The production process for connector terminals comprises 12 key stages, spanning from forming and surface treatment to assembly and the final product.
Stamping/Forming
In the initial stage, a high-speed stamping press shapes the metal strip into the basic terminal form, creating the first and second terminal carrier strips. The metal strip is pulled by a reel for continuous processing; the formed terminals establish the structural foundation for subsequent steps.
Etching (Optional)
For terminals requiring high precision, through-holes and positioning holes are etched first. The minimum diameter of the through-hole must be smaller than the width of the connecting web; the precision of this technique directly impacts the yield rate during subsequent terminal separation.
Terminal Separation (Performed if etching is used)
The first and second terminals are separated by cutting the second pre-cut section, and the second terminal is detached from the guide strip by cutting the third pre-cut section, resulting in independent functional units.
Electroplating
A metal coating is applied to the terminal contact surfaces to enhance conductivity. Strict monitoring for defects such as pin distortion or breakage is required at this stage, as the multi-angled surface design of connectors makes detecting minute flaws challenging.
When modular terminal packaging is involved:
Insert Molding: Terminals are placed into an injection mold cavity and molded integrally with plastic mounting components.
Terminal Shearing: A through-hole is used to cut the intermediate signal terminal, creating a break point.
Welding: Electronic components are welded at the break point to restore electrical continuity.
Potting: Curing compound encapsulates the components to form a protective layer.
Mating/Interlocking
Different terminal carrier strips are fed vertically and joined via plugging or press-fitting to form a composite strip, creating a three-dimensional connection structure.
Base Molding
Plastic resin is injection-molded to create the base, which serves as the main structural support for the connector.
Terminal Cutting
After electroplating, the terminal assemblies are separated from the carrier strip to obtain individual, ready-to-use terminals.
Riveting
Automated equipment rivets the base to the terminal assembly, completing the physical integration of the final connector product.