High-tolerance connector

Abstract

The invention belongs to the field of connectors, and discloses a high-tolerance type connector, which comprises a cable with an exposed conductive area at the end part, and a connector, an insertion cavity is formed in one end of the conductive assembly, an elastic conductive part is arranged on the inner side of the insertion cavity, and the end of the cable can be inserted into the insertion cavity in the first direction and is in elastic contact and conductive connection with the elastic conductive part; the first shell and the second shell are detachably connected, the first shell is fixedly arranged on the outer side of the conductive assembly, and the second shell covers the outer side of the end part of the cable. At least part of the second shell is configured to be a flexible part which can stretch out and draw back in the first direction and / or can deviate towards the periphery relative to the first direction, so that the plugging position of the end portion of the cable and the plugging cavity can deviate in the first direction. And / or the actual plugging direction of the end part of the cable and the conductive assembly can be shifted relative to the first direction. According to the invention, self-adaptive adjustment of the connector can be realized, and the connector has relatively high tolerance capability.

Description

Technical Field

[0001] The present invention relates to the technical field of connectors, and more particularly to a high-tolerance connector. Background Art

[0002] The connector is used to plug into the mating connector. The existing connector usually includes a shell, a terminal arranged in the shell and a cable. One end of the cable is inserted into the shell and connected to the terminal, and the other end is connected to the corresponding electrical component such as a charging seat. However, when the cable is made of a hard cable such as an aluminum busbar, based on the installation difference of the cable, the connector and the mating connector may be offset when plugged in, resulting in the cable being forced to be bent / stretched before the connector and the mating connector can be plugged in. Improper bending / stretching of the cable will generate a large force, affecting the normal operation of the cable, the connector as a whole and the corresponding electrical components, and easily causing structural damage, sealing failure and other problems. In addition, due to the existence of the installation difference, the hard cable is difficult to be bent / stretched, which also brings great trouble to the installation.

[0003] Therefore, it is necessary to develop connectors that can adaptively adjust to tolerate installation differences. Summary of the invention

[0004] The invention provides a high-tolerance connector to solve the problem that the existing connector cannot perform adaptive adjustment according to the installation difference.

[0005] The present invention provides a high-tolerance connector, comprising: a cable, wherein the end of the cable has an exposed conductive area; a conductive component, wherein one end of the conductive component matched with the cable is formed with a plug-in cavity for plugging the end of the cable, and an elastic conductive member is provided on the inner side of the plug-in cavity, and the end of the cable can be plugged into the plug-in cavity along a first direction so that the conductive area at least partially contacts the elastic conductive member elastically, so as to achieve a conductive connection between the cable and the conductive component; a shell, wherein the shell comprises a first shell fixedly arranged on the outside of at least part of the conductive component, and a second shell covered on the outside of the end of the cable, one end of the second shell is detachably connected to the first shell, and the other end is installed on the outside of the cable, so as to insulate and seal the conductive component and the end of the cable after the end of the cable is plugged into the plug-in cavity; the second shell is at least partially constructed as a flexible part that can be extended and retracted along the first direction and / or can be offset to all sides relative to the first direction, so that the plug-in position of the end of the cable and the plug-in cavity can be offset along the first direction, and / or the actual plug-in direction of the end of the cable and the conductive component can be offset relative to the first direction.

[0006] Optionally, the cable is a flat-belt structure, and the cross-section of the plug-in cavity and the cross-section of the end of the cable in the first direction are adapted and both are rectangular.

[0007] Optionally, at least one set of limiting parts for limiting the actual plugging direction of the end of the cable is symmetrically arranged on the inner walls of the plug-in cavity on both sides of the first direction.

[0008] Optionally, a plurality of limit portions are arranged at intervals along the first direction, and the end of the cable is a tapered structure that gradually shrinks inward along its extension direction on the offset plane. When the end of the cable is offset relative to the first direction, the tapered structure is positioned and matched with the corresponding limit portion to limit the extreme position of the actual plug-in direction of the end of the cable.

[0009] Optionally, elastic conductive parts are respectively provided on the two inner walls of the plug-in cavity where the limiting part is not provided, and the elastic conductive parts on the two inner walls are arranged opposite to each other, and the end of the cable is clamped between the opposite elastic conductive parts after being plugged into the plug-in cavity.

[0010] Optionally, the elastic conductive member includes a leaf spring structure and a plurality of spring claws with ends cantilevered and arranged on the leaf spring structure, and the plurality of spring claws elastically abut against the conductive area to achieve a conductive connection between the end of the cable and the conductive component.

[0011] Optionally, the plurality of spring claws are arranged in at least two groups at intervals in the first direction, and the cantilevered ends of at least two adjacent groups of spring claws are arranged opposite to each other in the first direction.

[0012] Optionally, the second shell includes a connecting part, a transition part and a wearing part connected in sequence, the transition part constitutes the flexible part, the connecting part is detachably connected to the first shell and sealed, and the wearing part can be slidably worn on the outside of the cable and sealed.

[0013] Optionally, one of the two opposite inner side walls of the insertion portion is provided with a blind hole, and the other is provided with a mounting hole, a bolt is passed through the mounting hole, a thread is provided on the inner wall of the blind hole, a positioning hole is provided on the cable, and the positioning hole is a long hole structure extending along the extension direction of the cable, the head of the bolt has an insulating cap, and the tail passes through the mounting hole and the positioning hole in sequence and then cooperates with the blind hole thread, and the bolt cooperates with the two end stops in the extension direction of the positioning hole to limit the sliding distance of the cable relative to the insertion portion.

[0014] Optionally, when the bolt and the positioning hole are stopped at one end of the plug-in cavity, the end of the cable has a predetermined distance from the bottom of the plug-in cavity, and the distance between the elastic contact portion of the elastic conductive part and the bottom of the plug-in cavity is not less than the predetermined distance.

[0015] Optionally, the transition part is made of deformable synthetic rubber and is connected to the connecting part and the wearing part through a secondary injection molding process.

[0016] Optionally, the conductive component includes a converter and a terminal, the terminal is fixedly disposed at one end of the converter, the plug-in cavity is disposed at an end of the converter away from the terminal, and at least a portion of the converter between the two ends is fixedly connected to the first shell.

[0017] Optionally, the adapter body is integrally stamped from a copper plate; or, the adapter is integrally stamped from a copper-aluminum composite plate, and the adapter is provided with a copper layer at least in an area in contact with the terminal and in an area in the plug-in cavity for providing an elastic conductive member.

[0018] Optionally, the cable includes an aluminum wire body and a copper contact body fixedly arranged at the end of the wire body, and the outer side of the contact body constitutes a conductive area; the other end of the second shell is installed on the outer side of the wire body.

[0019] The present invention has at least the following beneficial effects:

[0020] In the present invention, the other end of the conductive component is no longer rigidly connected to the end of the cable, but is movably connected through the plug-in cavity and the elastic conductive part, thereby avoiding the need to force the cable to bend / stretch under installation differences, realizing adaptive adjustment of the connector, having a higher tolerance capability, and preventing damage to the conductive component, shell and cable due to improper assembly position. The second shell, which is at least partially a flexible structure, can also adaptively surround and protect the ends of the conductive component and the cable, meeting the needs of adaptive adjustment of the connector and ensuring the protective effect.

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

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

[0023] Figure 1 It is a schematic diagram of the structure of the connector and the mating connector (unplugged);

[0024] Figure 2 is a schematic diagram of the structure after the conductive component is assembled with the first shell;

[0025] Figure 3 A schematic diagram of the structure of a conductive component from one perspective;

[0026] Figure 4 A schematic diagram of the structure of the conductive component from another perspective;

[0027] Figure 5 It is a schematic diagram of the partial cross-section structure of the conductive component passing through the plug-in cavity;

[0028] Figure 6 is a schematic diagram of the cable structure;

[0029] Figure 7 is a schematic structural diagram of the second shell;

[0030] Figure 8 is a schematic diagram of a cutaway structure of the second shell;

[0031] Fig. 9 is another schematic diagram of the cutaway structure of the second shell;

[0032] Fig.10 This is a schematic diagram of the assembly steps of the high tolerance connector;

[0033] Fig.11 It is a schematic diagram of the structure of the assembled high-tolerance connector;

[0034] Fig.12 It is a schematic diagram of the structure of a high-tolerance connector under the first limit state;

[0035] Fig.13 for Fig.12 A schematic diagram of a cutaway structure;

[0036] Fig.14 for Fig.12 Another schematic diagram of a cross-section structure;

[0037] Fig.15 It is a schematic diagram of the structure of a high-tolerance connector under the second limit state;

[0038] Fig.16 for Fig.15 A schematic diagram of a cutaway structure;

[0039] Fig.17 for Fig.15 Another schematic diagram of a cross-section structure;

[0040] Fig.18 It is a schematic diagram of the structure of a high-tolerance connector under the third limit state;

[0041] Fig.19 for Fig.18 A schematic diagram of a cutaway structure;

[0042] Fig. 20 for Fig.18 Another schematic diagram of a cross-section structure;

[0043] Fig.21 It is a schematic diagram of the structure of a high-tolerance connector under the fourth limit state;

[0044] Fig. 22 for Fig.21A schematic diagram of a cutaway structure;

[0045] Fig.23 for Fig.21 Another schematic diagram of a cross-section structure;

[0046] Fig.24 It is a schematic diagram of the structure of a high-tolerance connector under the fifth limit state;

[0047] Fig.25 for Fig.24 A schematic diagram of a cutaway structure;

[0048] Fig.26 for Fig.24 Another schematic diagram of a cross-section structure;

[0049] Fig. 27 It is a schematic diagram of the structure of a high-tolerance connector under the sixth limit state;

[0050] Fig.28 for Fig. 27 A schematic diagram of a cutaway structure;

[0051] Fig.29 for Fig. 27 Another schematic diagram of the cross-section structure of .

[0052] The following are marked in the figure:

[0053] 1. High tolerance connector;

[0054] 11. first housing; 111. conductive component; 112. card stand; 113. first sealing ring;

[0055] 12, second housing; 121, connecting portion; 1211, buckle; 122, adapter; 123, wearing portion; 1231, second sealing ring; 1232, mounting hole; 1233, blind hole; 124, bolt; 1241, insulating cap; 125, third sealing ring;

[0056] 13. Terminal;

[0057] 14. adapter body; 141. plug-in cavity; 142. plug-in interface; 143. limiter; 144. positioning portion;

[0058] 15. elastic conductive member; 151. spring leaf structure; 152. spring claw;

[0059] 16. Cable; 161. Contact body; 162. Tapered structure; 163. Line body; 164. Insulation layer; 165. Positioning hole;

[0060] 2. Mating connectors. DETAILED DESCRIPTION

[0061] Various exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that the relative arrangement of components and steps, numerical expressions and numerical values ​​set forth in these embodiments do not limit the scope of the present invention unless otherwise specifically stated.

[0062] The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses.

[0063] Technologies, methods, and equipment known to ordinary technicians in the relevant art may not be discussed in detail, but where appropriate, the technologies, methods, and equipment should be considered as part of the specification.

[0064] In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not limiting. Therefore, other examples of the exemplary embodiments may have different values.

[0065] like Figure 1-29 As shown, an embodiment of the present invention provides a high-tolerance connector 1 that can be plugged into a mating connector 2, including a cable 16, a conductive component 111, and a housing, wherein:

[0066] The cable 16 has an exposed conductive area at its end. In actual installation, the cable 16 is fixed to the vehicle body by conventional fixing devices such as wire clamps;

[0067] Conductive component 111, one end of the conductive component 111 that matches with the cable 16 is formed with an insertion cavity 141 for inserting the end of the cable 16, and an elastic conductive member 15 is provided inside the insertion cavity 141. The end of the cable 16 can be inserted into the insertion cavity 141 along the first direction A so that the conductive area at least partially contacts the elastic conductive member 15 elastically, so as to achieve a conductive connection between the cable 16 and the conductive component 111;

[0068] The housing includes a first housing 11 fixedly disposed on the outside of at least part of the conductive component 111, and a second housing 12 covered on the outside of the end of the cable 16, one end of the second housing 12 is detachably connected to the first housing 11, and the other end is installed on the outside of the cable 16, so as to insulate and seal the conductive component 111 and the end of the cable 16 after the end of the cable 16 is inserted into the insertion cavity 141;

[0069] The second shell 12 is at least partially constructed as a flexible part that can be extended and retracted along the first direction A and / or can be shifted in all directions relative to the first direction A, so that the plug-in position of the end of the cable 16 and the plug-in cavity 141 can be shifted along the first direction A, and / or the actual plug-in direction B of the end of the cable 16 and the conductive component 111 can be shifted relative to the first direction A.

[0070] In this solution, the other end of the conductive component 111 is no longer rigidly connected to the end of the cable 16, but is movably connected through the plug-in cavity 141 and the elastic conductive part 15, thereby avoiding the need to force the cable 16 to bend / stretch under installation differences, achieving adaptive adjustment of the connector, and having a high tolerance capability to prevent damage to the conductive component 111, the shell and the cable 16 due to improper assembly position. The second shell 12, which is at least partially a flexible structure, can also adaptively surround and protect the ends of the conductive component 111 and the cable 16, meeting the needs of adaptive adjustment of the connector and ensuring the protective effect.

[0071] Specifically, in consideration of possible deviation directions in actual applications and in order to minimize manufacturing difficulty and cost, in this embodiment, the flexible portion of the second shell 12 is constructed to be able to expand and contract along the first direction A and to be able to deflect in all directions relative to the first direction A.

[0072] Obviously, in other embodiments, the flexible portion of the second shell can be extended and retracted along the first direction A, or can be offset in all directions relative to the first direction A, both of which can achieve the purpose of movably connecting the conductive component and the end of the cable in this solution.

[0073] Furthermore, the problem to be solved by this solution will only occur when the cable 16 is a hard cable 16, and combined with common application scenarios, such as Figure 6 As shown, in this embodiment, the cable 16 is a flat belt structure, and the cross-section of the plug cavity 141 and the cross-section of the end of the cable 16 (ie, the contact body 161 described below) in the first direction A are adapted and both are rectangular. Figure 12-29 As shown, in this embodiment, the end of the cable 16 can be offset between two relatively far sides of the rectangle, namely the second direction C and the third direction D, and the end of the cable 16 can also be offset in the first direction A.

[0074] Furthermore, in order to limit the deviation of the end of the cable 16 so that the end of the cable 16 can deviate within a predetermined range, at least one set of limiting parts 143 for limiting the actual insertion direction B of the end of the cable 16 is symmetrically provided on the inner walls of the insertion cavity 141 on both sides of the first direction A. Figure 5 As shown, in this embodiment, the limiting portion 143 is specifically located on two inner walls of the plug-in cavity 141 that are relatively far away from each other.

[0075] Furthermore, in order to ensure that the end of the cable 16 can be limited in different actual plug-in directions B, a plurality of groups of limiting portions 143 are arranged at intervals along the first direction A, such as Figure 5 As shown, in this embodiment, in combination with processing technology factors, in the first direction A, two groups of limiting portions 143 are provided on each inner wall and are located at two end positions respectively.

[0076] The end of the cable 16 is a tapered structure 162 that gradually shrinks inward along its extension direction on the offset plane. When the end of the cable 16 is offset relative to the first direction A, the tapered structure 162 is positioned and matched with the corresponding limit portion 143 to limit the extreme position of the actual plug-in direction B of the end of the cable 16. Obviously, the setting of the tapered structure 162 expands the angle range between the actual plug-in direction B and the first direction A.

[0077] Furthermore, in order to make the elastic conductive member 15 more stably conductively contact with the conductive area at the end of the cable 16 and meet the greater current carrying requirements, such as Figure 2-5 As shown, in this embodiment, elastic conductive members 15 are respectively provided on the two inner walls of the plug-in cavity 141 where the limiting portion 143 is not provided, and the elastic conductive members 15 on the two inner walls are arranged opposite to each other. After the end of the cable 16 is inserted into the plug-in cavity 141, it is clamped between the relative elastic conductive members 15.

[0078] Furthermore, in order to position the end of the cable 16 between the opposite elastic conductive members 15 and avoid the end of the cable 16 from deviating toward the elastic conductive member 15 on one of the inner walls, causing the elastic conductive member 15 to be crushed, as shown in FIG. Figure 5 As shown, in this embodiment, a plurality of positioning portions 144 are distributed on the two inner walls of the plug-in cavity 141 where the limiting portions 143 are not provided. After the end of the cable 16 is inserted into the plug-in cavity 141, the end of the cable 16 is clamped and positioned by the positioning portions 144, so that the end of the cable 16 can be offset between the relative first limiting portions 143, that is, it can be offset along the second direction C and the third direction D, and it can also be offset along the first direction A, but it cannot be offset between the two inner walls of the plug-in cavity 141 where the limiting portions 143 are not provided.

[0079] Furthermore, in order to make the elastic conductive member 15 easy to fix, not affect the plugging and unplugging, and have good contact ability, as Figure 5 As shown, in this embodiment, the elastic conductive member 15 includes a spring structure 151 and a plurality of spring claws 152 with their ends cantilevered and arranged on the spring structure 151. The plurality of spring claws 152 elastically abut against the conductive area to achieve a conductive connection between the end of the cable 16 and the conductive component 111. The spring structure 151 is fixed to the corresponding inner wall of the plug-in cavity 141 by laser welding or riveting technology.

[0080] Furthermore, in order to ensure that the spring claws 152 maintain good contact capability when the end of the cable 16 is offset, the plurality of spring claws 152 are arranged in at least two groups at intervals in the first direction A, and the overhanging ends of at least two adjacent groups of spring claws 152 are arranged opposite to each other in the first direction A, so that the contact points are more concentrated. Figure 5As shown, in this embodiment, two groups of spring claws 152 are disposed on each spring leaf structure 151 , and the overhanging ends of the two groups of spring claws 152 are disposed opposite to each other in the first direction A.

[0081] Furthermore, considering the reasonable manufacturing process and ensuring the good connection and protection effect of the second shell 12, as shown in FIG. Figure 7-9 As shown, in this embodiment, the second shell 12 includes a connecting portion 121, a transition portion 122 and a wearing portion 123 which are connected in sequence, the transition portion 122 constitutes the above-mentioned flexible portion, the connecting portion 121 is detachably connected to the first shell 11 and sealed, and the wearing portion 123 can be slidably worn on the outside of the cable 16 and sealed.

[0082] For specific sealing fits, such as Figure 7-10 As shown, in this embodiment, a first sealing ring 113 is fixedly installed on the outer side of the end of the first shell 11. After the connecting part 121 is detachably connected to the first shell 11, the first sealing ring 113 is sealed with the inner wall of the connecting part 121; a second sealing ring 1231 is fixedly installed on the inner wall of the wearing part 123, and the second sealing ring 1231 is sealed with the outer side of the cable 16.

[0083] For the detachable connection between the connecting portion 121 and the first housing 11, as shown in FIG. Figure 2 and Figure 7 , Fig. 9 As shown, in this embodiment, a buckle 1211 is provided at the end of the connecting portion 121 , and a clamping platform 112 is provided on the first shell 11 . The buckle 1211 is clamped with the clamping platform 112 to achieve a detachable connection between the connecting portion 121 and the first shell 11 .

[0084] Furthermore, in order to limit the sliding distance of the cable 16 relative to the insertion portion 123, the cable 16 is prevented from sliding and causing the end of the cable 16 to escape from the insertion cavity 141 or hit the bottom of the insertion cavity 141. Figure 7-13As shown, in this embodiment, one of the two inner side walls opposite to each other of the insertion portion 123 is provided with a blind hole 1233, and the other is provided with a mounting hole 1232, a bolt 124 is inserted into the mounting hole 1232, a thread is provided on the inner wall of the blind hole 1233, and a positioning hole 165 is provided on the cable 16, and the positioning hole 165 is a long hole structure extending in the extension direction of the cable 16, the head of the bolt 124 has an insulating cap 1241, and the tail passes through the mounting hole 1232 and the positioning hole 165 in sequence and then cooperates with the blind hole 1233 thread, and is in the second housing After the first shell 12 is connected to the first shell 11 and the end of the cable 16 is inserted into the plug-in cavity 141, the bolts 124 respectively cooperate with the two end stops of the positioning hole 165 in the extension direction to limit the sliding distance of the cable 16 relative to the insertion portion 123. The sliding distance, that is, the extension length L3 of the positioning hole 165 is not greater than the depth H of the plug-in cavity 141 from the plug-in interface 142 to the bottom. In addition, in order to achieve the sealing between the insulating cap 1241 and the outer side of the cable 16, a third sealing ring 125 is also provided between the insulating cap 1241 and the outer side of the cable 16.

[0085] Furthermore, in order to ensure that the end of the cable 16 can maintain good conductive contact with the elastic conductive member 15, as Fig.13 As shown, in this embodiment, when the bolt 124 and the positioning hole 165 are stopped near one end of the plug-in cavity 141, the end of the cable 16 has a predetermined distance L1 from the bottom of the plug-in cavity 141, and the distance L2 between the elastic contact portion of the elastic conductive part 15 and the bottom of the plug-in cavity 141 is not less than the predetermined distance L1.

[0086] Furthermore, in combination with insulation, flexibility, weather resistance and other properties, in this embodiment, the adapter part 122 is made of deformable synthetic rubber and is connected to the connecting part 121 and the wearing part 123 through a secondary injection molding process. The first shell 11, the connecting part 121 and the wearing part 123 are made of conventional plastics in the field. The above-mentioned synthetic rubber is also called thermoplastic elastomer (TPE, Thermoplastic Elastomer) or artificial rubber, which is an existing material. The appropriate model or component can be selected according to specific flexibility requirements.

[0087] In addition, in this embodiment, combined with the above description, the flexible part of the second shell 12, namely the adapter part 122, is constructed to be able to expand and contract along the first direction A and to be able to deflect in all directions relative to the first direction A. However, based on the limiting effect of the bolts 124 in the above-mentioned second shell 12 on the sliding of the cable 16 relative to the insertion part 123, in this embodiment, the adapter part 122 is set to have a deformation ability of expansion and contraction in the first direction A that is weaker than the deformation ability of deflection in all directions relative to the first direction A. This setting can be achieved by adjusting the wall thickness of the adapter part 122, adjusting the length in the first direction A, and selecting a material model that is soft and hard compatible. This is a technology that can be easily implemented by technical personnel in this field through existing conventional technologies according to needs, so it will not be discussed in detail.

[0088] Furthermore, in order to adapt and plug with the mating connector 2, combined with the commonly used structures in the field, such as Figure 2-5 As shown, in this embodiment, the conductive component 111 includes a transfer body 14 and a terminal 13, the terminal 13 is fixedly disposed at one end of the transfer body 14, the plug-in cavity 141 is disposed at the end of the transfer body 14 away from the terminal 13, and the two ends of the transfer body 14 are at least partially fixedly connected to the first shell 11. In this embodiment, the transfer body 14 is embedded in the first shell 11 by injection molding to achieve a fixed connection between the transfer body 14 and the first shell 11, and the terminal 13 can be fixed to one end of the transfer body 14 by a riveting process.

[0089] Furthermore, the adapter 14 can be integrally stamped from a copper sheet and bent into a suitable shape having a plug-in cavity 141. Before bending, the elastic conductive member 15 can be fixed at a corresponding position by laser spot welding or riveting or other fixing processes; or, as a cost-reduction measure to replace copper sheets with copper-aluminum composite plates to reduce the amount of copper material and ensure the conductivity of the conductive connection, the adapter can also be integrally stamped from a copper-aluminum composite plate and then bent into a suitable shape having a plug-in cavity 141. Before bending, the elastic conductive member 15 can be fixed at a corresponding position by laser spot welding or riveting or other fixing processes. At the same time, the adapter should be provided with a copper layer at least in the area in contact with the terminal 13 and in the area in the plug-in cavity 141 for setting the elastic conductive member 15.

[0090] The above-mentioned copper plate, copper-aluminum composite plate, and integrated stamping, bending, and fixing processes are all existing technologies, and the final structure of the adapter 14 is mainly involved here.

[0091] Furthermore, as a cost-reduction measure, the amount of copper material used is reduced and the conductivity of the conductive connection is ensured, such as Figure 6 As shown, in this embodiment, the cable 16 includes an aluminum wire body 163 and a copper contact body 161 fixedly arranged at the end of the wire body 163, and the outer side of the contact body 161 constitutes a conductive area; the other end of the second shell 12 is installed on the outer side of the wire body 163, specifically, the outer side of the insulating layer 164 on the wire body 163.

[0092] In addition, if Figure 6 As shown, in this embodiment, the end of the wire body 163 exposes a portion of the aluminum conductor, the positioning hole 165 is arranged on the portion of the aluminum conductor, the contact body 161 is fixedly connected to the end of the wire body 163 by welding, and the contact body 161 is arranged as the tapered structure 162 mentioned above. In addition, the width of the wire body 163 is larger than that of the contact body 161 to meet the current carrying capacity requirements.

[0093] like Figure 1As shown, in this embodiment, the high-tolerance connector 1 is provided with two groups, and the two groups of high-tolerance connectors 1 are detachably assembled into a connecting component through a bolt structure and then adapted to be plugged with the mating connector 2. Thus, when the mating connector 2 is fixed on the vehicle body, after the high-tolerance connector 1 is assembled, when the cable 16 is fixed on the vehicle body and the end away from the conductive component 111 is connected to the corresponding electrical device, due to the actual installation difference, the conductive component 111 and the shell of the high-tolerance connector 1 may need to be offset before they can be plugged with the mating connector 2, and then, the connection between the end of the cable 16 and the conductive component 111 will be offset. The plug-in cavity 141 structure of this scheme can well solve the offset connection problem and realize the adaptive adjustment and high tolerance capability of the connector.

[0094] The assembly process of this high tolerance connector 1 is as follows:

[0095] like Figure 10-11 As shown, after the conductive component 111 and the first shell 11 have been pre-assembled and processed, S1, first, the insertion portion 123 is inserted on the wire body 163 to complete the pre-installation of the second shell 12 and the cable 16; S2, the end of the cable 16, that is, the contact body 161, is inserted into the plug-in cavity 141 along the first direction A, and the contact body 161 is clamped and positioned by the positioning portion 144, and the elastic conductive member 15 is conductively connected to the conductive area on the contact body 161; S3, then the second shell 12 is pushed to connect the connecting portion 121 to the first shell 11; S4, finally, the tail of the bolt 124 is passed through the mounting hole 1232 and the positioning hole 165 in turn and then threadedly matched with the blind hole 1233 to complete the assembly.

[0096] The high tolerance effect and adaptive adjustment capability of the high tolerance connector 1 are further illustrated below by using the extreme assembly states of the high tolerance connector 1 and the mating connector 2 under different installation difference situations.

[0097] 1. The first limit state.

[0098] like Figure 12-14 As shown, after the high-tolerance connector 1 is plugged into the mating connector 2 (not shown), the contact body 161 is located in the middle between the relative limit portions 143, the relative positioning portions 144 clamp and position the contact body 161, and the elastic conductive member 15 is in conductive contact with the contact body 161, the bolt 124 is stop-fitted with the positioning hole 165 at one end close to the plug-in cavity 141, and at this time, the contact body 161 is not offset along the first direction A, and is not offset to the second direction C or the third direction D relative to the first direction A, and the adapter 122 is not significantly deformed.

[0099] 2. The second limit state.

[0100] like Figure 15-17As shown, relative to the first extreme plug-in state, after the high-tolerance connector 1 is plugged into the mating connector 2 (not shown), the contact body 161 undergoes an extreme displacement along the second direction C between the relative limiting portions 143, but does not undergo a displacement along the first direction A until the contact body 161 abuts against the corresponding limiting portion 143 near the plug-in port 142, forming an actual plug-in direction B of the contact body 161. At this time, the relative positioning portions 144 clamp and position the contact body 161, and the elastic conductive member 15 is in conductive contact with the contact body 161, the bolt 124 is blocked and matched with the positioning hole 165 at one end near the plug-in cavity 141, and the adapter portion 122 undergoes adaptive deformation.

[0101] 3. The third limit state.

[0102] like Figure 18-20 As shown, relative to the first extreme plug-in state, after the high-tolerance connector 1 is plugged into the mating connector 2 (not shown), the contact body 161 undergoes an extreme displacement along the third direction D between the relative limiting portions 143, but does not undergo an displacement along the first direction A until the contact body 161 abuts against the corresponding limiting portion 143 near the plug-in port 142, forming an actual plug-in direction B of the contact body 161. At this time, the relative positioning portions 144 clamp and position the contact body 161, and the elastic conductive member 15 is in conductive contact with the contact body 161, the bolt 124 is blocked and matched with the end of the positioning hole 165 near the plug-in cavity 141, and the adapter portion 122 undergoes adaptive deformation.

[0103] 4. The fourth limit state.

[0104] like Figure 21-23 As shown, relative to the first extreme plug-in state, after the high-tolerance connector 1 is plugged into the mating connector 2 (not shown), the contact body 161 is located in the middle between the relative limit portions 143, the relative positioning portions 144 clamp and position the contact body 161, and the elastic conductive member 15 is in conductive contact with the contact body 161, the bolt 124 is blocked and matched with the positioning hole 165 at one end away from the plug-in cavity 141, and at this time, the contact body 161 is extremely displaced along the first direction A, but is not displaced toward the second direction C or the third direction D relative to the first direction A, and the adapter 122 is not significantly deformed.

[0105] 5. The fifth limit state.

[0106] like Figure 24-26As shown, relative to the first extreme plug-in state, after the high-tolerance connector 1 is plugged into the mating connector 2 (not shown), the contact body 161 undergoes an extreme displacement along the second direction C between the relative limiting portions 143, and simultaneously undergoes an extreme displacement along the first direction A, until the contact body 161 abuts against the corresponding limiting portion 143 away from the plug-in port 142, forming an actual plug-in direction B of the contact body 161. At this time, the relative positioning portions 144 clamp and position the contact body 161, and the elastic conductive member 15 is in conductive contact with the contact body 161, the bolt 124 is blocked and matched with the end of the positioning hole 165 away from the plug-in cavity 141, and the adapter portion 122 undergoes adaptive deformation.

[0107] 6. The sixth limit state.

[0108] like Figure 27-29 As shown, relative to the first extreme plug-in state, after the high-tolerance connector 1 is plugged into the mating connector 2 (not shown), the contact body 161 undergoes an extreme displacement along the third direction D between the relative limiting portions 143, and simultaneously undergoes an extreme displacement along the first direction A, until the contact body 161 abuts against the corresponding limiting portion 143 away from the plug-in port 142, forming an actual plug-in direction B of the contact body 161. At this time, the relative positioning portions 144 clamp and position the contact body 161, and the elastic conductive member 15 is in conductive contact with the contact body 161, the bolt 124 is blocked and matched with the end of the positioning hole 165 away from the plug-in cavity 141, and the adapter portion 122 undergoes adaptive deformation.

[0109] Obviously, based on the above six extreme states, the actual plugging direction B and the specific stop position of the contact body 161 of the high tolerance connector 1 in the plugging cavity 141 can be adjusted accordingly within the range defined by each extreme state according to actual conditions.

[0110] Although some specific embodiments of the present invention have been described in detail by way of example, it will be appreciated by those skilled in the art that the above examples are for illustration only and are not intended to limit the scope of the present invention. It will be appreciated by those skilled in the art that the above embodiments may be modified without departing from the scope and spirit of the present invention. The scope of the present invention is defined by the appended claims.

Claims

1. A high tolerance connector, characterized in that: include: A cable having an exposed conductive area at an end thereof; A conductive component, wherein one end of the conductive component that matches the cable is formed with an insertion cavity for inserting the end of the cable, and an elastic conductive member is provided inside the insertion cavity. The end of the cable can be inserted into the insertion cavity along a first direction so that the conductive area at least partially contacts the elastic conductive member elastically, so as to achieve a conductive connection between the cable and the conductive component; The housing includes a first shell fixedly arranged outside at least part of the conductive component, and a second shell covered outside the end of the cable, one end of the second shell is detachably connected to the first shell, and the other end is installed outside the cable, so as to insulate and seal the conductive component and the end of the cable after the end of the cable is inserted into the insertion cavity; The second shell is at least partially constructed as a flexible part that can be extended and retracted along a first direction and / or can be shifted in all directions relative to the first direction, so that the plug-in position of the end of the cable and the plug-in cavity can be shifted along the first direction, and / or the actual plug-in direction of the end of the cable and the conductive component can be shifted relative to the first direction.

2. A high tolerance connector as claimed in claim 1, characterized in that: The cable is a flat-belt structure, and the cross-section of the plug-in cavity and the cross-section of the end of the cable in the first direction are adapted and both are rectangular.

3. A high tolerance connector as claimed in claim 2, characterized in that: At least one set of limiting parts for limiting the actual plugging direction of the end of the cable is symmetrically arranged on the inner walls of the plugging cavity on both sides of the first direction.

4. A high tolerance connector as claimed in claim 3, characterized in that: The limiting portions are arranged in multiple groups at intervals along the first direction, and the end of the cable is a tapered structure that gradually shrinks inward along its extension direction on the offset plane. When the end of the cable is offset relative to the first direction, the tapered structure is positioned and matched with the corresponding limiting portion to limit the extreme position of the actual plug-in direction of the end of the cable.

5. A high tolerance connector as claimed in claim 3, characterized in that: Elastic conductive members are respectively arranged on the two inner walls of the plug-in cavity where the limiting portion is not arranged, and the elastic conductive members on the two inner walls are arranged opposite to each other. After the end of the cable is plugged into the plug-in cavity, it is clamped between the opposite elastic conductive members.

6. A high tolerance connector as claimed in claim 5, characterized in that: The elastic conductive member includes a leaf spring structure and a plurality of spring claws with overhanging ends arranged on the leaf spring structure. The plurality of spring claws elastically abut against the conductive area to achieve conductive connection between the end of the cable and the conductive component.

7. A high tolerance connector as claimed in claim 6, characterized in that: The plurality of spring claws are arranged in at least two groups at intervals in the first direction, and the overhanging ends of at least two adjacent groups of spring claws are arranged opposite to each other in the first direction.

8. A high tolerance connector as claimed in claim 1, characterized in that: The second shell includes a connecting part, a transition part and a wearing part which are connected in sequence, the transition part constitutes the flexible part, the connecting part is detachably connected to the first shell and sealed, and the wearing part can be slidably worn on the outside of the cable and sealed.

9. A high tolerance connector as claimed in claim 8, characterized in that: The two opposite inner side walls of the insertion portion are provided with a blind hole on one and a mounting hole on the other, a bolt is passed through the mounting hole, a thread is provided on the inner wall of the blind hole, a positioning hole is provided on the cable, and the positioning hole is a long hole structure extending along the extension direction of the cable. The head of the bolt has an insulating cap, and the tail passes through the mounting hole and the positioning hole in sequence and then cooperates with the blind hole thread. The bolt cooperates with the two end stops in the extension direction of the positioning hole to limit the sliding distance of the cable relative to the insertion portion.

10. A high tolerance connector as claimed in claim 9, characterized in that: When the bolt and the positioning hole are stopped at one end close to the plug-in cavity, the end of the cable has a predetermined distance from the bottom of the plug-in cavity, and the distance between the elastic contact portion of the elastic conductive part and the bottom of the plug-in cavity is not less than the predetermined distance.

11. A high tolerance connector as claimed in claim 8, characterized in that: The transition part is made of deformable synthetic rubber and is connected with the connecting part and the wearing part through a secondary injection molding process.

12. A high tolerance connector as claimed in claim 1, characterized in that: The conductive component includes a transfer body and a terminal. The terminal is fixedly arranged at one end of the transfer body. The insertion cavity is arranged at one end of the transfer body away from the terminal. At least a portion between the two ends of the transfer body is fixedly connected to the first shell.

13. A high tolerance connector as claimed in claim 12, characterized in that: The adapter body is integrally stamped from a copper plate; or, the adapter is integrally stamped from a copper-aluminum composite plate, and the adapter is provided with a copper layer at least in the area in contact with the terminal and in the area in the plug-in cavity for providing an elastic conductive member.

14. A high tolerance connector as claimed in claim 1, characterized in that: The cable includes an aluminum wire body and a copper contact body fixedly arranged at the end of the wire body, and the outer side of the contact body constitutes a conductive area; the other end of the second shell is installed on the outer side of the wire body.

Images