Talk about the production process of the connector


The connector is mainly composed of two parts: plastic shell and terminal.

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1. Plastic shell:

 

Injection process:

Most connectors use injection molded plastic shells, so we will focus on the basic injection molding process, which is made of plastic to make plastic shells.

Injection molding converts raw materials into plastic shells of connectors;

Sophisticated, computer-controlled injection molding machine heats and melts the plastic, then pushes and injects the plastic into the mold under pressure;

The melted plastic cools and solidifies in the mold. Finally, it was taken out with a complete plastic shell.

Material of plastic shell

Plastic shells are molded with many common materials such as plastics and resins;

The chemical and electrical properties of plastics make them ideal connector housings

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Let’s talk about common plastic shell materials

 

Nylon

 Advantage 

On the production process of connectors

Low-cost engineering grade plastic

Provide good strength, toughness, elasticity

Disadvantages

will absorb moisture, and then cause dimensional instability:

Polyester (PET)

advantage:

1, Very good dimensional stability

2, high strength

disadvantages

The price is higher than nylon.

Liquid Crystal Polymer

Advantage:

1, very tough

2, can shape a very thin wall thickness

3. Able to withstand high temperature in surface tissue technology

Disadvantages

The price is higher than other plastics

Injection molding machine

Common connector suppliers use two injection molding machines: injection molding and extrusion molding

Injection molding:

On the production process of connectors

A Feeding mechanism: Plastic particles are loaded into the funnel

B heating tube: the funnel will put the plastic into the heating tube Nozzle

C Once the plastic reaches the proper temperature, it is injected into the mold through the nozzle.

D Mold: During the injection process, the mold is closed. One side is stationary, while the other side can be moved to switch

E ejection mechanism: When the part cools and forms in the mold, an ejection mechanism forces him to come out of the mold and reach a storage system. The excess plastic will be recovered and used again.

Extrusion:

Extrusion molding squeezes the melted plastic through a mold, which eventually wraps the wire. Extrusion is generally used to produce products like ribbon cables

On the production process of connectors

Second, the terminal

Crimp

The terminal crimping uses a flat metal strip at the beginning, and finally converts the raw materials into terminals and pins

There are two common terminals

1 pin

The pin is a male terminal in PCB connection. Mainly switch with iron wire, come from bending

On the production process of connectors

2 Terminals

Terminals are generally considered to be relatively complex, crimped connectors. We use flat strip metal to make the terminals.

On the production process of connectors

General terminal suppliers use many different types of copper alloys to provide the best electrical and mechanical properties for terminal designs.

Brass Brass

characteristic:

1 Zinc accounts for 5% -40%

2 Very good elasticity, strength, and electrical properties

3 Cheapest metal per unit mass

Phosphor bronze

Features:

1 Very good strength, toughness, and conductivity

2 Very good elasticity, fatigue resistance

3 Used on a typical electrical contact spring

Crimping requires two types of equipment, a punching machine and a punching die

On the production process of connectors

Mold: When the metal strip is introduced into the mold through the conveying mechanism, the mold is cut and used to shape the metal strip to form the terminal. A typical terminal requires 200-1200 mold operation process. .

Crimping process: The crimping process provides molds to make the terminals. The force provided by these dies is estimated to be in the range of 18-20 tons, with nearly 1,000 strokes or crimps per minute.

There are 4 processes of crimping

First, the mold enters the crimping process, the crimping equipment provides pressure, and the mold cuts the terminal and it is formed

On the production process of connectors

Secondly, the strip metal is introduced into the crimping equipment and the mold, and the metal strip may be coated or uncoated.

On the production process of connectors

Next, the metal is cut and formed into a connected shape. When these parts pass through the mold, this is done in a small cutting and forming process.

On the production process of connectors

Finally, the finished terminal is removed from the mold and dropped into the collection box for collection. They may be rolled into a tube to enter the next process, such as coating or assembly

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There are hundreds of types of waterproof connectors used in general cars, and there are hundreds of connectors required for a single model. With the increase in people ’s requirements for safety, environmental protection, intelligence and economy, The higher the future, the more perfunctory applications of automotive electronic equipment are also increasing, so the number and scope of practical applications of the product will show a gradual increase in the future.