Power supply terminals having a multi-layer structure and a set of power supply terminals having different numbers of layers

Abstract

The present application relates to a power terminal having a multi-layer structure and a set of power terminals having different numbers of layers. A power terminal (7) comprises a contact portion (10), a connection portion (11) and an intermediate portion (12). The contact portion (10) and the intermediate portion (12) comprise electrically conductive layers (13) stacked along a direction corresponding to their respective thicknesses. The contact portion (10) comprises a main top surface (14) and at least one contact area (15) protruding from said main top surface (14). Each layer (13) in the contact portion (10) comprises at least one first impression area (16), the at least one first impression area (16) of each layer (13) being aligned with the at least one first impression area (16) of an adjacent layer (13), and the at least one first impression area (16) of the top layer (13) forming the at least one contact area (15).

Description

Technical Field

[0001] This invention relates to the field of electrical interconnection in motor vehicles. For example, this invention relates to power terminals for interconnecting battery packs, converters, charging plugs, engines, etc., in electric or hybrid vehicles. Background Technology

[0002] Power terminals typically consist of a contact portion, a connecting portion, and an intermediate portion between the two. The current intensity that such a power terminal can conduct without excessive temperature rise depends on the cross-sectional area of ​​at least the contact portion. The greater the current intensity that a power terminal can conduct, the larger the cross-sectional area of ​​the contact portion. Among power terminals, some have a plate-like shape in at least the contact portion. The thickness of the plate that can be used to manufacture such power terminals is also limited by the fact that the greater the thickness, the more difficult operations such as stamping, embossing, and bending become. More specifically, for example, for copper alloys, a thickness of 3 mm for a large block of material is a difficult limit to overcome. Therefore, it becomes easier to manufacture power terminals with a greater width than power terminals with a greater thickness. However, increasing the width of a power terminal has a greater impact on the size of the connector that houses it than increasing its thickness.

[0003] The purpose of this disclosure is to provide a power terminal that can conduct relatively high current intensity without excessively raising the temperature or making its manufacture overly complicated. Summary of the Invention

[0004] In practice, this power terminal includes a contact portion having a main top surface and at least one contact area protruding from the main top surface. The contact area protruding from the main top surface improves the connection between the power terminal and the power terminal of the mating connector. However, this protrusion is caused by embossing or stamping of the multilayer structure of the contact portion. Embosing a multilayer structure is easier than a bulk structure. Therefore, even if the thickness of the multilayer structure is greater than the thickness of the bulk structure, manufacturing the power terminal does not require more precise and / or complex tools. In other words, by increasing the thickness, i.e., the number of layers in the multilayer structure, the cross-section of the contact portion can be increased.

[0005] In this document, regardless of the technique used to achieve this deformation (embossing, stamping, punching, etc.), the terms “embossing,” “stamping,” and “embossed” should be understood in the general sense corresponding to one or more layers of deformation.

[0006] According to another aspect, a power terminal assembly is disclosed.

[0007] According to another aspect, a connector is disclosed. Attached Figure Description

[0008] Other features, objects, and advantages of the invention will become apparent upon reference to the following detailed description given with reference to the accompanying drawings and by way of non-limiting examples, wherein:

[0009] Figure 1 This is a cross-sectional schematic diagram of the connector assembly;

[0010] Figure 2 This is a perspective view of an example of a female power terminal configured to be housed in a connector assembly, such as... Figure 1 Connector assembly;

[0011] Figure 3 yes Figure 2 A three-dimensional schematic diagram and a longitudinal cross-sectional schematic diagram of the negative power supply terminal shown;

[0012] Figure 4 Is it like this? Figure 2 and Figure 3 A three-dimensional schematic diagram of a variant of the contact portion of the negative power terminal shown;

[0013] Figure 5 Is it like this? Figure 2 and Figure 3 A three-dimensional schematic diagram of a variant of the middle portion of the negative power terminal shown;

[0014] Figure 6 yes Figure 2 and Figure 3 A schematic diagram of a variant of the negative power terminal shown as a side elevation view;

[0015] Figure 7 yes Figure 2 and Figure 3 The diagram shown is a side elevation view of the negative power terminal.

[0016] Figure 8 yes Figure 2 and Figure 3 A schematic diagram of a variant of the negative power terminal shown as a side elevation view; and

[0017] Figure 9 yes Figure 1 A cross-sectional schematic diagram of a variant of the connector assembly shown. Detailed Implementation

[0018] Figure 1An example embodiment of connector assembly 1 is shown. According to this example, connector assembly 1 includes a male connector 2 and a female connector 3. The male connector 2 has a housing made of dielectric material, and the housing includes a cavity 4 configured to receive at least one male power terminal 5. The female connector 3 has a housing made of dielectric material, and the housing includes a cavity 6 configured to receive at least one female power terminal 7. When the male connector 2 and the female connector 3 mate, the male power terminal 5 and the female power terminal 7 are electrically connected to each other.

[0019] like Figure 2 and Figure 3 As shown, the negative power terminal 7 includes a terminal body 8 and a retainer 9. The terminal body 8 includes a contact portion 10, a connecting portion 11, and an intermediate portion 12 between the two.

[0020] The terminal body 8 has a generally plate-like shape. In the illustrated example, the contact portion 10 and the intermediate portion 12 are aligned, while the connecting portion 11 extends from the intermediate portion 12 at a right angle. The contact portion 10, the connecting portion 11, and the intermediate portion 12 are formed as a multi-layered structure. Figure 2 and Figure 3 In the example shown, contact portion 10 includes eight conductive layers 13, while connection portion 11 and intermediate portion 12 include six conductive layers 13. For example, each layer 13 is made of a copper alloy. Each layer 13 has a thickness of approximately 0.5 mm. Each layer 13 has a width W of approximately 35 mm. Each layer 13 has two main surfaces that define a direction D corresponding to its thickness. Layers 13 are stacked along a direction D perpendicular to the main surfaces 14, 18 of contact portion 10 and intermediate portion 12.

[0021] The contact portion 10 includes a main top surface 14 and two contact areas 15 protruding from the main top surface 14. For example... Figure 3 As shown, each layer 13 of the contact portion 10 includes two first imprinted areas 16. The first imprinted areas 16 of each layer 13 are aligned with the first imprinted areas 16 of the adjacent layer. The first imprinted areas 16 of the top layer 13A respectively form contact regions 15. Figure 2 and Figure 3 In the example illustrated, the negative power terminal 7 has two contact areas 15 (each contact area corresponds to a first imprinted area 16). However, in variations, the contact portion 10 may include only one contact area 15. Alternatively, as Figure 4 As shown, in a variant, the contact portion 10 may include more than two contact areas 15 (e.g., as shown in the diagram). Figure 4 The twelve contact areas shown in Figure 15).

[0022] In the intermediate region 12, each layer 13 includes at least one second imprinting region 17. Figure 2 and Figure 3 In the example illustrated, the negative power terminal 7 has four second imprinted areas 17. Alternatively, as... Figure 5 As shown, in the variant, the intermediate region 12 may include more or fewer than four second imprint regions 17 (e.g., as shown in the diagram). Figure 5 The eight second imprinted regions 17 shown are illustrated. The second imprinted regions 17 can be created by imprinting, stamping, or another operation suitable for deforming the stacked layers 13. These operations (imprinting, stamping, etc.) mechanically connect the layers 13 together. They strengthen the multilayer structure and improve the conductivity between adjacent layers 13. The second imprinted regions 17 can be generated from the main top surface 14 (see...). Figure 2 and Figure 3 ) or embossed or stamped from the main bottom surface 18. Alternatively, such as Figure 5 As shown, several second imprinted areas 17 can be imprinted or stamped from the main top surface 14, and other areas can be imprinted or stamped from the main bottom surface 18 (in other words, each of the plurality of conductive layers 13 includes imprinted or stamped areas 17 imprinted or stamped in opposite directions).

[0023] The cage 9 is cut and shaped in a thin sheet of metal (e.g., stainless steel). Figure 2 and Figure 3 As shown, the retainer 9 is U-shaped, having a top wall 19, a bottom wall 20, and a side wall 21. The top wall 19 and bottom wall 20 correspond to branches of the U, and the side wall 21 engages the top wall 19 and bottom wall 20. A resilient tongue 22 extends from the top wall 19 toward the bottom wall 20. The tongue 22 is configured to allow the male terminal 5 to be inserted between the top wall 19 and the main top surface 14 of the contact portion 10 of the female terminal 7. More specifically, the tongue 22 is configured to press the contact portion of the male terminal 5 against the contact area 15. The retainer 9 includes hooks 23A, 23B, and 23C configured to hold the retainer 9 on a plurality of conductive layers 13 of the contact portion 10. The hooks 23A, 23B, and 23C also facilitate the assembly of the retaining layers 13 together. Figure 2 and Figure 3 In the example shown, there are front hooks 23A and side hooks 23B, each hook engaging a notch 24A or 24B cut in layer 13 of the contact portion 10, respectively. These front hooks 23A and side hooks 23B do not cover the main top surface 14. Possibly, since the contact area 15 protrudes from the main top surface 14, the front hook 23A can extend further than the main top surface 14 while remaining below the top of the contact area 15. The side hooks 23B are advantageously flush with the main top surface 14. The retainer 9 also includes two rear hooks 23C that return above the main top surface 14 and capture the layers 13 together. The rear hooks 23C can also be used to block forward movement of the male terminal 5. Each rear hook 23C is inserted behind a shoulder 25 cut in layer 13 and located behind the contact portion 10.

[0024] Figures 6 to 8 Various variations of the assembly of the negative power terminal 7 are shown (without a cage). Figures 6 to 8 The three variants shown differ from each other in the number of conductive layers 13 stacked in the intermediate portion 12 and the connecting portion 11. For example, Figure 6 The shown negative power terminal 7 comprises eight layers 13 in the contact portion 10, the intermediate portion 12, and the connecting portion 11. Therefore, the cross-section of these contact portions 10, the connecting portion 11, and the intermediate portion 12 is approximately 8 times 0.5 times the width of the negative power terminal 7 (e.g., if the width is approximately 25 mm, the cross-section is approximately 8 x 0.5 x 25 = 100 mm). 2 This cathode power terminal 7 is suitable for conducting currents up to 450 amps at temperatures not exceeding 85°C. Figure 7 The negative power terminal 7 shown includes eight layers 13 in the contact portion 10, but only six layers in the intermediate portion 12 and the connecting portion 11. Therefore, the cross-section of the contact portion 10 is similar to... Figure 6 The variant remains the same, but the cross-section of the connecting portion 11 and the intermediate portion 12 is approximately 6 times 0.5 times the width of the negative power terminal 7 (for example, if the width is approximately 25 mm, then the cross-section is approximately 6 x 0.5 x 25 = 75 mm). 2 This cathode power terminal 7 is suitable for conducting currents up to 400 amps at temperatures not exceeding 85°C. Figure 8 The negative power terminal 7 shown includes eight layers 13 in the contact portion 10, but only four layers in the intermediate portion 12 and the connecting portion 11. Therefore, the cross-section of the contact portion 10 is similar to... Figure 6 and Figure 7 The variant remains the same, but the cross-section of the connecting portion 11 and the intermediate portion 12 is approximately 4 times 0.5 times the width of the negative power terminal 7 (for example, if the width is approximately 25 mm, then the cross-section is approximately 4 x 0.5 x 25 = 50 mm). 2 This cathode power terminal 7 is suitable for conducting currents up to 250 amps at temperatures not exceeding 85°C.

[0025] exist Figures 6 to 8 In the power terminal 7 shown, the contact portion 10 has a thickness greater than 3 mm. Advantageously, the contact portion between the male terminal 5 and the female terminal 7 has a thicker portion. In practice, the temperature at the contact point (i.e., in the contact area 15) may rise higher than in other areas.

[0026] exist Figures 6 to 8 In the set of negative power terminals 7 shown, each of the three terminals has N (N=8) conductive layers 13 stacked in the contact portion 10. Figure 6The cathode power terminal 7 shown has N conductive layers 13 stacked in the middle portion 12 and the connecting portion 11. Figure 7 The cathode power terminal 7 shown has N-2=6 conductive layers 13 stacked in the middle portion 12 and the connecting portion 11. Figure 8 The cathode power terminal 7 shown has N-4 = 4 conductive layers 13 stacked in the intermediate portion 12 and the connecting portion 11. More broadly, if the number of conductive layers 13 stacked in the contact portion 10 is a positive integer N, then the number of conductive layers 13 stacked in the intermediate portion 12 and / or the connecting portion 11 is Nn, where n is chosen as a positive integer less than N.

[0027] The advantage of the above-disclosed set of female power terminals 7 is that it allows the number of conductive layers 13 to be adapted to the application (i.e., to the cost) while maintaining the same interface for the male power terminals 5 with the male connector 2 and the female connector 3.

[0028] A connector, such as a female connector 3, can accommodate one or more female power terminals 7 from a set of female terminals 7. When the connector 3 accommodates multiple terminals 7, the multiple female power terminals 7 can be identical, but the number of conductive layers 13 stacked in the intermediate portion 12 and the connecting portion 11 can differ, while the number of conductive layers 13 stacked in the contact portion 10 is similar to... Figure 9 The same as shown.

[0029] The above disclosure relates to the negative power terminal 7, but it can be easily converted into the positive power terminal 5.

Claims

1. A power terminal (5, 7) comprising a contact portion (10), a connection portion (11), and an intermediate portion (12) between the contact portion (10) and the connection portion (11), the contact portion (10) and the intermediate portion (12) comprising a plurality of conductive layers (13) stacked along a direction corresponding to their respective thicknesses, the contact portion (10) comprising a main top surface (14) and at least one contact region (15) protruding from the main top surface (14). Its features are, Each of the plurality of conductive layers (13) in the contact portion (10) includes at least one first imprinted region (16), the at least one first imprinted region (16) of each layer (13) being aligned with the at least one first imprinted region (16) of the adjacent layer (13), and the at least one first imprinted region (16) of the top layer (13) forming the at least one contact area (15), and In the intermediate portion (12), each of the plurality of conductive layers (13) includes at least one second imprinted area (17) for mechanically connecting the layers (13) together.

2. The power terminals (5, 7) according to claim 1, wherein, The number of conductive layers (13) stacked in the contact portion (10) is different from the number of conductive layers (13) stacked in the intermediate portion (12) or the connecting portion (11).

3. The power supply terminals (5, 7) according to claim 1 or 2, wherein, Each of the plurality of conductive layers (13) includes imprinted areas (16, 17) imprinted in opposite directions.

4. The power supply terminals (5, 7) according to claim 1 or 2, wherein, The thickness of the contact portion (10) is greater than 3 mm.

5. The power terminal (5, 7) according to claim 1 or 2, wherein the power terminal is formed as a female terminal (7) and includes a retainer (9), the retainer (9) having at least one resilient tongue (22) configured to press a contact portion of the male terminal (2) against the at least one contact area (15), and the retainer (9) having at least one hook (23A, 23B, 23C) configured to retain the retainer (9) on the plurality of conductive layers (13) of the contact portion (10) of the female terminal (7).

6. A set of power terminals (5, 7) comprising at least two power terminals (5, 7) according to any one of the preceding claims, wherein, The two power terminals (5, 7) differ from each other in the number of conductive layers (13) stacked in the intermediate portion (12) or the connecting portion (11), while the number of conductive layers (13) stacked in the contact portion (10) is the same for both power terminals (5, 7).

7. The set of power terminals (5, 7) according to claim 6, the set of power terminals comprising at least three power terminals (5, 7), each power terminal having N conductive layers (13) stacked in the contact portion (10), one power terminal having N conductive layers (13) stacked in the intermediate portion (12) or the connecting portion (11), one power terminal having N-2 conductive layers (13) stacked in the intermediate portion (12) or the connecting portion (11), and one power terminal having N-4 conductive layers (13) stacked in the intermediate portion (12) or the connecting portion (11).

8. The assembly of power terminals (5, 7) according to claim 7, wherein, The cross-sections of the three power terminals (5, 7) are each 100mm². 2 75mm 2 and 50mm 2 .

9. The assembly of power terminals (5, 7) according to any one of claims 6 to 8, wherein, The width of the contact portion (10) of all power terminals (5, 7) is the same.

10. A connector comprising at least one power terminal (5, 7) housed in a cavity (4, 6) formed in a housing made of dielectric material, the at least one power terminal (5, 7) being selected from the set of power terminals (5, 7) according to any one of claims 6 to 9.

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