Understand what energy storage connectors and manufacturing processes are

Energy storage battery connectors can be used for wiring energy storage systems, energy storage batteries, lithium power supplies, solar energy storage systems, and various other energy storage devices.

What are the advantages of energy storage connectors

1. Improve production process

The energy storage connector simplifies the assembly process of electronic products. It also simplifies the mass production process;

2. Easy to repair

If an electronic component malfunctions, the faulty component can be quickly replaced when installing the energy storage connector;

3. Easy to upgrade

With the advancement of technology, when installing energy storage connectors, components can be updated and replaced with new and better components;

4. Improve design flexibility

The use of energy storage connectors provides engineers with greater flexibility in designing and integrating new products and building systems from components;

Interface mode between energy storage connector circuit boards

The interface methods and types of energy storage connector circuit boards are different, and each type has its own characteristics. The following is a brief and detailed introduction to these aspects:

1. Pin arrangement, male/female. Pai mother and Pai pin are relatively cheap, cost-effective, and common interface methods, applied in low-end, large-scale intelligent products, development boards, debugging boards, etc;

Advantages: Cheap and cost-effective, convenient, sturdy hard connection, strong overcurrent capacity, and conducive to wire bonding and detection;

Defects: Large volume, difficult to bend, large spacing, and inability to connect hundreds of pins (too large).

2. Some board to board connectors are used for compact products with a higher density than row pins. Application field: It is widely used, and basic intelligent hardware products are basically in use.

Advantages: Small size, large number of stitches, capable of producing 40 stitches with a length of 1 cm (within 20 stitches for the same specification).

Defect: The overall design must be fixed and expensive, and cannot be frequently plugged in and out.

3. Thickened board to board connectors that can be merged, disassembled, and inserted on the pins. Application scenarios: detection board, development board, large fixed equipment (such as main chassis wiring). Advantages: It is cheap, cost-effective, and common to use with pins, and it is very convenient to connect and measure accurately. Defects: Not easy to repair, bulky, and unsuitable for mass production scenarios.

4. FPC connector insertion/ZIF connector. Many intelligent products and equipment must pull data signals out of the computer motherboard, and FPCs are small, flexible, and versatile, making them a great choice. Application scenarios: Power circuit bending, connection between computer motherboard and external devices, connection between auxiliary board and computer motherboard, and tight indoor space of the product. Advantage: Small and affordable.

Connection form of energy storage connector plug

1. Thread connection method of energy storage connector plug

This is a commonly used connection form for connector plugs with larger contact sizes and working in strong vibration environments. This type of connection can be installed with a fuse or nut to prevent loosening after the connection is completed. It is reliable in use, but the connection speed is slow.

2. Connection method of energy storage connector plug bayonet

This is a reliable and fast form of connection and separation. Most electrical connectors with card 121 connections have a visual display of correct connection and locking, which can be observed from the small hole on the side of the electrical connector connection nut.

3. Insertion and unplugging connection method of energy storage connector plug

This is a versatile form of connection. The direction of movement of the plug and socket of an electrical connector during connection and separation is usually a reciprocating linear motion, without the need for twisting or rotation. It only requires a small working space to complete the connection and removal. There are two common types of plug-in connections: ball or pin structures. This type of connection does not have a mechanical labor-saving mechanism, and once inserted incorrectly, the mechanical resistance increases significantly, which can be detected in a timely manner.

4. Connection method of energy storage connector plug cabinet

This is an electrical connector used on certain devices that need to be blindly connected near the frame, which can make the electrical equipment lighter, smaller, easier to maintain, and more reliable. This type of connection makes it impossible for the operator to feel the connection, and a precise positioning device must be designed to avoid forcibly connecting the incorrectly inserted connector plugs together, making it impossible to do so. Connector plugs usually adopt floating or elastic contact design structures to ensure their correct connection.

Characteristics of energy storage connectors:

1. The energy storage battery connector has the characteristics of high temperature resistance, voltage resistance, chemical corrosion resistance, and high cleanliness.

2. Featuring high reliability, precise positioning, low noise and vibration, strong impact resistance, easy installation, and high reliability, it is widely used in various power systems with high requirements.

3. Fine workmanship, high strength, stable quality, good protection effect, good ventilation, high temperature resistance, safety and reliability, voltage resistance and other characteristics can greatly shorten the replacement and fixation time, and be easy to disassemble

Brief description of the manufacturing process for energy storage connectors

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

1. Stamping

Stamping is the process of stamping electronic energy storage connectors (pins) from thin metal strips using a large high-speed stamping machine. One end of the large roll 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 is wrapped in a winding wheel. The winding wheel pulls out the metal strip and rolls it up to punch out the finished terminal.

2. Electroplating

After stamping the energy storage connector pins, they should be sent to the electroplating stage. During the electroplating stage, the electronic contact surface of the energy storage connector will be coated with various metal coatings, including nickel, tin, and semi gold, to prevent oxidation and enhance conductivity. During the process of feeding stamped pins into electroplating equipment, the pins may also undergo twisting, fracture, or deformation. These quality defects are easily detected through the aforementioned techniques.

3. Injection molding

Injection molding refers to the plastic box seat of an electronic energy storage connector that is formed by injecting molten plastic into a metal tire film and then rapidly cooling.

Also pay attention to detecting "Short Shorts" when the molten plastic is not completely filled with film, which is a typical defect that needs to be detected during the injection molding stage. Other defects include complete or partial blockage of sockets (these sockets must be kept clean and unobstructed in order to properly connect with the pins during final assembly).

4. Assembly

The final stage of manufacturing electronic energy storage connectors is the assembly of finished products. There are two ways to connect and assemble the electroplating contact pin and the injection box seat: the first way is to insert it separately, that is, insert one contact pin at a time;

The second type is a combination plug, which refers to connecting multiple pins to the box socket simultaneously. Regardless of the connection method used for assembly, ensure that all pins are not missing and must be positioned correctly.