All-insulation quick snap-in lead clamp and production process thereof

Abstract

The invention relates to an all-insulation rapid occlusion connection lead wire clamp and a production process thereof, the all-insulation rapid occlusion connection lead wire clamp comprises a base, a middle body and a gland, the middle body comprises a middle block and a plurality of thorn pieces, the thorn pieces are arranged in the middle block in an up-and-down penetrating mode, the base is arranged below the middle body, the gland is arranged above the middle body, and the middle block is arranged above the gland. The middle body and the pressing cover are arranged on the base, a branch line hole is defined between the middle body and the base, a main line hole is defined between the middle body and the pressing cover, and the stabbing pieces in the middle body extend out towards the main line hole and the branch line hole respectively. No matter how large the line diameters of the main line and the branch line are combined, it can be guaranteed that the stabbing pieces pierce the center of the conductor.

Description

TECHNICAL FIELD

[0001] The present application relates to a kind of electric power fittings, especially a kind of full insulation quick engagement terminal wire clamp and its production process, belong to electric power connection technical field. BACKGROUND

[0002] In power system, in order to realize the reliable connection of main line and branch circuit, while ensuring the safety and insulation performance of circuit, piercing clamp is widely used as an important connecting device.The traditional piercing clamp structure adopts the structure of horizontal arrangement of main and branch line, there are insufficient insulation performance, installation wire is easy to deflect, structure is bulky, manufacturing cost is high, installation is complex, easy to damage and other problems, especially in humid or high voltage environment, these problems are particularly prominent.Therefore, a kind of full insulation quick engagement terminal wire clamp with simple structure, light, stable installation quality, convenient installation and excellent insulation performance is proposed to meet market demand. SUMMARY

[0003] In view of the above shortcomings, the present application provides a kind of full insulation quick engagement terminal wire clamp and its processing technology.

[0004] In order to achieve the above purpose, the present application adopts a kind of full insulation quick engagement terminal wire clamp, including base, intermediate body, gland, the intermediate body includes intermediate block and multiple pieces of thorn sheet, the thorn sheet is arranged in the intermediate block up and down, the base is arranged below the intermediate body, the gland is arranged above the intermediate body, the intermediate body and the base form a branch hole, the intermediate body and the gland form a main line hole, the thorn sheet in the intermediate body respectively towards the main line hole and the branch hole extends.

[0005] The present application adopts up and down arrangement structure relative to traditional horizontal arrangement clamp wire, can ensure that the main branch line diameter no matter how big the combination can ensure that the thorn sheet pierces into the positive center of conductor, solve the problem that the thorn sheet cannot all pierce into the conductor and appear bad contact when traditional product main branch line is installed due to the large deviation of main line and branch line diameter, lead to clamping angle and deflection, ensure that the installation quality of various main branch line various combination diameter is stable and reliable, good universality and better performance;Up and down arrangement structure relative to horizontal arrangement structure, structure is more compact, current conduction is faster, under the same thorn sheet quantity, its structure is smaller, manufacturing cost is about 50% lower than traditional structure;Thorn sheet adopts up and down arrangement structure, structure is compact, relative to traditional structure material utilization is higher, more economical, energy saving and consumption reduction.

[0006] In particular, the intermediate body further includes an insulating elastomer, and the insulating elastomer wraps the thorn sheet. The thorn sheet is insulated by a TPE integral encapsulation process using an insulating elastomer material. The insulating elastomer ensures that the thorn sheet is insulated and waterproof after piercing into the wire, ensuring long-term normal operation of the circuit.

[0007] Specifically, the lower side of the pressure cap forms an arc-shaped upper main wire groove, the upper side of the base forms an arc-shaped lower branch wire groove, the upper side of the intermediate body forms an arc-shaped lower main wire groove, and the lower side of the intermediate body forms an arc-shaped upper branch wire groove. The upper and lower main wire grooves constitute the main wire hole, and the upper and lower branch wire grooves constitute the branch wire hole. Multiple spikes are formed at the upper and lower ends of the spikes, and these spikes are arranged in an arc shape along the lower main wire groove and the upper branch wire groove, respectively. The base, pressure cap, and intermediate body are modularly configured and can be freely combined into wire clamps according to different wire diameters, facilitating production and management. If grounding is required, a grounding ring can be added.

[0008] Specifically, both the base and the pressure cap are integrally molded using an alloy insert encased in engineering plastic. Bolt holes penetrating the alloy insert are formed on both sides of both the base and the pressure cap. Intermediate sleeves coaxial with the bolt holes are provided on both sides of the intermediate block. Bolts are provided on both sides of the base, and torque nuts are provided on both sides of the pressure cap. The bolts pass through the bolt holes in the base, the intermediate sleeves, and the bolt holes in the pressure cap, and connect to the torque nuts, thus connecting the base and the pressure cap together. The base and pressure cap, integrally molded using an alloy insert encased in engineering plastic and connected by bolts and torque nuts, provide stronger support and are more stable and reliable.

[0009] Specifically, the bolt is integrally molded within the base, and the bolt holes of the base and the gland are formed with sleeves that can be fitted onto both ends of the intermediate sleeve. Insulating covers are provided on both sides of the gland, covering the torque nut. The insulating covers can be opened and closed to seal the exposed metal parts of the bolt and nut, ensuring complete insulation. Simultaneously, the base, gland, and intermediate block all have structures to cover the bolts, ensuring that the bolts are not exposed, providing complete insulation and preventing foreign objects from adhering to them.

[0010] Specifically, an opening is provided on the side of the bolt hole on one side of the pressure cap, and the outer side of the insulating cover is hinged to the pressure cap. The insulating covers are connected to each other by snap-fit ​​devices. The opening allows the pressure cap to be opened directly without the nut disengaging from the bolt, and the main cable can be directly inserted into the main cable hole.

[0011] This invention also includes a manufacturing process for producing the above-mentioned fully insulated quick-engaging lead clamp, comprising: Step 1: Stamp the alloy insert, then perform surface micro-arc oxidation on the formed alloy insert and spray an epoxy resin insulating layer. Step 2: The alloy inserts, bolts, and engineering plastics are bonded together using injection molding to form the base; the alloy inserts and engineering plastics are bonded together using injection molding to form the pressure cap. Step 3: injection molding the insulating cover by using engineering plastics; Step 4: injection molding the intermediate block, and riveting the stab blade integrally by an automatic riveting press, and placing the stab blade into a rubber coating mold by a mechanical hand to perform full insulation rubber coating processing on the stab blade; Step 5: assembling the intermediate body and the gland to the base through a torque nut, and performing overall immersion coating of insulating silicon grease after installation.

[0012] The process of the present application solves the problem of easy peeling of the metal-plastic interface of the traditional wire clamp by synchronous molding of micro-arc oxidation and injection molding when the alloy insert is combined with engineering plastics; and realizes full insulation performance by triple protection of injection molding of the insulating cover, spraying of epoxy resin, and immersion coating of silicon grease through composite insulation processing.

[0013] In particular, the full insulation rubber coating processing adopts segmented temperature control, the initial temperature is 80 DEG C, pre-pressing for 30 seconds, the temperature is raised to 150 DEG C, and pressurized curing for 2 minutes, and cooling to 50 DEG C for demolding.

[0014] The present application also includes a stab blade production process, comprising the following steps: Base preparation: using high-purity oxygen-free copper for multi-pass low-temperature rolling to obtain ultra-fine grain copper strip with grain size≥ASTM 13 level, and punching the ultra-fine grain copper strip into a stab blade; Composite reinforced coating: depositing a nickel-tungsten carbide gradient coating on the blade edge of the stab blade by pulse plating, the coating thickness is 15-20 μm, and the surface hardness is HV 650-800; High-conductivity structure forming: etching a bionic sharkskin microgroove array with a depth of 50-80 μm on the surface of the stab blade by femtosecond laser, the groove density is 200-300 / mm²; Conductive optimization processing: growing a 2-5 nm thick graphene film in the microgroove by atomic layer deposition to form a three-dimensional conductive network, and the contact resistance is≤5 μΩ.

[0015] In particular, the low-temperature rolling is performed in an environment with a temperature≤-150 DEG C, and the rolling rate is≤0.5 m / min.

[0016] The stab blade process of the present application improves the blade edge hardness of the stab blade, while reducing the contact resistance, and ensures the conductive performance of the wire clamp. BRIEF DESCRIPTION OF DRAWINGS

[0017] Figure 1 is a schematic diagram of embodiment one of the present application.

[0018] Figure 2 is an exploded view of embodiment one of the present application.

[0019] Figure 3 is an exploded view of the intermediate body of embodiment one of the present application.

[0020] Figure 4 This is a cross-sectional view of the base according to a specific embodiment of the present invention.

[0021] Figure 5 This is a cross-sectional view of the pressure cap according to a specific embodiment of the present invention.

[0022] Figure 6 This is a schematic diagram of a specific embodiment two of the present invention. Detailed Implementation

[0023] like Figures 1-5 As shown, a specific embodiment of the present invention is a fully insulated quick-connecting lead clamp, including a base 1, an intermediate body 2, and a pressure cap 3. The base 1 includes an alloy insert 11 and a bolt 14. The base 1 is integrally molded with engineering plastic over the alloy insert 11 and the bolt 14. The pressure cap 3 is integrally molded with an alloy insert 31 covered with engineering plastic. The intermediate body 2 includes an intermediate block 21 and multiple barbs 22. The intermediate block 21 is provided with multiple strip grooves 211 for installing and fixing the barbs 22. The barbs 22 are arranged vertically through the strip grooves 211 of the intermediate block 21. The barbs 22 are wrapped with an insulating elastomer 23 to achieve full insulation. The number of barbs 22 can be freely configured according to the current carrying capacity of the installed wire.

[0024] The base 1 is positioned below the intermediate body 2, and the pressure cap 3 is positioned above the intermediate body 2. The lower side of the pressure cap 3 forms an arc-shaped upper main line groove 32, the upper side of the base 1 forms an arc-shaped lower branch line groove 12, the upper side of the intermediate body 2 forms an arc-shaped lower main line groove 24, and the lower side of the intermediate body 2 forms an arc-shaped upper branch line groove 25. The upper main line groove 32 of the pressure cap 3 and the lower main line groove 24 of the intermediate body 2 constitute a main line hole 6, which is used to fix the main line 8. The upper branch groove 25 and the lower branch groove 12 of the base 1 form a branch hole 7, which is used to fix the branch line 9. The base 1 is also provided with an end cap 19, which is connected to the end of the branch line 9. The barbs 22 in the intermediate body 2 extend toward the main line hole 6 and the branch hole 7 respectively. The upper and lower ends of the barbs 22 form multiple barbs, which are arranged in an arc shape along the lower main groove 24 and the upper branch groove 25 respectively. The barbs 22 penetrate the main line 8 and the branch line 9 through the barbs.

[0025] The base 1 and the gland 3 are formed with bolt holes (13, 33) penetrating the alloy inserts (14, 31), the middle block 21 is provided with middle sleeves 212 coaxial with the bolt holes (13, 33) on both sides, the gland 3 is provided with torque nuts 4 on both sides, the torque nuts 4 are provided with limiting snap rings 41, the bolts 11 on both sides of the base 1 pass through the bolt holes 13 of the base 1, the middle sleeves 212 and the bolt holes 33 of the gland 3 and are connected with the torque nuts 4, so that the base 1 and the gland 3 are connected together. The bolt holes (13, 33) of the base 1 and the gland 3 are formed with sheaths (15, 35) which can be sleeved on both ends of the middle sleeves 212, the gland 3 is provided with insulating covers 5 on both sides, the insulating covers 5 cover the torque nuts 4, the limiting snap rings 41 limit the insulating covers 5, the insulating covers 5 are hinged on the outside of the gland 3, and buckles 51 are arranged between the two insulating covers 5 to be connected with each other. The insulating covers 5 can be opened and closed to cover the metal exposed parts of the bolts 14 and the torque nuts 4, so that full insulation is ensured, meanwhile, the base 1, the gland 3 and the middle block 21 are all provided with structures covering the bolts 14, so that the bolts 14 are not exposed, full insulation is achieved, and foreign matter is prevented from being connected. The bolt hole 33 on one side of the gland 3 is provided with an opening 34 on the side surface, the opening 34 can directly open the gland 3 without the torque nut 4 being separated from the bolt 14, so that the main wire 8 can be directly placed into the main wire hole 6.

[0026] As shown in Figure 6 the specific embodiment two of the present application is a full-insulation quick engagement terminal lead clamp adopting a grounding ring, and the branch wire hole 7 is provided with the grounding ring 10.

[0027] The specific embodiment three of the present application is a production process of the full-insulation quick engagement terminal lead clamp, which comprises the following steps. Step 1: base and gland processing: the alloy insert is processed by precise stamping process, the surface is subjected to micro-arc oxidation and is sprayed with an epoxy resin insulating layer, so that the problem of easy peeling of the metal-plastic interface of the traditional lead clamp is solved; the connecting bolt is made of stainless steel, the surface is plated with nickel for rust prevention and is subjected to polishing treatment, so that the bolt is smoothly and smoothly matched with the torque nut without jamming; the alloy insert, the bolt and the engineering plastic are combined by injection molding process to form the base, the alloy insert and the engineering plastic are combined by injection molding process to form the gland, the engineering plastic is selected from nylon 66 or polycarbonate, the injection molding temperature is 220-250 DEG C, and the pressure maintaining time is 30-60 seconds; ‌Step 2: insulating cover forming: the insulating cover is formed by engineering plastic injection molding.

[0028] ‌Step 3: intermediate body processing: the middle block is selected from nylon 66 or polycarbonate injection molding and is riveted and pressed integrally with the prongs by an automatic riveting and pressing machine, the prongs are placed into a rubber coating mold by a mechanical hand for full-insulation rubber coating processing of the prongs, the rubber coating layer can ensure that the prongs are inserted into the wire and the insertion point is insulated and waterproof, so that the line can be normally operated for a long time.

[0029] ‌Step 4: Assemble the intermediate and the cap to the base through the torque nut, which is made of aluminum alloy material and processed by cold upsetting and T6 heat treatment, and the tightening torque is controlled at 23-26 N.m; after installation, the whole is immersed in insulating silicone grease.

[0030] ‌Step 5: Performance detection: the finished product is subjected to pressure test (power frequency withstand voltage ≥ 35 kV, lasting 1 minute) and insulation resistance test (≥ 1000 MΩ), to ensure no leakage and breakdown.

[0031] In the encapsulation process of the insulating elastomer on the thorn sheet in step 3, segmented temperature control is adopted: initial temperature 80℃, pre-pressing for 30 seconds, temperature rising to 150℃, pressure curing for 2 minutes, cooling to 50℃, demolding.

[0032] The surface oxidation treatment of the alloy insert in step 1 adopts micro-arc oxidation process, the thickness of the oxidation film is 10-15μm, and the film layer uniformity error is ≤5%.

[0033] The epoxy resin spraying process of the alloy insert in step 1 adopts electrostatic spraying, the coating thickness is 0.2-0.3mm, the curing temperature is 120℃, and the curing time is 30 minutes.

[0034] In the process of immersing the insulating silicone grease in step 4, the whole wire clamp is preheated to 60℃, the excess silicone grease is spun off by centrifugal after immersing, and dried in an 80℃ oven for 20 minutes.

[0035] The fourth embodiment of the present application is a thorn sheet processing process, comprising: (1) Base preparation: high-purity oxygen-free copper (Cu-OFE, purity ≥ 99.99%) is subjected to multi-pass low-temperature rolling (single deformation amount 8%-12%, total deformation amount ≥ 70%) to obtain ultra-fine grain copper strip with grain size ≥ ASTM 13 level; (2) Composite reinforced coating: deposit nickel-tungsten carbide (Ni-WC) gradient coating (WC content 10%-30% gradient increasing) on the blade edge by pulse plating, coating thickness 15-20μm, surface hardness HV 650-800; (3) High-conductive structure forming: etch a bionic sharkskin microgroove array (unit size 20μm×50μm) with a depth of 50-80μm on the surface of the blade by femtosecond laser, groove density 200-300 / mm²; (4) Conductivity optimization treatment: grow a 2-5nm thick graphene film in the microgroove by atomic layer deposition (ALD) to form a three-dimensional conductive network, contact resistance ≤ 5μΩ.

[0036] The low-temperature rolling process is carried out in a liquid nitrogen cooling environment (temperature ≤-150℃), and the rolling rate is ≤0.5 m / min; the Ni-WC coating is doped with 0.5%-1.0% nanodiamond particles, and the porosity of the coating is ≤0.3%; the bionic microgrooves are asymmetrically distributed in a spiral shape, the inclination angle is 30°-45°, and the roughness Ra is 1.6-3.2 μm; the graphene film needs to be subjected to argon plasma activation treatment before deposition, and the surface oxygen content is ≤0.5 at%.

[0037] The preferred embodiments of the application in the above specific embodiments, other obvious changes or combinations are also within the protection scope of the claims.

Claims

1. A fully insulated quick-acting snap-in lead clamp comprising a base, an intermediate body, and a cover, characterized in that: The intermediate body includes an intermediate block and a plurality of piercing pieces, the piercing pieces are arranged in the intermediate block in up and down directions, the base is arranged below the intermediate body, the cover is arranged above the intermediate body, a branch wire hole is formed between the intermediate body and the base, a main wire hole is formed between the intermediate body and the cover, and the piercing pieces in the intermediate body respectively extend towards the main wire hole and the branch wire hole. ​ 2. The all-insulated quick-acting pincer terminal according to claim 1, characterized by: The intermediate body further includes an insulating elastic body, and the insulating elastic body is wrapped outside the piercing pieces.

3. The fully insulated quick-acting snap-in lead clip according to claim 1 or 2 or 3, characterized in that: The lower side of the cover forms an arc-shaped upper main wire groove, the upper side of the base forms an arc-shaped lower branch wire groove, the upper side of the intermediate body forms an arc-shaped lower main wire groove, the lower side of the intermediate body forms an arc-shaped upper branch wire groove, the upper main wire groove and the lower main wire groove constitute the main wire hole, the upper branch wire groove and the lower branch wire groove constitute the branch wire hole, and the upper ends and the lower ends of the piercing pieces respectively form a plurality of piercing heads, and the piercing heads are arranged in a circular arc shape along the lower main wire groove and the upper branch wire groove.

4. The all-insulated quick-acting snap-on lead wire terminal according to claim 1 or 2, characterized by: The base and the cover are integrally formed by alloy insert over-molding of engineering plastics, bolt holes are formed on both sides of the base and the cover and penetrating the alloy insert, intermediate sleeves coaxial with the bolt holes are arranged on both sides of the intermediate block, bolts are arranged on both sides of the base, torque nuts are arranged on both sides of the cover, the bolts pass through the bolt holes of the base, the intermediate sleeves and the bolt holes of the cover and are connected with the torque nuts to connect the base and the cover together.

5. The all-insulated quick-acting grip terminal according to claim 4, characterized in that: The bolts are integrally formed in the base by plastic over-molding, protective sleeves are formed outside the bolt holes of the base and the cover and can be sleeved on both ends of the intermediate sleeves, and insulating covers are arranged on both sides of the cover and cover the torque nuts.

6. The all-insulated quick-acting pincer terminal according to claim 5, characterized by: An opening is formed on the side surface of the bolt hole on one side of the cover, the outer sides of the insulating covers are hinged on the cover, and buckles are arranged between the insulating covers to be connected with each other.

7. A production process of the fully insulated quick snap-in lead clamp according to claim 5 or 6, characterized in that: Step 1: punch forming the alloy insert, surface micro-arc oxidation of the formed alloy insert and spraying of an epoxy resin insulating layer, Step 2: combining the alloy insert, the bolt and the engineering plastic by injection molding process to form the base; combining the alloy insert and the engineering plastic by injection molding process to form the cover; Step 3: injection molding the insulating cover by engineering plastic; Step 4: injection molding the intermediate block, riveting the piercing pieces by an automatic riveting press, placing the piercing pieces in a rubber coating mold by a mechanical hand, and performing insulating elastic body rubber coating processing on the piercing pieces; Step 5: assembling the intermediate body and the cover to the base by torque nuts, and immersing the whole in insulating silicone grease after installation.

8. The process for producing an all-insulated quick-acting pincer lead holder according to claim 7, characterized by: The insulating elastic body rubber coating processing adopts segmented temperature control, the initial temperature is 80°C, pre-pressing is performed for 30 seconds, the temperature is raised to 150°C, pressure curing is performed for 2 minutes, and the mold is demolded after cooling to 50°C.

9. A process for the production of a lancet, characterized by: including the following steps: Base preparation: high-purity oxygen-free copper is used for multi-pass low-temperature rolling to obtain ultra-fine grain copper strip with grain size ≥ASTM 13 grade, and the ultra-fine grain copper strip is punched into a stab piece; Composite reinforced plating layer: a nickel-tungsten carbide gradient plating layer is deposited on the blade edge of the stab piece by pulse plating, the plating layer has a thickness of 15-20 μm and a surface hardness of HV 650-800; High-conductivity structure forming: a biomimetic sharkskin microgroove array with a depth of 50-80 μm is etched on the surface of the stab piece by femtosecond laser, and the groove density is 200-300 / mm²; Conductive optimization treatment: a 2-5 nm thick graphene film is grown in the microgrooves by atomic layer deposition to form a three-dimensional conductive network, and the contact resistance is ≤5 μΩ.

10. The process for producing a stab plate according to claim 9, characterized by: The low-temperature rolling is performed at a temperature ≤-150℃ and a rolling rate ≤0.5 m / min.

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