Integrated folding connector

Abstract

The present invention discloses an integral folding connector, comprising an integrally stamped socket structure and an integrally stamped plug structure. After the socket structure is folded, an outer layer structure is formed to tightly wrap around an inner layer spring structure. After the plug structure is folded, an overlapping structure is formed in which the outer layer spring structure clamps the middle structure. When plugged in, the outer contact spring in the outer layer spring structure contacts the inner contact spring in the inner layer spring structure. This technical solution avoids secondary contact of the springs and reduces welding or riveting processes, while achieving the effects of simple processing and reliable contact. By coating the concave surface of the spring with electromagnetic material, when no power is applied, a small positive pressure is generated during the plug-in and plug-out process between the plug and the socket, thereby achieving low or zero plug-in and plug-out force. When the plug-in is completed and the power is applied, the electromagnetic material generates a magnetic adsorption force, which can increase the positive pressure to ensure good conductivity, thereby achieving intelligent control of electrical contact and plug-in and plug-out force.

Description

Technical Field

[0001] The present invention relates to the technical field of connectors, and in particular to an integrated folding connector. Background Art

[0002] New energy vehicles feature high voltages exceeding 800V and high currents exceeding 350A. However, conventional automotive connector contact structures fail to meet standard requirements for electrical safety and contact resistance. For example, the petal-shaped structure currently used in new energy vehicle high-voltage sockets offers simpler processing but suffers from a low number of contact points and high contact resistance. Designs that embed a double-helical crown spring within a smooth socket cavity offer more contact points but require complex crown spring processing. High-voltage rectangular connectors, while simpler to process, require contact springs to be welded or riveted to the housing for secondary contact, creating a conflict between the need for high positive pressure to ensure good electrical contact and the need for low positive pressure to reduce insertion and removal forces. Furthermore, sockets and conductors often utilize square or hexagonal crimping, which can lead to high crimp resistance and low pull-out force.

[0003] Therefore, developing a new high-voltage connector structure that enables linear contact between the plug and the smooth socket is of great significance to ensure the contact reliability of the high-voltage connector.

[0004] It should be noted that the above technical information is only intended to deepen the understanding of the overall background technology of the present invention, and should not be regarded as an admission or implication in any form that the above technical information constitutes prior art already known to those skilled in the art. Summary of the Invention

[0005] In view of the deficiencies in the above-mentioned background technology, the present invention proposes an integrated folding connector, which solves the technical problem that the existing connector cannot achieve both simple processing and reliable contact.

[0006] The technical solution of this application is:

[0007] An integral folding connector includes an integrally stamped socket structure and an integrally stamped plug structure. The socket structure, when folded, forms a cavity structure in which an outer layer tightly wraps around an inner layer spring structure. The plug structure, when folded, forms a laminated structure in which the outer layer spring structure sandwiches an intermediate structure. When the laminated structure is inserted into the cavity structure, the outer contact spring in the outer layer spring structure contacts the inner contact spring in the inner layer spring structure. This technical solution integrally stamps and forms the socket structure and the plug connector body. The contact spring and the outer layer contact housing are integrally structured and integrally formed. The folded, integrated multi-layer structure not only simplifies the structure and facilitates processing and forming, but also integrates the contact spring and the contact housing, avoiding secondary contact between the spring and the contact spring, reducing the number of welding or riveting steps, and improving stability and efficiency. It also solves the problem of insufficient elasticity caused by excessive thickness of the contact spring in a single layer, achieving both simple processing and reliable contact.

[0008] On the basis of the above technical solution, as a preferred technical solution of the integrated folding connector, the outer contact spring and the inner contact spring are both springs arranged obliquely along the plug-in direction. When the superimposed structure is inserted into the cavity structure, the outer contact spring and the inner contact spring are in cross contact. That is, in this technical solution, the inclination direction of the spring in the outer contact spring and the inclination direction of the spring in the inner contact spring intersect with each other, which not only facilitates plugging and unplugging, but also further improves the contact reliability. Preferably, the cross contact is a degree contact, that is, the inclination direction of the spring in the outer contact spring is perpendicular to the inclination direction of the spring in the inner contact spring. In addition to the degree contact, the cross contact can also be other angles, but it is necessary to ensure that the inclination direction of the spring in the outer contact spring and the inclination direction of the spring in the inner contact spring are not perpendicular to the plug-in direction of the superimposed structure, thereby ensuring the convenience of plugging.

[0009] Based on the above technical solution, as a preferred technical solution for the integrated folding connector, the concave surface of the outer spring structure and the concave surface of the inner spring structure are coated with electromagnetic material or attached with electromagnetic sheets. In this technical solution, since the outer contact spring and the inner contact spring are attached to each other through the convex surface, a positive pressure is formed at the contact position. If the positive pressure is too large, it is not convenient to plug and unplug, and the maintenance of the positive pressure is affected as the number of plug and unplug increases. If the positive pressure is too small, it is difficult to ensure the reliability of the contact. Therefore, the electromagnetic material is coated on the concave surface of the spring. When the power is not turned on, the plug and socket generate a small positive pressure during the plug-in and plug-out process, so as to achieve low plug-in and plug-out force, or even zero plug-in and plug-out force. After the plug-in is completed and the power is turned on, the electromagnetic material generates a magnetic attraction force, which can increase the positive pressure to ensure good conductivity. Coating the electromagnetic material on the concave surface or attaching the electromagnetic sheet to the concave surface can avoid the friction caused by the plugging and unplugging process on the electromagnetic material or the electromagnetic sheet, fully ensuring the service life of the electromagnetic material or the electromagnetic sheet, and thus ensuring the service life of the entire connector.

[0010] Based on the above technical solution, as a preferred technical solution for the integrated folding connector, the cavity structure includes at least two plug-in ports for inserting the stacking structure; when the cavity structure includes two plug-in ports, the two plug-in ports are arranged at right angles relative to each other. This technical solution provides the cavity structure with multiple plug-in ports, allowing the plug and socket to be plugged in at different angles. In addition, by setting different plug-in ports to different sizes, different connector plugs can be adapted.

[0011] Based on the above technical solutions, as a preferred technical solution for the integrated folding connector, the interior of the cavity structure is a rectangular parallelepiped cavity, and two inner spring structures are provided, one located on opposite sides of the rectangular parallelepiped. The outer contour of the stacked structure is a rectangular parallelepiped structure, and two outer spring structures are provided, one located on opposite sides of the rectangular parallelepiped structure. This technical solution configures the socket with a dual-contact spring structure, which can form more contact surfaces with the plug. The two contact surfaces are located in opposite directions, which can further reduce contact resistance and thereby improve contact reliability.

[0012] Based on the above technical solutions, as a preferred technical solution for the integrated folding connector, the edge of the inner layer structure of the cavity structure is provided with an inner and outer layer combined folding piece, the edge of the outer layer structure is provided with a folding piece yielding groove that matches the inner and outer layer combined folding piece, the end of the outer layer structure close to the inner layer structure is provided with a connecting groove, the end away from the inner layer structure is provided with a connecting piece that matches the connecting groove, and the end of the inner layer structure away from the outer layer structure is provided with a connecting piece yielding groove that yields to the connecting piece. This technical solution can prevent the inner and outer layer combined folding piece 2-1 and the connecting piece 1-3 from affecting the insertion space inside the cavity after folding. This technical solution makes the inner wall of the cavity structure smooth and unobstructed, thereby further improving the reliability of the connection between the plug and the socket.

[0013] On the basis of the above technical solution, as a preferred technical solution of the integrated folding connector, the outer layer spring structure includes an outer layer spring one and an outer layer spring two respectively located on both sides of the intermediate structure, and the outer layer spring one and the outer layer spring two are folded in reverse to clamp the intermediate structure in the middle.

[0014] Based on the above technical solution, as a preferred technical solution for the integrated folding connector, the outer spring piece 1 is provided with a multi-layer combined folded piece 1 at the edge facing away from the intermediate structure, and a multi-layer combined folded piece clearance groove 2 is provided near the edge of the intermediate structure. The outer spring piece 2 is provided with a multi-layer combined folded piece 2 that matches the multi-layer combined folded piece clearance groove 2 at the edge facing away from the intermediate structure, and a multi-layer combined folded piece clearance groove 1 that matches the multi-layer combined folded piece 1 is provided near the edge of the intermediate structure. This technical solution ensures that the outer wall of the laminated structure formed after the plug structure is folded is smooth and unobstructed by other components, thereby further improving the reliability of the connection between the plug and the socket.

[0015] On the basis of the above technical solution, as an optimal technical solution for the integrated folding connector, the outer structure is provided with a hanging hole for connecting with the connector sheath, the socket structure and the plug structure are respectively connected with conductor welding plates, and the conductor welding plates are provided with welding ribs and insulation layer tails.

[0016] On the basis of the above technical solution, as a preferred technical solution of the one-piece folding connector, the conductor welding plate is connected to the high-voltage cable, and the insulation layer of the high-voltage cable includes an outer insulation layer, a shielding plastic layer, and an inner insulation layer which are sequentially sleeved from the outside to the inside. The shielding plastic layer is a composite material of plastic and graphite. The inner insulation layer wraps the conductor. The exposed end of the conductor is pre-pressed into a rectangular shape and then cold-welded to the conductor welding plate. The insulation layer tail is crimped to the insulation layer.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] (1) The technical solution provided by the present invention has a simple structure, reliable performance, and a wide range of applications. It can effectively promote the application of high-voltage connectors and is not only applicable to automotive high-voltage systems, but also to other high-voltage systems and low-voltage electrical systems.

[0019] (2) The technical solution provided by the present invention adopts a multi-layer structural design, in which the contact spring and the contact shell are integrated, which not only avoids the secondary contact of the spring, but also reduces the welding or riveting process of the spring, improves stability and efficiency, and solves the problem of insufficient elasticity caused by the excessive thickness of the contact spring in a single layer.

[0020] (3) In the preferred technical solution provided by the present invention, both the plug and the socket have double contact springs. The double spring contact increases the number of contact points, which can reduce contact resistance and improve reliability.

[0021] (4) In the preferred technical solution provided by the present invention, the concave surface of the reed is coated with an electromagnetic material, which generates a small positive pressure during the plug-in and plug-out process when the power is not turned on, thereby achieving a low plug-in and pull-out force, or even zero plug-in and pull-out force; after the plug-in is completed and the power is turned on, the electromagnetic material generates a magnetic adsorption force, which can increase the positive pressure to ensure good electrical conductivity, thereby realizing intelligent control of electrical contact and plug-in and pull-out force.

[0022] (5) In the preferred technical solution provided by the present invention, the shielding plastic of the high-voltage conductor adopts a plastic-graphite composite material instead of the conventional copper braided mesh and aluminum foil shielding layer, which can achieve 100% shielding and improve processing efficiency.

[0023] (6) In the preferred technical solution provided by the present invention, cold welding of the welding plate and the pre-stressed aluminum conductor can prevent galvanic corrosion, improve the pull-off force and reduce costs; cold welding does not cause the temperature of the weld joint to rise, and there is no obvious diffusion of interface atoms. The bonding of dissimilar metals is the intergranular occlusion formed by the interlocking fine grains at the interface. The interlocking fine grains increase the effective bonding area of the metals, making the cold welding have higher strength. At the same time, due to the low temperature, cold welding will not form a heat-affected zone and a brittle intermediate phase in the welding area. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0025] Figure 1This is a schematic diagram of the three-dimensional structure of the socket structure of the present invention after folding;

[0026] Figure 2 for Figure 1 A plan view of the socket structure before folding;

[0027] Figure 3 Schematic diagram of the structure of the high-voltage cable in the present invention;

[0028] Figure 4 for Figure 3 sectional view of ;

[0029] Figure 5 for Figure 3 Schematic diagram of the state of the high-voltage cable after pre-stressing;

[0030] Figure 6 for Figure 3 High voltage cables and Figure 1 Schematic diagram of the socket after welding;

[0031] Figure 7 This is a plan view of the plug structure of the present invention before folding;

[0032] Figure 8 for Figure 7 Schematic diagram of the three-dimensional structure of the plug structure after folding.

[0033] Description of Figure Numbers:

[0034] Outer structure 1: folding sheet giving way slot 1-1, connecting slot 1-2, connecting sheet 1-3, hanging hole 1-4, plug interface 1-5;

[0035] Inner spring structure 2: inner contact spring 2-0, inner and outer layer combined folded piece 2-1, connecting piece give way groove 2-2;

[0036] Outer layer reed structure 3: outer contact reed 3-0;

[0037] Outer layer spring piece 1 3-1, multi-layer combined folded piece 1 3-11, multi-layer combined folded piece yielding groove 2 3-12;

[0038] Outer layer reed second 3-2, multi-layer combined folded piece yielding groove one 3-21, multi-layer combined folded piece second 3-22;

[0039] Intermediate structure 4: conductor welding plate 5, welding rib 6, insulation layer tail 7;

[0040] High-voltage cable 8: outer insulation layer 8-1, shielding plastic layer 8-2, inner insulation layer 8-3, conductor 8-4. DETAILED DESCRIPTION

[0041] The following will be combined with the accompanying drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the core concept of the present invention and the following embodiments, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0042] The present application provides these embodiments to make this application thorough and complete, and to fully express the scope of this application to those skilled in the art. It should be noted that: unless otherwise specifically stated, the relative arrangement of parts and steps, the composition of materials, numerical expressions and numerical values set forth in these embodiments should be interpreted as merely exemplary, and not as limiting.

[0043] It should be noted that, in the description of this application, unless otherwise specified, "several" means greater than or equal to two; the terms "upper," "lower," "left," "right," "inner," "outer," "axial," "radial," and the like, indicating orientations or positional relationships, are intended solely to facilitate the description of this application and simplify the description, and do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this application. When the absolute position of the object being described changes, the relative positional relationship may also change accordingly.

[0044] In addition, the terms "first," "second," and similar terms used in this application do not denote any order, quantity, or importance, but are simply used to distinguish different parts. "Perpendicular" does not mean perpendicular in the strict sense, but rather means within the tolerance range. "Parallel" does not mean parallel in the strict sense, but rather means within the tolerance range. "Include" or "comprising" and similar terms mean that the elements preceding the word include the elements listed after the word, and do not exclude the possibility of other elements being included.

[0045] It should also be noted that in the description of this application, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be internal communication between two components. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to the specific circumstances. When a specific device is described as being located between a first device and a second device, there may or may not be an intermediate device between the specific device and the first device or the second device.

[0046] All terms used in this application have the same meaning as understood by one of ordinary skill in the art to which this application belongs, unless otherwise specifically defined. It should also be understood that terms defined in, for example, common dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant technology and should not be interpreted in an idealized or highly formal sense, unless explicitly defined as such herein.

[0047] Technologies, methods, and equipment known to ordinary technicians in the relevant art may not be discussed in detail, but where appropriate, the corresponding technologies, methods, and equipment should be considered part of the specification.

[0048] The purpose of the present invention is to provide an integrated folding connector, which is mainly used for the high-voltage electrical system of new energy vehicles. It is an integrated folding multi-layer structure and a transmission interconnection device with low insertion force and high reliability. The shell and the spring are directly folded, which reduces the process and can improve the application safety and stability of the high-voltage connector while ensuring simple processing.

[0049] The specific embodiments are as follows:

[0050] An integrated folding connector, such as Figure 2 and Figure 7 As shown, it includes an integrally stamped socket structure and an integrally stamped plug structure.

[0051] like Figure 1 and Figure 8 The socket structure is folded to form a cavity structure in which the outer layer structure 1 tightly wraps the inner layer spring structure 2 , and the plug structure is folded to form a superimposed structure in which the outer layer spring structure 3 clamps the middle structure 4 .

[0052] When the stacked structure is inserted into the cavity structure, the outer contact spring 3 - 0 in the outer layer spring structure 3 contacts the inner contact spring 2 - 0 in the inner layer spring structure 2 .

[0053] In this embodiment, the socket structure and the plug connector body are integrally stamped and formed, and the contact spring and the outer contact shell are integrally structured and formed in one piece. By folding, an integrated multi-layer structure is formed. Not only is the structure simple and easy to process and form, but the contact spring and the contact shell itself are integrated, which avoids secondary contact of the spring and reduces the welding or riveting process of the spring, thereby improving stability and efficiency. At the same time, it solves the problem of insufficient elasticity caused by the excessive thickness of the contact spring in a single layer, and achieves the effects of simple processing and reliable contact.

[0054] On the basis of the above embodiment, as a preferred embodiment of the integrated folding connector, Figure 2 and Figure 7As shown, the outer contact spring 3-0 and the inner contact spring 2-0 are both springs arranged obliquely along the plugging direction. When the stacked structure is inserted into the cavity structure, the outer contact spring 3-0 cross-contacts the inner contact spring 2-0.

[0055] That is, in this embodiment, the inclination direction of the outer contact spring 3-0 intersects with the inclination direction of the inner contact spring 2-0, which not only facilitates insertion and removal but also further improves contact reliability. Preferably, the cross-contact is a 90-degree contact, that is, the inclination direction of the outer contact spring 3-0 is perpendicular to the inclination direction of the inner contact spring 2-0. The cross-contact can be at other angles besides 90 degrees, but it must be ensured that the inclination direction of the outer contact spring 3-0 and the inclination direction of the inner contact spring 2-0 are not perpendicular to the insertion direction of the stacked structure, thereby ensuring convenient insertion.

[0056] Based on the above embodiment, as a preferred embodiment of the integrated folding connector, the concave surface of the outer layer spring structure 3 and the concave surface of the inner layer spring structure 2 are coated with electromagnetic material or provided with electromagnetic sheets, which are not shown in the figure.

[0057] In this embodiment, the outer contact spring 3-0 and the inner contact spring 2-0 are bonded together via their convex surfaces, creating positive pressure at the contact point. Excessive positive pressure can make plugging and unplugging difficult, and increasing plugging and unplugging cycles can affect the maintenance of positive pressure. However, too little positive pressure can make contact reliability difficult to ensure. Therefore, an electromagnetic material is coated on the concave surface of the spring. When power is off, the plug and socket generate a low positive pressure during insertion, achieving low or zero insertion force. Once plugged and receptacle are energized, the electromagnetic material generates magnetic attraction, increasing the positive pressure and ensuring good electrical conductivity.

[0058] Coating the electromagnetic material on the concave surface or attaching the electromagnetic sheet to the concave surface can avoid the friction caused by the plugging and unplugging process on the electromagnetic material or the electromagnetic sheet, fully ensuring the service life of the electromagnetic material or the electromagnetic sheet, and thus ensuring the service life of the entire connector.

[0059] On the basis of the above embodiment, as a preferred embodiment of the integrated folding connector, Figure 1 and Figure 6As shown, the cavity structure includes at least two insertion ports 1-5 for inserting the stacked structure. When the cavity structure includes two insertion ports, the two insertion ports 1-5 are arranged at 90 degrees relative to each other. This embodiment provides the cavity structure with multiple insertion ports 1-5, allowing the plug and socket to be plugged in at different angles. In addition, by setting different insertion ports 1-5 to different sizes, different connector plugs can be adapted.

[0060] On the basis of the above embodiment, as a preferred embodiment of the integrated folding connector, Figure 1 and Figure 6 As shown, the interior of the cavity structure is a rectangular parallelepiped cavity, and two inner-layer spring leaf structures 2 are provided, one located on two opposite sides of the rectangular parallelepiped. The outer contour of the laminated structure is a rectangular parallelepiped structure, and two outer-layer spring leaf structures 3 are provided, one located on two opposite sides of the rectangular parallelepiped structure.

[0061] This embodiment configures the socket with a dual-contact spring structure, creating more contact surfaces with the plug. These two contact surfaces are located in opposite directions, further reducing contact resistance and improving contact reliability. The rectangular interior of the cavity structure in this embodiment is merely a preferred embodiment; provided the plug and socket are compatible, the cavity structure can also adopt other shapes. Similarly, in addition to having two inner spring structures 2, other numbers, such as three or four, can be adaptively configured based on the shape of the cavity structure.

[0062] On the basis of the above embodiment, as a preferred embodiment of the integrated folding connector, Figure 2 As shown, an inner and outer layer combining folding piece 2-1 is provided at the edge of the inner layer structure of the cavity structure, a folding piece yielding groove 1-1 matching the inner and outer layer combining folding piece 2-1 is provided at the edge of the outer layer structure 1, a connecting groove 1-2 is provided at one end of the outer layer structure close to the inner layer structure, and a connecting piece 1-3 matching the connecting groove is provided at the end away from the inner layer structure, and a connecting piece yielding groove 2-2 for yielding to the connecting piece 1-3 is provided at the end of the inner layer structure away from the outer layer structure 1.

[0063] This embodiment provides a preferred stamping structure and folding method for the socket structure, and its forming process is: first fold 180 degrees in the opposite direction along line a, overlap line b-1 and line b-2, line c-1 and line c-2, line d-1 and line d-2, and then fold 90 degrees at a right angle along the overlapping line b-1 and line b-2 toward the spring leaf, then fold the overlapping line c-1 and line c-2 at a right angle in the forward direction, and finally fold the overlapping line d-1 and line d-2 at 90 degrees in the forward direction. All inner and outer folded sheets are folded outward 180 degrees along the folding sheet yield groove to fix the inner and outer layers to form a contact cavity.

[0064] Among them, the inner and outer layer combined folding pieces 2-1 are matched with the folding piece yielding groove 1-1 after being bent, and the connecting piece 1-3 is matched with the connecting piece yielding groove 2-2 and the connecting groove 1-2 in sequence after being bent, thereby ensuring that the inner layer structure and the outer layer structure are tightly fitted without gaps. At the same time, since the outer layer combined folding piece 2-1 and the connecting piece 1-3 are both bent outward, it can avoid that the inner and outer layer combined folding piece 2-1 and the connecting piece 1-3 are folded to affect the insertion space inside the cavity. This embodiment makes the inner wall of the cavity structure in a smooth state without any obstruction, thereby further improving the reliability of the connection between the plug and the socket.

[0065] On the basis of the above embodiment, as a preferred embodiment of the integrated folding connector, Figure 7 As shown, the outer layer spring structure 3 includes an outer layer spring 1 3-1 and an outer layer spring 2 3-2 located on both sides of the intermediate structure 4 respectively. The outer layer spring 1 3-1 and the outer layer spring 2 3-2 are folded in reverse to clamp the intermediate structure 4 in the middle.

[0066] This embodiment provides a preferred stamping structure and folding method of the plug structure, such as Figure 7 As shown, after the plane is stamped, the two sides are folded in reverse around the middle layer, that is, the plug structure forms an integrated three-layer folded structure through an integrated folding method, as shown in FIG. Figure 8 shown.

[0067] On the basis of the above embodiments, as a preferred embodiment of the integrated folding connector, the edge position of the outer layer spring piece 1 3-1 away from the intermediate structure 4 is provided with a multi-layer combined folding piece 1 3-11, and the edge position close to the intermediate structure 4 is provided with a multi-layer combined folding piece yielding groove 2 3-12; the edge position of the outer layer spring piece 2 3-2 away from the intermediate structure 4 is provided with a multi-layer combined folding piece 2 3-22 matching the multi-layer combined folding piece yielding groove 2 3-12, and the edge position close to the intermediate structure 4 is provided with a multi-layer combined folding piece yielding groove 1 3-21 matching the multi-layer combined folding piece 1 3-11.

[0068] This embodiment provides a preferred stamping structure and folding method of the plug structure, such as Figure 7 and Figure 8 As shown, when the outer layer spring piece 1 3-1 and the outer layer spring piece 2 3-2 are folded in opposite directions relative to the intermediate structure 4, the outer layer spring piece 1 3-1, the outer layer spring piece 2 3-2, and the intermediate structure 4 form a sandwich structure that fits together. Then, the multi-layer combined folding piece 1 3-11 and the multi-layer combined folding piece 2 3-22 are folded so that the multi-layer combined folding piece 1 3-11 mates with the multi-layer combined folding piece 1 groove 3-21 after bending, and the multi-layer combined folding piece 2 3-22 mates with the multi-layer combined folding piece 2 groove 3-12 after bending. Ultimately, the outer wall of the laminated structure formed by the folding of the plug structure is smooth and unobstructed, further improving the reliability of the connection between the plug and the socket.

[0069] On the basis of the above embodiment, as a preferred embodiment of the integrated folding connector, Figure 1 and Figure 2 As shown, the outer structure 1 is provided with attachment holes 1-4 for connecting to the connector sheath. The attachment holes 1-4 are preferably rectangular, and at least two attachment holes 1-4 are provided on the outer structure 1. The socket structure and the plug structure are respectively connected to a conductor welding plate 5, each of which is provided with welding ribs 6 and an insulation layer tail 7. The conductor welding plate 5 is used to weld the conductor of the high-voltage cable 8, and the welding ribs 6 are used to increase the strength of the weld.

[0070] On the basis of the above embodiment, as a preferred embodiment of the integrated folding connector, Figures 3 to 6 As shown, the conductor welding plate 5 is connected to the high-voltage cable 8. The insulation layer of the high-voltage cable 8 includes an outer insulation layer 8-1, a shielding plastic layer 8-2, and an inner insulation layer 8-3 which are sequentially sleeved from the outside to the inside.

[0071] The shielding plastic layer 8-2 is a composite material composed of plastic and graphite. The inner insulating layer 8-3 wraps around the conductor 8-4, which is a copper or aluminum conductor. The exposed end of the conductor 8-4 is pre-pressed into a rectangular shape and then cold-welded to the conductor welding plate 5. The insulation layer tail 7 is crimped to the insulation layer.

[0072] Preferably, the pre-pressed conductor 8 - 4 and the conductor welding plate 5 are placed in a cold pressing die, a pressure of 1500-2000 MPa is applied, and a welding connection is formed under a cold pressing welding process with 3 upsetting times.

[0073] Any details not provided in the present invention are conventional technical means known to those skilled in the art.

[0074] The above content shows and describes the basic principles, main features and beneficial effects of the present invention. The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention shall be included in the scope of protection of the present invention.

Claims

1. One-piece folding connector, characterized by: The invention comprises an integrally stamped socket structure and an integrally stamped plug structure. The socket structure is folded to form a cavity structure in which an outer layer structure tightly wraps an inner layer spring structure. The plug structure is folded to form a superimposed structure in which the outer layer spring structure clamps the intermediate structure. When the superimposed structure is inserted into the cavity structure, the outer contact spring in the outer layer spring structure contacts the inner contact spring in the inner layer spring structure. The interior of the cavity structure is a rectangular parallelepiped cavity, the inner layer spring leaf structures are provided with two, and the two inner layer spring leaf structures are respectively located on two opposite sides of the rectangular parallelepiped. The outer contour of the stacked structure is a rectangular parallelepiped structure, the outer layer spring leaf structures are provided with two, and the two outer layer spring leaf structures are respectively located on two opposite sides of the rectangular parallelepiped structure. The edge of the inner layer structure of the cavity structure is provided with an inner and outer layer combined folding sheet, and the edge of the outer layer structure is provided with a folding sheet yielding groove matching the inner and outer layer combined folding sheet; The concave surface of the outer layer reed structure and the concave surface of the inner layer reed structure are coated with electromagnetic material or attached with electromagnetic sheets; The socket structure and the plug structure are respectively connected with conductor welding plates. The exposed ends of the conductors are pre-pressed into a rectangular shape and then cold-pressed and welded to the conductor welding plates.

2. The integrated folding connector according to claim 1, wherein: The outer contact spring and the inner contact spring are both arranged obliquely along the insertion direction. When the stacked structure is inserted into the cavity structure, the outer contact spring crosses and contacts the inner contact spring.

3. The integrated folding connector according to claim 1, wherein: The cavity structure includes at least two plug-in ports for inserting the stacked structure; when the cavity structure includes two plug-in ports, the two plug-in ports are arranged at 90 degrees relative to each other.

4. The integrated folding connector according to any one of claims 1 to 3, characterized in that: The outer layer structure is provided with a connecting groove at one end close to the inner layer structure, and a connecting piece matching the connecting groove is provided at the end away from the inner layer structure; the inner layer structure is provided with a connecting piece giving way groove for giving way to the connecting piece at one end away from the outer layer structure.

5. The integrated folding connector according to claim 4, characterized in that: The outer layer spring structure comprises an outer layer spring leaf 1 and an outer layer spring leaf 2 respectively located on both sides of the intermediate structure. The outer layer spring leaf 1 and the outer layer spring leaf 2 are folded in opposite directions to clamp the intermediate structure in the middle.

6. The integrated folding connector according to claim 5, characterized in that: The edge position of the outer layer spring piece 1 away from the intermediate structure is provided with a multi-layer combined folding piece 1, and the edge position close to the intermediate structure is provided with a multi-layer combined folding piece yielding groove 2. The edge position of the outer layer spring piece 2 away from the intermediate structure is provided with a multi-layer combined folding piece 2 matching the multi-layer combined folding piece yielding groove 2, and the edge position close to the intermediate structure is provided with a multi-layer combined folding piece yielding groove 1 matching the multi-layer combined folding piece 1.

7. The integrated folding connector according to any one of claims 1 to 3, 5 and 6, characterized in that: The outer structure is provided with a hanging hole for connecting with the connector sheath, and the conductor welding plates are provided with welding ribs and insulation layer pressing tails.

8. The integrated folding connector according to claim 7, wherein: The conductor welding plate is connected to a high-voltage cable. The insulation layer of the high-voltage cable includes an outer insulation layer, a shielding plastic layer, and an inner insulation layer, which are sequentially arranged from the outside to the inside. The shielding plastic layer is a composite material of plastic and graphite. The inner insulation layer wraps the conductor, and the insulation layer tail is crimped to the insulation layer.

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