Power connector and assembling method

Abstract

The invention provides a power connector and an assembling method thereof. The power supply connector comprises a jack socket and a plug which can be connected together. The socket receptacle includes an insulative socket receptacle housing, an electrically conductive body, and a lock attached to the body but also movable relative to the body. The main body and the locking member are seated within the socket receptacle housing. The locking member has a top portion and a rear portion angled relative to each other, and the rear portion has an opening therethrough. The plug comprises a plug housing and a conductive pin. The pin passes through the main body and is engaged with the rear portion of the locking member in a locked state.

Description

[0001] Related applications

[0002] This application claims the benefit of Indian Provisional Application 202321027925, filed on April 17, 2023, and Indian Provisional Application 202441019868, filed on March 18, 2024, each of which is incorporated herein by reference in its entirety. Background Technology

[0003] Power connectors are used in high-current, high-voltage energy storage and power distribution units. Such power connectors can be used in high-power applications such as computers, data servers, bus applications, and electric vehicle (EV) systems. Summary of the Invention

[0004] A power connector and its assembly method are provided.

[0005] In one embodiment, the power connector includes a socket and a plug that can be connected together. The socket includes an insulated socket housing, a conductive body, and a locking member attached to the body but movable relative to it. The body and the locking member are located within the socket housing. The locking member has a top and a rear portion angled relative to each other, and the rear portion has an opening therethrough. The plug includes a plug housing and a conductive pin. The pin passes through the body and engages with the rear portion of the locking member in a locked state.

[0006] In one embodiment, the pin can be released from the locking member.

[0007] A method for assembling a power connector is provided. The method includes: inserting a conductive pin into a channel of a conductive body having a flexible locking member thereon, the locking member having a top and a rear portion angled relative to each other, the top engaging the body, the rear portion having an opening therethrough that partially obscures the channel; engaging a free end of the pin with the rear portion of the locking member, thereby causing the locking member to move relative to the body; passing the free end of the pin through the locking member; and engaging the locking member with a shank of the pin. Attached Figure Description

[0008] Many aspects of this disclosure can be better understood by referring to the accompanying drawings. The components in the drawings are not necessarily drawn to scale, but the emphasis is on clearly illustrating the principles of this disclosure. Furthermore, in the drawings, the same reference numerals denote corresponding parts throughout several views.

[0009] Figure 1A perspective view of a power connector according to various aspects of the present disclosure is shown, the power connector being mounted on a substrate.

[0010] Figure 2 An exploded perspective view shows a power connector and a substrate to which the power connector is attached.

[0011] Figure 3 An exploded perspective view shows a socket and a terminal of a power connector.

[0012] Figure 4 A perspective view of an assembled socket body with sockets and terminals is shown, wherein a locking element is disassembled from the assembled socket body.

[0013] Figure 5 A side view of the locking mechanism is shown.

[0014] Figure 6 This shows a cross-sectional view of the socket and terminals before they are assembled with a plug of the power connector.

[0015] Figures 7 to 10 The diagram shows a cross-sectional view of the socket, terminals, and plug during assembly.

[0016] Figure 11 and Figure 12 The diagram shows a cross-sectional view of the socket, terminals, and plug during disassembly. Detailed Implementation

[0017] While this disclosure can be readily embodied in various forms of implementation, specific embodiments are shown in the accompanying drawings and will be described in detail herein. It is understood that this disclosure should be considered as an example of the principles of this disclosure and is not intended to limit it to what is shown and described herein. Thus, unless otherwise stated, the features disclosed herein may be combined to form other combinations not given for purposes of simplicity. It will be further appreciated that in some embodiments, one or more components illustrated by way of example in the drawings may be removed and / or replaced with alternative components within the scope of this disclosure.

[0018] This disclosure relates to a power connector 20 for high-current, high-voltage energy storage and power distribution units. The power connector 20 can be used in high-power applications such as computers, data servers, bus applications, and electric vehicle (EV) systems.

[0019] The power connector 20 includes a socket receptacle 22 in which a terminal 24 is mounted, and a plug 26 configured to mate with the terminal 24. The socket receptacle 22 includes an insulated socket receptacle housing 28, a conductive socket 30, and a locking element 32. The plug 26 includes an insulated plug housing 34 and a conductive pin 36. The pin 36 is located within the terminal 24 and is releasably locked to the socket 30 by the locking element 32.

[0020] like Figure 1 and Figure 2 As shown, the socket housing 28 has a top wall 38, a front wall 40 and a rear wall 42 extending downward from the top wall 38, and opposing side walls 44, 46 extending between the front wall 40 and the rear wall 42. The top wall 38, the front wall 40 and the rear wall 42, and the opposing side walls 44, 46 define a cavity 48 that is open at one end therein. The cavity 48 opens to the bottom of the socket housing 28. The top wall 38 includes a fastener 50 that can be pressed into the cavity 48 to flex inward relative to the remainder of the top wall 38. The front wall 40 has an opening 52 through it, communicating with the cavity 48. A chamfer 54 extends from the front surface of the front wall 40 to the opening 52. Each of the side walls 44, 46 has a fastener 56 thereon, each fastener 56 having a barb extending into the cavity 48. Fastener 56 is able to flex outward relative to the remaining portion of sidewalls 44 and 46.

[0021] like Figure 4 As best shown, the socket 30 includes an upper portion 58 and a lower portion 60 extending from a lower end of the upper portion 58. The upper portion 58 has a top surface 62, an opposing bottom surface 64, a front surface 66, an opposing rear surface 68, and side surfaces 70, 72 extending between the front surface 66 and the rear surface 68. Each side surface 70, 72 has an elongated slot 74 extending from the rear surface 68 at its lower end. The lower portion 60 may be a threaded shank. An elongated slot 76 is provided on the top surface 62 and extends parallel to the front surface 66. The slot 76 may extend between the two side surfaces 70, 72. A step 78 is provided in a middle portion of the slot 76. A cylindrical wall forms a pin receiving channel 80 that extends through the socket 30 from the front surface 66 to the rear surface 68. An axial centerline of the socket 30 is defined between the front surface 66 and the rear surface 68. A chamfer 80a is provided at the entrance on the front surface 66 of the pin receiving channel 80. A countersunk hole 80b is provided on the rear surface 68 surrounding the exit of the pin receiving channel 80.

[0022] The locking member 32 is formed as a flexible spring and may be made of stainless steel. The locking member 32 has a rear portion 84 and a top 86 extending from an upper end of the rear portion 84. The top 86 has a front lip 88 extending from its front end. Before assembly with the socket 30, as... Figure 5 As shown, the rear portion 84 and the top portion 86 are preferably at a non-orthogonal angle A relative to each other, for example, an angle of 82 degrees, but they may also be orthogonal. The front lip 88 has a length significantly smaller than that of the rear portion 84. The rear portion 84 includes an opening 90 extending through it. A top edge 92 of the opening 90 may be straight, and a lower edge 94 of the opening 90 may be generally U-shaped. The lower edge 94 has a rounded edge 94a on a front side of the rear portion 84. The front lip 88 has a central notch 96 that generally reflects the shape of the step 78.

[0023] like Figure 1 and Figure 2 As shown, terminal 24 includes a conductive contact 98 and a conductive cap 100. Contact 98 is formed by an annular connection 102, with a plurality of spaced-apart flexible beams 104 cantilevered from the annular connection 102, thereby forming a channel 106 extending from a front end to a rear end of contact 98 within them. In one embodiment, the connection 102 is discontinuous on its circumference, thus a slot is provided. In one embodiment, the connection 102 has a plurality of spaced-apart protrusions extending from its rear end. The plurality of flexible beams 104 extend from one end of the connection 102, and each beam 104 is generally parallel to and radially spaced from an axial centerline of contact 98. The plurality of beams 104 are spaced apart from each other around the circumference of the connection 102. Each beam 104 may have: a first portion extending at an angle from the connecting portion 102 at a corner; and a second portion extending at an angle from one end of the first portion at a corner. The first portion is inclined inward toward the axial centerline, and the second portion is inclined outward relative to the axial centerline. Multiple corners may be rounded and aligned around the circumference of the contact member 98, defining an inner diameter. The cap body 100 has: an annular first wall 108 defining an opening forming part of the channel 106; and a second wall 110 extending radially outward from and perpendicular to the first wall 108.

[0024] like Figure 6As shown, the contact 98 is situated within the channel 80 of the socket 30 such that the rear end of the contact 98 is substantially aligned with the rear end of the socket 30, the front end of the contact 98 is spaced apart from the front end of the socket 30, and the axial centerline of the socket 30 is aligned with the axial centerline of the contact 98. An outer surface of the connecting portion 102 abuts against an inner surface of the wall forming the pin receiving channel 80 of the socket 30. A cap 100 secures the socket 30 and the contact 98 together. In one embodiment, the cap 100 is press-fitted to the socket 30 and press-fitted to the contact 98. In another embodiment, the cap 100 is press-fitted to the socket 30 and press-fitted to the contact 98. The wall 108 of the cap 100 engages against the inner surface of the connecting portion 102. The wall 110 is situated within the countersunk hole 80b. Other means for attaching the contact 98 to the socket 30 are within the scope of this disclosure.

[0025] Locking member 32 is seated on socket 30. The rear portion 84 of locking member 32 extends along and engages with the rear surface 68 of socket 30, the top portion 86 of locking member 32 extends close to the top surface 62 of socket 30, and the front lip 88 of locking member 32 is seated within groove 76. The rear portion 84 and the top portion 86 form an angle greater than ninety (90) degrees relative to each other. The central notch 96 of the front lip 88 engages with the step 78 of groove 76 in an interference fit to secure locking member 32 to socket 30. Wall 110 is located between the rear portion 84 of locking member 32 and the rear surface 68 of socket 30.

[0026] A socket 30, having terminals 24 and locking elements 32 mounted thereon, is inserted into the cavity 48 of a socket housing 28 through the bottom end of an opening. The socket 30 and terminals 24 form a conductive body. A fastener 56 flexes outward to allow the upper portion 58 of the socket 30 to slide into the cavity 48. After the upper portion 58 of the socket 30 passes over the barb on the fastener 56, the fastener 56 returns to its initial state and the barb engages within a slot 74 of the upper portion 58 to prevent the socket 30 from moving within the cavity 48. A lower portion 60 extends downward from the socket housing 28. The lower surface of the fastener 50 on the top wall 38 of the socket housing 28 can engage with the upper surface of the top 86 of the locking element 32. The front surface 66 of the upper portion 58 of the socket 30 rests against the front wall 40 of the socket housing 28, and the axial channel 80 of the socket 30 is aligned with the opening 52 on the socket housing 28. A space 132 is provided between the rear portion 84 and the rear wall 42 of the socket 22 for the circular end 128 to be seated therein.

[0027] like Figure 6As shown, before assembly with plug 26, a portion of the opening 90 on the rear portion 84 of locking member 32 is aligned with the channel 106 of terminal 24, and a bottom of the lower edge 94 of opening 90 is above a bottom of the channel 106 of terminal 24, so that a portion of the channel 106 of terminal 24 is partially obscured in the axial direction.

[0028] like Figure 1 and Figure 2 As shown, the plug housing 34 includes a front wall 112 and a side wall 114 extending rearward from the front wall 112. The front wall 112 has an opening 116 therethrough, and the two walls 112, 114 define a cavity 118 therein that opens to a rear end of the plug housing 34. An axial centerline extends from the front wall 112 to the rear end of the plug housing 34. The opening 116 communicates with the cavity 118. The side wall 114 is shown in a cylindrical shape, but the side wall 114 can take other forms, such as, for example, a square cross-section. A plurality of spaced-apart flexible arms 120 extend inwardly from the side wall 114 into the cavity 118. The plurality of flexible arms 120 extend in the direction of the axial centerline of the plug housing 34.

[0029] In one embodiment, the pin 36 has a shank formed by a front portion 122 and a rear portion 124 extending from a rear end of the front portion 122. Each of the front portion 122 and the rear portion 124 may be cylindrical, and a flange 126 extends radially outward from the front end of the rear portion 124. The front portion 122 has a diameter smaller than that of the rear portion 124. The inner diameter defined by the corner of the contact member 98 is smaller than the diameter of the front portion 122 of the pin 36. The front portion 122 has a circular free end 128, which may be hemispherical. A groove 130, which may be annular, extends approximately around at least a portion of the circumference of the front portion 122 near the circular free end 128. The rear portion 124 may have a cavity therein extending from its rear end.

[0030] To assemble the pin 36 with the plug housing 34, the free end 128 of the pin 36 is inserted through the rear end, through the cavity 118, and then through the front opening 116. The front portion 122 extends in front of the front wall 112 of the plug housing 34. The flange 126 engages a plurality of arms 120 and causes the plurality of arms 120 to move toward the side wall 114. Once the flange 126 has passed the plurality of arms 120, the plurality of arms 120 return to their initial state and engage the rear end of the flange 126. This secures the pin 36 to the plug housing 34.

[0031] To form the power connector 20, the plug 26 is inserted into the socket 22, such as... Figures 7 to 10 As shown. Locking member 32 is initially in an unflexed state, as... Figure 6 and Figure 7As shown. The free end 128 of the pin 36 passes through the opening 52 at the front end of the socket 22 and through the entrance of the pin receiving channel 80. Two chamfers 54, 80a assist in guiding the pin 36 into the channel 106 of the terminal 24. As the pin 36 is further pushed into the socket 22, the free end 128 of the pin 36 engages with a plurality of flexible beams 104 and causes the plurality of beams 104 to flex outward, see [reference]. Figure 7 As the pin 36 is further pushed into the socket 22, with the plurality of corner engagement front portions 122, the front portion 122 of the pin 36 passes through the plurality of beams 104, and the rounded free end 128 engages with the lower edge 94 of the rear portion 84 of the locking member 32, see [link to relevant documentation]. Figure 8 As the pin 36 is further pushed into the socket 22, the rounded free end 128 causes the rear portion 84 to move vertically downward and places the locking member 32 in a flexed state. See [reference needed] Figure 9 The opening 90 on the rear portion 84 is sized such that the top edge 92 of the opening 90 does not engage with the rounded end 128 of the pin 36. A rounded edge 94a on the front side of the lower edge 94 assists in this movement of the rear portion 84. The rounded end 128 passes through the opening 90, and once the slot 130 is aligned with the rear portion 84, the locking member 32 returns to its unbent state, and the lower edge 94 sits within the slot 130. See [reference needed]. Figure 10 This causes the locking element 32 to move into a locked state. The rounded end 128 sits within the space 132. As a result, the locking element 32 locks the plug 26 into the socket 22.

[0032] By pressing down the fastener 50 on the socket housing 28, the plug 26 can be released from the socket 22, as... Figure 10 and Figure 11 As shown. The depressed fastener 50 engages the top 86 of the locking member 32, causing the rear 84 of the locking member 32 to move downward and out of the slot 130, see... Figure 11 And enter a locked-out state. The top edge 92 of the opening 90 does not engage with the pin 36. Once the lower edge 94 of the opening 90 on the rear part 84 of the locking member 32 is no longer in the slot 130, the pin 36 can be axially pulled out of the socket 22, see Figure 12 .

[0033] The lower portion 60 of the connector 30 is mounted on a substrate 134, such as a printed circuit board or a bus. Figure 2In this design, substrate 134 is shown as a printed circuit board, wherein a conductive contact pad 136 on an upper surface of substrate 134 surrounds a plated conductive through-hole 138. In the case of the printed circuit board, the bottom surface 64 of socket 30 contacts the contact pad 136, and the lower portion 60 of socket 30 extends into the through-hole 138. If a bus is provided as substrate 134, the bus has a through-hole (similar to through-hole 138), the lower portion 60 of socket 30 extends through this through-hole, and the bottom surface 64 of socket 30 contacts a mating surface of the bus surrounding the through-hole. If the lower portion 60 of socket 30 is threaded, a washer 140 and a nut 142 can be secured to the opposite side of substrate 134 to mount socket 22 onto substrate 134. The pins 36 of plug 26 are electrically connected to another component (not shown). Current travels through the pins 36 of the plug 26, through the terminals 24, through the socket 30, and to the substrate 134. The contact between the bottom surface 64 of the socket 30 and the contact pads 136 provides a large contact surface between the socket 30 and the substrate 134 for current transmission.

[0034] Although the socket 30 and the terminal 24 are described and shown as two separate parts forming a conductive body, the socket 30 and the terminal 24 can be formed as a single piece.

[0035] This disclosure enables the provision of a right-angle screw mount for the power connector 20.

[0036] Directional terms such as front, back, horizontal, and vertical are used for convenience of explanation, but do not indicate the posture required in use.

[0037] While specific embodiments are shown and illustrated in the accompanying drawings, it is contemplated that those skilled in the art can devise various modifications without departing from the spirit and scope of the appended claims. Therefore, it will be appreciated that the scope of this disclosure and the appended claims is not limited to the specific embodiments shown and illustrated in the drawings, and that modifications and other embodiments will be included within the scope of this disclosure and the appended drawings. Furthermore, although the foregoing description and associated drawings illustrate exemplary embodiments in the context of certain exemplary combinations of elements and / or functions, it should be recognized that different combinations of elements and / or functions may be provided by alternative embodiments without departing from the scope of this disclosure and the appended claims. Moreover, the foregoing description illustrates a method of performing multiple steps. Unless stated to the contrary, one or more steps in a method may be optional, one or more steps may be performed in a different order than described, and one or more steps may be performed substantially simultaneously. Finally, the drawings are not necessarily drawn to scale.

Claims

1. A power connector, comprising: A socket includes a socket housing, a conductive body, and a locking member, the locking member being connected to the body and movable relative to the body. The socket housing includes a cavity in which the main body and the locking member are located. The main body has a channel running through it, and The locking member has a top and a rear portion that are angled relative to each other; the top portion engages the body, and the rear portion has an opening therethrough. as well as A plug includes a plug housing and a conductive pin extending from the plug housing, wherein the pin is situated within the channel and passes through the opening to engage with the rear of the locking member in a locked state.

2. The power connector as claimed in claim 1, wherein, Before the pin is assembled with the locking member, the rear portion of the locking member partially obscures one rear end of the channel.

3. The power connector as described in claim 2, wherein, The lower edge of the opening through the locking member has a chamfer.

4. The power connector as claimed in claim 1, wherein, The pin includes a groove in which the rear portion of the locking member is located when the locking member is in a locked state.

5. The power connector as claimed in claim 4, wherein, Before the pin is assembled with the locking member, the rear portion of the locking member partially obscures one rear end of the channel.

6. The power connector as claimed in claim 5, wherein, The socket housing includes a pressable fastener that engages with the top of the locking member when the locking member is moved to a locked-out state.

7. The power connector as claimed in claim 1, wherein, The socket housing includes a pressable fastener that engages with the top of the locking member when the locking member is moved to a locked-out state.

8. The power connector as claimed in claim 1, wherein, The main body includes a socket and a terminal installed in the socket, the terminal having multiple flexible beams.

9. The power connector as claimed in claim 1, wherein, Both the socket housing and the plug housing are made of insulating material.

10. The power connector as claimed in claim 1, wherein, The locking element is made of stainless steel.

11. The power connector as claimed in claim 1, wherein, Before being assembled with the main body, the top and the rear are angled relative to each other at an angle of 82 degrees.

12. The power connector as claimed in claim 1, wherein, Before being assembled with the main body, the top and the rear are angled relative to each other at an angle of less than 90 degrees, and after being assembled with the main body, the top and the rear are angled relative to each other at an angle of greater than 90 degrees.

13. The power connector as claimed in claim 1, wherein, The top also includes a front lip that extends downward and engages with a top surface of the body.

14. The power connector as claimed in claim 13, wherein, The front lip is positioned within a groove of the body with an interference fit.

15. The power connector as claimed in claim 1, wherein, The main body has a lower portion that can be connected to a substrate.

16. The power connector as claimed in claim 15, wherein, The lower part is threaded.

17. The power connector as claimed in claim 1, wherein, The rear end of the main body and the rear end of the locking member are spaced apart from a rear wall of the socket housing by a space. Furthermore, in the locked state, one free end of the pin is situated within the space.

18. The power connector as claimed in claim 1, wherein, The locking element is a spring.

19. A method of assembling a power connector, comprising: A conductive pin is inserted into a channel of a conductive body having a flexible locking member thereon, the locking member having a top and a rear portion that are angled relative to each other, the top engaging the body, and the rear portion having an opening that extends through and partially obscures the channel. as well as One free end of the pin engages with the rear of the locking member, thereby allowing the locking member to move relative to the body; The free end of the pin passes through the locking element; as well as Engage the locking member with one shank of the pin.

20. The method of claim 19, further comprising: The pin is removed from the body by pressing down a fastener that engages with the locking element.

Images