Integrated injection molding connector

Abstract

An integrated injection molding connector relates to the technical field of connectors, and comprises at least two electric connection assemblies, and each electric connection assembly comprises a cylindrical terminal and a conductor which are connected in sequence; the shell is fixedly connected with the at least two electric connection assemblies and at least covers a connection area of the columnar terminal and the conductor; the shell and the electric connection assemblies are integrally formed in an injection molding mode, and the electric connection assemblies are arranged in an insulated mode. The electric connection assembly and the shell are integrally formed in an injection molding mode, the shell has the shape suitable for installation, the shell can protect the connection portion of the columnar terminal and the conductor from being impacted, and the integrally-formed design can also prevent water or dust from entering the connector. Due to the integrally-formed design, the sealing performance can be improved while the number of sealing pieces is reduced, materials are saved, and the assembling efficiency is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of connectors, and more specifically, to an integrated injection-molded connector. Background Art

[0002] Nowadays, new energy vehicles are developing rapidly, and the connectors of new energy vehicles are also constantly being updated. The connectors on the market now include conductors and shells for electrical transmission. Currently, the conductor and the shell are two parts that need to be assembled, which increases the cost of the sheath to a certain extent. Assembling the back cover will also cause more assembly processes for the product, increase the assembly man-hours, and increase the manufacturing cost of the product. In addition, the sealing between the shell and the conductor is poor, and water or dust is easy to enter the connector. Therefore, a new solution is urgently needed in the prior art to solve the above problems. Utility Model Content

[0003] The utility model provides a connector with simple assembly and good sealing performance.

[0004] One-piece injection molded connector, including:

[0005] At least two electrical connection assemblies, each of which comprises a columnar terminal and a conductor connected in sequence;

[0006] A housing fixedly connecting at least two of the electrical connection components and covering at least a connection area between the columnar terminal and the conductor;

[0007] The shell and the electrical connection components are integrally injection-molded, and the electrical connection components are insulated from each other.

[0008] The end of the conductor is a flat surface, and the columnar terminal is vertically connected to the flat surface by crimping, welding or screwing.

[0009] At least one of the conductors has a bent portion bent along the flat surface.

[0010] The creepage distance between the electrical connection components is not less than 3.5 mm.

[0011] The housing is provided with a cylindrical portion, the columnar terminal is arranged in the cylindrical portion, and at least one end of the columnar terminal is exposed to the outside.

[0012] The columnar terminal has a screw connection structure, which includes a through hole and a bolt arranged on the columnar terminal. One end of the bolt passes through the through hole, and an insulating pad is arranged on the other end.

[0013] The conductor is covered with an insulating layer, and the insulating layer is integrally formed with the shell.

[0014] The end surface of the columnar terminal exposed to the outside has a plating layer.

[0015] The axes of the columnar terminals are parallel to each other, the lengths of the columnar terminals are different, and the end surfaces of the columnar terminals exposed to the outside are located in the same plane.

[0016] The conductors are arranged in layers.

[0017] A terminal connector is also included, and the conductor is connected to the terminal connector.

[0018] The conductor includes at least one flexible section.

[0019] A fuse is arranged on the conductor.

[0020] The utility model has the following beneficial effects: the electrical connection assembly and the housing are integrally injection molded, the housing has a shape suitable for installation, the housing can protect the connection part of the columnar terminal and the conductor from impact, and the integral molding design can also prevent water or dust from entering the connector. The integral molding design can improve the sealing performance while reducing the sealing parts, saving materials and improving assembly efficiency.

[0021] Other features and advantages of the present invention will become apparent from the following detailed description of exemplary embodiments of the present invention with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the present invention.

[0023] Figure 1 It is a top view of the one-piece injection-molded connector of the utility model.

[0024] Figure 2 It is a front view of the one-piece injection-molded connector of the utility model.

[0025] Figure 3 It is a schematic diagram of the structure of the electrical connection component of the one-piece injection-molded connector of the utility model.

[0026] Figure 4 It is a schematic diagram of the terminal connector of the one-piece injection-molded connector of the utility model.

[0027] The following are marked in the figure:

[0028] 1-electrical connection assembly, 11-column terminal, 112-bolt, 113-insulating pad, 12-conductor, 121-bend, 122-insulating layer, flexible section-123;

[0029] 2-housing, 21-cylindrical portion;

[0030] 3-Terminal connector. DETAILED DESCRIPTION

[0031] Various exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that unless otherwise specifically stated, the relative arrangements of components and steps, numerical expressions and numerical values ​​set forth in these embodiments do not limit the scope of the present invention.

[0032] The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the present invention, its application, or uses.

[0033] Technologies, methods, and equipment known to ordinary technicians in the relevant art may not be discussed in detail, but where appropriate, the technologies, methods, and equipment should be considered as part of the specification.

[0034] In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not limiting. Therefore, other examples of the exemplary embodiments may have different values.

[0035] One-piece injection molded connector, such as Figure 1-Figure 3 As shown, including:

[0036] At least two electrical connection components 1, each of which comprises a columnar terminal 11 and a conductor 12 connected in sequence;

[0037] A housing 2, fixedly connecting at least two of the electrical connection components 1, and covering at least a connection area between the columnar terminal 11 and the conductor 12;

[0038] The housing 2 and the electrical connection component 1 are integrally injection-molded, and the electrical connection component 1 is insulated.

[0039] The electrical connection component 1 is used to transmit electrical energy or electrical signals. Its columnar terminal 11 is used to be electrically connected to the docking terminal, and its conductor 12 is used to be electrically connected to a power source or electrical equipment. The electrical connection component 1 and the housing 2 are integrally injection molded. The housing 2 has a shape suitable for installation. The housing 2 can protect the connection between the columnar terminal and the conductor from impact. The one-piece design can also prevent water or dust from entering the connector. The number of electrical connection components 1 is 2 or more, which are used to transmit electrical energy such as connecting to the positive pole of DC, connecting to the negative pole of DC, and connecting to AC power. They can also be used for signal transmission such as control signals or grounding. The one-piece design can improve the sealing performance while reducing the number of seals, which not only saves materials but also improves assembly efficiency.

[0040] In some embodiments, the end of the conductor 12 is a flat surface, and the columnar terminal 11 is vertically connected to the flat surface by crimping, welding or screwing. Figure 3As shown, the columnar terminal 11 facilitates electrical connection of the butted terminals, and the conductor 12 has a flat end portion that can ensure sufficient contact area with the columnar terminal 11 .

[0041] In some embodiments, at least one of the conductors 12 has a bent portion 121 bent along the flat surface. Figure 3 As shown, when there are two or more electrical connection components, they need to be arranged in parallel and plugged into the connector, and the conductors 12 need to be stacked to offset the electromagnetic interference generated when the conductors are energized. Therefore, at least one conductor 12 needs to have a bending portion 121 so that it can avoid other columnar terminals.

[0042] In some embodiments, the creepage distance between the electrical connection components 1 is not less than 3.5 mm. The creepage distance is the shortest distance between two conductive components along the surface of a solid insulating material. If the distance is too small, short circuit or leakage may occur easily, and the housing 2 may be charged, endangering personal safety. If the distance between charged components with different potentials is too small, it may also easily cause short circuit or leakage between poles, causing fire or failure of the insulation function, and reducing the insulation performance of the electrical product. Therefore, the present application preferably sets the creepage distance between the electrical connection components 1 to be not less than 3.5 mm to ensure that the electrical connection components 1 are safe at least when passing a voltage of 300V.

[0043] In some embodiments, the housing 2 has a cylindrical portion 21, the columnar terminal 11 is disposed in the cylindrical portion 21, and at least one end of the columnar terminal 11 is exposed to the outside. Figure 1 As shown, the columnar terminal 11 is injection molded in the cylindrical portion 21, and one end surface thereof is exposed outwardly and can be used for connection with a mating terminal.

[0044] In some embodiments, the columnar terminal 11 has a screw connection structure, which includes a through hole 111 and a bolt 112 provided in the columnar terminal 11. One end of the bolt 112 passes through the through hole 111, and an insulating pad 113 is provided on the other end. Figure 3 As shown, the columnar terminal 11 can be connected to the docking terminal by means of a bolt 112, and the insulating pad 113 can prevent the operator from accidentally touching the terminal and causing the risk of electric shock.

[0045] In some embodiments, the conductor 12 is covered with an insulating layer 122, and the insulating layer 122 is integrally formed with the housing 2. The insulating layer 122 and the housing 2 are integrally injection molded, which can achieve a very high sealing effect, save sealing components, reduce assembly time, and reduce costs.

[0046] In some embodiments, the end surface of the columnar terminal 11 exposed to the outside has a coating. Some metal materials may cause electrochemical corrosion when energized after connection, such as the connection between the aluminum columnar terminal 11 and the copper docking terminal. Therefore, a coating is provided on the end surface of the columnar terminal 11 for protection, and the material of the coating can be one of zinc, nickel, copper, tin, gold, silver, cadmium, manganese, zirconium, cobalt, titanium, chromium, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver and silver-gold-zirconium alloy.

[0047] In some embodiments, the axes of the columnar terminals 11 are parallel to each other, the lengths of the columnar terminals 11 are different, and the end faces of the columnar terminals 11 exposed to the outside are located in the same plane. The multiple columnar terminals 11 are parallel to each other and the end faces for electrical connection are on the same plane, which is suitable for connection with a plug-in connector. The stacked arrangement of the conductors 12 has different axial connection positions of the columnar terminals 11 and the conductors 12. In order to ensure that the end faces of the columnar terminals 11 are flush, the lengths of the columnar terminals 11 are different to compensate for the position differences between the conductors 12.

[0048] In some embodiments, the conductors 12 are arranged in layers. The conductors 12 arranged in layers can cancel out electromagnetic interference generated when the conductors 12 are powered on, thereby reducing the number of shielding layers sheathed around the conductors 12 and reducing costs.

[0049] In some embodiments, a terminal connector 3 is also included, such as Figure 4 As shown, the conductor 12 is connected to the terminal connector 3. The conductor 12 is used to realize the power transmission between the terminal connector 3 and the integral injection molded connector.

[0050] In some embodiments, the conductor 12 includes at least one flexible segment 123. The material of the flexible segment 123 is a multi-core cable or a braided cable or a flexible row of multiple layers of thin plates. The material of the flexible segment 123 is easy to bend and has excellent conductivity. The thin plate is soft and easy to deform, which is suitable as the flexible segment 123. The stacking of multiple layers of thin plates can ensure both flexibility and power efficiency. The conductor 12 is connected by a combination of rigid material and flexible material, and can also reduce the rigidity to better protect the connector during vibration. At the same time, when installing the connector, since tolerance may cause the connector to be unable to be installed, the tolerance can be compensated by the flexible segment 123.

[0051] In some embodiments, a fuse is provided on the conductor 12. Specifically, the conductor 12 includes a first conductor and a second conductor, and the two ends of the fuse are connected to the first conductor and the second conductor respectively. The fuse is a conductive material with a melting point below the limit temperature of the conductor. When the conductor causes excessive current due to abnormal operation, causing the temperature of the entire circuit to rise, the fuse will ensure that it burns first to disconnect the circuit, thereby preventing the current overload from causing damage to the connector or other electrical equipment.

[0052] Although some specific embodiments of the present invention have been described in detail by way of examples, it should be understood by those skilled in the art that the above examples are for illustration only and are not intended to limit the scope of the present invention. It should be understood by those skilled in the art that the above embodiments may be modified without departing from the scope and spirit of the present invention. The scope of the present invention is defined by the appended claims.

Claims

1. One-piece injection molded connector, characterized in that: include: At least two electrical connection assemblies, each of which comprises a columnar terminal and a conductor connected in sequence; A housing fixedly connecting at least two of the electrical connection components and covering at least a connection area between the columnar terminal and the conductor; The shell and the electrical connection components are integrally injection-molded, and the electrical connection components are insulated from each other.

2. The one-piece injection molded connector according to claim 1, characterized in that: The end of the conductor is a flat surface, and the columnar terminal is vertically connected to the flat surface by crimping, welding or screwing.

3. The one-piece injection molded connector according to claim 2, characterized in that: At least one of the conductors has a bent portion bent along the flat surface.

4. The one-piece injection molded connector according to claim 1, characterized in that: The creepage distance between the electrical connection components is not less than 3.5 mm.

5. The one-piece injection molded connector according to claim 1, characterized in that: The housing is provided with a cylindrical portion, the columnar terminal is arranged in the cylindrical portion, and at least one end of the columnar terminal is exposed to the outside.

6. The one-piece injection molded connector according to claim 3, characterized in that: The columnar terminal has a screw connection structure, which includes a through hole and a bolt arranged on the columnar terminal. One end of the bolt passes through the through hole, and an insulating pad is arranged on the other end.

7. The one-piece injection molded connector according to claim 3, characterized in that: The conductor is covered with an insulating layer, and the insulating layer is integrally formed with the shell.

8. The one-piece injection molded connector according to claim 3, characterized in that: The end surface of the columnar terminal exposed to the outside has a plating layer.

9. The one-piece injection molded connector according to claim 3, characterized in that: The axes of the columnar terminals are parallel to each other, the lengths of the columnar terminals are different, and the end surfaces of the columnar terminals exposed to the outside are located in the same plane.

10. The one-piece injection molded connector according to claim 1, characterized in that: The conductors are arranged in layers.

11. The one-piece injection-molded connector according to claim 1, characterized in that: A terminal connector is also included, and the conductor is connected to the terminal connector.

12. The one-piece injection molded connector according to claim 1, characterized in that: The conductor includes at least one flexible section.

13. The integral injection molded connector according to claim 1, characterized in that: A fuse is arranged on the conductor.

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