Introduction of energy storage battery connector and manufacturing process brief description

Features of battery connector for energy storage

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

It has the characteristics of high reliability, precise positioning, low noise and vibration, strong impact resistance, convenient installation and high reliability, making it widely used in various power systems with high requirements.

The energy storage battery connector has the characteristics of fine workmanship, high strength, stable quality, good protection effect, good ventilation, high temperature resistance, safety and reliability, and voltage resistance. It can greatly shorten the replacement fixing time, and it is easy to disassemble.

What are the advantages of the energy storage battery connector

Improve production process

The energy storage battery connector simplifies the assembly process of electronic products and also simplifies the mass production process.

Easy maintenance

If an electronic component fails, the failed component can be quickly replaced while the battery connector is installed.

Easy to upgrade

As technology advances, components can be updated when installing energy storage battery connector, replacing old ones with new and better ones.

Improve design flexibility

The use of energy storage battery connector provides engineers with greater flexibility when designing and integrating new products and building systems from components.

Interface mode between energy storage battery connector circuit boards

The interface between the battery connector circuit boards is different, and the types are also different, each type has its own characteristics. The following are brief details on these aspects:

Pin header female/pin header. Female headers and pin headers are cheaper, cost-effective and more common interface methods.

● Application fields: low-end, large-scale smart products, development boards, debugging boards, etc.;
● Advantages: cheap and cost-effective, convenient, strong hard connection, strong over-current capability, conducive to wire bonding and detection;
● Disadvantages: large size, not easy to bend, large spacing, hundreds of pins cannot be connected (too large).

Some board-to-board connectors are used for compact products, which are denser than pin headers.

● Application fields: widely used, and basic smart hardware products are basically in use.
● Advantages: small size, large number of needles, 40 needles can be made in 1 cm length (the same specification can only be made within 20 needles).
● Disadvantages: the overall design must be fixed and expensive and cannot be plugged and unplugged frequently.

Thickened board-to-board connectors capable of merging, demounting and insertion on pin headers.

● Application scenarios: detection boards, development boards, large fixed equipment (such as main chassis wiring).
● Advantages: it is cheap and common to use with pins, and it is very convenient to connect and measure.
● Disadvantages: not easy to repair, bulky, not suitable for mass production scenarios.

FPC connector plug / ZIF connector. Many smart products and devices need to pull data signals from the motherboard, and FPC is a good choice for its small size, flexibility, and versatile shape.

● Application scenarios: bending of the power circuit, connection of the motherboard and external equipment, connection of the auxiliary board and the motherboard, and compact product interior space.
● Advantages: small and cheap.

Plug connection form of energy storage battery connector

Energy storage battery connector plug thread connection method

This is a connection form often used in some connector plugs with large-sized contacts and working in a strong vibration environment. This connection form can be installed with a fuse or nut to prevent loosening after the connection is completed. This connection form is reliable in use, but the connection and removal speed is slow.

Energy storage battery connector plug bayonet connection mode

This is a reliable and rapid form of connection and detachment. Most card 121 connection style electrical connectors have a visual indication of proper connection and locking, which can be viewed through the small hole on the side of the battery connector connection nut.

Energy storage battery connector plug plug connection

This is a versatile form of connection. When the plug and socket of the battery connector are connected and separated, the moving direction is usually a reciprocating linear motion, without twisting and rotating, and only a small working space is required to complete the connection and detachment.

Common plug-in connections have two structures: balls or pins. Because there is no mechanically labor-saving mechanism for this type of connection, once it is inserted by mistake, the mechanical resistance will increase significantly and can be detected in time.

Energy storage battery connector plug cabinet connection method

This is a battery connector for some devices that need to be blindly connected close to the frame, which can make electrical devices lighter and smaller, easier to maintain and more reliable.

This type of connection makes it impossible for the operator to feel the connection, and an accurate positioning device must be designed to avoid forcing the misinserted connector plugs together, making misinsertion impossible. Connector plugs are usually designed with floating or resilient contacts to ensure their proper connection.

Brief description of energy storage battery connector manufacturing process

Many people think that there are too many types of energy storage connectors. Some energy storage battery manufacturers such as top 5 energy storage battery companies have different requirements for energy storage connectors, and the manufacturing process should be different.

In fact, the manufacturing process of energy storage battery connector is basically the same, which can be divided into four manufacturing processes: stamping, electroplating, injection molding, and assembly.

Stamping

Stamping is through a large high-speed stamping machine, so that the energy storage battery connector (pin) is stamped from a thin metal strip. One end of the large roll of metal strip is sent to the front end of the punching machine, and the other end passes through the hydraulic worktable of the punching machine and is wound into the take-up wheel, and the metal strip is pulled out by the take-up wheel and rolled up to punch out the finished terminal.

Electroplating

After the stamping of the energy storage battery connector pins is completed, it should be sent to the electroplating stage. In the electroplating stage, the electronic contact surface of the energy storage connector will be plated with various metal coatings, such as nickel plating, tin plating, and half gold plating, to prevent oxidation and enhance conductivity.

Pins can also be twisted, broken or deformed during the process of feeding the stamped pins into the plating equipment. These quality defects are easily detected by the techniques described above.

Injection molding

Injection molding refers to the plastic box seat of the electronic energy storage battery connector by injecting molten plastic into the metal tire film, and then rapidly cooling and forming.

Also take care to detect “leaks” when the molten plastic does not completely fill the film, a typical defect that needs to be detected during the injection molding stage. Other defects include total or partial blockage of receptacles (these receptacles must be kept clean and unobstructed to properly mate with the pins during final assembly).

To assemble

The final stage of energy storage battery connector manufacturing is finished product assembly. There are two ways to connect and assemble the electroplated pins and the injection molded box seat:

The first is to insert them separately, that is, insert one pin at a time; the second type is a combined combination plug, which refers to connecting multiple pins to the box socket at the same time. No matter what connection method is used for assembly, make sure that all pins cannot be missing and must be positioned correctly.