Metallic reed structure and electrical connector

Abstract

This invention provides a metal spring structure, comprising: a first side plate and a second side plate disposed opposite to each other, and a third side plate and a fourth side plate disposed opposite to each other. The first side plate and the third side plate are in the same plane, and the second side plate and the fourth side plate are in the same plane. It also includes at least one pair of similarly arranged first connecting springs and second connecting springs. The two ends of the first connecting springs are respectively connected to the first side plate and the third side plate, and the two ends of the second connecting springs are respectively connected to the second side plate and the fourth side plate. This invention not only enables the insertion and removal of male and female terminals in 90° and 180° directions, but also allows for direct electrical connection between the male and female terminals via this metal spring structure without the need for other adapter mechanisms, facilitating assembly and saving costs.

Description

Technical Field

[0001] This invention relates to the field of electrical connection technology, and in particular to a metal spring structure and an electrical connector. Background Technology

[0002] In practical applications of high-voltage connectors, the connection between male and female terminals is a common combination in electrical connectors. Currently, most male and female terminals are machined, which is not only costly and inefficient but also has limited current-carrying capacity. The insertion and removal directions of male terminals are also currently limited. To meet the insertion and removal requirements of male terminals in 90° and 180° directions, two different female terminals are often required. Therefore, there is an urgent need for a terminal that is easy to manufacture, lightweight, low-cost, and has better current-carrying capacity. Summary of the Invention

[0003] The purpose of this invention is to provide a metal spring structure that not only enables the male and female terminals to be inserted and removed in 90° and 180° directions, but also allows the male and female terminals to be directly electrically connected through this metal spring structure without the need for other adapters, which facilitates assembly and saves costs.

[0004] The above-mentioned objective of the present invention can be achieved by the following technical solution: a metal spring structure, comprising: a first side plate and a second side plate disposed opposite to each other, and a third side plate and a fourth side plate disposed opposite to each other, wherein the first side plate and the third side plate are in the same plane, and the second side plate and the fourth side plate are in the same plane; further comprising at least one pair of first connecting springs and second connecting springs disposed opposite to each other, wherein the two ends of the first connecting springs are respectively connected to the first side plate and the third side plate, and the two ends of the second connecting springs are respectively connected to the second side plate and the fourth side plate; further comprising at least one pair of first cantilever springs and second cantilever springs disposed opposite to each other, wherein one end of the first cantilever spring is connected to the first side plate and the other end forms a free end, and one end of the second cantilever spring is connected to the second side plate and the other end forms a free end.

[0005] In a preferred embodiment, the first connecting spring and the second connecting spring are arranged in a mirror image of each other.

[0006] In a preferred embodiment, the first cantilever spring and the second cantilever spring are arranged in a mirror image of each other.

[0007] In a preferred embodiment, the longitudinal sections of the first connecting spring and the second connecting spring are corrugated along the extending direction of the first connecting spring and the second connecting spring, and the longitudinal sections of the first cantilever spring and the second cantilever spring are corrugated.

[0008] In a preferred embodiment, at least at the crest or trough of the first connecting spring and / or the second connecting spring, a first protrusion protruding outward from the crest or trough is provided; at least at the crest or trough of the first cantilever spring and / or the second cantilever spring, a second protrusion protruding outward from the crest or trough is provided.

[0009] In a preferred embodiment, the minimum vertical distance between the crest and trough of the first or second connecting spring is 1 to 12 times the thickness of the first or second connecting spring.

[0010] In a preferred embodiment, the minimum vertical distance between the crest and trough of the first or second cantilever spring is 1 to 12 times the thickness of the first or second cantilever spring.

[0011] In a preferred embodiment, the distance between adjacent peaks of the first or second connecting spring is 3 to 32 times the thickness of the first or second connecting spring.

[0012] In a preferred embodiment, the distance between adjacent peaks of the first cantilever spring or the second cantilever spring is 3 to 32 times the thickness of the first cantilever spring or the second cantilever spring.

[0013] In a preferred embodiment, the first side plate, the third side plate, the first connecting spring and the first cantilever spring form a terminal slot with the second side plate, the fourth side plate, the second connecting spring and the second cantilever spring.

[0014] In a preferred embodiment, the system includes a plurality of first connecting springs and a plurality of first cantilever springs, the plurality of first connecting springs and the plurality of first cantilever springs being spaced apart; it also includes a plurality of second connecting springs and a plurality of second cantilever springs, the plurality of second connecting springs and the plurality of second cantilever springs being spaced apart.

[0015] In a preferred embodiment, the spacing between adjacent first connecting springs and first cantilever springs is 1%-100% of the width of the first cantilever spring; the spacing between adjacent second connecting springs and second cantilever springs is 1%-100% of the width of the second cantilever spring.

[0016] In a preferred embodiment, at least one U-shaped side lug is connected in the extending direction of the first side plate, the second side plate, the third side plate and the fourth side plate.

[0017] In a preferred embodiment, the first side plate and the second side plate are connected to at least one top lug with a U-shaped cross-section in the lateral direction.

[0018] In a preferred embodiment, the third side plate and the fourth side plate are connected by at least one plate-shaped connecting bridge in the lateral direction.

[0019] In a preferred embodiment, the material of the metal reed structure contains one or more of the following: nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium, beryllium, and lead.

[0020] In a preferred embodiment, at least a portion of the surface of the metal spring is coated.

[0021] In a preferred embodiment, the coating material contains one or more of the following: gold, silver, nickel, tin, zinc, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, hard silver, and silver-gold-zirconium alloy.

[0022] An electrical connector includes a female terminal with a U-shaped structure, a male terminal with a sheet-like structure, and a metal spring structure. The female terminal has a top opening and side openings on both sides. The top lug of the metal spring structure is configured to connect to the top opening or to one of the side openings.

[0023] In a preferred embodiment, the side lugs of the metal spring structure are configured to connect to the top opening, or to one of the side openings, or to the side openings on both sides respectively.

[0024] In a preferred embodiment, the first connecting spring, the second connecting spring, the first cantilever spring, and the second cantilever spring are disposed in the female terminal. The inner crests of the first connecting spring, the second connecting spring, the first cantilever spring, and the second cantilever spring are in contact with the insertion surface of the male terminal, and the outer troughs are in contact with the inner surface of the female terminal.

[0025] In a preferred embodiment, the elastic force applied to the male terminal by the first or second connecting spring is 0.3N-98N.

[0026] In a preferred embodiment, the elastic force applied to the male terminal by the first or second connecting spring is 0.3N-55N.

[0027] In a preferred embodiment, the elastic force applied to the male terminal by the first cantilever spring or the second cantilever spring is 0.3N-98N.

[0028] In a preferred embodiment, the elastic force applied to the male terminal by the first cantilever spring or the second cantilever spring is 0.3N-55N.

[0029] In a preferred embodiment, the metal spring structure is integrally stamped from a plate material.

[0030] The features and advantages of this invention are:

[0031] 1. This metal spring structure not only enables the mating installation of the female terminal and the metal spring structure in the 90° and 180° directions, but also enables the plugging and unplugging connection of the male terminal in the 90° and 180° directions. Moreover, the male and female terminals can be directly electrically connected through this metal spring structure without the need for other adapter mechanisms, which facilitates assembly and saves costs.

[0032] 2. In terms of electrical contact, the design of this metal spring structure, due to the use of corrugated connecting springs and cantilever springs, has the function of elastic deformation. When vibration occurs during the use of the electrical connector, the female or male terminal may be displaced. This metal spring structure design can ensure that the connecting springs and cantilever springs always maintain contact with the male or female terminal, thereby ensuring the stability of contact resistance and better current carrying capacity.

[0033] 3. In terms of mechanical performance, the design of this metal spring structure adopts connecting springs and cantilever springs in terms of structural form. At the same time, there are gaps between multiple connecting springs and multiple cantilever springs, which can not only distribute the force of the male terminal when inserted into the metal spring structure, but also effectively reduce the contact temperature rise and contact resistance.

[0034] 4. This metal spring structure is equipped with top and side lugs, which can better achieve a mating connection with the female terminal in the 90° or 180° direction during the connection process between the metal spring and the female terminal.

[0035] 5. This metal spring structure is equipped with a connecting bridge, which can limit the insertion of the male terminal during the insertion process.

[0036] 6. This metal spring adopts an integrated stamping structure, which effectively improves processing efficiency and reduces costs. Attached Figure Description

[0037] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0038] Figure 1 This is a schematic diagram of the metal spring structure of the present invention;

[0039] Figure 2 This is a left view of the metal spring structure of the present invention;

[0040] Figure 3 This is a front view of the metal spring structure of the present invention;

[0041] Figure 4 This is a schematic diagram of the insertion of the 180° male terminal of the metal spring of the present invention;

[0042] Figure 5 This is a schematic diagram of the insertion of the 90° male terminal of the metal spring of the present invention;

[0043] Figure 6 This is a schematic diagram of another embodiment of the metal spring of the present invention;

[0044] Figure 7 This is a left view of another embodiment of the metal spring of the present invention;

[0045] Figure 8 This is a schematic diagram of the metal spring and the female terminal of the present invention installed at 180°.

[0046] Figure 9 This is a schematic diagram of the metal spring and the female terminal of the present invention installed at a 90° angle;

[0047] Figure 10 This is a schematic diagram of the insertion of the 180° male terminal of the electrical connector of the present invention;

[0048] Figure 11 This is a schematic diagram of the insertion of the 90° male terminal of the electrical connector of the present invention;

[0049] Figure 12 This is a schematic diagram of another embodiment of the metal spring structure of the present invention;

[0050] Figure 13 This is a schematic diagram of one embodiment of the electrical connector of the present invention;

[0051] Figure 14 This is a schematic diagram of another embodiment of the electrical connector of the present invention.

[0052] Explanation of icon numbers:

[0053] 1. First side plate; 2. Second side plate; 3. Third side plate; 4. Fourth side plate; 5. First connecting spring; 6. Second connecting spring; 7. First cantilever spring; 8. Second cantilever spring; 9. First boss; 10. Second boss; 11. Terminal slot; 12. Side hanging ear; 13. Top hanging ear; 14. Connecting bridge; 15. Female terminal; 16. Male terminal; Detailed Implementation

[0054] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0055] In one implementation, such as Figure 1 , Figure 2 As shown, a metal spring structure includes: a first side plate 1 and a second side plate 2 disposed opposite to each other, and a third side plate 3 and a fourth side plate 4 disposed opposite to each other. The first side plate 1 and the third side plate 3 are in the same plane, and the second side plate 2 and the fourth side plate 4 are in the same plane. It also includes at least one pair of first connecting springs 5 ​​and second connecting springs 6 disposed opposite to each other. The two ends of the first connecting spring 5 are respectively connected to the first side plate 1 and the third side plate 3, and the two ends of the second connecting spring 6 are respectively connected to the second side plate 2 and the fourth side plate 4. It also includes at least one pair of first cantilever springs 7 and second cantilever springs 8 disposed opposite to each other. One end of the first cantilever spring 7 is connected to the first side plate 1, and the other end forms a free end. One end of the second cantilever spring 8 is connected to the second side plate 2, and the other end forms a free end.

[0056] The first connecting spring 5 and the second connecting spring 6 can be set at a certain angle, with the angle being 0°-50°. When the surfaces of the female terminal 15 or the male terminal 16 are not relatively parallel planes, the first connecting spring 5 or the second connecting spring 6 can be set at a certain angle to improve the electrical connection between the first connecting spring 5 and the second connecting spring 6 and the female terminal 15 or the male terminal 16. The specific angle can be set to 5°, 10°, 20°, etc.

[0057] Similarly, the included angle between the first cantilever spring 7 and the second cantilever spring 8 is 0°-50°, specifically 5°, 10°, 20°, etc.

[0058] The first cantilever spring 7 and the second cantilever spring 8 of the present invention differ from the common symmetrical structure. They adopt a structure with the same insertion direction as the male terminal 16. This is because in practical applications, if the male terminal 16 is not inserted perpendicularly or is inserted and removed too many times, the first cantilever spring 7 and the second cantilever spring 8 may be bent or broken if they are not in the same direction as the male terminal 16.

[0059] like Figure 4As shown, the first side plate 1 and the second side plate 2 of this metal spring structure are respectively connected to one inner side of the female terminal 15, and the third side plate 3 and the fourth side plate 4 are respectively connected to the other inner side of the female terminal 15. The above connection methods can be one or more of welding connection, screw connection, snap connection, splicing connection and crimping connection.

[0060] One embodiment may provide a protrusion at the contact point between the female terminal 15 and the first side plate 1 and the second side plate 2, and provide corresponding holes at the corresponding positions of the first side plate 1 and the second side plate 2. After the holes are connected to the protrusion for limiting, the first side plate 1 and the second side plate 2 are then welded to the female terminal 15.

[0061] The welding method of the holes in the above-mentioned metal spring structure allows the third side plate 3 and the fourth side plate 4 to be left unwelded at the movable end. When the male terminal 16 is inserted, the metal spring structure has an elastic extension, and the structure of the connecting spring and the cantilever spring will not yield due to excessive insertion force of the male terminal 16.

[0062] Alternatively, the first side plate 1, the second side plate 2, the third side plate 3, and the fourth side plate 4 can all be welded to the female terminal 15.

[0063] With the design of this metal spring, the female terminal 15 can be installed at 90° and 180° with this metal spring structure, and the male terminal 16 can also be plugged in and unplugged in the 90° and 180° directions. At the same time, the male terminal 16 and the female terminal 15 can be directly electrically connected through this metal spring structure without the need for other adapter mechanisms, which is convenient for assembly and saves costs. Adapter mechanisms generally refer to the parts that normally require the female terminal 15 and the male terminal 16 to be connected by screws or welding to achieve electrical connection between the female terminal 15 and the male terminal 16.

[0064] In one embodiment, the first connecting spring 5 and the second connecting spring 6 are arranged in a mirror image of each other. Generally, the male terminal 16 is integrally machined, and the contact surfaces of the male terminal 16 with the first connecting spring 5 and the second connecting spring 6 are generally parallel. The mirror image arrangement can ensure the maximum contact surface and better electrical contact.

[0065] Similarly, in another embodiment, the first cantilever spring 7 and the second cantilever spring 8 are also mirror images of each other.

[0066] In one embodiment, along the extending direction of the first connecting spring 5 and the second connecting spring 6, the longitudinal section of the first connecting spring 5 and the second connecting spring 6 is corrugated, and the longitudinal section of the first cantilever spring 7 and the second cantilever spring 8 is corrugated, such as... Figure 2As shown in the figure, the vertical direction represents the extension direction of the first connecting spring 5 and the second connecting spring 6, as well as the extension direction of the first cantilever spring 7 and the second cantilever spring 8. This metal spring structure uses a corrugated structure, which provides elastic deformation. During the use of the electrical connector, vibrations may occur, and the female terminal 15 or male terminal 16 may shift. This design ensures that the first connecting spring 5, the second connecting spring 6, the first cantilever spring 7, and the second cantilever spring 8 maintain contact with the male terminal 16 or the female terminal 15, thereby ensuring stable contact resistance and better current carrying capacity.

[0067] In one implementation, such as Figure 2 , Figure 3 As shown, at least at the crests or troughs of the first connecting spring 5 and / or the second connecting spring 6, a first protrusion 9 protruding outwards from the crest or trough is provided; at least at the crests or troughs of the first cantilever spring 7 and / or the second cantilever spring 8, a second protrusion 10 protruding outwards from the crest or trough is provided. To improve conductivity, the inventors provide the first protrusion 9 at the crests or troughs of the first connecting spring 5 and the second connecting spring 6, or at the crests or troughs of either the first connecting spring 5 or the second connecting spring 6. Specifically, the first protrusion 9 can be provided at corresponding crests or troughs according to actual usage. The provision of the first protrusion 9 allows for better contact between the metal spring structure and the male terminal 16 and the female terminal 15. The first protrusion can be integrally stamped with the first connecting spring 5 and the second connecting spring 6, or it can be milled. The second protrusion 10 provides the same effect as the first protrusion 9.

[0068] In one embodiment, the minimum vertical distance between the crest and trough of the first connecting spring 5 or the second connecting spring 6 is 1 to 12 times the thickness of the first connecting spring 5 or the second connecting spring 6. For example... Figure 12 As shown, the distance H1 is the minimum vertical distance between the crest and trough of the first connecting spring 5 or the second connecting spring 6. The larger the value of H1, the larger the amplitude of the ripples; the smaller the value of H1, the closer the ripples are to being flat.

[0069] To verify the effect of the minimum vertical distance H1 between the crest and trough of the first connecting spring 5 or the second connecting spring 6 and its thickness as a multiple of the thickness of the first connecting spring 5 or the second connecting spring 6 on the contact resistance between the first connecting spring 5 or the second connecting spring 6 and the male terminal 16, as well as on the overall thickness of the electrical connector, the inventors selected the same thickness of the first connecting spring 5 or the second connecting spring 6, the same straight length of the first connecting spring 5 or the second connecting spring 6, the same male terminal 16, different minimum vertical distances H1 between the crests and troughs, and female terminals 15 with corresponding thicknesses to manufacture a series of electrical connector samples. The contact resistance and overall thickness of the electrical connector samples were tested, and the test values ​​were recorded in Table 1.

[0070] Test method for contact resistance of electrical connector sample: Use a micro resistance tester to connect the male terminal 16 and the first connecting spring 5 or the second connecting spring 6 respectively, and measure the resistance value between them. In this embodiment, a contact resistance value of less than 9mΩ is considered a qualified value.

[0071] Test method for the overall thickness of the electrical connector sample: Use a vernier caliper to measure the thickness of the outer side of the female terminal 15. In this embodiment, a thickness of less than 10mm on the outer side of the female terminal 15 is considered acceptable.

[0072] Table 1: The influence of the minimum vertical distance between the crest and trough of the first connecting spring 5 or the second connecting spring 6, as a multiple of the thickness of the first connecting spring 5 or the second connecting spring 6, on the contact resistance of the first connecting spring 5 or the second connecting spring 6 and on the overall thickness of the electrical connector.

[0073]

[0074] As can be seen from Table 1 above, when the minimum vertical distance between the crest and trough of the first connecting spring 5 or the second connecting spring 6 is less than 1 times the thickness of the first connecting spring 5 or the second connecting spring 6, the deformation of the first connecting spring 5 or the second connecting spring 6 is very small, resulting in a small force applied to the male terminal 16. Consequently, the contact area between the first connecting spring 5 or the second connecting spring 6 and the male terminal 16 is small, leading to a contact resistance greater than 9mΩ, which is considered unqualified. When the minimum vertical distance between the crest and trough of the first connecting spring 5 or the second connecting spring 6 is less than 1 times the thickness of the first connecting spring 5 or the second connecting spring 6, the contact resistance between the first connecting spring 5 or the second connecting spring 6 and the male terminal 16 is less than 9mΩ, which is considered unqualified. When the vertical distance is greater than 12 times the thickness of the first connecting spring 5 or the second connecting spring 6, the deformation of the first connecting spring 5 or the second connecting spring 6 is large, resulting in a contact resistance of less than 9mΩ, which meets the requirement. However, the decreasing trend of the contact resistance slows down. Moreover, in order to obtain a larger vertical distance between the peaks and troughs, with the thickness of the male terminal 16 unchanged, the thickness of the female terminal 15 can only be increased, increasing the gap between the female terminal 15 and the male terminal 16. However, this will cause the thickness of the female terminal 15 to exceed the requirement, resulting in a non-compliant state. In this case, the electrical connector will not be able to mate with the corresponding mating sleeve and will not function. Therefore, the inventors selected the minimum vertical distance H1 between the peaks and troughs of the first connecting spring 5 or the second connecting spring 6 to be 1 to 12 times the thickness of the first connecting spring 5 or the second connecting spring 6.

[0075] In one embodiment, the minimum vertical distance between the crest and trough of the first cantilever spring 7 or the second cantilever spring 8 is 1 to 12 times the thickness of the first cantilever spring 7 or the second cantilever spring 8. For example... Figure 12 As shown, the distance H2 is the minimum vertical distance between the crest and trough of the first cantilever spring 7 or the second cantilever spring 8. The larger the value of H2, the larger the amplitude of the ripples; the smaller the value of H2, the closer the ripples are to being flat.

[0076] To verify the effect of the minimum vertical distance between the crest and trough of the first cantilever spring 7 or the second cantilever spring 8 and its thickness as a multiple of the first cantilever spring 7 or the second cantilever spring 8 on the contact resistance between the first cantilever spring 7 or the second cantilever spring 8 and the male terminal 16, as well as on the overall thickness of the electrical connector, the inventors selected the same thickness of the first cantilever spring 7 or the second cantilever spring 8, the same straight length of the first cantilever spring 7 or the second cantilever spring 8, the same male terminal 16, different minimum vertical distances between the crests and troughs, and female terminals 15 with corresponding thicknesses to manufacture a series of electrical connector samples. The contact resistance and overall thickness of the electrical connector samples were tested, and the test values ​​were recorded in Table 2.

[0077] Test method for contact resistance of electrical connector sample: Use a micro resistance tester to connect the male terminal 16 and the first cantilever spring 7 or the second cantilever spring 8 respectively, and measure the resistance value between them. In this embodiment, a contact resistance value of less than 9mΩ is considered a qualified value.

[0078] Test method for the overall thickness of the electrical connector sample: Use a vernier caliper to measure the thickness of the outer side of the female terminal 15. In this embodiment, a thickness of less than 10mm on the outer side of the female terminal 15 is considered acceptable.

[0079] Table 2: The influence of the minimum vertical distance between the crest and trough of the first or second cantilever spring and the multiple of the thickness of the first or second cantilever spring on the contact resistance of the first or second cantilever spring and on the overall thickness of the electrical connector.

[0080]

[0081] As shown in Table 2 above, when the minimum vertical distance between the crest and trough of the first cantilever spring 7 or the second cantilever spring 8 is less than 1 times the thickness of the first cantilever spring 7 or the second cantilever spring 8, the deformation of the first cantilever spring 7 or the second cantilever spring 8 is very small, resulting in a small force applied to the male terminal 16. Consequently, the contact area between the first cantilever spring 7 or the second cantilever spring 8 and the male terminal 16 is small, leading to a contact resistance greater than 9mΩ, which is considered unqualified. When the minimum vertical distance between the crest and trough of the first cantilever spring 7 or the second cantilever spring 8 is less than 1 times the thickness of the first cantilever spring 7 or the second cantilever spring 8, the deformation of the first cantilever spring 7 or the second cantilever spring 8 is very small, resulting in a small force applied to the male terminal 16. This leads to a small contact area between the first cantilever spring 7 or the second cantilever spring 8 and the male terminal 16, resulting in a contact resistance greater than 9mΩ, which is considered unqualified. When the vertical distance is greater than 12 times the thickness of the first cantilever spring 7 or the second cantilever spring 8, the deformation of the first cantilever spring 7 or the second cantilever spring 8 is large, resulting in a contact resistance of less than 9mΩ, which meets the requirement. However, the decreasing trend of the contact resistance slows down. Moreover, in order to obtain a larger vertical distance between the crest and trough, with the thickness of the male terminal 16 unchanged, the thickness of the female terminal 15 can only be increased, increasing the gap between the female terminal 15 and the male terminal 16. However, this will cause the thickness of the female terminal 15 to exceed the requirement, resulting in a non-compliant state. In this case, the electrical connector will not be able to mate with the corresponding mating sleeve and will not function. Therefore, the inventors selected the minimum vertical distance between the crest and trough of the first cantilever spring 7 or the second cantilever spring 8 to be 1 to 12 times the thickness of the first cantilever spring 7 or the second cantilever spring 8.

[0082] In one embodiment, the distance between adjacent peaks of the first connecting spring 5 or the second connecting spring 6 is 3 to 32 times the thickness of the first connecting spring 5 or the second connecting spring 6. For example... Figure 12As shown, the distance L1 is the distance between adjacent peaks of the first connecting spring 5 or the second connecting spring 6. The larger the value of L1, the fewer the ripples within the same length; the smaller the value of L1, the denser the ripples within the same length.

[0083] To verify the effect of the distance between adjacent peaks of the first connecting spring 5 or the second connecting spring 6 and the multiple of the thickness of the first connecting spring 5 or the second connecting spring 6 on the contact resistance between the first connecting spring 5 or the second connecting spring 6 and the male terminal 16, as well as on the deformation of the first connecting spring 5 or the second connecting spring 6, the inventors selected the same thickness of the first connecting spring 5 or the second connecting spring 6, the same straight length of the first connecting spring 5 or the second connecting spring 6, the same male terminal 16 and the female terminal 15, and different distances between adjacent peaks to manufacture a series of electrical connector samples. The contact resistance and deformation of the first connecting spring 5 or the second connecting spring 6 of the electrical connector samples were tested, and the test values ​​were recorded in Table 3.

[0084] Test method for contact resistance of electrical connector sample: Use a micro resistance tester to connect the male terminal 16 and the first connecting spring 5 or the second connecting spring 6 respectively, and measure the resistance value between them. In this embodiment, a contact resistance value of less than 9mΩ is considered a qualified value.

[0085] Test method for deformation of the first connecting spring 5 or the second connecting spring 6: Use a push-pull force gauge to apply a push force at the crest of the first connecting spring 5 or the second connecting spring 6 so that the reaction force reaches 30N. Record the distance the crest of the first connecting spring 5 or the second connecting spring 6 moves at this time. In this embodiment, a crest movement distance of less than 0.5mm is a non-compliant value.

[0086] Table 3: The influence of the distance between adjacent peaks of the first or second connecting spring and the multiple of the thickness of the first or second connecting spring on the contact resistance between the first or second connecting spring and the male terminal, and on the deformation of the first or second connecting spring.

[0087]

[0088] As can be seen from Table 3 above, when the distance between adjacent peaks of the first connecting spring 5 or the second connecting spring 6 is less than 3 times the thickness of the first connecting spring 5 or the second connecting spring 6, the number of peaks and troughs increases for the same length. This increases the contact area between the first connecting spring 5 or the second connecting spring 6 and the male terminal 16, resulting in a contact resistance of less than 9mΩ, which meets the requirement. However, because the two sides of the peaks or troughs are close together, the deformation of the first connecting spring 5 or the second connecting spring 6 is small under pressure, and the peak movement distance is less than 0.5mm, which does not meet the requirement. This increases the insertion and extraction force of the male terminal 16, causing inconvenience to the user. When the first connecting spring 5 or the second connecting spring 6 is less than 3 times the thickness of the first connecting spring 5 or the second connecting spring 6, the number of peaks and troughs increases for the same length, causing inconvenience to the user. When the distance between adjacent peaks of the first connecting spring 5 or the second connecting spring 6 is greater than 32 times the thickness of the first connecting spring 5 or the second connecting spring 6, the number of peaks and troughs decreases for the same length, resulting in a smaller contact area with the male terminal 16. This leads to a contact resistance between the first connecting spring 5 or the second connecting spring 6 and the male terminal 16 that is greater than 9mΩ, which does not meet the requirements. Since the distance between the two sides of the peak or trough is relatively large, the deformation of the first connecting spring 5 or the second connecting spring 6 is large when subjected to pressure, and the distance the peak moves is greater than 0.5mm, which meets the requirements. Therefore, the inventors selected the distance between adjacent peaks of the first connecting spring 5 or the second connecting spring 6 to be 3 to 32 times the thickness of the first connecting spring 5 or the second connecting spring 6.

[0089] In one embodiment, the distance between adjacent peaks of the first cantilever spring 7 or the second cantilever spring 8 is 3 to 32 times the thickness of the first cantilever spring 7 or the second cantilever spring 8. Figure 12 As shown, the distance L2 is the distance between adjacent peaks of the first cantilever spring 7 or the second cantilever spring 8. The larger the value of L2, the fewer the ripples within the same length; the smaller the value of L2, the denser the ripples within the same length.

[0090] To verify the effect of the distance between adjacent peaks of the first cantilever spring 7 or the second cantilever spring 8 and the multiple of the thickness of the first cantilever spring 7 or the second cantilever spring 8 on the contact resistance between the first cantilever spring 7 or the second cantilever spring 8 and the male terminal 16, as well as on the deformation of the first cantilever spring 7 or the second cantilever spring 8, the inventors selected the same thickness of the first cantilever spring 7 or the second cantilever spring 8, the same straight length of the first cantilever spring 7 or the second cantilever spring 8, the same male terminal 16 and the female terminal 15, and different distances between adjacent peaks to manufacture a series of electrical connector samples. The contact resistance and deformation of the first cantilever spring 7 or the second cantilever spring 8 of the electrical connector samples were tested, and the test values ​​were recorded in Table 4.

[0091] Test method for contact resistance of electrical connector sample: Use a micro resistance tester to connect the male terminal 16 and the first cantilever spring 7 or the second cantilever spring 8 respectively, and measure the resistance value between them. In this embodiment, a contact resistance value of less than 9mΩ is considered a qualified value.

[0092] Test method for deformation of the first cantilever spring 7 or the second cantilever spring 8: Use a push-pull force gauge to apply a push force at the crest of the first cantilever spring 7 or the second cantilever spring 8 so that the reaction force reaches 30N. Record the distance the crest of the first cantilever spring 7 or the second cantilever spring 8 moves at this time. In this embodiment, a crest movement distance of less than 0.5mm is a non-compliant value.

[0093] Table 4: The influence of the distance between adjacent peaks of the first or second cantilever spring and the multiple of the thickness of the first or second cantilever spring on the contact resistance between the first or second cantilever spring and the male terminal, and on the deformation of the first or second cantilever spring.

[0094]

[0095] As can be seen from Table 4 above, when the distance between adjacent peaks of the first cantilever spring 7 or the second cantilever spring 8 is less than 3 times the thickness of the first cantilever spring 7 or the second cantilever spring 8, the number of peaks and troughs increases for the same length. This increases the contact area between the first cantilever spring 7 or the second cantilever spring 8 and the male terminal 16, resulting in a contact resistance of less than 9mΩ, which meets the requirement. However, because the two sides of the peaks or troughs are close together, the deformation of the first cantilever spring 7 or the second cantilever spring 8 is small under pressure, and the peak movement distance is less than 0.5mm, which does not meet the requirement. This increases the insertion and extraction force of the male terminal 16, causing inconvenience to the user. When the first cantilever spring 7 or the second cantilever spring 8 is less than 3 times the thickness of the first cantilever spring 7 or the second cantilever spring 8, the number of peaks and troughs increases for the same length, causing inconvenience to the user. When the distance between adjacent peaks of the first cantilever spring 7 or the second cantilever spring 8 is greater than 32 times the thickness of the first cantilever spring 7 or the second cantilever spring 8, the number of peaks and troughs decreases for the same length, and the contact area with the male terminal 16 decreases. This results in a contact resistance between the first cantilever spring 7 or the second cantilever spring 8 and the male terminal 16 that is greater than 9mΩ, which does not meet the requirements. Since the distance between the two sides of the peak or trough is relatively large, the deformation of the first cantilever spring 7 or the second cantilever spring 8 is large when subjected to pressure, and the distance the peak moves is greater than 0.5mm, which meets the requirements. Therefore, the inventors selected the distance between adjacent peaks of the first cantilever spring 7 or the second cantilever spring 8 to be 3 to 32 times the thickness of the first cantilever spring 7 or the second cantilever spring 8.

[0096] In one implementation, such as Figure 4 , Figure 5As shown, the first side plate 1, the third side plate 3, the first connecting spring 5 and the first cantilever spring 7 form a terminal slot 11 with the second side plate 2, the fourth side plate 4, the second connecting spring 6 and the second cantilever spring 8. The terminal slot 11 is provided for the insertion and connection of the male terminal 16.

[0097] In one implementation, such as Figure 1 , Figure 3 As shown, the metal spring structure includes a plurality of first connecting springs 5 ​​and first cantilever springs 7, which are spaced apart; it also includes a plurality of second connecting springs 6 and a plurality of second cantilever springs 8, which are spaced apart.

[0098] In terms of mechanical performance, the structure employs multiple first connecting springs 5 ​​and multiple first cantilever springs 7, with gaps between them. Multiple second connecting springs 6 and multiple second cantilever springs 8 are also provided, spaced apart. This design effectively disperses the force required to insert the male terminal 16 into the terminal slot 11, and also reduces the temperature rise and contact resistance between the metal springs and the male terminal 16.

[0099] In one embodiment, the spacing between adjacent first connecting spring 5 and first cantilever spring 7 is 1%-100% of the width of the first cantilever spring 7; the spacing between adjacent second connecting spring 6 and second cantilever spring 8 is 1%-100% of the width of the second cantilever spring 8.

[0100] To verify the effect of the spacing between adjacent first connecting springs 5 ​​and first cantilever springs 7 on the contact resistance of the metal spring structure, the inventors selected a metal spring structure composed of first connecting springs 5 ​​and first cantilever springs 7 of the same shape and size, and male terminals 16 and female terminals 15 of the same shape and size. The metal springs were then connected to the female terminals 15 to observe the contact resistance between the male terminals 16 and the metal springs.

[0101] The contact resistance is detected by using a micro resistance meter to measure the resistance at the contact position between the male terminal 16 and the metal spring, and then reading the value on the micro resistance meter. In this embodiment, a contact resistance of less than 50 μΩ is considered ideal.

[0102] Table 5 shows the effect of the spacing between the first connecting spring 5 and the first cantilever spring 7 on the contact resistance between the male terminal 16 and the metal spring structure.

[0103]

[0104] As can be seen from Table 5, when the interval between the first connecting spring 5 and the first cantilever spring 7 is greater than 100% of the width of the first cantilever spring 7, the contact resistance is greater than 50μΩ, which does not meet the requirements. In addition, the existing processing methods for metal spring structures are stamping or cutting. If the interval between the first connecting spring 5 and the first cantilever spring 7 is too narrow, it is not easy to process. Therefore, the interval between the first connecting spring 5 and the first cantilever spring 7 is defined as 1%-100% of the width of the first cantilever spring.

[0105] As described above, the interval between the second connecting spring 6 and the second cantilever spring 8 is set to 1%-100% of the width of the second cantilever spring 8.

[0106] In one embodiment, at least one U-shaped side lug 12 is connected in the extending direction of the first side plate 1, the second side plate 2, the third side plate 3, and the fourth side plate 4. For example... Figure 6 As shown, the extension directions of the first side plate 1, the second side plate 2, the third side plate 3 and the fourth side plate 4 are perpendicular to the direction of the first connecting spring 5.

[0107] In one embodiment, the first side plate 1 and the second side plate 2 are connected in the lateral direction by at least one top lug 13 with a U-shaped cross-section, such as... Figure 6 As shown, the sides of the first side plate 1 and the second side plate 2 are opposite to the first connecting spring 5 and the second connecting spring 6 that connect the first side plate 1 and the second side plate 2.

[0108] Depending on actual use, specifically, such as Figures 8-11 As shown, when the metal spring structure is installed at a 90° or 180° angle to the female terminal 15, both the top lug 13 and the side lug 12 can be provided simultaneously, or only one of the top lug 13 or the side lug 12 can be used, depending on the actual needs. The use of the side lug 12 and the top lug 13 can make the connection between the metal spring structure and the female terminal 15 more secure and improve conductivity.

[0109] In one implementation, such as Figures 6-7 As shown, the third side plate 3 and the fourth side plate 4 are connected by at least one plate-shaped connecting bridge 14 in the lateral direction.

[0110] like Figures 8-11 As shown, the application of the connecting bridge 14 is different from the two-piece metal spring structure when the metal spring structure is connected to the female terminal 15. The metal spring structure can be directly inserted into the female terminal 15 as a whole to form the terminal slot 11. When the male terminal 16 is inserted, the connecting bridge 14 can play a certain limiting role on the male terminal 16.

[0111] In one embodiment, the material of the metal reed structure contains one or more of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium, beryllium, and lead.

[0112] To demonstrate the influence of different materials on the conductivity of the metal spring structure, the inventors used different materials to make metal spring structure samples with the same specifications and dimensions, and tested the conductivity of the metal spring structure respectively. The experimental results are shown in Table 6. In this embodiment, the conductivity of the metal spring structure is greater than 99%, which is the ideal value.

[0113] Table 6: Conductivity of metal spring structures made of different materials

[0114]

[0115] As shown in Table 6, the conductivity of the metal spring structures made from different metal materials is within the ideal range. Furthermore, phosphorus is a non-metallic material and cannot be directly used as a material for metal spring structures, but it can be added to other metals to form alloys, improving the conductivity and mechanical properties of the metals themselves. Therefore, the inventors specified that the metal spring structures contain one or more of the following materials: nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium, beryllium, and lead.

[0116] In one embodiment, the metal spring structure is made of a copper tellurium alloy, and the tellurium content in the copper tellurium alloy is 0.1%-5%, which gives the metal spring structure good electrical conductivity and easy cutting performance, ensures electrical performance, and also improves machinability.

[0117] To verify the effect of tellurium content in the tellurium-copper alloy on the conductivity of the metal spring structure, the inventors selected 10 identical metal spring structures for testing. Each metal spring structure had the same dimensions and was made of tellurium-copper alloy, with tellurium content percentages of 0.05%, 0.1%, 0.2%, 0.5%, 0.8%, 1.2%, 2%, 3%, 5%, 6%, and 7%, respectively. Current was passed through the metal spring structures, and their conductivity was measured. The test results are shown in Table 7. In this embodiment, a conductivity greater than 99% is considered ideal.

[0118] Table 7: Effect of tellurium-copper alloys with different tellurium contents on the conductivity of metal spring structures

[0119]

[0120] As shown in Table 7, when the tellurium content is less than 0.1% or greater than 5%, the conductivity decreases significantly and fails to meet the ideal conductivity requirement. The conductivity is best when the tellurium content is greater than or equal to 0.2% and less than or equal to 1.2%. While the conductivity meets the ideal requirement when the tellurium content is greater than 0.1% and less than 0.2%, or greater than 1.2% and less than or equal to 5%, the conductivity gradually decreases. Therefore, the inventors selected a tellurium-copper alloy with a tellurium content of 0.1%-5%. Ideally, a tellurium-copper alloy with a content of 0.2%-1.2% is selected.

[0121] In one embodiment, the metal spring structure material contains a beryllium copper alloy, and the beryllium content in the beryllium copper alloy is 0.05%-5%. Preferably, the beryllium content in the metal spring structure material is 0.1% to 3.5%.

[0122] Metal spring structures containing beryllium have high hardness, elastic limit, fatigue limit and wear resistance, as well as good corrosion resistance, thermal conductivity and electrical conductivity, and do not produce sparks when subjected to impact.

[0123] To test the effect of beryllium content on the conductivity of the metal spring structure, the inventors selected 10 metal spring structures of the same shape and width for testing. Each metal spring structure contained beryllium, with beryllium content percentages of 0.03%, 0.05%, 0.1%, 0.2%, 1%, 1.8%, 3%, 3.5%, 5%, and 6%, respectively. The test results are shown in Table 8. In this embodiment, a conductivity greater than 99% is considered ideal.

[0124] Table 8: Effect of different beryllium contents on the conductivity of metal spring structures

[0125]

[0126] As shown in Table 8, when the beryllium content is less than 0.05% or greater than 5%, the conductivity decreases significantly and cannot meet practical requirements. The conductivity is best when the beryllium content is greater than or equal to 0.1% and less than or equal to 3.5%. Therefore, the inventors selected a metal spring structure with a beryllium content of 0.05%-5%. Ideally, a metal spring structure with a beryllium content of 0.1% to 3.5% is selected.

[0127] In one embodiment, the metal spring structure material contains a phosphor bronze alloy, and the phosphorus content in the phosphor bronze alloy is 0.01% to 1.5%. The advantages of phosphor bronze are that it has better corrosion resistance and wear resistance, which can ensure good contact of the metal spring structure, good elasticity, and excellent machinability, which can quickly shorten the part processing time.

[0128] To test the effect of phosphorus content on the conductivity of the metal spring structure, the inventors selected 10 metal spring structures of the same shape and width for testing. Each metal spring structure contained phosphorus, with phosphorus content percentages of 0.001%, 0.005%, 0.01%, 0.05%, 0.1%, 0.5%, 1%, 1.5%, 2%, and 2.5%, respectively. The test results are shown in Table 9. In this embodiment, a conductivity greater than 99% is considered ideal.

[0129] Table 9: Effect of different phosphorus contents on the conductivity of metal spring structures

[0130]

[0131] Table 9 shows that when the phosphorus content is less than 0.01% or greater than 1.5%, the conductivity decreases significantly and cannot meet practical requirements. The conductivity is best when the phosphorus content is greater than or equal to 0.05% and less than or equal to 0.5%. Therefore, the inventors selected a metal spring structure with a phosphorus content of 0.01%-1.5%. Ideally, a metal spring structure with a phosphorus content of 0.05% to 0.5% is selected.

[0132] In one embodiment, the metal spring structure is made of a leaded brass alloy, wherein the lead content in the leaded brass alloy is 0.1% to 5%. The advantages of leaded brass alloy are high strength, dense and uniform structure, good corrosion resistance, and excellent machinability such as cutting and drilling.

[0133] To test the effect of lead content on the conductivity of the metal spring structure, the inventors selected 10 metal spring structures of the same shape and width for testing. Each metal spring structure contained lead, with lead content percentages of 0.05%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, 6%, and 7%, respectively. The test results are shown in Table 10. In this embodiment, a conductivity greater than 99% is considered ideal.

[0134] Table 10: Effect of different lead contents on the conductivity of metal spring structure

[0135]

[0136] As shown in Table 10, when the lead content is less than 0.1% or greater than 5%, the conductivity decreases significantly and cannot meet practical requirements. The conductivity is best when the lead content is greater than or equal to 1% and less than or equal to 3%. Therefore, the inventors selected a metal spring structure with a lead content of 0.1%-5%. Ideally, a metal spring structure with a lead content of 1% to 3% is selected.

[0137] In one embodiment, the first connecting spring 5, the second connecting spring 6, the first cantilever spring 7, and the second cantilever spring 8 are made of one or more of the following materials: nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium, beryllium, and lead.

[0138] In one embodiment, at least a portion of the surface of the metal spring structure is coated to improve corrosion resistance, enhance electrical conductivity, and extend service life.

[0139] Specifically, the first protrusion 9 and the second protrusion 10 are provided with a plating layer. When the metal spring structure and the male terminal 16 are made of different materials, the plating layer can effectively reduce the contact resistance between the two, reduce the voltage drop between the metal spring structure and the male terminal 16, and improve the electrical performance.

[0140] In another embodiment, a plating layer is provided at the crests and troughs of the first connecting spring 5 and the second connecting spring 6, and at the crests and troughs of the first cantilever spring 7 and the second cantilever spring 8, to reduce the voltage drop between the metal spring structure and the female terminal 15 and the male terminal 16, thereby improving electrical performance.

[0141] In another embodiment, the entire metal spring structure is coated to give the metal spring structure better electrical performance and extend its service life.

[0142] In one embodiment, the plating material contains one or more of the following: gold, silver, nickel, tin, zinc, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, hard silver, and silver-gold-zirconium alloy. In most cases, copper is used in metal spring structures. However, copper is a reactive metal and will oxidize with oxygen and water during use. Therefore, one or more inactive metals are needed as the plating to extend the service life of the metal spring structure. The aforementioned metals have better conductivity and stability than copper or copper alloys, enabling the metal spring structure to achieve better electrical performance and a longer service life.

[0143] To demonstrate the impact of different coating materials on the overall performance of the metal spring structure, the inventors used metal spring structures of the same specifications and materials but with different coating materials. All metal spring structures were coated, and a series of corrosion resistance time tests were conducted. The experimental results are shown in Table 11.

[0144] The corrosion resistance time test in Table 11 involves placing the metal spring structure sample into a salt spray test chamber and spraying salt spray on various parts of the sample. Every 20 hours, the sample is removed, cleaned, and the surface corrosion is observed; this constitutes one cycle. The test is stopped when the corroded area exceeds 10% of the total area, and the cycle number is recorded. In this embodiment, a cycle count less than 80 is considered unqualified.

[0145] Table 11: Influence of different coating materials on the corrosion resistance of metal spring structure samples

[0146]

[0147] As can be seen from Table 11, when the coating material contains commonly used metals such as tin, nickel, and zinc, the experimental results are not as good as those with other selected metals. The experimental results with other metals exceed the standard values ​​by a large margin, and the performance is more stable. Therefore, the inventors selected a coating material containing one or more of the following: gold, silver, nickel, tin, zinc, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, hard silver, and silver-gold-zirconium alloy.

[0148] In one embodiment, the coating is applied by electroplating, chemical plating, magnetron sputtering, or vacuum plating.

[0149] Electroplating is a process that uses the principle of electrolysis to plate a thin layer of another metal or alloy onto the surface of a metal.

[0150] Chemical plating is a process in which metal is deposited through a controlled redox reaction catalyzed by a metal.

[0151] Magnetron sputtering utilizes the interaction of magnetic and electric fields to cause electrons to spiral near the target surface, thereby increasing the probability of electrons colliding with argon gas to generate ions. The generated ions then collide with the target surface under the influence of the electric field, thus sputtering the target material.

[0152] Vacuum plating is a method of depositing various metal and non-metal thin films on the surface of parts under vacuum conditions by means of distillation or sputtering.

[0153] In one embodiment, an electrical connector includes a female terminal 15 with a U-shaped structure, a male terminal 16 in the form of a sheet, and a metal spring structure. The female terminal 15 has a top opening and side openings on both sides. A top lug 13 of the metal spring structure is configured to connect to the top opening or to one of the side openings. The top opening corresponds to the direction in which the male terminal 16 is inserted, and the side openings correspond to the direction perpendicular to the insertion direction of the male terminal 16. Figure 8-11 As shown,

[0154] When the metal spring structure is installed at a 90° or 180° angle to the female terminal 15, both the top lug 13 and the side lug 12 can be provided simultaneously, or only the top lug 13 or the side lug 12 can be used, depending on actual needs. Figure 9 As shown, the top hook 13 is connected to the side opening, as... Figure 10 As shown, the top hook 13 is connected to the top opening.

[0155] In one specific implementation, such as Figures 9-11 As shown, the side lugs 12 of the metal spring structure are connected to the top opening, or to one of the side openings, or to the side openings on both sides respectively. Specifically, as shown... Figure 9 As shown, the side lug 12 of the metal spring structure is connected to the top opening, as... Figure 10 As shown, the side lug 12 is connected to one of the side openings, as... Figure 11 As shown, the side lugs 12 are connected to the side openings on both sides.

[0156] In one specific implementation, such as Figures 10-11 As shown, the first connecting spring 5, the second connecting spring 6, the first cantilever spring 7, and the second cantilever spring 8 are disposed in the female terminal 15. The inner crests of the first connecting spring 5, the second connecting spring 6, the first cantilever spring 7, and the second cantilever spring 8 contact the insertion surface of the male terminal 16, and the outer troughs contact the inner surface of the female terminal 15. The direction towards the terminal slot 11 is considered internal, and the opposite direction is considered external.

[0157] This invention designs the metal spring structure, the U-shaped female terminal 15, and the male terminal 16 as three separate components. This not only facilitates assembly but also reduces the machining difficulty of the female terminal 15 mold. Simultaneously, it allows for insertion and removal in both 90° and 180° directions, making it suitable for connections in different directions of electrical connectors and reducing costs. The metal spring structure, with multiple corrugated first connecting springs 5 ​​and second connecting springs 6, as well as multiple corrugated first cantilever springs 7 and multiple corrugated second cantilever springs 8, effectively ensures the stability of contact resistance and effectively disperses the force during insertion of the male terminal 16. The overall structure is simple and low-cost.

[0158] In one implementation, such as Figure 13 As shown by Fn1 and Fn2, the spring force applied to the male terminal 16 by the first connecting spring 5 or the second connecting spring 6 is 0.3N-98N. When the metal spring structure is installed into the U-shaped female terminal 15 and the male terminal 16 is inserted into the metal spring structure, the first connecting spring 5 or the second connecting spring 6 will be compressed and deformed, thereby applying a spring force to the male terminal 16.

[0159] To verify the effect of the spring force applied by the first connecting spring 5 or the second connecting spring 6 to the male terminal 16 on the contact resistance between the first connecting spring 5 or the second connecting spring 6 and the male terminal 16, as well as on the insertion and extraction force of the male terminal 16, the inventors used the same size of the first connecting spring 5 or the second connecting spring 6, the same male terminal 16 and the same female terminal 15, and different spring forces of the first connecting spring 5 or the second connecting spring 6 to make a series of electrical connector samples. The contact resistance of the electrical connector samples and the insertion and extraction force of the male terminal 16 were tested, and the test values ​​were recorded in Table 12.

[0160] Test method for contact resistance of electrical connector sample: Use a micro resistance tester to connect the male terminal 16 and the first connecting spring 5 or the second connecting spring 6 respectively, and measure the resistance value between them. In this embodiment, a contact resistance value of less than 9mΩ is considered a qualified value.

[0161] Test method for insertion and extraction force of male terminal 16: Use a precision push-pull force gauge to push male terminal 16 into the metal spring structure or pull it out of the metal spring structure, measure the force of both and take the average value. In this embodiment, the insertion and extraction force of male terminal 16 is greater than 25N and is unqualified.

[0162] Table 12: The effect of the elastic force applied by the first or second connecting spring to the male terminal on the contact resistance between the first or second connecting spring and the male terminal, and on the insertion and extraction force of the male terminal.

[0163]

[0164] As shown in Table 12, when the elastic force applied by the first connecting spring 5 or the second connecting spring 6 to the male terminal 16 is less than 0.3N, the contact force between the first connecting spring 5 or the second connecting spring 6 and the male terminal 16 is small, resulting in a small contact area. This leads to a contact resistance greater than 9mΩ between the first connecting spring 5 or the second connecting spring 6 and the male terminal 16, which does not meet the required value. The greater the elastic force, the smaller the contact resistance. When the elastic force applied by the first connecting spring 5 or the second connecting spring 6 to the male terminal 16 is greater than 98N, the clamping force of the first connecting spring 5 or the second connecting spring 6 on the male terminal 16 is too large. This results in a large frictional force when the male terminal 16 is inserted into or pulled out of the metal spring structure. The insertion and extraction force of the male terminal 16 is greater than 25N, which does not meet the required value. The smaller the elastic force, the smaller the insertion and extraction force of the male terminal 16. Therefore, the inventors set the elastic force applied by the first connecting spring 5 or the second connecting spring 6 to the male terminal to be between 0.3N and 98N.

[0165] Furthermore, when the spring force applied to the male terminal 16 by the first connecting spring 5 or the second connecting spring 6 is greater than 55N, the insertion and extraction force of the male terminal 16 is significantly increased. Therefore, the inventors further set the spring force applied to the male terminal by the first connecting spring 5 or the second connecting spring 6 to be 0.3N-55N.

[0166] In one implementation, such as Figure 14 As shown in Fn3, the spring force applied to the male terminal 16 by the first cantilever spring 7 or the second cantilever spring 8 is 0.3N-98N. When the metal spring structure is installed into the U-shaped female terminal 15 and the male terminal 16 is inserted into the metal spring structure, the first cantilever spring 7 or the second cantilever spring 8 will be compressed and deformed, thereby giving the first cantilever spring 7 or the second cantilever spring 8 a spring force applied to the male terminal 16.

[0167] To verify the effect of the elastic force applied by the first cantilever spring 7 or the second cantilever spring 8 to the male terminal 16 on the contact resistance between the first cantilever spring 7 or the second cantilever spring 8 and the male terminal 16, as well as on the insertion and extraction force of the male terminal 16, the inventors used the same size of the first cantilever spring 7 or the second cantilever spring 8, the same male terminal 16 and the female terminal 15, and different elastic forces of the first cantilever spring 7 or the second cantilever spring 8 to make a series of electrical connector samples. The contact resistance of the electrical connector samples and the insertion and extraction force of the male terminal 16 were tested, and the test values ​​were recorded in Table 13.

[0168] Test method for contact resistance of electrical connector sample: Use a micro resistance tester to connect the male terminal 16 and the first cantilever spring 7 or the second cantilever spring 8 respectively, and measure the resistance value between them. In this embodiment, a contact resistance value of less than 9mΩ is considered a qualified value.

[0169] Test method for insertion and extraction force of male terminal 16: Use a precision push-pull force gauge to push male terminal 16 into the metal spring structure or pull it out of the metal spring structure, measure the force of both and take the average value. In this embodiment, the insertion and extraction force of male terminal 16 is greater than 25N and is unqualified.

[0170] Table 13: The effect of the elastic force applied by the first or second cantilever spring to the male terminal on the contact resistance between the first or second cantilever spring and the male terminal, and on the insertion and extraction force of the male terminal.

[0171]

[0172] As can be seen from Table 13, when the elastic force applied to the male terminal by the first cantilever spring 7 or the second cantilever spring 8 is less than 0.3N, the contact force between the first cantilever spring 7 or the second cantilever spring 8 and the male terminal 16 is small, and the corresponding contact area is small. This results in a contact resistance between the first cantilever spring 7 or the second cantilever spring 8 and the male terminal 16 being greater than 9mΩ, which does not meet the required value. The greater the elastic force, the smaller the contact resistance. When the elastic force applied to the male terminal 16 by the first cantilever spring 7 or the second cantilever spring 8 is greater than 98N, the clamping force of the first cantilever spring 7 or the second cantilever spring 8 on the male terminal 16 is too large. This results in a large frictional force when the male terminal 16 is inserted into or pulled out of the metal spring structure. The insertion and extraction force of the male terminal 16 is greater than 25N, which does not meet the required value. The smaller the elastic force, the smaller the insertion and extraction force of the male terminal 16. Therefore, the inventors set the elastic force applied to the male terminal by the first cantilever spring 7 or the second cantilever spring 8 to be 0.3N-98N.

[0173] Furthermore, when the elastic force applied to the male terminal 16 by the first cantilever spring 7 or the second cantilever spring 8 is greater than 55N, the insertion and extraction force of the male terminal 16 is significantly increased. Therefore, the inventors further set the elastic force applied to the male terminal by the first cantilever spring 7 or the second cantilever spring 8 to be 0.3N-55N.

[0174] In one specific embodiment, the metal spring structure is integrally stamped from a plate-shaped material. For example... Figure 1 and Figure 6 As shown, the metal spring structure is a one-piece stamped structure, which is easy to process and has low cost.

[0175] The above descriptions are merely a few embodiments of the present invention. Those skilled in the art can make various modifications or variations to the embodiments of the present invention based on the content disclosed in the application documents without departing from the spirit and scope of the present invention. It should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention.

[0176] Furthermore, the terms “first,” “second,” “third,” and “fourth” are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated.

[0177] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

Claims

1. A metal spring structure, characterized in that, include: A first side plate and a second side plate are arranged opposite to each other, and a third side plate and a fourth side plate are arranged opposite to each other, wherein the first side plate and the third side plate are in the same plane, and the second side plate and the fourth side plate are in the same plane; It also includes at least one pair of opposing first connecting springs and second connecting springs, wherein the two ends of the first connecting springs are respectively connected to the first side plate and the third side plate, and the two ends of the second connecting springs are respectively connected to the second side plate and the fourth side plate; It also includes at least one pair of opposing first cantilever springs and second cantilever springs, wherein one end of the first cantilever spring is connected to the first side plate and the other end forms a free end, and one end of the second cantilever spring is connected to the second side plate and the other end forms a free end. The first connecting spring and the second connecting spring are arranged as mirror images of each other, and the first cantilever spring and the second cantilever spring are also arranged as mirror images of each other. In a cross-section along the extending direction of the first and second connecting springs and perpendicular to the opposing direction of the first and second side plates, the cross-sectional shape of the first and second connecting springs is corrugated, and the cross-sectional shape of the first and second cantilever springs is also corrugated. At least at the crest or trough of the first connecting spring and / or the second connecting spring, a first protrusion protruding outward from the crest or trough is provided; at least at the crest or trough of the first cantilever spring and / or the second cantilever spring, a second protrusion protruding outward from the crest or trough is provided. The distance between the second protrusions on the wave crests of the first cantilever spring and the second cantilever spring that are arranged opposite to each other is less than the distance between the first protrusions on the wave crests of the first connecting spring and the second connecting spring that are arranged opposite to each other. The first connecting spring and the second connecting spring are provided with two peaks, and the first cantilever spring and the second cantilever spring are provided with one peak. The peaks of the first cantilever spring and the second cantilever spring are respectively located between the two peaks of the first connecting spring and the second connecting spring. A metal spring structure is set in the female terminal with a U-shaped structure to realize plug-in connection with the male terminal in the 90-degree and 180-degree directions.

2. The metal spring structure according to claim 1, characterized in that, The minimum vertical distance between the crest and trough of the first or second connecting spring is 1 to 12 times the thickness of the first or second connecting spring.

3. The metal spring structure according to claim 1, characterized in that, The minimum vertical distance between the crest and trough of the first or second cantilever spring is 1 to 12 times the thickness of the first or second cantilever spring.

4. The metal spring structure according to claim 1, characterized in that, The distance between adjacent peaks of the first or second connecting spring is 3 to 32 times the thickness of the first or second connecting spring.

5. The metal spring structure according to claim 1, characterized in that, The distance between adjacent peaks of the first cantilever spring or the second cantilever spring is 3 to 32 times the thickness of the first cantilever spring or the second cantilever spring.

6. The metal spring structure according to claim 1, characterized in that, The first side plate, the third side plate, the first connecting spring and the first cantilever spring form a terminal slot with the second side plate, the fourth side plate, the second connecting spring and the second cantilever spring.

7. The metal spring structure according to claim 1, characterized in that, It includes a plurality of first connecting springs and a plurality of first cantilever springs, the plurality of first connecting springs and the plurality of first cantilever springs being spaced apart; it also includes a plurality of second connecting springs and a plurality of second cantilever springs, the plurality of second connecting springs and the plurality of second cantilever springs being spaced apart.

8. The metal spring structure according to claim 7, characterized in that, The spacing between adjacent first connecting springs and first cantilever springs is 1%-100% of the width of the first cantilever spring; the spacing between adjacent second connecting springs and second cantilever springs is 1%-100% of the width of the second cantilever spring.

9. The metal spring structure according to claim 1, characterized in that, At least one U-shaped side lug is connected in the extending direction of the first side plate, the second side plate, the third side plate and the fourth side plate.

10. The metal spring structure according to claim 1, characterized in that, The first side plate and the second side plate are connected to at least one top lug with a U-shaped cross-section in the lateral direction.

11. The metal spring structure according to claim 1, characterized in that, The third side plate and the fourth side plate are connected by at least one plate-shaped connecting bridge in the lateral direction.

12. The metal spring structure according to claim 1, characterized in that, The material of the metal spring structure contains one or more of the following: nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium, beryllium, and lead.

13. The metal spring structure according to claim 1, characterized in that, The metal spring has a plating layer on at least a portion of its surface.

14. The metal spring structure according to claim 13, characterized in that, The coating material contains one or more of the following: gold, silver, nickel, tin, zinc, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, hard silver, and silver-gold-zirconium alloy.

15. An electrical connector, characterized in that, It includes a female terminal with a U-shaped structure, a sheet-like male terminal, and a metal spring structure as described in any one of claims 1 to 14, wherein the female terminal has a top opening and side openings on both sides, and the top lug of the metal spring structure is configured to connect to the top opening or to one of the side openings.

16. The electrical connector according to claim 15, characterized in that, The side lugs of the metal spring structure are configured to connect to the top opening, or to one of the side openings, or to the side openings on both sides respectively.

17. The electrical connector according to claim 15, characterized in that, The first connecting spring, the second connecting spring, the first cantilever spring, and the second cantilever spring are disposed in the female terminal. The inner crests of the first connecting spring, the second connecting spring, the first cantilever spring, and the second cantilever spring are in contact with the insertion surface of the male terminal, and the outer troughs are in contact with the inner surface of the female terminal.

18. The electrical connector according to claim 17, characterized in that, The spring force applied to the male terminal by the first or second connecting spring is 0.3N-98N.

19. The electrical connector according to claim 18, characterized in that, The spring force applied to the male terminal by the first or second connecting spring is 0.3N-55N.

20. The electrical connector according to claim 17, characterized in that, The elastic force applied to the male terminal by the first or second cantilever spring is 0.3N-98N.

21. The electrical connector according to claim 20, characterized in that, The elastic force applied to the male terminal by the first or second cantilever spring is 0.3N-55N.

22. The electrical connector according to claim 15, characterized in that, The metal spring structure is integrally stamped from a plate material.

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