阅读说明：本技术 电连接器制作方法及电连接器 (Electric connector manufacturing method and electric connector ) 是由 陈宇平 王继发 李叶标 谢天宏 罗冰波 于 2020-05-09 设计创作，主要内容包括：本申请提供一种电连接器及其制作方法,所述电连接器包括导电端子组、功能件、第一绝缘体和第二绝缘体,所述导电端子组包括第一导电端子和第二导电端子,所述功能件连接所述第一导电端子和第二导电端子,所述第一绝缘体在所述功能件连接至所述第一导电端子和第二导电端子后与导电端子组一体成型,所述第二绝缘体在所述第二导电端子的接线端与线缆的中心导体连接后与所述第一绝缘体一体成型,所述第二绝缘体包裹所述接线端和连接至对应接线端的线缆的中心导体。本申请提供的电连接器制作方法及电连接器,生产效率高、尺寸小且可靠性好。(The application provides an electric connector and manufacturing method thereof, electric connector includes conductive terminal group, functional part, first insulator and second insulator, conductive terminal group includes first conductive terminal and second conductive terminal, the functional part is connected first conductive terminal and second conductive terminal, first insulator is in the functional part is connected to with conductive terminal group integrated into one piece behind first conductive terminal and the second conductive terminal, the second insulator is in the wiring end of second conductive terminal is connected with the centre conductor of cable after with first insulator integrated into one piece, the second insulator parcel the wiring end with be connected to the centre conductor of the cable that corresponds the wiring end. The electric connector manufacturing method and the electric connector are high in production efficiency, small in size and good in reliability.)

1. The utility model provides an electric connector, its characterized in that, electric connector includes conductive terminal group, functional part, first insulator and second insulator, conductive terminal group includes first conductive terminal and second conductive terminal, the functional part is connected first conductive terminal and second conductive terminal, first insulator is in the functional part is connected to first conductive terminal and second conductive terminal after with conductive terminal group integrated into one piece, the second insulator be in the wiring end of second conductive terminal is connected with the centre conductor of cable after with first insulator integrated into one piece, the second insulator parcel the central conductor of wiring end and the cable that is connected to corresponding wiring end.

2. The electrical connector of claim 1, wherein the set of conductive terminals further includes a third conductive terminal disposed on the same side as the second conductive terminal and having a terminal connected to the cable, the terminals of the second and third conductive terminals are disposed on the same side and connected to a central conductor of a corresponding cable, respectively, and the second insulator covers the terminals of the second and third conductive terminals and the central conductor of the cable connected to the corresponding terminal.

3. The electrical connector of claim 2, wherein the first and second conductive terminals each have a functional member connecting portion, and the functional member connecting portion is provided with a slot; the functional part is respectively connected with the functional part connecting parts of the first conductive terminal and the second conductive terminal in a resistance welding mode.

4. The electrical connector of claim 3, wherein the function connecting portion is provided with a wire connecting groove, and the cable is connected to the function connecting portion by resistance welding after being clamped into the wire connecting groove.

5. The electrical connector of claim 2, wherein the terminals of the second and third conductive terminals are connected to the center conductor of the corresponding cable by resistance welding.

6. The electrical connector of claim 2, wherein before the first insulator is molded, the first conductive terminal, the second conductive terminal, and the third conductive terminal are located on the same terminal member, and the cable is connected to the connection points in the conductive terminal group of the cut terminal member and the connection points between the conductive terminal group and the tape.

7. The electrical connector of claim 2, wherein the functional element is a sensor.

8. A method for manufacturing an electrical connector is characterized by comprising the following steps:

providing a conductive terminal group;

welding a functional part between the two conductive terminals so as to electrically connect the two conductive terminals through the functional part;

performing primary insert injection molding outside the conductive terminal group and the functional part to form a first insulator;

at least part of the conductive terminals are provided with wiring ends arranged on the same side, and each wiring end is connected with a cable in a welding way;

and after the cables are welded, performing secondary insert injection molding outside the first insulator to form a second insulator, wherein the second insulator wraps the terminals and the central conductors of the cables welded to the corresponding terminals.

9. The method of claim 8, wherein the set of conductive terminals includes a first conductive terminal, a second conductive terminal, and a third conductive terminal, wherein two ends of the functional element are resistance welded to the first conductive terminal and the second conductive terminal, respectively, and the second conductive terminal and the third conductive terminal have the terminals that are resistance welded to the corresponding cables.

10. The method of claim 9, wherein the first, second and third terminals are located on a same terminal member, and the first insulator is formed and then the connection points of the terminal member and the carrier tape are punched.

Technical Field

The present disclosure relates to electrical connectors, and particularly to a method for manufacturing an electrical connector and an electrical connector.

Background

With the national standard of six-emission automobiles, a six-national-vehicle-type exhaust detection electric connector is developed in an automobile exhaust detection system. The form of present electric connector's inserts is too single, if need use a plurality of parts in the inserts, and the integrated level is lower and occupation space is great, and the part is too much to make electric connector's reliability lower, and then makes the maintenance in later stage and replacement cost higher, hardly satisfies the functional requirement of customer to the product.

In view of the above, it is desirable to provide a new method for manufacturing an electrical connector and an electrical connector.

Disclosure of Invention

In view of the above, it is desirable to provide a method for manufacturing an electrical connector and an electrical connector with high production efficiency, small size and high reliability.

For solving above-mentioned technical problem, the present application provides one kind electric connector includes conductive terminal group, functional part, first insulator and second insulator, conductive terminal group includes first conductive terminal and second conductive terminal, the functional part is connected first conductive terminal and second conductive terminal, first insulator is in the functional part is connected to behind first conductive terminal and the second conductive terminal with conductive terminal group integrated into one piece, the second insulator is in the wiring end of second conductive terminal is connected with the central conductor of cable after with first insulator integrated into one piece, the second insulator parcel the central conductor of wiring end and the cable that is connected to corresponding wiring end.

Preferably, the conductive terminal group further includes a third conductive terminal, the third conductive terminal is disposed on the same side as the second conductive terminal and also has a terminal connected to the cable, the terminals of the second conductive terminal and the third conductive terminal are disposed on the same side and are respectively connected to a central conductor of a corresponding cable, and the second insulator wraps the terminals of the second conductive terminal and the third conductive terminal and the central conductor of the cable connected to the corresponding terminal.

Preferably, the first conductive terminal and the second conductive terminal are both provided with a functional part connecting part, and a clamping groove is arranged on the functional part connecting part; the functional part is respectively connected with the functional part connecting parts of the first conductive terminal and the second conductive terminal in a resistance welding mode.

Preferably, a wiring groove is formed in the wiring end, and the cable is clamped into the wiring groove and then connected with the functional part connecting portion in a resistance welding mode.

Preferably, the terminals of the second conductive terminal and the third conductive terminal are respectively connected with the central conductor of the corresponding cable in a resistance welding manner.

Preferably, before the first insulator is molded, the first conductive terminal, the second conductive terminal and the third conductive terminal are located on the same terminal piece, and the cable is connected with a connection point in a conductive terminal group of the cut-off terminal piece and a connection point of the conductive terminal group and the material strip.

Preferably, the function is a sensor.

The application also provides a manufacturing method of the electric connector, which comprises the following steps:

providing a conductive terminal group;

welding a functional part between the two conductive terminals so as to electrically connect the two conductive terminals through the functional part;

performing primary insert injection molding outside the conductive terminal group and the functional part to form a first insulator;

at least part of the conductive terminals are provided with wiring ends arranged on the same side, and each wiring end is connected with a cable in a welding way;

and after the cables are welded, performing secondary insert injection molding outside the first insulator to form a second insulator, wherein the second insulator wraps the terminals and the central conductors of the cables welded to the corresponding terminals.

Preferably, the conductive terminal group comprises a first conductive terminal, a second conductive terminal and a third conductive terminal, two ends of the functional part are respectively connected with the first conductive terminal and the second conductive terminal in a resistance welding manner, the second conductive terminal and the third conductive terminal are respectively provided with the wiring terminal, and the wiring terminals are connected with corresponding cables in a resistance welding manner.

Preferably, the first conductive terminal, the second conductive terminal and the third conductive terminal are located on the same terminal piece, and the first insulator is formed and then used for punching connection points in a conductive terminal group of the terminal piece and connection points of the conductive terminal group and the material belt.

According to the manufacturing method of the electric connector, the functional piece is welded between the two conductive terminals, so that the electric connector with different functions can be produced in batch and in a modularized mode; the conductive terminal group is positioned on the same terminal piece, so that the conductive terminals and the first insulator are conveniently molded by means of insert molding on one hand, and the electric connector is conveniently produced in batch and in high efficiency on the other hand. The electric connector manufacturing method and the electric connector are high in production efficiency, small in size and good in reliability.

Drawings

The accompanying drawings, which are included to provide a further understanding of the application and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the application and together with the description serve to explain the application and not to limit the application. In the drawings:

fig. 1 is a perspective view of an electrical connector of the present application.

Fig. 2 is a perspective view illustrating the connection between the conductive terminal set and the functional element of the electrical connector of the present application;

fig. 3 is a perspective view of the conductive terminal set, the material strip and the first insulator of the electrical connector of the present application;

fig. 4 is a perspective view of the conductive terminal set of the electrical connector of the present application in cooperation with the material tape;

fig. 5 is a perspective view of the conductive terminal set, the material strip and the second insulator of the electrical connector of the present application;

fig. 6 is a flowchart of a method for manufacturing an electrical connector according to the present application.

Description of the symbols of the main mechanisms

An electrical connector-100; a conductive terminal set-10; a first conductive terminal-11; functional part connecting part-111; a card slot-1111; a second conductive terminal-12; a terminal-121; wiring groove-1211; a third conductive terminal-13; -20, a functional part; connecting column-21; a first insulator-30; a second insulator-40; a cable-50.

Detailed Description

In order to make the objects, technical solutions and advantages of the present application more apparent, the technical solutions of the present application will be described in detail and completely with reference to the following specific embodiments of the present application and the accompanying drawings. It should be apparent that the described embodiments are only some of the embodiments of the present application, and not all of the embodiments.

Referring to fig. 1 to 5, the present application provides an electrical connector 100, where the electrical connector 100 includes a conductive terminal group 10, a functional element 20, a first insulator 30, and a second insulator 40.

The conductive terminal group 10 includes a first conductive terminal 11 and a second conductive terminal 12, the functional component 20 is connected to the first conductive terminal 11 and the second conductive terminal 12, the first insulator 30 is integrally formed with the conductive terminal group 10 after the functional component 20 is connected to the first conductive terminal 11 and the second conductive terminal 12, the second insulator 40 is integrally formed with the first insulator 30 after the terminal 121 of the second conductive terminal 12 is connected to the central conductor of the cable 50, and the second insulator 40 wraps the terminal 121 and the central conductor of the cable 50 connected to the corresponding terminal 121.

Further, the conductive terminal group 10 further includes a third conductive terminal 13, the third conductive terminal 13 is disposed on the same side as the second conductive terminal 12 and also has a terminal 121 connected to the cable 50, the terminals 121 of the second conductive terminal 12 and the third conductive terminal 13 are disposed on the same side and are respectively connected to a central conductor of the cable 50, and the second insulator 40 wraps the second conductive terminal 12, the terminal 121 of the third conductive terminal 13 and the central conductor of the cable 50 connected to the corresponding terminal 121.

In this embodiment, each of the first conductive terminal 11 and the second conductive terminal 12 has a function connecting portion 111, and the function connecting portion 111 is provided with a slot 1111; the functional part 20 is connected to the functional part connecting portions 111 of the first and second conductive terminals 11 and 12 by resistance welding. The functional part 20 comprises two connecting columns 21, and the two connecting columns 21 are respectively clamped in the clamping grooves 1111 of the first conductive terminal 11 and the second conductive terminal 12 and are connected with the corresponding terminal 111 in a welding manner through resistance welding. The arrangement of the clamping groove 1111 facilitates the connection post 21 to be fully contacted with the wiring terminal 111 on the one hand, and facilitates subsequent welding on the other hand.

The connecting column 21 with the functional part connecting portion 111 adopts resistance welding welded connection, has following advantage: firstly, because the nuggets are surrounded by the plastic ring all the time when being formed, the molten metal is isolated from the air, so that the metallurgical process is simple; secondly, the heating time is short, and the heat is concentrated, so that the heat affected zone is small, and the deformation and the stress are small; thirdly, filler metals such as welding wires and welding rods, and welding materials such as oxygen, acetylene and hydrogen are not needed, so that the welding cost is low; fourthly, the operation is simple, the mechanization and the automation are easy to realize, and the labor condition is improved; fifthly, the production efficiency is high, no noise and harmful gas exist, and the high-speed electric wire can be woven on an assembly line together with other manufacturing processes in mass production. However, flash butt welding requires isolation due to spark spray.

In addition, the terminal 121 is further provided with a wire connecting groove 1211, and the cable 50 is connected to the functional part connecting portion 111 by resistance welding after being clamped into the wire connecting groove 1211.

Furthermore, the terminals 121 of the second conductive terminal 12 and the third conductive terminal 13 are respectively connected to the central conductor of the corresponding cable 50 by resistance welding.

Connectable, before the first insulator 30 is formed, the first conductive terminal 11, the second conductive terminal 12 and the third conductive terminal 13 are located on the same terminal piece, so that the automatic punching and integration of the conductive terminal group 10 are facilitated, and the conductive cable 50 is connected with a connection point in the conductive terminal group 10 of the front punching terminal piece and a connection point of the conductive terminal group 10 and a material belt, so that the conductive terminal group 10 is separated from the material belt.

In this embodiment, the functional element 20 is a sensor.

The electric connector 100 provided by the application is respectively welded with the first conductive terminal 11 and the second conductive terminal 12 through the functional part 20 in an electric resistance welding manner, and in addition, the first insulator 30 wraps the conductive terminal group 10 and the second insulator wraps the first insulator 30, so that the conductive terminal group 10 is electrically insulated and pressure-resistant, and the reliability of the performance of the electric connector is further ensured. The electrical connector 100 provided by the application has a small size and good reliability.

Referring to fig. 6, the present application further provides a method for manufacturing an electrical connector, including the following steps:

in step S01, the conductive terminal group 10 is provided.

The conductive terminal group 10 includes a first conductive terminal 11 and a second conductive terminal 12, and the first conductive terminal 11 and the second conductive terminal 12 both have a functional part connecting portion 111.

In step S02, the functional part 20 is soldered between the two conductive terminals to electrically connect the two conductive terminals through the functional part 20.

Specifically, the two conductive terminals are a first conductive terminal 11 and a second conductive terminal 12, respectively, and the functional element 20 is connected to the functional element connecting portions 111 of the first conductive terminal 11 and the second conductive terminal 12, respectively, in a resistance welding manner.

Further, a card slot 1111 is arranged on the functional part connecting part 111; the functional part 20 comprises two connecting columns 21, and the two connecting columns 21 are respectively clamped in the clamping grooves 1111 of the first conductive terminal 11 and the second conductive terminal 12 and are connected with the corresponding terminal 111 in a welding manner through resistance welding. The arrangement of the clamping groove 1111 facilitates the connection post 21 to be fully contacted with the wiring terminal 111 on the one hand, and facilitates subsequent welding on the other hand.

In step S03, the first insulator 30 is formed by performing the first insert molding outside the conductive terminal group 10 and the functional element 20.

The first insulator 30 is used for fixing and isolating the conductive terminal group 10 and the functional element 20, so that the conductive terminal group 10 and the functional element 20 are electrically insulated and withstand voltage.

In step S04, at least some of the conductive terminals have terminals 121 disposed on the same side, and each terminal 121 is connected to a cable 50 by soldering.

The conductive terminal group 10 further includes a third conductive terminal 13, the third conductive terminal 13 and the second conductive terminal 12 are disposed on the same side, the second conductive terminal 12 and the third conductive terminal both have a terminal 121 connected to the cable 50, the terminals 121 of the second conductive terminal 12 and the third conductive terminal 13 are disposed on the same side and are respectively connected to a central conductor of the corresponding cable 50, and the second insulator 40 wraps the second conductive terminal 12, the terminal 121 of the third conductive terminal 13, and the central conductor of the cable 50 connected to the corresponding terminal 121.

Step S05, performing a second insert molding process on the first insulator 30 after the cables 50 are soldered to form a second insulator 40, where the second insulator 40 wraps the terminals 121 and the central conductors of the cables 50 soldered to the corresponding terminals 121.

The fourth insulator 40 includes the third insulator 30, the terminal 121, and the cable 50 connected to the terminal 121, so that the electrical connector 100 is electrically insulated and withstand voltage as a whole.

Before the first insulator 30 is molded, the first conductive terminal 11, the second conductive terminal 12 and the third conductive terminal 13 are located on the same terminal piece, so that the automatic punching integration of the conductive terminal group 10 is facilitated, the conductive cable 50 is connected with a connecting point in the conductive terminal group 10 of the front punching terminal piece and a connecting point of the conductive terminal group 10 and a material belt, and the conductive terminal group 10 is separated from the material belt.

According to the manufacturing method of the electric connector, the functional piece 20 is respectively welded with the first conductive terminal 11 and the second conductive terminal 12 in an electric resistance welding mode, in addition, the first insulator 30 wraps the conductive terminal group 10 and the second insulator wraps the first insulator 30, so that the conductive terminal group 10 is electrically insulated and pressure-resistant, and the reliability of the performance of the electric connector is further ensured. In addition, the conductive terminal set 10 is formed by stamping, which facilitates mass production of the electrical connector 100. The electrical connector 100 provided by the application has a small size and good reliability.

The above description is only an example of the present application and is not intended to limit the present application. Various modifications and changes may occur to those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application should be included in the scope of the claims of the present application.