TW202207546A - Power connector - Google Patents

Abstract

The present invention provides a power connector, which includes a conductive terminal, an insulating body, and a wire. The conductive terminal has an integrally formed guide portion, an interference portion, and a bending portion. The guide portion has a solid rod shape, and an extending direction of the bending portion is perpendicular to an extending direction of the guide portion and the interference portion. The insulating body and the conductive terminal are integrally injection-molded, and the bending portion extends to an outside of the insulating body. One end of the wire has a core and engages with the bending portion.

Description

power connector

The present invention provides a power connector, especially a power connector in which conductive terminals and insulating bodies are integrally formed by injection molding.

As shown in FIG. 1A , the conventional power connector 1 includes a conductor 11 and an insulating body 12 . The front section of the conductor 11 is formed by turning, and the rear section is formed by stamping, wherein the stamping and forming can only be in a flat shape, and the structure with only a flat shape cannot be improved with the existing process capability. The rear portion of the conductor 11 is connected to the conductive piece 13 through the insulating body 12 . Specifically, the existing power connector 1 is assembled by a two-piece riveting method, and then the wire 2 is clamped to form an electrical connection.

As shown in FIG. 1B , after the wire 13 and the guide piece 12 are clamped and fixed, a riveting operation is performed, so that the conductor 11 is riveted and fixed to the guide piece 12 . The power connector 1 will be placed on the lower punching jig (not shown) and abut the front section of the conductor 11, and the conductive piece 12 will pass through the conductor 11 and then the rear section of the conductor 11 will be riveted with the upper punching jig (not shown). . Since the front section of the conductor 11 is easily subjected to impact force, the front section conductor 11 is squeezed and deformed, so that the front section conductor 11 affects the butt connector (not shown) to be difficult to plug or completely unable to butt. The two-piece riveting method also has another difficulty that cannot be improved, that is, the riveting method cannot ensure the stable position of the front and rear sections of the conductor 11, and there is a great possibility that the conductor 11 will be skewed during riveting. Therefore, because the conductor 11 adopts the riveting process, it is easy to cause low conduction and high impedance when transmitting signals or power, thereby causing the phenomenon of temperature rise and reducing the overall transmission efficiency.

Since the rear portion of the conductor 11 of the conventional power connector 1 is exposed outside the insulating body 12 , if there is a power conflict or other metal contacts, a short circuit is likely to be caused and the equipment will be damaged. The wire 2 is also exposed outside the power connector 1 , and is easily broken when pulled, thereby causing the device to fail. In addition, the outgoing direction of the wires 2 of the existing power connector 1 is limited and cannot be changed according to the needs of customers/users. To sum up, the existing power connector 1 manufacturing method is cumbersome, has low production efficiency, cannot be mass-produced, and has unstable processing procedures, which needs to be improved.

The purpose of the present invention is to provide a power connector, the integrally formed conductive terminal and the insulating body are made of embedded injection molding, so that the conductive terminal has good insulation protection, improves power surge or avoids accidental metal contact Problems with short circuits or equipment damage caused by bends/wires.

Another object of the present invention is to provide a power connector with high conduction and low impedance when transmitting signals or power, thereby improving the temperature rise phenomenon and improving the overall transmission efficiency.

Another object of the present invention is to provide a manufacturing method of a power connector, which has simple manufacturing procedures/steps, improves productivity, can be mass-produced, and greatly improves the unstable processing procedures of the existing manufacturing methods.

In order to achieve the above object, the present invention provides a power connector comprising at least one conducting terminal, an insulating body and at least one wire. The conducting terminal has a conducting portion, an interference portion and a bending portion which are integrally formed. The guide portion is in the shape of a solid rod, and the width of the guide portion is smaller than that of the interference portion. The extension direction of the bent portion is perpendicular to the extension direction of the guide portion and the interference portion. The insulating body and the conducting terminal are integrally injection-molded and clamped with the interference portion, and the insulating body forms a docking space for inserting the conducting portion. The bent portion extends to the outside of the insulating body. One end of the wire has a core, and the core is engaged with the bent part.

In one embodiment, the number of the at least one conducting terminal and the at least one conducting wire respectively includes three, and the central connection line of each conducting terminal is arranged in an isosceles triangle or an isosceles triangle in the insulating body.

In one embodiment, the cross-sectional shape of each of the guide portions is a circle, a rectangle or a triangle, and the diameter of one of the guide portions is larger than the diameter of two of the guide portions, and each of the guide portions externally pass signal, power or ground.

In one embodiment, the conducting portion with the largest cross-sectional shape transmits a ground signal, and the other two conducting portions transmit one of power or signal.

In one embodiment, the insulating body further includes a protruding portion, and the protruding portion covers the interference portion, part of the conducting portion and part of the bending portion.

In one embodiment, the bending portion further includes a notch, and the notch is exposed outside the protruding portion and is used for the core portion to be fastened and positioned.

In one embodiment, an injection molding mold connected to the insulating body is further included, and the injection molding mold covers the bent portion, the core portion and part of the wire.

The present invention also provides a method for manufacturing a power connector, comprising the following steps:

at least one conducting terminal is provided, and the at least one conducting terminal forms a conducting part, an interference part and a bending part which are integrally formed;

an insulating body is provided, which is integrally formed with the at least one conducting terminal, the insulating body forms a butt space for inserting the conducting portion, wherein the bent portion extends to the outside of the insulating body; and

At least one wire is provided, and one end of the at least one wire forms a core, and the core is snapped and positioned on the bent part.

In one embodiment, in the step of providing the at least one conducting terminal, after the conducting portion is formed by forging, the interference portion and the bending portion are formed by stamping.

In one embodiment, the bending portion further includes a notch formed by punching, and the notch is used to be fastened and positioned with the core portion.

In one embodiment, the forging forming method includes forging the lead portion into a solid rod shape with three forging dies, and the inner contour of each forging die is forged to form the outer contour of the lead portion.

In one embodiment, the cross-sectional shape of the guide portion is a circle, a rectangle or a triangle, the width of the guide portion is smaller than the width of the interference portion, and the extension direction of the bent portion is the same as that of the guide portion and the The extending direction of the interference portion is vertical.

In one embodiment, in the step of providing the insulating body and the conducting terminal integrally formed, the insulating body is further formed with a protruding portion covering the interference portion, part of the conducting portion and part of the bending portion, The insulating body and the conducting terminal are integrally formed by embedded injection.

In one embodiment, an injection molding die connected to one side of the insulating body is further included, and the molding temperature of the injection molding die is lower than the molding temperature of the integral injection molding of the insulating body and the conductive terminal.

In one embodiment, before implementing the injection molding die, the method further includes buckling the at least one wire on the bent portion, and the injection molding mold covers the bent portion, the core portion and part of the wire.

In one embodiment, the number of the at least one wire provided includes three, and each of the wires respectively transmits signal, power or ground.

As shown in FIGS. 2A to 4 , the present invention provides a power connector 100 , which includes at least one conductive terminal 110 , an insulating body 120 and at least one wire 150 . The conducting terminal 110 has a conducting portion 112 , an interference portion 114 and a bending portion 116 which are integrally formed. The guide portion 112 is a solid rod shape, and the width of the guide portion 112 is smaller than the width of the interference portion 114 . The extending direction of the bending portion 116 is perpendicular to the extending direction of the guiding portion 112 and the interfering portion 114 , so as to be fastened with the wire 150 , improve productivity and facilitate mass production.

It should be noted that the solid rod-shaped conductive terminal 110 is integrally formed, and has high conduction and low impedance characteristics when transmitting signals or power, and can effectively improve the temperature rise phenomenon and improve the overall transmission efficiency. The insulating body 120 and the conductive terminal 110 are integrally injection-molded. The insulating body 120 is formed with a docking space 122 for inserting the guiding portion 112 to ensure that the counterpart connector (not shown in the figure) can be easily inserted, wherein the two sides of the interference portion 114 are interfering and clamped in the insulating body 120 . The shape of the docking space 122 shown in FIG. 2A is preferably a triangle, but it is not limited. The bent portion 116 extends to the outside of the insulating body 120 . One end of the wire 150 has a core portion 152 , and the core portion 152 engages with the bent portion 116 .

In this embodiment, the number of the at least one conducting terminal 110 and the at least one conducting wire 150 respectively includes three, and the central connection of each conducting terminal 110 in the insulating body 120 is an isosceles triangle, a contour triangle or Other equilateral triangle arrangements, vary as needed. The cross-sectional shape of each guiding portion 112 is preferably a circle; however, in other different embodiments, the cross-sectional shape of each guiding portion 112 can also be a rectangle, a triangle or other suitable geometric shapes, and its appearance shape Diversified and able to change according to customer needs. In the embodiment shown in FIG. 2A and FIG. 2B , the diameter of one of the conducting parts 112 is larger than that of the other two of the conducting parts 112 for transmitting signals, power or grounding. In this embodiment, the conducting portion 112 with the largest cross-sectional shape transmits the ground signal, and the other two conducting portions 112 transmit power or signal, but it is not limited thereto.

The insulating body 120 also includes a protruding portion 124 . The protruding portion 124 partially protrudes from one side of the insulating body 120 and covers the interference portion 114 , part of the conducting portion 112 and part of the bending portion 116 . The bending portion 116 further includes a notch 118 , and the notch 118 is exposed outside the protruding portion 124 and is used for the core portion 152 to be fastened and positioned.

In addition, in this embodiment, an injection molding die 130 connected to the insulating body 120 is also included. The injection molding die 130 is formed on the protruding portion 124 and covers the bending portion 114 , the core portion 152 and part of the wire 150 . The molding temperature of the injection molding die 130 is lower than the molding temperature of the integral injection molding of the insulating body 120 and the conductive terminal 110 . Therefore, the low temperature injection molding will not damage the wire 150 or other components, effectively and stably fix the engagement relationship between the core portion 150 and the bent portion 116 , thereby preventing the wire 150 from breaking or equipment failure when pulled. In addition, the integrally formed conductive terminal 110 and the insulating body 120 are made by injection molding, so that the conductive terminal 110 has good insulation protection, improves power surge or avoids accidental contact and bending of other metals (not shown). Short circuit or equipment damage caused by section 116/conductor 150.

As shown in FIG. 5 to FIG. 7 , they are diagrams of various embodiments of different outlet directions of the wires of the power connectors. As shown in FIG. 5 , each lead 150 is in a straight out state, each lead 150 in FIG. 6 is in a side straight out state, and each lead 150 in FIG. 7 is in a side out state. The outlet direction of the wire 150 is not limited, and can be changed according to the needs of the user. Furthermore, the core portion 152 of the wire 150 can be easily bent and fastened to the notch 118 of the bent portion 116 , which increases the convenience of assembly and simplifies the subsequent positioning process.

It should be noted that the power connector 100 of this embodiment can be applied to, for example, a power adapter, a power supplier, an adapter or a transformer, etc., and is applicable to a wide range of applications ranging from aerospace It is also applicable to people's daily necessities, and even the fields of special needs, and is not limited.

Referring to FIG. 8, a method for manufacturing a power connector is also provided, which includes the following steps: Step S1, providing at least one conducting terminal 110, and the at least one conducting terminal 110 forms an integrally-molded conducting portion 112 , an interference portion 114 and a bending portion 116 . In step S2 , an insulating body 120 is provided, which is integrally formed with the at least one conductive terminal 110 . The insulating body 120 forms a docking space 122 for inserting the conductive portion 112 , wherein the bent portion extends to the outside of the insulating body. In step S3 , at least one wire 150 is provided, and one end of the at least one wire 150 forms a core 152 , and the core 152 is positioned on the bending part 116 by engaging.

In step S1, after the guide portion 110 is preferably formed by forging, then the interference portion 114 and the bending portion 116 are formed by stamping. The portion 152 is snapped and positioned. The cross-sectional shape of the conducting portion 112 shown in FIG. 3 is preferably circular. However, in other different embodiments, the cross-sectional shape of the conducting portion 112 may also be a rectangle, a triangle or other geometric shapes. The width of the guide portion 112 is smaller than the width of the interference portion 114 , and the extension direction of the bent portion 116 is perpendicular to the extension directions of the guide portion 112 and the interference portion 114 .

In the forging method, three forging dies (not shown) are used to forge the guide portion 112 into a solid rod shape, and the inner contour of each forging die is forged to form the outer contour of the guide portion 112. 112, the surface is smooth, with almost no burrs, scratches, dents, deformations, etc., so when the conductive part 112 transmits signals or power, it has high conduction and low impedance, thereby improving the temperature rise phenomenon and improving the overall transmission efficiency.

In step S2 , the insulating body 120 is further formed with a protruding portion 124 covering the interference portion 114 , a portion of the conducting portion 112 and a portion of the bending portion 116 . Preferably, the insulating body 120 and the conducting terminal 110 are integrally formed by embedded injection molding. In this step S2, an injection molding die 130 connected to one side of the insulating body 120 is also included. The molding temperature of the injection molding die 130 is lower than the molding temperature of the integral injection molding of the insulating body 120 and the conductive terminal 110 . Before implementing the injection molding mold 130 , the step S3 also includes buckling the at least one wire 150 on the notch 118 of the bending portion 116 , so that the injection molding mold 130 can be easily wrapped around the bending portion 116 , the core portion 152 and the notch 118 . Part of the wire 150.

The number of wires 150 in this embodiment includes three, and each wire 150 transmits signals, power or grounding, respectively. Therefore, the manufacturing method of the power connector provided by this embodiment has simple manufacturing procedures/steps, improves productivity, can be mass-produced, and greatly improves the unstable processing procedure of the existing manufacturing method.

While the invention has been disclosed and described in detail in the accompanying drawings and the foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments. Other modifications to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims.

100: Power Connector 110: Conductor terminal 112: Conductor 114: Interference Department 116: Bending part 118: Notch 120: Insulation body 122: Docking space 124: Projection 130: Injection molding die 150: Wire 152: Core S1-S3: Steps

In order to make the above-mentioned content of the present invention more obvious and easy to understand, the preferred embodiments are exemplified below and combined with the accompanying drawings, and are described in detail as follows: 1A is a cross-sectional view of a conventional power connector; FIG. 1B is a schematic diagram of the riveted conductor of the lead plate of the existing power connector; 2A is a schematic perspective view of the power connector of the present invention; 2B is a perspective view of the power connector of the present invention from another angle; FIG. 3 is a three-dimensional schematic view of a lead terminal made by integral molding of the present invention; 4 is a schematic cross-sectional view of the power connector of the present invention; FIG. 5 is a diagram of an embodiment of the power connector of the present invention; 6 is a diagram of another embodiment of the power connector of the present invention; FIG. 7 is a diagram of another embodiment of the power connector of the present invention; and FIG. 8 is a block diagram of a manufacturing method of a power connector according to the present invention.

100: Power Connector

110: Conductor terminal

116: Bending part

118: Notch

120: Insulation body

122: Docking space

124: Projection

Claims (16)

A power connector comprising: At least one lead terminal, the lead terminal has a lead part, an interference part and a bending part integrally formed, the lead part is a solid rod, and the width of the lead part is smaller than the width of the interference part , the extension direction of the bent portion is perpendicular to the extension direction of the guide portion and the interference portion; an insulating body, which is integrally injection-molded with the conductive terminal and fastened to the interference portion, the insulating body forms a docking space for inserting the conductive portion, and the bent portion extends to the outside of the insulating body; and At least one wire has a core part at one end, and the core part is engaged with the bending part. The power connector of claim 1, wherein the number of the at least one conducting terminal and the at least one wire respectively includes three, and the central connection of each conducting terminal is in the shape of an isosceles triangle or the like in the insulating body. High triangle arrangement. The power connector of claim 2, wherein the cross-sectional shape of each of the conducting portions is a circle, a rectangle or a triangle, and the diameter of one of the conducting portions is larger than the diameter of two of the conducting portions, Each of the leads transmits signal, power or ground. The power connector of claim 4, wherein the conducting portion with the largest cross-sectional shape transmits a ground signal, and the other two conducting portions transmit power or signals. The power connector of claim 1, wherein the insulating body further comprises a protruding portion, and the protruding portion covers the interference portion, part of the conducting portion and part of the bending portion. The power connector of claim 4, wherein the bent portion further includes a notch, the notch is exposed outside the protruding portion and is used for the core portion to be fastened and positioned. The power connector of claim 1, further comprising an injection molding die connected to the insulating body, the injection molding die covering the bent portion, the core portion and part of the wire. A manufacturing method of a power connector, comprising the following steps: at least one conducting terminal is provided, and the at least one conducting terminal forms a conducting part, an interference part and a bending part which are integrally formed; an insulating body is provided, which is integrally formed with the at least one conducting terminal, the insulating body forms a butt space for inserting the conducting portion, wherein the bent portion extends to the outside of the insulating body; and At least one wire is provided, and one end of the at least one wire forms a core, and the core is snapped and positioned on the bent part. The method for manufacturing a power connector according to claim 8, wherein, in the step of providing the at least one conducting terminal, after the conducting portion is formed by forging, the interference portion and the bending portion are then formed by stamping. Department. The method for manufacturing a power connector according to claim 9, wherein the bent portion further comprises a notch formed by punching, and the notch is used to be fastened and positioned with the core portion. The method for manufacturing a power connector according to claim 9, wherein the forging method includes forging the lead portion into a solid rod shape with three forging dies, and the inner contour of each forging die is forged to form the outer portion of the lead portion. type outline. The method for manufacturing a power connector of claim 11, wherein the cross-sectional shape of the lead portion is a circle, a rectangle or a triangle, the width of the lead portion is smaller than the width of the interference portion, and the extension of the bent portion is The direction is perpendicular to the extending direction of the guide portion and the interference portion. The method for manufacturing a power connector according to claim 8, wherein, in the step of providing the insulating body and the conductive terminal to be integrally formed, the insulating body is further formed with a covering portion, a portion of the conducting portion, and a portion of the bending portion. A protruding part of the folded part, the insulating body and the conducting terminal are integrally formed by embedded injection. The method for manufacturing a power connector according to claim 8, further comprising an injection molding die connected to one side of the insulating body, and the molding temperature of the injection molding die is lower than the molding temperature at which the insulating body and the conductive terminal are integrally injection molded. The method for manufacturing a power connector as claimed in claim 14, wherein, before implementing the injection molding die, the method further comprises buckling the at least one wire on the bent portion, and the injection molding mold covers the bent portion and the core. part and part of the wire. The method for manufacturing a power connector of claim 8, wherein the number of the at least one wire provided includes three, and each of the wires transmits signal, power or grounding respectively.

Images