CN116487972A - Manufacturing method of female terminal of high-current connector - Google Patents
Manufacturing method of female terminal of high-current connector Download PDFInfo
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- CN116487972A CN116487972A CN202310468155.7A CN202310468155A CN116487972A CN 116487972 A CN116487972 A CN 116487972A CN 202310468155 A CN202310468155 A CN 202310468155A CN 116487972 A CN116487972 A CN 116487972A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 29
- 239000007769 metal material Substances 0.000 claims abstract description 21
- 238000004080 punching Methods 0.000 claims abstract description 11
- 238000005452 bending Methods 0.000 claims description 17
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 12
- 229910052802 copper Inorganic materials 0.000 claims description 12
- 239000010949 copper Substances 0.000 claims description 12
- 239000000463 material Substances 0.000 claims description 9
- 239000002184 metal Substances 0.000 claims description 9
- 229910052751 metal Inorganic materials 0.000 claims description 9
- 230000000149 penetrating effect Effects 0.000 claims description 7
- 229910000881 Cu alloy Inorganic materials 0.000 claims description 5
- 239000000956 alloy Substances 0.000 claims description 5
- 239000010935 stainless steel Substances 0.000 claims description 4
- 229910001220 stainless steel Inorganic materials 0.000 claims description 4
- 238000003466 welding Methods 0.000 claims description 4
- 238000000034 method Methods 0.000 claims 3
- 239000002131 composite material Substances 0.000 description 3
- 239000004020 conductor Substances 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000013459 approach Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/02—Contact members
- H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/02—Contact members
- H01R13/22—Contacts for co-operating by abutting
- H01R13/24—Contacts for co-operating by abutting resilient; resiliently-mounted
- H01R13/2407—Contacts for co-operating by abutting resilient; resiliently-mounted characterized by the resilient means
- H01R13/2414—Contacts for co-operating by abutting resilient; resiliently-mounted characterized by the resilient means conductive elastomers
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/70—Energy storage systems for electromobility, e.g. batteries
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Connector Housings Or Holding Contact Members (AREA)
Abstract
The invention discloses a manufacturing method of a female terminal of a high-current connector, which comprises the following steps: 1. punching and buckling the high-conductivity metal material to manufacture an inner-layer high-conductivity terminal, wherein the inner-layer high-conductivity terminal comprises an inner-layer main body and a plurality of inner-layer elastic arms which are distributed in two rows relatively; 2. punching and buckling the high-elastic metal material to manufacture an outer-layer high-elastic terminal, wherein the outer-layer high-elastic terminal comprises an outer-layer main body and a plurality of outer-layer elastic arms which are distributed oppositely in two rows, and the inner dimension of the outer-layer high-elastic terminal is larger than the outer dimension of the inner-layer high-conductivity terminal, so that an assembly gap is formed between the outer-layer high-elastic terminal and the inner-layer high-conductivity terminal; 3. the inner layer high-conductivity terminal is inserted into the outer layer high-elasticity terminal in an axial embedding mode, and the inner side surface of the outer layer elastic arm partially abuts against the outer surface of the inner layer elastic arm to form an elastic forward force applied to the inner layer elastic arm; the inner layer main body is embedded into the outer layer main body, and the inner layer main body and the outer layer main body are positioned by interference of a retaining structure so as to prevent the inner layer main body from retreating relative to the outer layer main body, so that the female terminal of the high-current connector is manufactured.
Description
Technical field:
the invention relates to the technical field of connectors, in particular to a manufacturing method of a female terminal of a high-current connector.
The background technology is as follows:
with the high-speed development of new energy automobiles, various domain controllers are integrated, high-current power supply, high-current conversion and high-current quick charging, and higher requirements are provided for the power supply current of each module, and under a 12V-48V voltage platform, the single PIN current carrying capacity needs to reach 150A-300A, and the international standard of automobile standard class (USCAR, LV 214) low-voltage connectors is required to be met.
To increase the current carrying capacity, the best approach is to increase the conductivity of the conductor material, with the same carrier cross-sectional area of the connector. It is known that the higher the conductivity of a copper material, the poorer the elasticity; the connector is in separable connection requiring multiple plugging and unplugging, and the female terminal of the connector is required to bear high current and even have good high-temperature stress relaxation resistance under certain high-temperature conditions, so that the performance of the copper conductor is a difficult problem.
In order to solve the above-mentioned problems, it is proposed to wrap a layer of high-elastic outer terminal on the outer surface of the copper terminal to form a composite terminal, wherein the copper terminal has high current-carrying capacity, and the first elastic arm of the outer terminal applies elastic forward force to the second elastic arm of the copper terminal, so that the copper terminal has high-temperature stress relaxation resistance and vibration resistance, and can realize high-quality multiple plug assembly. However, the spring arms of the outer terminals fully engage the spring arms of the copper terminals, which can result in insufficient elastic positive force being applied to the second spring arms.
When the composite terminal is manufactured, the copper terminal is manufactured through the die, and then the outer terminal is manufactured by wrapping the copper terminal in the die, so that the manufacturing process is difficult, the used die is complex in structure and high in cost, and the manufactured composite terminal is poor in quality.
In view of this, the present inventors have proposed the following means.
The invention comprises the following steps:
the invention aims to overcome the defects of the prior art and provides a manufacturing method of a female terminal of a high-current connector.
In order to solve the technical problems, the invention adopts the following technical scheme: the manufacturing method of the high-current connector female terminal comprises the following steps: the first step: punching and buckling the high-conductivity metal material to manufacture an inner-layer high-conductivity terminal, wherein the inner-layer high-conductivity terminal comprises an inner-layer main body which surrounds and buckles and is fixed into a square structure and a plurality of inner-layer elastic arms which are integrally connected to the lower end of the inner-layer main body and are distributed in two rows relatively; and a second step of: punching and buckling the high-elastic metal material to manufacture an outer-layer high-elastic terminal, wherein the outer-layer high-elastic terminal comprises an outer-layer main body and a plurality of outer-layer elastic arms, wherein the outer-layer main body surrounds and buckles and is fixed into a square structure, the outer-layer elastic arms are integrally connected to the lower end of the outer-layer main body and are distributed in two rows oppositely, the inner size of the outer-layer high-elastic terminal is larger than the outer size of the inner-layer high-conductive terminal, and an assembly gap is formed between the outer-layer high-elastic terminal and the inner-layer high-conductive terminal; and a third step of: the inner layer high-conductivity terminal is inserted into the outer layer high-elasticity terminal in an axial embedding mode, wherein the inner side surface of the outer layer elastic arm partially presses the outer surface of the inner layer elastic arm to form an elastic forward force applied to the inner layer elastic arm; the inner layer main body is embedded into the outer layer main body, and the inner layer main body and the outer layer main body are positioned by interference of a retaining structure so as to prevent the inner layer main body from retreating relative to the outer layer main body, so that the female terminal of the high-current connector is manufactured.
Furthermore, in the above technical solution, the side surface of the inner layer main body is formed by punching to form a hook extending outwards; the outer layer main body is provided with a clamping hole in a punching mode, and the clamping hook is embedded into and hooks the clamping hole to form the retaining structure.
In the above technical solution, the number of hooks is two, and the hooks are distributed on two symmetrical outer sides of the inner body; the number of the clamping holes is two, and the clamping holes are distributed on two symmetrical inner sides of the outer layer main body.
In the above technical solution, the end of the inner layer elastic arm is bent to form an R portion as a contact point; the tail end of the outer layer elastic arm is bent to form a convex arc part, the inner side surface of the convex arc part is attached to and pressed against the outer side surface of the R part, so that elastic forward force is applied to the R part, and the inner layer elastic arm is not contacted with other parts of the outer layer elastic arm.
Furthermore, in the above technical solution, the high-conductivity metal material is a copper material or a copper alloy material; the high-elastic metal material is a stainless steel material.
In the above technical solution, a connection structure is disposed at the upper end of the inner layer main body, and the inner layer main body is fixedly connected with the wire harness through the connection structure and forms electrical conduction; wherein, this connection structure all protrudes outside main part upper end.
Furthermore, in the above technical scheme, the connecting structure comprises a guide plate integrally formed at the upper end of the inner layer main body and protruding upwards, and the guide plate is in contact with the wire harness and fixed by ultrasonic welding.
Furthermore, in the above technical scheme, the connecting structure comprises a bending part integrally formed at the upper end of the inner layer main body and a covered wire part integrally connected at the tail end of the bending part, wherein the covered wire part is provided with a plurality of groups of metal core wires used for covering and fixing the wire harness and covered clamping pieces used for covering and covering.
In the above technical solution, the bending portion is bent at 90 degrees, so that the covered wire portion is perpendicular to the inner layer main body; the cross section of the bending part is U-shaped, or alternatively, the cross section of the bending part is annular with a seam.
In the above technical solution, the inner layer main body has a front end face and a rear end face opposite to each other, a left end face integrally connecting the front end face and one side of the rear end face, and a right end face integrally connecting the front end face and the other side of the rear end face, the left end face having a first fastening seam penetrating through the upper end and the lower end; the first row of inner layer elastic arms are integrally connected to the lower side of the front end face; the second row of inner layer elastic arms are integrally connected to the lower side of the rear end face; the outer layer main body is provided with a front side surface, a rear side surface, a left side surface, a right side surface, a second buckling seam, a first buckling seam and a second buckling seam, wherein the front side surface and the rear side surface are opposite, the left side surface is integrally connected with one side of the front side surface and the rear side surface, the right side surface is integrally connected with the other side of the front side surface and the rear side surface, and the second buckling seam penetrates through the upper end and the lower end; the first outer layer elastic arms are integrally connected to the lower side of the front side surface; the second row of outer elastic arms are integrally connected to the lower side of the rear side surface.
By adopting the technical scheme, compared with the prior art, the invention has the following beneficial effects: the invention adopts the high conductivity metal material and the high elastic metal material to respectively manufacture the inner layer high conductive terminal and the outer layer high elastic terminal, the requirement on the die is relatively low, the structure is relatively simple, the cost is lower, the inner dimension of the outer layer high elastic terminal is controlled to be slightly larger than the outer dimension of the inner layer high conductive terminal, and an assembly gap is formed between the outer layer high elastic terminal and the inner layer high conductive terminal, so that the inner layer high conductive terminal can be quickly and stably arranged in the outer layer high elastic terminal in the later period, and the outer layer main body can not be propped open; and finally, the inner layer high-conductivity terminal is inserted into the outer layer high-elasticity terminal in an axial embedding way, wherein the inner side surface of the outer layer elastic arm is partially propped against the outer surface of the inner layer elastic arm to form the elastic forward force applied to the inner layer elastic arm, and the elastic forward force is sufficiently large due to the fact that the inner layer elastic arm and the outer layer elastic arm are only partially contacted, the inner layer elastic arm can be ensured to have larger elastic clamping force at all times and longer service life, stable high-current carrying capacity is ensured, in other words, the outer layer elastic arm increases the forward force of the inner layer elastic arm to the opposite-inserting terminal, and the high conductivity of the inner layer high-conductivity terminal and the opposite-inserting terminal is ensured due to the high elasticity and the yield strength of the outer layer elastic arm, so that the current carrying capacity, the high-temperature stress relaxation resistance and the high-temperature stress resistance of the terminal are greatly increased. In addition, the inner layer main body and the outer layer main body are positioned by interference of the retaining structure, so that the inner layer main body is prevented from retreating relative to the outer layer main body, the stability and strength of the assembly structure of the inner layer main body and the outer layer main body are ensured, the inner layer high-conductivity terminal and the outer layer high-elasticity terminal can be effectively prevented from being separated relatively, and the service life of a product is prolonged.
Description of the drawings:
FIG. 1 is a flow chart of the steps of the present invention;
fig. 2 is a perspective view of a female terminal of a high current connector made in accordance with the present invention;
fig. 3 is a right side view of a female terminal of a high current connector made in accordance with the present invention;
fig. 4 is a perspective view of an inner high conductivity terminal of a female terminal of a high current connector made in accordance with the present invention;
fig. 5 is a perspective view of an outer layer high-elastic terminal in a female terminal of a high-current connector made in accordance with the present invention;
fig. 6 is a cross-sectional view of a female terminal of a high current connector made in accordance with the present invention;
fig. 7 is a first assembled structure view of the female terminal of the high-current connector and the wire harness made in accordance with the present invention;
fig. 8 is a second assembly structure view of the female terminal of the high-current connector and the wire harness made in accordance with the present invention;
fig. 9 is a perspective view of a second structure of an inner high conductivity terminal in a female terminal of a high current connector made in accordance with the present invention;
fig. 10 is a cross-sectional view of a second construction of an inner high conductivity terminal in a female terminal of a high current connector made in accordance with the present invention;
fig. 11 is a perspective view of a third structure of an inner high conductivity terminal in a female terminal of a high current connector made in accordance with the present invention;
fig. 12 is a cross-sectional view of a third construction of an inner high conductivity terminal in a female terminal of a high current connector made in accordance with the present invention.
The specific embodiment is as follows:
the invention will be further described with reference to specific examples and figures.
The invention relates to a manufacturing method of a female terminal of a high-current connector, which is shown in fig. 1-12, and comprises the following steps:
the first step: punching and buckling high-conductivity metal materials to manufacture an inner-layer high-conductivity terminal 1, wherein the inner-layer high-conductivity terminal 1 comprises an inner-layer main body 11 which surrounds and buckles and is fixed into a square structure, and a plurality of inner-layer elastic arms 12 which are integrally connected to the lower end of the inner-layer main body 11 and are distributed in two rows relatively;
and a second step of: punching and buckling the high-elastic metal material to manufacture an outer-layer high-elastic terminal 2, wherein the outer-layer high-elastic terminal 2 comprises an outer-layer main body 21 surrounding and buckling and fixing the outer-layer high-elastic terminal 2 into a square structure and a plurality of outer-layer elastic arms 22 integrally connected to the lower end of the outer-layer main body 21 and distributed in two rows oppositely, and the inner dimension of the outer-layer high-elastic terminal 2 is larger than the outer dimension of the inner-layer high-conductive terminal 1, so that an assembly gap is formed between the outer-layer high-elastic terminal 2 and the inner-layer high-conductive terminal 1;
and a third step of: the inner-layer high-conductivity terminal 1 is inserted into the outer-layer high-elasticity terminal 2 in an axial embedding mode, wherein the inner side surface of the outer-layer elastic arm 22 partially presses the outer surface of the inner-layer elastic arm 12 to form an elastic forward force applied to the inner-layer elastic arm 12; the inner layer main body 11 is embedded into the outer layer main body 21, and the inner layer main body 11 and the outer layer main body 21 are positioned by interference of a retaining structure so as to prevent the inner layer main body 11 from retreating relative to the outer layer main body 21, so that the female terminal of the high-current connector is manufactured.
The invention adopts the high conductivity metal material and the high elastic metal material to respectively manufacture the inner layer high conductive terminal 1 and the outer layer high conductive terminal 2, the requirement on a die is relatively low, the structure is relatively simple, the cost is low, the inner dimension of the outer layer high conductive terminal 2 is controlled to be slightly larger than the outer dimension of the inner layer high conductive terminal 1, and an assembly gap is formed between the outer layer high conductive terminal 2 and the inner layer high conductive terminal 1, so that the inner layer high conductive terminal 1 can be quickly and stably arranged in the outer layer high conductive terminal 2 in the later period, and the outer layer main body is not propped up; and finally, the inner layer high-conductivity terminal 1 is inserted into the outer layer high-conductivity terminal 2 in an axial embedding way, wherein the inner side surface of the outer layer elastic arm 22 is partially pressed against the outer surface of the inner layer elastic arm 12 to form the application of elastic forward force to the inner layer elastic arm 12, and the application of elastic forward force is large enough due to the partial contact between the inner layer elastic arm and the outer layer elastic arm, so that the inner layer elastic arm 12 has larger elastic clamping force at all times, longer service life and stable high current carrying capacity, and realizes high current conduction, in other words, the outer layer elastic arm 22 increases the forward force of the inner layer elastic arm 12 to the opposite-plug terminal, and due to the high elasticity and yield strength of the outer layer elastic arm 22, the high conductivity of the inner layer high-conductivity terminal 1 and the opposite-plug terminal is ensured, and the high elasticity of the outer layer elastic arm 22 is ensured, and the current carrying capacity, high-temperature stress relaxation resistance and high-temperature stress relaxation resistance of the terminal are greatly increased. In addition, interference positioning is carried out between the inner layer main body 11 and the outer layer main body 21 through a retaining structure so as to prevent the inner layer main body 11 from retreating relative to the outer layer main body 21, ensure the stability and strength of the assembly structure of the inner layer main body 11 and the outer layer main body, effectively prevent the inner layer high-conductivity terminal 1 and the outer layer high-elasticity terminal 2 from being separated relatively, and prolong the service life of products.
In addition, the inner layer main body 11 and the outer layer main body 21 are all of a square structure formed by surrounding and fastening, and have stable structure and high strength, so that the service life of the female terminal of the high-current connector can be ensured, and the areas of the inner layer main body 11 and the outer layer main body 21 are large, so that the high-current can be conducted better. In addition, the number of the inner elastic arms 12 and the outer elastic arms 22 is two, so that the large current conducted by the inner main body 11 and the outer main body 21 can be split, the current passing through each inner elastic arm 12 and each outer elastic arm 22 becomes smaller, the female terminal of the large current connector has extremely high current carrying capacity, and larger current can be conducted.
The specific structure of the retaining structure is as follows: the side surface of the inner layer main body 11 is stamped and formed with a clamping hook 111 which extends outwards; the outer body 21 is punched with a hole 211, and the hook 111 is inserted into and hooks the hole 211 to form the retaining structure. The hook 111 hooks the upper inner wall of the hook hole 211, so as to realize locking and achieve the function of stopping. In order to secure the stability of the assembly structure of the inner layer body 11 and the outer layer body 21, the following design is made: the number of the hooks 111 is two, and the hooks are distributed on two symmetrical outer sides of the inner layer main body 11; the number of the two clamping holes 211 is two, the two clamping holes are distributed on two symmetrical inner sides of the outer layer main body 21, and the stability of the assembly structure of the inner layer main body 11 and the outer layer main body 21 can be effectively ensured by locking the two clamping hooks 111 and the two clamping holes 211 which are distributed oppositely, and the backstop effect can be enhanced.
The inner body 11 has a first buckling seam 105 penetrating the upper and lower ends, the outer body 21 has a second buckling seam 205 penetrating the upper and lower ends, and after the inner body 11 and the outer body 21 are assembled, the first buckling seam 105 and the second buckling seam 205 are not in the same direction or in the same plane, so that the structural stability of the manufactured female terminal of the heavy current connector can be ensured, for example, the first buckling seam 105 is arranged on the left side of the inner body 11, and the second buckling seam 205 is arranged on the right side of the outer body 21, so that the two buckling seams are distributed in a staggered manner. Of course, the first fastening seam 105 may be provided on the right side of the inner layer main body 11, but the second fastening seam 205 may be provided on the left side of the outer layer main body 21, as long as the two fastening seams are offset from each other.
The high-conductivity metal material is a copper material or a copper alloy material, preferably, the high-conductivity metal material is a copper alloy material, and the copper alloy material has high conductivity; the high-elastic metal material is a stainless steel material, and the stainless steel material has high elasticity and yield strength.
The specific structures of the inner layer main body 11 and the outer layer main body 21 are specifically described below.
The inner layer main body 11 has a front end face 101 and a rear end face 102 which are opposite to each other, a left end face 103 integrally connecting one side of the front end face 101 and the rear end face 102, and a right end face 104 integrally connecting the other side of the front end face 101 and the rear end face 102, wherein the left end face 103 has a first fastening seam 105 penetrating the upper and lower ends; the first row of inner layer elastic arms 12 are integrally connected to the lower side of the front end face 101; the second row of inner layer elastic arms 12 are integrally connected to the lower side of the rear end surface 102; the two hooks 111 are respectively disposed on the front end face 101 and the rear end face 102, and protrude outwards. That is, the inner body 11 may be considered as a surrounding square frame structure, and the heights of the surrounding sides are substantially uniform, and of course, the inner body 11 may be slightly higher/lower, which can ensure that the structure of the entire inner body 11 is stable enough, the strength is high, the service life of the female terminal of the high-current connector can be ensured, and the inner body 11 has a large area, which can better realize the conduction of high current.
The outer body 21 has a front side 201 and a rear side 202 opposite to each other, a left side 203 integrally connecting one side of the front side 201 and the rear side 202, and a right side 204 integrally connecting the other side of the front side 201 and the rear side 202, wherein the right side 204 has a second fastening seam 205 penetrating the upper and lower ends; the first row of outer elastic arms 22 are integrally connected to the lower side of the front side 201; the second row of outer resilient arms 22 is integrally connected to the underside of the back side 202. The two clamping holes 211 are respectively arranged on the front side surface 201 and the rear side surface 202. That is, the outer body 21 may be considered as a surrounding square frame structure, and the heights of the surrounding sides are substantially uniform, and of course, the outer body 21 may be slightly higher/lower, which can ensure that the structure of the whole outer body 21 is stable enough, the strength is high, the service life of the female terminal of the high-current connector can be ensured, and the outer body 21 has a large area, which can better realize the conduction of high current.
The end of the inner elastic arm 12 is bent to form an R part 121 as a contact point; the outer elastic arm 22 is bent at the end to form a convex arc 221, the inner side of the convex arc 221 is pressed against the outer side of the R121 to apply an elastic positive force to the R121, and the inner elastic arm 12 is not in contact with other parts of the outer elastic arm 22, that is, only the R121 of the inner elastic arm 12 and the outer elastic arm 22 are directly in contact with the convex arc 221, and the other parts of the inner elastic arm 12 and the outer elastic arm 22 are formed with gaps so as not to be in contact, only the design ensures that the outer elastic arm 22 can provide a higher and durable elastic positive force for the inner elastic arm 12, so that the R121 at the end of the inner elastic arm 12 can stably conduct the connection of the plug terminal, the stability of the conduction connection is ensured, and the current carrying capacity and the high temperature stress relaxation resistance and vibration resistance of the high-current connector female terminal manufactured by the invention are greatly increased.
The upper end of the inner layer main body 11 is provided with a connecting structure, and the inner layer main body is fixedly connected with the wire harness through the connecting structure and forms electrical conduction. Wherein, this connection structure all protrudes outside main part 21 upper end to when leading this connection structure and pencil fixed connection, can not receive outside main part 21's influence, its assembly is more convenient.
The connecting structure at least comprises the following two structures:
the first structure is: the connection structure includes a guide plate 112 integrally formed at the upper end of the inner body 11 and protruding upward, and the guide plate 112 is contacted with the wire harness 3 and fixed by ultrasonic welding. Specifically, the wire harness 3 is first connected with the metal plate 31, and after the metal plate 31 is attached to the conductive plate 112, the metal plate is fixed by ultrasonic welding to realize electrical conduction. The wire harness 3 may be perpendicular to the inner layer body 11 or may be on the same line as the inner layer body 11, as shown in fig. 7 to 8.
The second structure is as follows: the connecting structure comprises a bending part 113 integrally formed at the upper end of the inner layer main body 11 and a wrapping part 114 integrally connected to the tail end of the bending part 113, wherein the wrapping part 114 is provided with a plurality of groups of wrapping clips 110 for wrapping and fixing the metal core wires of the wire harness 3 and the outer cover. In this way, the wire harness 3 is not required to be connected with the metal plate 31, only the metal core wires are required to be exposed after peeling, and at least two groups of wrapping clips 110 respectively wrap and fix the metal core wires and the outer covers of the wire harness 3, so that the assembly structure is stable, and stable electrical conduction is realized.
The bending part 113 is bent at 90 degrees, so that the covered wire part 114 is perpendicular to the inner layer main body 11, and after the wire harness 3 is assembled with the covered wire part 114, the inner layer main body 11 of the wire harness 3 is perpendicular to meet the assembly requirement. The cross section of the bending portion 113 is U-shaped, or the cross section of the bending portion 113 is ring-shaped with a seam, as shown in fig. 9-12. The bending portion 113 has a ring shape with a seam in cross section, and the bending portion 113 has high strength and high stability, so that the wire harness 3 can be connected with the inner-layer high-conductivity terminal 1 more stably.
The above-mentioned opposite terminals are terminals opposite to the female terminals of the high-current connector of the present invention, and more specifically, the opposite terminals are terminals inserted between two rows of inner elastic arms 12 and electrically connected to the inner elastic arms 12.
In summary, the inner layer high-conductivity terminal 1 and the outer layer high-conductivity terminal 2 are respectively manufactured by adopting the high-conductivity metal material and the high-elasticity metal material, the requirements on the die are relatively low, the structure is relatively simple, the cost is low, the inner dimension of the outer layer high-conductivity terminal 2 is controlled to be slightly larger than the outer dimension of the inner layer high-conductivity terminal 1, and an assembly gap is formed between the outer layer high-conductivity terminal 2 and the inner layer high-conductivity terminal 1, so that the inner layer high-conductivity terminal 1 can be quickly and stably arranged in the outer layer high-conductivity terminal 2 in the later period, and the outer layer main body cannot be expanded; and finally, the inner layer high-conductivity terminal 1 is inserted into the outer layer high-conductivity terminal 2 in an axial embedding way, wherein the inner side surface of the outer layer elastic arm 22 is partially pressed against the outer surface of the inner layer elastic arm 12 to form the application of elastic forward force to the inner layer elastic arm 12, and the application of elastic forward force is large enough due to the partial contact between the inner layer elastic arm and the outer layer elastic arm, so that the inner layer elastic arm 12 has larger elastic clamping force at all times, longer service life and stable high current carrying capacity, and realizes high current conduction, in other words, the outer layer elastic arm 22 increases the forward force of the inner layer elastic arm 12 to the opposite-plug terminal, and due to the high elasticity and yield strength of the outer layer elastic arm 22, the high conductivity of the inner layer high-conductivity terminal 1 and the opposite-plug terminal is ensured, and the high elasticity of the outer layer elastic arm 22 is ensured, and the current carrying capacity, high-temperature stress relaxation resistance and high-temperature stress relaxation resistance of the terminal are greatly increased. In addition, interference positioning is carried out between the inner layer main body 11 and the outer layer main body 21 through a retaining structure so as to prevent the inner layer main body 11 from retreating relative to the outer layer main body 21, ensure the stability and strength of the assembly structure of the inner layer main body 11 and the outer layer main body, effectively prevent the inner layer high-conductivity terminal 1 and the outer layer high-elasticity terminal 2 from being separated relatively, and prolong the service life of products.
It is understood that the foregoing description is only illustrative of the present invention and is not intended to limit the scope of the invention, but rather is to be accorded the full scope of all such modifications and equivalent structures, features and principles as set forth herein.
Claims (10)
1. A method of manufacturing a female terminal of a high-current connector, characterized by: which comprises the following steps:
the first step: punching and buckling high-conductivity metal materials to manufacture an inner-layer high-conductivity terminal (1), wherein the inner-layer high-conductivity terminal (1) comprises an inner-layer main body (11) which is surrounded and buckled and fixed into a square structure and a plurality of inner-layer elastic arms (12) which are integrally connected to the lower end of the inner-layer main body (11) and are distributed in two rows relatively;
and a second step of: punching and buckling high-elastic metal materials to manufacture an outer-layer high-elastic terminal (2), wherein the outer-layer high-elastic terminal (2) comprises an outer-layer main body (21) which surrounds and buckles and fixes the outer-layer high-elastic terminal (2) into a square structure and a plurality of outer-layer elastic arms (22) which are integrally connected to the lower end of the outer-layer main body (21) and are distributed in two rows oppositely, the inner size of the outer-layer high-elastic terminal (2) is larger than the outer size of the inner-layer high-conductive terminal (1), and an assembly gap is formed between the outer-layer high-elastic terminal (2) and the inner-layer high-conductive terminal (1);
and a third step of: the inner-layer high-conductivity terminal (1) is inserted into the outer-layer high-elasticity terminal (2) in an axial embedding mode, wherein the inner side surface of the outer-layer elastic arm (22) is partially pressed against the outer surface of the inner-layer elastic arm (12) to form an elastic forward force applied to the inner-layer elastic arm (12); the inner layer main body (11) is embedded into the outer layer main body (21), and the inner layer main body (11) and the outer layer main body (21) are positioned by interference of a retaining structure so as to prevent the inner layer main body (11) from retreating relative to the outer layer main body (21) and manufacture the female terminal of the high-current connector.
2. The method of manufacturing a female terminal of a high-current connector according to claim 1, wherein: the side surface of the inner layer main body (11) is provided with a clamping hook (111) which extends outwards in a stamping mode; the outer layer main body (21) is provided with a clamping hole (211) in a punching mode, and the clamping hook (111) is embedded into and hooks the clamping hole (211) to form the retaining structure.
3. The method of manufacturing a female terminal of a high-current connector according to claim 2, wherein: the number of the clamping hooks (111) is two, and the clamping hooks are distributed on two symmetrical outer side surfaces of the inner layer main body (11); the number of the clamping holes (211) is two, and the clamping holes are distributed on two symmetrical inner sides of the outer layer main body (21).
4. The method of manufacturing a female terminal of a high-current connector according to claim 2, wherein: the tail end of the inner layer elastic arm (12) is bent to form an R part (121) serving as a contact point; the tail end of the outer layer elastic arm (22) is bent to form a convex arc part (221), the inner side surface of the convex arc part (221) is abutted against the outer side surface of the R part (121) in a fit mode so as to apply elastic forward force to the R part (121), and the inner layer elastic arm (12) is not contacted with other parts of the outer layer elastic arm (22).
5. The method for manufacturing a female terminal of a high-current connector according to any one of claims 1 to 4, wherein: the high-conductivity metal material is a copper material or a copper alloy material; the high-elastic metal material is a stainless steel material.
6. The method for manufacturing a female terminal of a high-current connector according to any one of claims 1 to 4, wherein: the upper end of the inner layer main body (11) is provided with a connecting structure, and the connecting structure is fixedly connected with the wire harness and forms electrical conduction; wherein, this connection structure all protrudes outside main part upper end.
7. The method of manufacturing a female terminal of a high-current connector according to claim 6, wherein: the connecting structure comprises a guide connection plate (112) which is integrally formed at the upper end of the inner layer main body (11) and protrudes upwards, and the guide connection plate (112) is contacted with the wire harness and is fixed through ultrasonic welding.
8. The method of manufacturing a female terminal of a high-current connector according to claim 6, wherein: the connecting structure comprises a bending part (113) integrally formed at the upper end of the inner layer main body (11) and a wrapping wire part (114) integrally connected to the tail end of the bending part (113), wherein the wrapping wire part (114) is provided with a plurality of groups of wrapping clamping pieces (110) for wrapping and fixing metal core wires of the wire harness and an outer cover.
9. The method of manufacturing a female terminal of a high-current connector according to claim 8, wherein: the bending part (113) is bent at 90 degrees, so that the covered wire part (114) is perpendicular to the inner layer main body (11); the cross section of the bending part (113) is U-shaped, or the cross section of the bending part (113) is annular with joints.
10. The method for manufacturing a female terminal of a high-current connector according to any one of claims 1 to 4, wherein: the inner layer main body (11) is provided with a front end face (101) and a rear end face (102) which are opposite, a left end face (103) which integrally connects one side of the front end face (101) and the rear end face (102), and a right end face (104) which integrally connects the other side of the front end face (101) and the rear end face (102), wherein the left end face (103) is provided with a first buckling seam (105) penetrating through the upper end and the lower end; the first row of inner layer elastic arms (12) are integrally connected to the lower side of the front end surface (101); the second row of inner layer elastic arms (12) are integrally connected to the lower side of the rear end face (102); the outer layer main body (21) is provided with a front side surface (201) and a rear side surface (202) which are opposite, a left side surface (203) which integrally connects one side of the front side surface (201) and the rear side surface (202), and a right side surface (204) which integrally connects the other side of the front side surface (201) and the rear side surface (202), wherein the right side surface (204) is provided with a second buckling seam (205) penetrating through the upper end and the lower end; the first outer layer elastic arms (22) are integrally connected to the lower side of the front side surface (201); the second row of outer resilient arms (22) is integrally connected to the underside of the rear side (202).
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310468155.7A CN116487972A (en) | 2023-04-26 | 2023-04-26 | Manufacturing method of female terminal of high-current connector |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310468155.7A CN116487972A (en) | 2023-04-26 | 2023-04-26 | Manufacturing method of female terminal of high-current connector |
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| Publication Number | Publication Date |
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| CN116487972A true CN116487972A (en) | 2023-07-25 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202310468155.7A Pending CN116487972A (en) | 2023-04-26 | 2023-04-26 | Manufacturing method of female terminal of high-current connector |
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Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN2601467Y (en) * | 2003-01-21 | 2004-01-28 | 胡连精密股份有限公司 | Composite terminal structure |
| CN202308462U (en) * | 2011-11-15 | 2012-07-04 | 宏致电子股份有限公司 | Power supply connector |
| US20130273786A1 (en) * | 2012-04-12 | 2013-10-17 | Rockwell Automation Technologies, Inc. | Electrical power stab system and method for making same |
| CN106410464A (en) * | 2016-11-29 | 2017-02-15 | 河南天海电器有限公司 | Side-mounted terminal |
| CN109980397A (en) * | 2019-04-02 | 2019-07-05 | 实盈电子(东莞)有限公司 | High current connector |
| CN114976715A (en) * | 2022-05-31 | 2022-08-30 | 惠州尼索科连接技术有限公司 | Low-cost large-current flat terminal structure |
-
2023
- 2023-04-26 CN CN202310468155.7A patent/CN116487972A/en active Pending
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN2601467Y (en) * | 2003-01-21 | 2004-01-28 | 胡连精密股份有限公司 | Composite terminal structure |
| CN202308462U (en) * | 2011-11-15 | 2012-07-04 | 宏致电子股份有限公司 | Power supply connector |
| US20130273786A1 (en) * | 2012-04-12 | 2013-10-17 | Rockwell Automation Technologies, Inc. | Electrical power stab system and method for making same |
| CN106410464A (en) * | 2016-11-29 | 2017-02-15 | 河南天海电器有限公司 | Side-mounted terminal |
| CN109980397A (en) * | 2019-04-02 | 2019-07-05 | 实盈电子(东莞)有限公司 | High current connector |
| CN114976715A (en) * | 2022-05-31 | 2022-08-30 | 惠州尼索科连接技术有限公司 | Low-cost large-current flat terminal structure |
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