating can not be subject to external force again and splits or peel off, more can not be subject to material strip and hinder plating processing, and then can reach complete plating and object easy to process.

Another object of the present invention is to be that the plurality of terminal forms convex shoulder in connecting portion and docking section binding site two sides, two terminals of adjacent fit in when mould ejaculation is Overmolded insulating base, each terminal utilizes convex shoulder inlay card, be fixedly arranged in insulating base, and when insulating base is assembled in insulating body, a plurality of clamping parts of insulating base are fastened in a plurality of draw-in grooves that insulating body is inserted groove relatively, make not displacement backwards of insulating base, and a plurality of block grooves of insulating base are held in the stop block of inserting groove, make not displacement forward of insulating base, form thus the location of fore-and-aft direction, while allowing default attaching plug electrically be plugged in power connector, be difficult for producing loosening or come off, and then can extend useful life of power connector.

Accompanying drawing explanation

For reaching above-mentioned purpose and effect, the method for the technology used in the present invention means and structure thereof, enforcement, below in conjunction with the explanation of preferred embodiment and Toyota as after, wherein:

Fig. 1 is flow chart of the present invention (one).

Fig. 2 is flow chart of the present invention (two).

Fig. 3 is the stereo appearance figure of terminal cold-draw stretch process of the present invention.

Fig. 4 is the three-dimensional exploded view of material strip of the present invention and terminal.

Fig. 5 is the stereo appearance figure of terminal of the present invention processing after moulding.

Fig. 6 is the stereo appearance figure of mould of the present invention.

Fig. 7 is the stereo appearance figure before insulating body assembling of the present invention.

Fig. 8 is the stereo appearance figure after insulating body assembling of the present invention.

Fig. 9 is the top plan view of power connector of the present invention.

Figure 10 is the side cutaway view of power connector of the present invention.

Figure 11 is the side cutaway view of another embodiment of the present invention.

Figure 12 is the terminal stereo appearance figure of existing power supply connector.

Figure 13 is the side cutaway view of existing power supply connector.

Embodiment

Refer to shown in Fig. 1,2,3,4,5,6,7,8,9,10, the stereo appearance figure, the stereo appearance figure before insulating body assembling, the stereo appearance figure after assembling, top plan view and the side cutaway view of power connector of stereo appearance figure after moulding of three-dimensional exploded view for stereo appearance figure, material strip and the terminal of flow chart of the present invention (), (two), terminal cold-draw stretch process, terminal processing, mould, by knowing and find out shown in figure, power connector forming step of the present invention be for:

(100) by large diameter terminal pole material 1, through the various scaled version aperture 20 of a plurality of cold-draw drawing dies 2, to carry out the above cold-draw stretch process of secondary or secondary and process, machine-shaping is thin round bar material 11.

(101) again by the thin round bar material 11 after cold-draw stretch process, one end is shaped to docking section 32 by punch process.

(102) by the thin round bar material 11 of predetermined length, the appropriate position of rear predetermined length, then punch process is to be shaped to connecting portion 31.

(103) the thin round bar material 11 of predetermined length, in the predetermined appropriate position of rear connecting portion 31, is embedded in the locating groove 40 of material strip 4, thinner round bar material 11 is cut into the terminal 3 of predetermined length.

(104), by a plurality of terminals 3 of moulding, be embedded at respectively one by one in each locating groove 40 of material strip 4.

(105) to being embedded at a plurality of terminals 3 of material strip 4, process moulding.

(106) each terminal 3 is separated on material strip 4.

(107) for all terminals 3, electroplate processing.

(108), by the part of the docking section of two terminals of adjacent 3 32, connecting portion 31, in the die cavity 50 of burying forming mould 5, can utilize mould 5 to penetrate Overmoldedly has insulating base 6, and is coated on two-terminal 3 outsides by insulating base 6.

(109) complete and penetrate after processing operation, remove mould 5, again two-terminal 3 and insulating base 6 are installed in to inserting in groove 71 of insulating body 7, and insulating base 6 is fastened in a plurality of draw-in grooves 711 of inserting groove 71 relatively with a plurality of clamping parts 61 in surface, meanwhile, the block groove 62 of insulating base 6 be relatively held in insert groove 71 stop block 712 to form location.

(110) be shaped to power connector.

Terminal 3 one sides of the invention described above power connector are shaped to flat connecting portion 31 through punch process, can be for being electrically connected with the default wire rod in outside, and connecting portion 31 can be welded type, clamping type or dual inline type (DIP) etc., the pattern that various and default wire rod is electrically connected; And the another side of terminal 3 is for to be shaped to the shaft-like docking section of circular cone 32 through punch process, and protrudes outwardly and form convex shoulder 311 by the dual side-edge of connecting portion 31.

Moreover, material strip 4 is the shapes that take the shape of the letter U, and be formed separately a plurality of relative locating grooves 40 in upright two sidewalls of U-shaped material strip 4, be positioned a plurality of terminals 3 on each locating groove 40 of material strip 4, for advanced person's row is processed moulding, and each terminal 3 is remake after separation on material strip 4 all, the plating processing of part or section (also can be immersion plating, loose pin barrel plating or brush plating), with two adjacent terminal 3 burst modes, insert respectively again that in mould 5 inner two or two above die cavitys 50, (the present invention be take two die cavitys 50 as embodiment, but do not limit the quantity of die cavity 50, in mould 5, also can be provided with one or three, four, five, six or a plurality of die cavity 50 etc.), mould 5 forms respectively insulating base 6 with the Overmolded processing mode of plastic injection in each two terminals of adjacent, 3 outsides, can pass through the convex shoulder 311 of each two terminals of adjacent 3, build-in is in insulating base 6 interior formation location and difficult loosening respectively, come off, its insulating base 6 two sidewalls or two sidewalls with upper surface for being protruding with respectively one or more clamping part 61, clamping part 61 is cumulative formation guiding inclines 611 backwards in front side, and each corner of insulating base 6 front side walls is concaved with respectively block groove 62 again.

Insulating body 7 is other manufacture, its insulating body 7 the place aheads are arranged with and are formed with docking space 70, insulating body 7 rears be penetrated be communicated with docking space 70 insert groove 71, insert groove 71 2 sides or internal faces more than two sides for being concaved with respectively one or more draw-in groove 711, insert each corner at groove 71 connection docking 70 places, space, the place aheads for convexing with respectively stop block 712, each insulating base 6 is inserted to inserting in groove 71 of insulating body 7 together with its two-terminal 3 by rear, allow each clamping part 61 utilize guiding incline 611 to be held in to insert the side wall surface of groove 71 and guide insulating base 6 and enter and insert groove 71, and insulating base 6 just can utilize rear side vertical configuration stop surface 612 relatively to support each draw-in groove 711 rear surfaces to stop forming fixing in continuing to insert rear each clamping part 61, simultaneously, each stop block 712 of inserting groove 71 supports backstop for entering the interior formation of each block groove 62 of insulating base 6 the place aheads, the front and back of its insulating base 6 are convenient can be subject to backstop and form location and come off avoiding, and the docking space 70 that is arranged in insulating body 7 the place aheads is stretched in 32 of the docking sections of the two-terminal 3 of each insulating base 6, 31 of the connecting portions of another side extend insulating body 7 outsides, rear.

Utilize the architectural feature of a plurality of locating grooves 40 of material strip 4, can set respectively for a plurality of terminals 3, location, can utilize automation, the facility such as semi-automation or manual equipment is assembled a plurality of terminals 3 on material strip 4, and coordinate material strip 4, control the shift position of a plurality of terminals 3, distance, moulding to process (as the taper shape finishing of docking section 32, the kenel of connecting portion 31 changes or is processed to form the kink 312 of vertical bending), the separation on material strip 4 of each terminal 3 is gone forward side by side after electroplating processing, fit in mould 5 plastic injection processing technology once, plastic at least two or two above insulating bases 6, and a plurality of insulating bases 6 and terminal 3 can be assembled in to insulating body 7, can effectively promote the efficiency of processing technology, while shortening worker to increase output, and can improve product yield, and docking space 60 (one of preferred embodiments of the present invention of the inner accommodating two-terminal of each insulating base 63 docking sections 32, female type power connector), default attaching plug that can the relative pattern of sacrificial vessel is relatively electrically pegged graft, because each terminal 3 utilizes convex shoulder 311 inlay cards, be fixed in insulating base 6, and insulating base 6 is positioned in insulating body 7 really by each clamping part 61 and block groove 62, when power connector is electrically pegged graft with the default attaching plug of outside relative pattern, do not affect the structure that each terminal 3 is fixedly arranged on insulating base 6, it is interior difficult loosening that each terminal 3 is positioned insulating base 6, come off, can effectively extend the useful life of power connector.

And above-mentioned steps (101)-(103), can be repeated, to make a plurality of terminals 3 (as: a plurality of terminals 3 of the predetermined number such as 50,100 or 150 or 200) of predetermined number, carry out again follow-up step (104)-(109), can utilize a plurality of terminals 3 to fit in mould 5 making and be shaped to power connector.

Refer to Fig. 1, 2, 3, 4, 5, 6, shown in 11, to be flow chart of the present invention (one), (2), the stereo appearance figure of terminal cold-draw stretch process, the three-dimensional exploded view of material strip and terminal, stereo appearance figure after terminal processing is moulding, the stereo appearance figure of mould, the side cutaway view of another embodiment, by knowing and find out shown in figure, procedure of processing of the present invention, for via cold-draw drawing die 2 by the terminal pole material 1 of major diameter size, the thin round bar material 11 of moulding small diameter size by cold-draw stretch process, and utilize punch process to be shaped to the shaft-like docking section of circular cone 32 thin round bar material 11 1 sides, the appropriate position of rear predetermined length, punch forming is flat connecting portion 31 again, the terminal 3 that thinner round bar material 11 is cut into suitable length (can be according to the size of the power connector of moulding, adjust the length dimension of terminal 3, the present invention is not limited the length dimension of terminal 3).

And terminal 3 one side connecting portions 31, except can punch forming being tabular, be outside welded type connection, combination for the default wire rod in outside, also can by connecting portion 31 1 side blows molded be I shape, U-shaped or T-shaped, I shape or T-shaped connecting portion 31 1 sides are incorporated into docking section 32, the another side of connecting portion 31 punch forming is U-shaped or pin type, the wire ends of U-shaped connecting portion 31 coated outside default wire rods, form the connection of clamping type, in conjunction with, or for pin type connecting portion 31, be dual inline type (DIP) with default wire rod and be connected, in conjunction with, the connecting portion 31 of above-mentioned terminal 3 is shaped to different types, its only tool be connected with outside default wire rod, in conjunction with function, its connecting portion 31 can be after insulating base 6 moulding, before moulding or insulating base 6 be assembled in rear connections of insulating body 7 in conjunction with presetting wire rod, non-so limit to the scope of the claims of the present invention, as utilize other modifications and equivalent structure to change, all should in like manner be contained in the scope of the claims of the present invention.

Separately, can utilize three terminal 3 (not shown)s of adjacent storehouse shape triangular in shape, with three docking sections 32, stretch through respectively in the die cavity 50 of mould 5 respectively, can utilize the die cavity 50 of mould 5 outside three docking sections 31, by plastic injection is Overmolded, there is an insulating base 6, again related three terminals 3 of each insulating base 6 are assembled in insulating body 7, may be molded to the different size power connector of another pattern, and each connecting portion 31 of three terminal 3 another sides of the power connector of moulding, extends respectively insulating body 51 outsides.

Separately, also can be by the part of the docking section of two terminals of adjacent 3 32, connecting portion 31, the interior mould 5 that utilizes of die cavity 50 of burying forming mould 5 directly penetrates the Overmolded insulating base 6 that has tool docking space 60, the Assembly Action that so just can save step (109); And connecting portion 31 also can be after connecting the wire ends of outside default wire rod, again by the part of the docking section of two terminals of adjacent 3 32, connecting portion 31, in the die cavity 50 of burying forming mould 5, penetrate the Overmolded insulating base 6 that has, it is only preferred embodiment of the present invention, non-so limit to the scope of the claims of the present invention.

Power connector after moulding of the present invention, can be assembled on default electronics/electric product, can relatively electrically peg graft with the default attaching plug of the relative pattern in outside, by power connector, provides default electronics/electric product required electric energy.

In addition, refer to Fig. 1, 2, 4, shown in 5, to be flow chart of the present invention (one), (2), the three-dimensional exploded view of material strip and terminal, stereo appearance figure after terminal processing is moulding, by knowing and find out shown in figure, this terminal 3 is directly stretched shape except can integral body being, also can be processed to form by the connecting portion 31 of contiguous convex shoulder 311 kink 312 of vertical bending, or further again connecting portion 31 is processed to form to bending and is another skewed kink 312, allow terminal 3 be bending, because two kinks 312 are to be all exposed to insulating base 6 outsides, so need be embedded at after material strip 4 in a plurality of terminals 3 of step (104), the moulding processing of processing of carrying out, and by each terminal 3 after separating on material strip 4, for all terminals 3, electroplate processing, because each terminal 3 is separated material strip 4 and is just electroplated processing, so can not allow terminal 3 contact material strip 4 places that electrodeposited coating cannot be formed, form the shortcoming of naked copper, and just electroplate processing in terminal 3 processing moulding being after bending and separate material strip 4, just can not allow electrodeposited coating when processing is moulding, produce the situation of splitting or peeling off, moreover, while reeling because of material strip 4 after terminal 3 bendings, connecting portion 31 can fasten mutually, so cannot utilize material strip 4, electroplate processing, but after being separated to material strip 4, a plurality of terminals 3 just can utilize loose pin barrel plating mode to electroplate smoothly processing, and then can reach complete plating and object easy to process.

Be with, the foregoing is only preferred embodiment of the present invention, non-so limit to the scope of the claims of the present invention, power connector manufacturing step of the present invention, by large diameter pole material 1, by cold-draw drawing die 2 with secondary or cold-draw stretch process more than secondary, the thin round bar material 11 of moulding reduced size, by one end punch forming, it is docking section 32, appropriate location, rear is punch forming connecting portion 31 again, and cut into the terminal 3 of preset length, get final product a plurality of terminals 3 of machine-shaping, and a plurality of terminals 3 are embedded at one by one to the locating groove 40 of material strip 4, can process moulding to being embedded at a plurality of terminals 3 of material strip 4, again by the separated laggard electroplating processing on material strip 4 of each terminal 3, can be respectively at two terminals of adjacent 3 outsides, utilize mould 5 to be penetrated Overmolded machine-shaping and have insulating base 6, again a plurality of insulating bases 6 and terminal 3 are assembled in to insulating body 7, to can reach processing fast, save time, the object of saving of labor's manufacture moulding, and can promote operating efficiency, reduce manufacturing cost, and utilize a plurality of terminals 3 through cold-draw stretch process, not only can reduce processing waste material, more can strengthen the structural strength of a plurality of terminals 3, and a plurality of terminals 3 can be fitted in to the insulating base 6 that mould 5 plastic ejection mouldings make and be assembled in insulating body 7, effect with rapid shaping power connector, therefore such as can reach the structure of aforementioned effect, device is contained by the present invention all should, this kind of simple and easy modification and equivalent structure change, all should in like manner be contained within the scope of claim of the present invention.

The forming method of the power connector of the invention described above when reality is used, for thering is following advantage, as:

(1) major diameter pole material 1, via cold-draw drawing die 2 with secondary or cold-draw stretch process more than secondary, be shaped to thin round bar material 11 and in punch process moulding docking section, one end 32, appropriate position, rear is punch forming connecting portion 31 again, and thin round bar material 11 is embedded at respectively to each locating groove 40 of material strip 4, cut into again the terminal 3 of predetermined length, pass through above-mentioned steps iterative process and a plurality of terminals 3 of moulding, be embedded at one by one each locating groove 40 of terminal material belt 4, and the manufacture forming process of a plurality of terminals 3 can not produce a large amount of waste materials, increase the structural strength of a plurality of terminals 3, can reduce manufacturing cost.

(2) a plurality of terminals 3 are embedded at after material strip 4, first process moulding processing, and by each terminal 3 after separating on material strip 4, for all terminals 3, electroplate processing again, avoiding thus producing terminal 3 contact material strip 4 places cannot form electrodeposited coating and form naked copper, and process the moulding shortcoming that allows electrodeposited coating split or peel off, and a plurality of terminal 3 just can utilize the pin barrel plating mode of faling apart to electroplate smoothly processing after separating material strip 4, and then can reach complete plating and object easy to process.

(3) connecting portion 31 and docking section 32 binding sites of a plurality of terminals 3, utilize connecting portion 31 2 sides to form convex shoulder 311, two terminals of adjacent 3 fit in mould 5 and penetrate the Overmolded insulating base 6 that has, each terminal 3 utilizes convex shoulder 311 inlay cards, is fixedly arranged in insulating base 6, and when insulating base 6 is assembled in insulating body 7, insulating base 6 relatively fixes or is held in insulating body 7 with a plurality of clamping parts 61 and block groove 62 and inserts a plurality of draw-in grooves 711 of groove 71, stop block 712 formation front and back to location, it is difficult for loosening or comes off, and can extend the useful life of power connector.

(4) a plurality of terminals 3 are each locating grooves 40 that are positioned respectively material strip 4, can utilize automation or manual equipment to assemble a plurality of terminals 3 on material strip 4, coordinate material strip 4, control shift position, the distance of a plurality of terminals 3, moulding to process, just can accelerate manufacturing speed, can shorten man-hour, promote operating efficiency.

Therefore, the present invention processes and designs for the manufacture mainly for power connector, that the stretching of major diameter pole material use cold-draw and punch process are shaped to terminal, again by a plurality of terminal position in each locating groove of material strip, first a plurality of terminals are processed moulding, and in the separated laggard electroplating processing on material strip of each terminal, fit in again a plastic injection processing operation of mould, a plurality of insulating bases of moulding, again insulating base and terminal group are loaded on to insulating body, make fast power connector, and can reach to shorten, be processed into, promote operating efficiency, reduce manufacturing cost, the structural strength that increase terminal is fixedly arranged on insulating body is main key protection point, can reduce the waste material that processing technology produces, terminal can strong fix in insulating body, be difficult for loosening or come off, be only to make power connector tool compared with the advantage of long life, and a plurality of terminals be embedded at first process after material strip moulding, and each terminal is electroplated after material strip separation again to processing, can allow and electroplate complete do not peel off and easy to process, only, the foregoing is only preferred embodiment of the present invention, non-so limit to the scope of the claims of the present invention, the simple and easy modification that every utilization specification of the present invention and Toyota's content are done and equivalent structure change, all should in like manner be contained within the scope of claim of the present invention.

In sum, the forming method of the power connector that the present invention is above-mentioned is when implementing, manufacturing, for really reaching its effect and object, therefore the present invention is really the research and development of a practicality excellence, for meeting the application condition of patent of invention, thus file an application in accordance with the law, as auditor have any check doubtful, the indication of please writing to us without sparing, settled the doing one's utmost of inventor coordinates.

Claims (14)

1. a forming method for power connector, the step of this power connector moulding is:

(a01) large diameter terminal pole material is processed through secondary or the above cold-draw stretch process of secondary, machine-shaping is thin round bar material;

(a02) by the thin round bar material of predetermined length one end, punch forming is docking section;

(a03) pre-position, rear, docking section of the thin round bar material of predetermined length, then be shaped to connecting portion through punch process;

(a04) thin round bar material is embedded at material strip each locating groove, cut into again the terminal of predetermined length;

(a05) a plurality of terminals of machine-shaping, for being embedded at respectively one by one each locating groove of material strip;

(a06) to being embedded at a plurality of terminals of material strip, process moulding;

(a07) each terminal is separated on material strip;

(a08) for all terminals, electroplate processing;

(a09), by the die cavity of the local burying forming moulds of two terminals of adjacent, utilizing mould to penetrate Overmoldedly has insulating base outside in two-terminal.

2. the forming method of power connector as claimed in claim 1, wherein this terminal pole material is copper material or copper alloy material or metal material.

3. the forming method of power connector as claimed in claim 1, the thin round bar material of this predetermined length wherein, one end punch process is shaped to the shaft-like docking section of circular cone, the side of being combined with docking section can punch forming be the connecting portion of tabular I shape or T shape, the docking section of another side is shaped to U-shaped or aciculiform, for carrying out welded type, clamping type or dual inline type and outside default wire rod electric connection.

4. the forming method of power connector as claimed in claim 3, wherein this terminal one side connecting portion can punch forming have the convex shoulder of being protruded respectively outside, docking section by connecting portion two sides with the binding site place of another side docking section.

5. the forming method of power connector as claimed in claim 1, this step (a02)-(a04) repeated wherein, and after a plurality of predetermined number terminals of moulding, then perform step (a05)-(a09) step.

6. the forming method of power connector as claimed in claim 1, wherein the plurality of terminal is first electrically connected with default power line in connecting portion, then in the die cavity with the local burying forming mould in docking section of two terminals of adjacent, carries out the Overmolded processing of plastic injection.

7. the forming method of power connector as claimed in claim 1, wherein this material strip is the shape that takes the shape of the letter U, and is formed separately a plurality of relative locating grooves in upright two sidewalls of U-shaped material strip.

8. the forming method of power connector as claimed in claim 1, the docking section that wherein this adjacent each terminal extends respectively storehouse shape triangular in shape, for three terminal docking sections of shape storehouse triangular in shape, the die cavity with plastic ejection moulding insulating base frame into mould inside stretches through respectively.

9. the forming method of power connector as claimed in claim 1, when wherein this two terminals of adjacent is assembled in insulating body together with insulating base, insulating base is inserted the groove of inserting of insulating body by rear together with its two-terminal, the docking section of two terminals of adjacent is inserted into insulating body the place ahead and is arranged with and is communicated with in the docking space of inserting groove, moulding docking space in outside insulating body, and the connecting portion of the another side of two terminals of adjacent extends insulating body outside.

10. the forming method of power connector as claimed in claim 1, wherein this step (a09) utilizes mould to penetrate Overmoldedly has insulating base behind two-terminal outside, remove mould, each two-terminal and insulating base are installed in to inserting in groove of each insulating body, and each clamping part of insulating base surface is relatively fastened in each insulating body and inserts each draw-in groove in groove.

The forming method of 11. power connectors as claimed in claim 11, wherein this each insulating base together with its two-terminal by rear insert insulating body insert in groove time, the guiding incline of clamping part front side cumulative formation backwards supports the side wall surface guiding assembling of inserting groove, and when clamping part is fastened in each draw-in groove relatively, clamping part also supports each draw-in groove rear surface with rear side vertical configuration stop surface.

The forming method of 12. power connectors as claimed in claim 12, wherein these insulating base two sidewalls or two sidewalls with upper surface for being protruding with respectively one or more clamping part, clamping part is cumulative formation guiding incline backwards in front side, and each corner of insulating base front side wall is concaved with respectively block groove.

The forming method of 13. power connectors as claimed in claim 11, when wherein this two terminals of adjacent is assembled in insulating body together with insulating base, insulating base is inserted the groove of inserting of insulating body by rear together with its two-terminal, the docking section of two terminals of adjacent is inserted into insulating body the place ahead and is arranged with and is communicated with in the docking space of inserting groove, moulding docking space in outside insulating body, and the connecting portion of the another side of two terminals of adjacent extends insulating body outside.

The forming method of 14. power connectors as claimed in claim 1, wherein this step (a09) utilizes mould to penetrate Overmoldedly has insulating base behind two-terminal outside, removes mould, i.e. moulding power connector.