Introduction to energy storage connectors and a brief description of their manufacturing process

Interface methods for energy storage connectors between circuit boards

The interface methods for energy storage connectors between circuit boards vary, and each type has its own characteristics. The following is a brief description of these aspects:

1. Pin header/pin connector. Pin headers and pin connectors are relatively inexpensive and common interface methods. Applications include low-end, large-scale intelligent products, development boards, debug boards, etc.

Advantages: Cost-effective, convenient, solid and robust connection, strong overcurrent capability, conducive to wire bonding and testing.

Disadvantages: Large size, not easy to bend, large spacing, unable to connect hundreds of pins (too large).

2. Some board-to-board connectors are used for compact products with a higher pin density than pin headers. Applications include widespread use in basic intelligent hardware products.

Advantages: Compact size, high number of pins, can make 40 pins in a 1 cm length (compared to within 20 pins for the same specification).

Disadvantages: Overall design must be fixed, expensive, and not suitable for frequent insertion and removal.

3. Thickened board-to-board connectors can combine, disassemble, and insert onto pin headers. Applications include testing boards, development boards, large fixed equipment (such as mainframe wiring).

Advantages: Cost-effective and widely used when used together with pins, convenient and accurate connection measurement.

Disadvantages: Difficult to repair, large size, not suitable for mass production scenarios.

4. FPC connector insertion / ZIF connector. Many intelligent products and equipment need to extract data signals from a computer motherboard, and FPC is a very good choice due to its small size, flexibility, and various shapes. Applications include bending of power circuits, connection between computer motherboards and external devices, connection between accessory boards and computer motherboards, and tight product spacing.

Advantages: Compact and inexpensive.

Connection forms of energy storage connector plugs

1. Threaded connection form

This is a commonly used connection form for connector plugs with larger contact surfaces and those operating in highly vibrating environments. After connection, a locking nut or fuse can be installed to prevent loosening. Although this connection form is reliable, it has a slow connection and disconnection speed.

2. Latch connection form

This is a reliable and quick connection and disconnection form. The majority of latch connection connectors have clear indications of correct connection and locking, which can be observed from a small hole on the side of the connector plug.

3. Plug and unplug connection form

This is a versatile connection form. When connecting and disconnecting, the plug and socket of the connector usually move in a reciprocating linear motion without the need for twisting or rotating, only requiring a small workspace to complete the connection and disconnection. Common plug and unplug connections include ball or pin structures. This connection form has no mechanical mechanism for easy insertion, and once mistakently inserted, the mechanical resistance increases significantly, allowing for immediate detection.

4. Cabinet connection form for connector plugs

This is an electrical connector used on equipment that requires blind connections near a framework. It allows electrical equipment to be lighter, smaller, easier to maintain, and more reliable. Users cannot feel the connection, so a precise positioning device must be designed to prevent forced connection of mismatched connector plugs, making improper connections impossible. Connector plugs typically use a floating or elastic contact design structure to ensure correct connection.

The characteristics of energy storage battery connectors include high temperature resistance, voltage resistance, resistance to chemical corrosion, and high cleanliness.

They have high reliability, precise positioning, low noise and vibration, strong impact resistance, easy installation, and high reliability, making them widely used in power systems with high requirements.

They have fine workmanship, high strength, stable quality, good protection effect, good ventilation, high temperature resistance, safety and reliability, voltage resistance, etc., greatly reducing the time required for replacement and being easy to disassemble.

Brief description of the manufacturing process of energy storage connectors

Many people think that there are too many types of energy storage connectors, so the manufacturing processes should be different. In fact, the manufacturing process of energy storage connectors is generally the same and can be divided into four manufacturing processes: stamping, plating, injection molding, and assembly.

1. Stamping

Stamping is the process of using a large high-speed stamping machine to stamp electronic energy storage connectors (pins) from thin metal strips. One end of the large coil of metal strip is fed into the front end of the stamping machine, and the other end passes through the hydraulic workbench of the stamping machine and winds into a coil by the coil wheel. The metal strip is pulled out and wound into finished terminals by the coil wheel during stamping.

2. Plating

After the energy storage connector pins are stamped, they should be sent to the plating stage. In the plating stage, the electronic contact surfaces of the energy storage connectors will be plated with various metal coatings such as nickel plating, tin plating, or semi-gold plating to prevent oxidation and enhance conductivity. During the process of sending the stamped pins into the plating equipment, the pins may also twist, break, or deform. These quality defects are easily detected through the aforementioned technological inspections.

3. Injection molding

Injection molding refers to the process of injecting molten plastic into a mold film of a metal tire of the electronic energy storage connector, followed by rapid cooling and forming.

Attention should also be paid to detecting "leakage" (short shots) when the molten plastic has not completely filled the film. This is a typical defect to detect during the injection molding stage. Other defects include the blockage of all or part of the sockets (these sockets must be kept clean and unobstructed for proper insertion and connection with the pins during final assembly).

4. Assembly

The final stage of the manufacturing of electronic energy storage connectors is the assembly of finished products. The connection and assembly of electroplated pins with injection molded socket boxes can be done in two ways: the first is individual insertion, inserting one pin at a time; the second is a combination-type composite header, which means connecting multiple pins to the socket box simultaneously. Regardless of the connection method used for assembly, it is important to ensure that all pins are present without any missing pins and that they are correctly positioned.