TWI840656B - Electrical connector and making method of the same - Google Patents

Abstract

An electrical connector, comprising: a first insulative body defined with a first direction and a second direction perpendicular to each other; the first insulative body includes a first mating portion in front of the first direction and a receiving portion behind in the first direction; a first terminal fixed in the first insulative body includes a first contact portion located in the first mating portion and a first leg located in the receiving portion; a second insulative body is fixed to the outside of the first insulative body; a second terminal fixed in the second insulative body. The second insulative body includes a second mating portion extending along the second direction, the second terminal includes a second contact portion located at the second mating portion and a second leg extending toward the first insulative body and located in the receiving portion. The structure of two mating portions perpendicular to each other is stable, and the production of the structure is efficient.

Description

Electrical connector and method of manufacturing the same

The present invention relates to an electrical connector.

China Utility Model Patent No. CN209730378U discloses a power connector, which includes: a charging seat, a discharge plug, and a charging plug; the charging seat includes: a seat body, a plurality of spring pins arranged in a first inner cavity of the seat body, a second inner cavity located on both sides of the first inner cavity, and a charging female terminal arranged in the second inner cavity; the discharge plug includes: a body, a signal pin arranged on the top surface of the body and corresponding to the distribution of the spring pins, a discharge terminal arranged on the top surface of the body and distributed on both sides of the spring pins, a power pin arranged on the side surface of the body, and a portion of the power pin buried in the body is in electrical contact with a portion of the discharge terminal buried in the body; the charging plug includes: a shell, and a charging male terminal arranged at one end of the shell. The charging and discharging connector has both charging and discharging functions, and the discharge plug has a smaller volume through structural optimization design. In addition, the charging seat of the above-mentioned charging and discharging connector has a spring pin, which is conducive to providing a buffer during plugging and avoiding damage. The multiple plugging surfaces of the electrical connector are all protruding forward. When multiple plugs are inserted, the plugs are very likely to interfere with each other due to volume restrictions, resulting in failure to insert.

Therefore, it is necessary to provide an improved electrical connector to solve the above problems.

The purpose of the present invention is to provide an electrical connector having two pairs of interfaces perpendicular to each other.

To achieve the above-mentioned purpose, the present invention can adopt the following technical solutions: an electrical connector, comprising: a first insulating body, which defines a first direction and a second direction perpendicular to each other, the first insulating body comprising a first connecting portion located in front of the first direction and a receiving portion located behind the first direction; a first terminal, which is fixed to the first insulating body, the first terminal comprising a first contact portion located at the first connecting portion and a first pin located at the receiving portion; a second insulating body, which is fixed to the outer side of the first insulating body; and a second terminal, which is fixed to the second insulating body; wherein the second insulating body comprises a second connecting portion extending along the second direction, the second terminal comprises a second contact portion located at the second connecting portion and a second pin extending toward the first insulating body and also located at the receiving portion.

To achieve the above-mentioned purpose, the present invention can also adopt the following technical solution: A method for manufacturing an electrical connector, comprising the following steps: (1) providing a second insulating body, on which a second terminal is fixed; the second insulating body comprises a second mating portion, the second terminal comprises a second contact portion and a second pin located at the second mating portion, and the second contact portion extends along a second direction; (2) providing a plurality of first terminals, the first terminals comprising a first contact portion and a first pin, and the first terminals are connected to the second mating portion. The second insulating body is placed at a predetermined position, wherein the first contact portion extends along a first direction, the first pin and the second pin extend along the same direction, and the second direction is perpendicular to the first direction; (3) the first terminal and the second insulating body are subjected to an insulating material injection molding to form a first insulating body, wherein the first insulating body includes a first mating portion and a receiving portion extending along the first direction, the first contact portion is located at the first mating portion, and the first and second pins are located in the receiving portion.

Compared with the known technology, the present invention has the following effects: the electrical connector has two mutually perpendicular butt joint surfaces and is formed by two injection moldings, which has the advantages of high production efficiency, stable quality and high production yield.

100:Electrical connector

X: First direction

Y: Second direction

Z: Third direction

1: The first insulated body

11: First docking part

110: Receiving chamber

12: Storage area

120: Accommodation chamber

13: Base

130: Mounting slot

2: The second insulated body

21: Second docking part

211: The first straight line segment

212: Slash segment

213: Second straight line segment

214: Additional paragraph

22: Connection part

221: Supporting part

222: Terminal receiving part

23: Interference Department

231: Hook

232: Insulation block

233:Interference groove

3: Insulation body

31: Docking ring

32: Vertical block

33: Connecting strip

4, 4P, 4S: first terminal

401: First contact part

402: First fixed part

403: First pin

5, 5P, 5S: Second terminal

51: Flat plate

501: Second contact part

502: Second fixing part

503: Second pin

The first figure is a three-dimensional diagram of the electrical connector of the present invention; the second figure is a three-dimensional diagram of the electrical connector shown in the first figure at different angles; the third figure is a three-dimensional diagram of the electrical connector shown in the second figure at different angles; the fourth figure is a partial structural exploded diagram of the electrical connector shown in the first figure; the fifth figure is an exploded diagram of another angle shown in the fourth figure; the sixth figure is an exploded diagram of the entire structure of the electrical connector shown in the first figure; the seventh figure is a three-dimensional diagram of the second insulator and the second terminal in the electrical connector shown in the sixth figure; the eighth figure is an exploded diagram of another angle shown in the sixth figure; the ninth figure is a three-dimensional diagram of the second insulator and the second terminal in the electrical connector shown in the eighth figure; the tenth figure is a cross-sectional view of the electrical connector shown in the first figure along the dotted line X-X direction; the eleventh figure is a cross-sectional view of the electrical connector shown in the first figure along the dotted line XI-XI direction; and the twelfth figure is a cross-sectional view of the electrical connector shown in the third figure along the dotted line XII-XII direction.

In order to facilitate a better understanding of the purpose, structure, features and effects of the present invention, the present invention is further described with reference to the attached drawings and specific implementation methods.

Referring to the first to third figures, the present invention discloses an electrical connector 100, which defines a mutually perpendicular first direction X (front-rear direction), a second direction Y (up-down direction) and a third direction Z (left-right direction), and can be plugged into two types of connectors along the first direction X and the second direction Y.

Referring to the first to third figures, the electrical connector 100 includes a first insulating body 1, a first terminal 4 and an insulating body 3 fixed in the first insulating body. The first insulating body 1, the first terminal 4 and the insulating body 3 constitute an output terminal, which can be connected along the front-back direction X to output power and signals; the electrical connector 100 also includes a second insulating body 2 and a second terminal 5. The second insulating body 2 and the second terminal 5 constitute an input terminal, which can be connected along the up-down direction Y to input power and signals. The first and second terminals are connected through a circuit board (not shown) to achieve electrical transmission between the two.

As shown in the fourth to sixth figures, the first insulating body 1 includes a base 13, a first docking portion 11 located in front of the first direction X, and a receiving portion 12 located in the rear of the first direction. The first docking portion 11 is a receiving cavity 110 formed by a ring wall, and the receiving portion 12 is a cavity structure formed by a ring wall. Specifically, the first insulating body 1 includes two receiving cavities 110 extending along the first direction X, and the two receiving cavities 110 are separated from each other in the transverse direction (third direction Z), and each receiving cavity 110 penetrates forward, and the receiving portion 12 is a receiving cavity 120 formed by a square ring wall.

The first terminal 4 is a needle-shaped structure, including a first contact portion 401 located at the first mating portion 11 and a first pin 403 located at the receiving portion 12. Each receiving cavity 110 receives a set of first contact portions 401 of the first terminal 4. In this embodiment, each set of first terminals 4 includes four terminals, which are divided into a power terminal 4P with a larger diameter and a signal terminal 4S with a smaller diameter. The power terminal 4P transmits a larger current, and the signal terminal 4S transmits a smaller current. The four terminals are divided into two rows and two columns, and the terminals of the same type are distributed diagonally. The diameter of the first contact portion 401 of each first terminal is slightly larger than its first pin 403, and the first pins 403 of all first terminals are received in the receiving cavity 120. The first terminal 4 includes a first fixing portion 402 connecting the first contact portion and the first pin, and the first fixing portion 402 includes a section of annular sawtooth structure.

Continuing to refer to Figures 6 to 9, the second insulating body 2 is fixed to the outside of the first insulating body 1, and the first insulating body 1 and the second insulating body 2 are formed by plastic injection molding of one of them to the other insulating body. In this embodiment, the first insulating body 1 is injection molded to the second insulating body 2, and the first insulating body forms a base 13 and a mounting groove 130 for fixing the second insulating body, thereby enhancing the overall strength of the electrical connector. The second insulating body 2 includes a second abutting portion 21 extending along the second direction Y, and the second abutting portion is a flat plate structure. Viewed from the second direction Y, the flat plate of the second docking portion 21 includes a first straight line segment 211, an oblique line segment 212, and a second straight line segment 213 connected in sequence; the second docking portion 21 also includes an additional segment 214 extending from the oblique line segment 212. The second docking portion 21 with foolproof properties can prevent incorrect docking between electrical connectors.

The second insulating body 2 includes a connecting portion 22 and an interference portion 23 located below the second docking portion 21. The second docking portion 21 extends from the connecting portion 22 along the second direction Y. The connecting portion 22 includes a circular supporting portion 221 and a terminal receiving portion 222 surrounding a terminal groove for receiving the second terminal flat plate portion 51. The connecting portion 22 as a whole enters the first insulating body 1 along the second direction Y for a distance, which can be clearly seen in Figures 11 and 12. The interference part 23 is fixed in the first insulating body 1 by injection molding. The interference part 23 includes a pair of L-shaped hooks 231 and an insulating block 232 located in the middle of the hooks. The insulating block 232 is provided with a through slot 233 extending along the first direction, as shown in Figure 9. The first insulating body 1 is injection molded on the second insulating body 2, thereby filling the space around the hook 231 and the through slot 233, achieving full cooperation between the base 13 of the first insulating body 1 and the interference part 23, and strengthening the connection strength between the two.

The second terminal 5 is mounted on the second insulating body 2 and fixed in the first insulating body 1. The second terminal includes a second contact portion 501 located at the second docking portion 21 and a second pin 503 extending toward the first insulating body 1 and also located in the accommodating cavity 120. The second contact portion 501 is a flat plate portion 51 perpendicular to the second docking portion 21. At least one of the second contact portions 501 is disposed on both side surfaces of the flat plate of the second docking portion 21, and the second contact portions on both sides are perpendicular to the flat plate portion of the second docking portion 21 and aligned with each other in a direction perpendicular to the flat plate. One side of the second contact portions 501 on both sides is buried in the flat plate, and the two second contact portions are arranged in a large and a small configuration. The two side surfaces of the flat plate portion of the second docking portion 21 are respectively provided with two second contact portions 501, and the second contact portions on the same side of the flat plate are arranged in a large and a small configuration. Specifically, four second terminals 5 are fixed in the second insulating body 2, which are divided into two power terminals 5P of the larger flat plate portion 51 and two signal terminals 5S of the smaller flat plate portion 51. The power terminals 5P transmit a larger current, and the signal terminals 5S transmit a smaller current. One power terminal 5P and the signal terminal 5S are arranged on the two side surfaces of the first straight line segment 211, and the remaining power terminal 5P and the signal terminal 5S are arranged on the two side surfaces of the second straight line segment 213. The same side surface of the flat plate portion of the second docking portion 21 is arranged as a power terminal 5P and a signal terminal 5S. The additional section 214 is located between the two second contact portions 501 on the same side of the flat plate portion of the second mating portion 21 and is parallel to the second contact portions.

In this embodiment, the second docking portion 21 and the four flat second terminals 5 constitute an input terminal, which can input power and signals, and the first docking portion 11 and the eight needle-shaped first terminals 4 constitute an output terminal, which can output power and signals. Each second power terminal 5P is connected to a first power terminal 4P in each first docking portion 11 through a circuit board (not shown), that is, one second power terminal 5P is connected to two first power terminals 4P in different receiving cavities 110, so the two second power terminals 5P cooperate with the four first power terminals 4P in the two receiving cavities to form two sets of power transmission. Similarly, each second signal terminal 5S is connected to a first signal terminal 4S in each first docking portion 11 through a circuit board (not shown), that is, a second signal terminal 5S is connected to two first signal terminals 4S in different receiving cavities 110, so the two second signal terminals 5S cooperate with the four first signal terminals 4S in the two receiving cavities to form two sets of signal transmission. In this way, the input and output of power and signals are realized.

In this embodiment, a step portion 510 embedded in the plate is provided on the side of the plate portion of each second terminal close to the second docking portion 21, and a barb structure 511 is provided on the side of the plate portion of each terminal away from the second docking portion 21. The plate portion 51 includes second contact portions 501 fixed on both sides of the second docking portion 21 and a plate structure fixed in the terminal receiving portion 222. The second contact portions 501 on both sides of the same straight line segment of the second docking portion 21 are aligned with each other in a direction perpendicular to the plate, while the second pins 503 are staggered with each other. The second fixing portion 502 connects the flat portion 51 and the second pin 503 and is fixed in the first insulating body 1. The second pin 503 is formed by bending once or twice from the second fixing portion 502, so that the second pins 503 of the second terminal on both sides of the same straight line segment 211/213 are staggered in the first direction X. The pins 403 and 503 of all the first and second terminals are arranged in parallel in the receiving cavity 110, and the first pin 403 is arranged on both sides of the second pin 503.

The insulating body 3 is injection molded into the first insulating body 1. The insulating body 3 includes a docking ring 31 that covers the inner wall of the first docking portion 11. The docking ring does not extend forward beyond the front of the first contact portion 401 of the first terminal, and abuts against the rear wall of the accommodating cavity 110. The insulating body 3 includes a vertical block 32 located behind the docking ring 31 and dissolved in the first insulating body 1, as shown in Figures 10 to 12. Two symmetrical vertical blocks extend behind each docking ring 31. The insulating body 3 includes two docking rings 31 located in the ring wall and a connecting strip 33 connecting the docking rings, and the connecting strip is located in the first insulating body. The insulating body 3 includes a pair of vertical blocks 32 located behind the docking ring, and a connecting strip 33 connects the bottoms of the two vertical blocks located in the middle.

The docking ring 31 of the present invention can strengthen the strength of the ring wall surrounding the first docking portion 11, and at the same time enhance the plugging and unplugging force; the vertical block 32 and the connecting strip 33 are melted into the base 13 by injection molding and fixed in the first insulating body, which can ensure that the docking ring 31 will not separate from the first insulating body 1 during the plugging and unplugging test.

The manufacturing method of the electrical connector 100 specifically includes the following steps: (1) providing a second insulating body 2, on which a second terminal 5 is fixed; the second insulating body includes a second mating portion 21, and the second terminal 5 includes a second contact portion 501 and a second pin 503 located at the second mating portion, and the second contact portion extends along a second direction Y; (2) providing a plurality of first terminals 4, wherein the first terminals include a first contact portion 401 and a first pin 403, and placing the first terminals 4 and the second insulating body 2 at a predetermined position (in a molding die), wherein the first contact portion 401 extends along a first direction, the first pin 403 and the second pin 503 extend in the same direction, and the second direction Y is perpendicular to the first direction X; (3) the first terminals are connected to the first terminals 401, and the first terminals are connected to the second ... 4 and the second insulating body 2 are subjected to insulating material injection molding to form a first insulating body 1, wherein the first insulating body 1 includes a first connecting portion 11 and a receiving portion 12 extending along a first direction, wherein the first contact portion 401 is located at the first connecting portion 11, and the first and second pins 403 and 503 are located in the receiving portion 12; the single second terminal 5 is directly implanted into the molding die , the terminal will be skewed due to structural problems, and there is a risk of the molding mold failing to close the mold and scraping. This problem can be avoided by inserting the second terminal 5 into the second insulating body 2 and then implanting it into the mold as a whole inlay; (4) Injection molding of the insulating material is performed again in the first insulating body 1 to form an insulating body 3, and the insulating body 3 is attached to the inner wall of the first docking portion 11.

The first and second insulating bodies and the insulator are formed by injection molding of insulating materials, and the first terminal and the second terminal are formed by stamping of metal materials. The first insulating body 1 performs the first injection molding of the second insulating body 2 and the terminal 5 as a whole, and the insulator 3 is injected into the first insulating body 1 for the second time. The two-shot injection molding has the advantages of high production efficiency, stable quality and high production yield.

In summary, the present invention meets the patent requirements and a patent application is filed in accordance with the law. However, the above is only a preferred embodiment of the present invention, and the scope of the present invention is not limited to the above embodiments. Any equivalent modifications or changes made by people familiar with the art of the present invention based on the spirit of the present invention should be included in the scope of the following patent application.

100:Electrical connector

X: First direction

Y: Second direction

Z: Third direction

5: Second terminal

1: The first insulated body

2: The second insulated body

3: Insulation body

4: First terminal

Claims (10)

An electrical connector, comprising: a first insulating body, which defines a first direction and a second direction perpendicular to each other, the first insulating body comprising a first connecting portion located in front of the first direction and a receiving portion located behind the first direction; a first terminal, which is fixed to the first insulating body, the first terminal comprising a first contact portion located at the first connecting portion and a first pin located at the receiving portion, so that a first connecting head can be inserted into the first connecting portion along the first direction to connect the first terminal. a contact portion; a second insulating body fixed to the outer side of the first insulating body; and a second terminal fixed to the second insulating body; wherein the second insulating body includes a second docking portion extending along the second direction, and the second terminal includes a second contact portion located at the second docking portion and a second pin extending toward the first insulating body and also located at the accommodating portion, so that a second docking head can be inserted into the second docking portion along the second direction to connect the second contact portion. The electrical connector as described in claim 1, wherein the first docking portion is a receiving cavity formed by a surrounding wall, the first contact portion is a needle-shaped structure; the second docking portion is a flat plate structure, the second contact portion is a flat plate portion perpendicular to the docking plate structure; the receiving portion is a cavity structure formed by a surrounding wall. An electrical connector as described in claim 2, wherein the first insulating body and the second insulating body are formed by plastic injection molding of one of the insulating bodies onto the other insulating body. As described in claim 1, the first insulating body further defines a third direction perpendicular to the first and second directions, the first insulating body includes two annular walls extending along the first direction, the two annular walls are spaced apart from each other in the third direction, and each of the annular walls contains a first contact portion of a set of the first terminals on its inner side. The electrical connector as described in claim 1, wherein the second mating portion is a flat plate extending along the second direction, and at least one second contact portion is disposed on each of the two side surfaces of the flat plate, and the second contact portions on both sides are perpendicular to the flat plate and aligned with each other in a direction perpendicular to the flat plate. As described in claim 5, the electrical connector, wherein one side of the second contact portions on both sides is buried in the flat plate, and the two second contact portions are arranged in a large and a small configuration. As described in claim 6, the two second contact portions are respectively provided on the two sides of the plate, and the second contact portions on the same side of the plate are arranged in a large and a small configuration. An electrical connector as described in claim 7, wherein when viewed from the first direction, the flat plate of the second docking portion includes a straight line segment, an oblique line segment, and a straight line segment connected in sequence, and the second contact portion is located on both sides of the straight line segment; the second docking portion further includes an additional segment extending from the oblique line segment, and the additional segment and the second contact portion of the second terminal are parallel to each other. A method for manufacturing an electrical connector comprises the following steps: (1) providing a second insulating body, wherein a second terminal is fixed on the second insulating body; the second insulating body comprises a second mating portion, the second terminal comprises a second contact portion and a second pin located at the second mating portion, and the second contact portion extends along a second direction; (2) providing a plurality of first terminals, wherein the first terminals comprise a first contact portion and a first pin, and the first terminals and the second insulating body are placed in a predetermined position. (3) performing an insulating material injection molding on the first terminal and the second insulating body to form a first insulating body, wherein the first contact portion extends along a first direction, the first pin and the second pin extend in the same direction, and the second direction is perpendicular to the first direction; (4) performing an insulating material injection molding on the first terminal and the second insulating body to form a first insulating body, wherein the first insulating body includes a first mating portion and a receiving portion extending along the first direction, the first contact portion is located at the first mating portion, and the first and second pins are located in the receiving portion. A method for manufacturing an electrical connector as described in claim 9, wherein the insulating material is injection molded again in the first insulating body to form an insulating body, and the insulating body is attached to the inner wall of the first mating portion.

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