Fabrication of Core Components
Conductive Component Processing:Copper serves as the base conductor; parts are precision-stamped and then tin- or nickel-plated to inhibit oxidation and enhance solderability. Conductor cross-sectional areas are precisely calculated based on rated current to prevent risks of overload or overheating.
Insulating Housing Injection Molding: Flame-retardant materials-such as polycarbonate or flame-retardant reinforced polypropylene-are used. Precision molds shape the housing, with strict control over mold temperature, injection pressure, and cooling time to prevent structural defects like shrinkage or warping, ensuring compliance with flame-retardancy standards.
Internal Functional Component Processing: Spring tension and reset travel for safety shutter mechanisms undergo repeated testing and calibration. For models with overload protection, the thermal deformation coefficient of the bimetallic strip is precisely adjusted to ensure rapid tripping and power cutoff during an overload event.
Final Assembly and Integration
Internal components-such as conductive copper strips, safety shutters, and overload protection modules-are precisely fitted into the housing's positioning slots according to design specifications. Component spacing tolerances are kept within 0.05 mm to eliminate short-circuit risks.
Power Cord Processing: Steps include sheath stripping, insulation stripping, and terminal crimping. Wire stripping lengths are strictly controlled to avoid damaging the wire core or severing copper strands; mass production begins only after the first article passes inspection.
The processed power cord is securely soldered or riveted to the internal conductors. The upper and lower housing sections are joined and sealed via ultrasonic welding or screw fastening, completing the physical assembly of the unit.
