Description
Connector Mold Parts are core mold components used to produce electronic connectors, including key components such as concave molds, punches, frames, inserts, guide pillars, and ejector pins. Its core function is to achieve efficient and stable molding of connector metal structural parts through precision machining and combination, solve manufacturing problems such as complex curved surfaces, tiny corners, high corrosion resistance and wear resistance, and ensure that the connector maintains stable electrical and physical properties during repeated plugging and unplugging.
Product Features
1. μm-level machining accuracy
Using five-axis linkage CNC machining, EDM electric spark forming and other processes, the dimensional accuracy of the accessories can reach ±1μm, ensuring the perfect fit between the upper and lower molds, inserts and cavities, avoiding burrs and deformation caused by gap deviations, and meeting the stringent requirements of high-frequency signal transmission of 5G connectors.
2. Complex surface adaptation
For special-shaped structures such as automotive connectors and mobile phone backplane connectors, the surface of the accessories is designed with multi-curvature composite surfaces, and the finish below Ra0.4μm is achieved through high-speed milling and polishing technology, perfectly replicating the product design intent and reducing subsequent mold repair costs.
3. Multi-process integration
Accessories integrate milling, drilling, tapping, boring and other multi-functional structures, support “one clamping to complete multiple processes”, reduce the number of mold disassembly and assembly, shorten the single-piece processing time by 30%, and adapt to the connector industry’s “small batch, multiple varieties, fast delivery” needs.
4. Super corrosion and wear resistance
The surface is treated with PVD titanium plating or DLC coating, with a hardness of more than HV2500, and a salt spray test of more than 1000 hours. The surface integrity is maintained during repeated plugging and unplugging (≥100,000 times), avoiding increased contact resistance or signal attenuation due to wear.
5. Modular design
Provide standardized interfaces and replaceable modules (such as removable inserts and quick-change guide columns), support rapid adjustment of mold structure according to connector models, without the need to re-open the mold, and compress the customization cycle from 45 days to 15 days.
Application scenarios
1. 5G base station connector
5G connectors need to maintain impedance stability in the 30GHz frequency band, and traditional molds are prone to signal reflection due to dimensional deviations. μm-level precision accessories ensure that the terminal spacing error is ≤0.005mm, and with the gold-plated surface treatment, the insertion loss is reduced to less than 0.1dB.
2. New energy vehicle connectors
High-voltage connectors need to withstand voltages above 1000V and need to work stably in an environment of -40℃~150℃. Use corrosion-resistant stainless steel accessories, pass salt spray tests and thermal cycle tests to ensure that the insulation resistance is ≥1GΩ to avoid short circuit risks.
3. Consumer electronics connectors
The size of mobile phone/headphone connectors must be controlled within Φ2mm and must withstand a plug-in and pull-out force of 50N. High-hardness tungsten steel punches are combined with precision dies to achieve a terminal diameter error of ≤0.003mm and a plug-in and pull-out life of more than 100,000 times.
4. Industrial automation connectors
Industrial robot connectors need to maintain stable contact under high-frequency vibration (10-50Hz). Modular accessory design reduces assembly gaps, and with wear-resistant coatings, the contact resistance fluctuation range is controlled within ±5mΩ.
Cleaning and maintenance
1. Daily cleaning
Stamping mold: Use compressed air to blow away debris after each shift, and use neutral detergent to wipe the cavity surface to avoid metal powder jamming;
Injection mold: Use a brass brush to clean the residual glue on the parting surface. Do not use steel wool to scratch to prevent scratching the mirror coating.
2. Regular maintenance
Guide pin and guide sleeve: Apply high-temperature grease (working temperature ≥ 200℃) after every 2000 openings and closings, and check the verticality error ≤ 0.01mm;
Ejector assembly: Check the elastic coefficient every month, and replace it immediately when the wear exceeds 0.05mm to avoid product deformation caused by insufficient ejection force.
3. Storage management
When out of use for a long time, apply anti-rust oil to the accessories and seal them for storage. The ambient humidity should be controlled at ≤ 40% and the temperature should be 15-25℃;
Avoid coexistence with acidic and alkaline substances to prevent electrochemical corrosion from causing surface pitting.
FAQs
Q1: How to choose the material of the connector mold?
A: According to product requirements: tungsten steel (wear-resistant) is selected for high-frequency signal connectors; stainless steel (corrosion-resistant) is selected for high-voltage connectors; high-speed steel (easy to process) is selected for micro connectors.
Q2: What is the minimum tolerance of customized accessories?
A: The tolerance of standard parts is ±0.005mm; ultra-precision processing can achieve ±0.001mm (cost and process feasibility need to be evaluated).
Q3: How to quickly repair mold accessories after they are broken?
A: Minor cracks can be repaired by laser welding; severe damage requires module replacement, and we provide 48-hour emergency spare parts service.
Q4: What is the difference between PVD coating and DLC coating?
A: PVD coating (such as TiN) has better corrosion resistance; DLC coating (diamond-like carbon) has higher hardness and is suitable for high-speed stamping scenarios.
Q5: How to determine whether mold accessories need to be replaced?
A: When the product has burrs, out-of-tolerance dimensions, increased mold noise, or abnormal insertion and extraction force, the wear of the accessories must be checked immediately.
