Female contact with at least one new wire assembly

Abstract

The female electrical contact (1) is used to receive a male electrical contact. The contact (1) comprises at least one wire assembly (11) for receiving a pin (21) of a male electrical contact. Each wire assembly (11) comprises a wire carrier (13) and a plurality of wire parts (15) carried by the wire carrier. The conductor part (15) is configured to contact a pin (21) of a male electrical contact. The plurality of conductor parts (15) comprise a beryllium-free copper-nickel alloy, and in particular a copper-nickel-silicon alloy. The wire carrier (13) has a length L, and the plurality of wires (15) are configured to contact the pins (21) around a receiving diameter D, the ratio of length L to diameter D being less than 1.

Description

Technical Field

[0001] This disclosure relates to, but is not limited to, female electrical contacts for receiving male electrical contacts. This disclosure also relates to a method of manufacturing such a connector. Background Technology

[0002] Electrical connectors typically include at least one contact mounted in an insulator. The at least one contact may include a female contact (e.g., a socket) configured to mate with a male contact (e.g., a pin) and / or may include a male contact (e.g., a pin) configured to mate with a female contact (e.g., a socket).

[0003] Electrical plugs typically include a movable connector. The electrical plug may include male contacts (e.g., pins) and / or female contacts (e.g., receptacles).

[0004] Electrical receivers typically include a fixed connector (e.g., fixed in a wall). The electrical receiver may include male contacts (e.g., pins) and / or female contacts (e.g., receptacles).

[0005] The plug can be used with the receiver.

[0006] Some sockets can accommodate multiple wires for receiving public electrical contacts. These wires are typically made of a copper-beryllium (CuBe) alloy. Summary of the Invention

[0007] Aspects and embodiments of the invention are set forth in the appended claims. These and other aspects and embodiments of the invention are also described herein. Attached Figure Description

[0008] Various aspects of this disclosure will now be described by way of example with reference to the accompanying drawings, in which: Figure 1 A cross-sectional view of an exemplary bus electrical contact according to this disclosure is schematically shown; Figure 2A and 2B An isometric view of an exemplary conductor assembly according to this disclosure is shown schematically; Figure 3 A cross-sectional view of another exemplary female electrical contact according to this disclosure is schematically shown; Figure 4A , 4B and Figure 5A , 5B 5C and Figure 6A , 6B Figures 6C and 6C schematically illustrate an exemplary method of manufacturing a female electrical contact. Figure 7A cross-sectional view of the end of another exemplary female electrical contact according to this disclosure is schematically shown; Figure 8 A cross-sectional view of another exemplary female electrical contact element according to this disclosure is shown schematically in the longitudinal direction; Figure 9 The following is a schematic illustration of the crimping process. Figure 8 Axial cross-sectional view of the female electrical contact component; Figure 10 and Figure 11 Further example wiring end arrangements according to this disclosure are shown. Detailed Implementation

[0009] Overview This disclosure relates to, but is not limited to, a female electrical contact for receiving a male electrical contact. The female contact includes at least one conductor assembly for receiving pins of the male electrical contact. The conductor assembly includes a conductor carrier and a plurality of conductor components carried by the conductor carrier. The conductor assembly is sometimes referred to as a "cage".

[0010] The plurality of lead components comprise beryllium-free copper-nickel alloys. This may mean that the plurality of lead components are made of beryllium-free copper-nickel alloys. The plurality of lead components may be substantially composed of beryllium-free copper-nickel alloys. The plurality of lead components are beryllium-free. “Beryllium-free” means that the copper-nickel alloy does not contain beryllium or may contain only trace amounts of beryllium (e.g., less than 0.1% by weight or less than 0.01% by weight of beryllium).

[0011] Traditional wire cages used for electrical contacts employ copper-beryllium (CuBe) wire. CuBe is a copper alloy containing between 0.5% and 3% beryllium by weight. Beryllium can be toxic and carcinogenic to humans, especially when inhaled. Therefore, the use of CuBe wire components in electrical contacts poses a potential health risk to humans.

[0012] While the health risks of beryllium copper are known, there is no known suitable alternative to CuBe that meets the electrical performance requirements of conductor components for main electrical contacts. Conductor components may be required to provide relatively high current carrying capacity (e.g., 300A or greater), and therefore low contact resistance may be necessary. The material CuBe meets these challenging electrical performance requirements while still being able to be drawn into conductors and manipulated on conductor carriers to form desired conductor arrangements.

[0013] Advantageously, the inventors have discovered that, when used as conductor components carried on conductor carriers in electrical contacts, beryllium-free copper-nickel alloys offer the same or improved performance, such as high current carrying capacity and low resistance, compared to CuBe alloys. This avoids the use of beryllium as a potential health hazard.

[0014] In a preferred embodiment, the copper-nickel alloy is a copper-nickel-silicon (CuNiSi) alloy. Notably, CuNiSi alloys have been found to offer improved performance compared to CuBe alloys. Specifically, it has been found that bus contacts using CuNiSi conductors exhibit improved conductivity and lower contact resistance compared to CuBe conductors. Lower resistance translates to less power dissipation, less heat generation, and improved power transfer efficiency using the contacts. Therefore, using CuNiSi conductors not only avoids the use of beryllium but also provides improved contact performance. This is particularly advantageous in high-power applications, such as those using currents greater than 300A. CuNiSi conductors are capable of carrying more current than CuBe conductors of the same diameter.

[0015] For example, in other otherwise identical bus contact designs, it was found that bus contacts using CuNiSi wire components had an average resistance of 0.040 mΩ after 500 mating cycles, while bus contacts using CuBe wire components had an average resistance of 0.057 mΩ after 500 mating cycles.

[0016] The main component of CuNiSi alloy is copper. The combined weight percentage of copper, nickel, and silicon in CuNiSi alloy can be at least 99.5% by weight. CuNiSi alloy may include trace amounts of other elements such as tin, magnesium, zinc, lead, iron, manganese, and phosphorus.

[0017] The copper-nickel-silicon alloy may contain 94.0% to 99.1% copper by weight, and optionally 94.6% to 97.6% copper by weight.

[0018] The copper-nickel-silicon alloy may contain 0.8% to 4.2% nickel by weight, and optionally 2.2% to 4.2% nickel by weight.

[0019] The copper-nickel-silicon alloy may contain 0.1% to 1.2% silicon by weight, and optionally 0.3% to 1.2% silicon by weight.

[0020] The copper-nickel-silicon alloy comprises 94.1% to 97.5% copper, 2.2% to 4.2% nickel, and 0.2% to 1.2% silicon.

[0021] Multiple conductive components can be plated with a conductive material, such as gold, silver, or nickel. Multiple conductive components may include a silver-plated CuNiSi alloy. Advantageously, it has been found that silver plating reduces contact resistance compared to other plating materials such as gold.

[0022] Multiple conductor components may include multiple conductors or may be formed from a single conductor. A conductor carrier may define an internal portion and have a length L along its longitudinal axis. Multiple conductor components may be arranged within the interior of the conductor carrier. Multiple conductor components may extend along the length L of the conductor carrier.

[0023] The bus contact may include a conductive receptacle configured to receive the at least one conductor assembly. The bus contact may include a terminal for connecting the bus contact to a cable. The receptacle may be located at a first end of the bus contact, and the terminal may be located at a second end of the bus contact. The receptacle and the terminal may be located at opposite ends of the bus contact.

[0024] The terminal may define an internal space for receiving the cable. The internal space of the terminal may be defined by a closed end and an open end. A crimping pin may be located within the internal space and may extend from the closed end of the terminal toward the open end. The terminal is configured to be crimped to connect the female electrical contact and the cable. The crimping pin increases the contact surface area between the cable and the terminal to improve the electrical performance of the crimp.

[0025] This disclosure relates to, but is not limited to, a female electrical contact for receiving a male electrical contact. The female contact includes a wire assembly for receiving a pin of the male electrical contact. The wire assembly includes a wire carrier carrying a plurality of wires. The plurality of wires are arranged inside the wire carrier such that the extension direction of each of the wires is inclined relative to the longitudinal axis of the wire carrier. Therefore, the wires can define a hyperboloid receiving space for the pin of the male electrical contact. The diameter of the receiving space is substantially equal to D. The wire carrier has a length L along its longitudinal axis. The length L is less than the diameter D. The ratio r can be defined as the quotient r. .

[0026] In this example, the wire does not need to be a beryllium-free copper-nickel alloy and can be formed from any suitable conductive material. For example, the wire can be made of CuBe, CuSnP, or CuNiSi.

[0027] The plurality of conductors can provide a relatively high current-carrying capacity. However, in operation, the conductivity of the conductors is relatively low compared to the conductivity of any other component of the female electrical contact involved in current conduction. A ratio r of less than 1 compared to the total effective surface area of ​​other components of the female electrical contact involved in current conduction results in a relatively low total length of conductors in contact with the pins in operation, thereby increasing the total conductivity of the female contact.

[0028] For example, a female electrical contact having a wire contact that mates with a wire carrier having a length L substantially equal to 5 mm for a diameter D substantially equal to 8 mm (i.e., resulting in r being less than 1), for example, having a gold-plated CuBe wire, while a female contact having a length L substantially equal to 10.4 mm for a diameter D substantially equal to 8 mm (i.e., resulting in r being greater than 1) has a resistance of 0.18 mΩ. This embodiment shows that the female electrical contact of this disclosure having an r of less than 1 and a smaller resistance has higher conductivity.

[0029] During operation, the conductivity of the female contact increases relatively as the ratio r decreases below 1.

[0030] Making the ratio r less than 1 results in a relatively short conductor assembly length L, and allows a female contact of a given length Λ to accommodate more than one conductor assembly, such as two conductor assemblies, such that L = Λ / 2. Having more than one conductor assembly of length L for the female contact increases its current-carrying capacity compared to a female contact with a single conductor assembly of length 2L. Female contacts of any aspect of this invention can be used in many technical fields, especially, but not limited to, fields requiring currents of 300-350A, such as connectors for charging electric vehicles.

[0031] With the conductor defining a hyperboloid receiving space, the conductor assembly can have a relatively high cycle life when mating with male contacts (up to 100,000 mating cycles). The hyperboloid receiving space enables relatively low contact resistance. It provides relatively high immunity to mechanical shock, vibration, and / or triboelectric corrosion. It allows for relatively low insertion force. The hyperboloid receiving space can be self-cleaning and provides a wiping effect when mating with male electrical contacts.

[0032] The ratio r can be kept greater than 0.250 to maintain the above-mentioned mechanical properties of the female contact.

[0033] Detailed description of exemplary embodiments Figures 1 to 7 A cross-sectional view of an exemplary female electrical contact according to this disclosure is schematically shown. The female electrical contact is configured to receive a male electrical contact. Figures 1 to 7 In the figures, similar elements have the same reference numerals.

[0034] In the figure, the female electrical contact 1 includes at least one wire assembly 11 for receiving the pin 21 of the male electrical contact (see figure). Figure 1 ).

[0035] In the figure, each conductor assembly 11 mainly includes a conductor carrier 13 and multiple conductor components 15, with the conductor components 15 being carried by the conductor carrier 13.

[0036] In this embodiment, the plurality of wire components 15 are in the form of a plurality of wires 15, with the opposite ends of the wires respectively wound around the opposite ends of the wire carrier 13 to support the wires 15 on the wire carrier 13. In other embodiments, the plurality of wire components 15 may be formed from a single wire. A single wire may be subjected to multiple operations (e.g., winding) to form the wire component 15.

[0037] Multiple conductor components 15 are formed of beryllium-free copper-nickel alloys, particularly copper-nickel-silicon CuNiSi alloys. CuNiSi alloy is a copper alloy containing nickel and silicon, with copper comprising the majority of the alloy's weight percentage. Other elements may also be present in the alloy, but the weight percentage of copper, nickel, and silicon in CuNiSi alloys is typically at least 99.5% by weight.

[0038] Typically, CuNiSi alloys comprise between 94.0% and 99.1% by weight of copper, between 0.8% and 4.2% by weight of nickel, and between 0.1% and 1.2% by weight of silicon, and the combined percentage weight of copper, nickel, and silicon is at least 99.5% by weight.

[0039] The CuNiSi alloy compositions of the examples are provided in Table 1.

[0040]

[0041] The conductor component 15 is plated with a conductive material. The conductive material can be any of gold, silver, or nickel. The pins 21 of the power contact are typically plated with the same material as that used for the conductor component 15. It has been found that silver-plated CuNiSi conductor component 15 reduces contact resistance.

[0042] Multiple conductor components 15 are arranged such that the extension direction of each conductor component 15 is relative to the longitudinal axis XX of the conductor carrier 13 (see, for example, [reference]). Figure 1 and Figure 3 (Slant.) For example, as... Figure 3 As shown, the extension direction of each conductor component 15 is inclined at an angle α relative to the longitudinal axis XX of the conductor carrier 13, such that: 3°≤α≤15°.

[0043] In the example shown in the attached figure, multiple conductor components 15 are arranged hyperbolically so that when the pin is inserted into the female electrical contact 1, the conductors are configured to resiliently align themselves into contact lines around the pin (see Figure 1). Figure 1(Ref. 21 in the figure). The fact that multiple conductor components 15 extend along the longitudinal axis L of the conductor carrier 13 in a hyperboloidal structure means that the conductor components 15 define holes along the conductor carrier 13, and when the pins 21 of the male electrical contact are inserted into the holes, the conductor components 15 compliantly grip the pins 21 to provide multiple contact points.

[0044] In the example shown in the accompanying drawings, the wire carrier 13 is substantially cylindrical. The wire carrier 13 is configured to define an interior 17 (see, for example, [reference needed]). Figure 2A And has a length L along the longitudinal axis XX (see, for example, see...) Figure 1 and Figure 3 Multiple conductor components 15 are arranged inside the conductor carrier 13.

[0045] In the example of the accompanying drawings, each of the plurality of hyperbolically arranged conductor components 15 extends substantially as a straight but inclined line within the interior 17 of the conductor carrier 13. Each conductor component of the plurality of hyperbolically arranged conductor components 15 also has two curved portions, each curved portion located at a corresponding end of the straight line within the interior 17 of the conductor carrier 13. Each curved portion of the conductor component is mounted on a corresponding edge of the cylindrical conductor carrier 13. After each curved section is mounted on the edge of the cylindrical conductor carrier 13, each conductor assembly includes a straight section defining an end of the conductor assembly. Each end of each conductor component is mounted between the exterior of the cylindrical conductor carrier 13 and the interior of the substantially cylindrical sleeve 31 (see, for example, [reference needed]). Figure 3 ).

[0046] The conductor carrier does not need to be a continuous structure and can, for example, be a pair of spaced-apart retaining rings defining the ends of the conductor assembly. The conductor component can be attached to the rings and extend between the rings to define space for a pin 21 for receiving a male electrical contact. As described above, the conductor component can be inclined relative to the longitudinal axis of the conductor carrier 13 and can be arranged hyperbolically.

[0047] In the example shown in the attached figure, a plurality of wires 15 are configured to surround a pin that receives a male electrical contact of diameter D (see example). Figure 1 and 3 The ratio r of length L to diameter D, i.e., the quotient r. , and set it to: r<1.

[0048] As previously stated, during the operation of contact 1, making the ratio r less than 1 compared to the total effective surface of other components of the bus contact 1 involved in current conduction (e.g., conductor carrier 13) results in a relatively small total length of the conductor 15 in contact with the pin, thereby increasing the total conductivity of the bus contact 1. In some examples, r can be set as: r≤0.750.

[0049] As described above, setting the ratio r to be less than 1 makes the length L of each conductor assembly 11 relatively short and makes the female contact of a given length Λ (e.g., see...) Figure 3 It can accommodate more than one wire assembly, thereby increasing the overall conductivity of the female contact 1. For example, as Figure 3 As shown, the bus electrical contact 1 may include at least two wire assemblies 11, which are mounted in the bus electrical contact 1 such that the longitudinal axes XX of the wire assemblies 11 are substantially aligned with each other and correspond to each other. Figure 3 The example includes two wire assemblies 11, but examples with more than two wire assemblies are envisioned.

[0050] As described above, in the example in the attached figures, the bus contact is configured to conduct a current of 300-350A. This is not necessary in all examples, and the bus contact can be configured to conduct higher or lower currents. The current-carrying capacity of the bus contact can be determined by the receiving diameter D, the number of conductor components, and the thickness of the conductor. Typically, the bus contact is configured to conduct any current of at least 20A, at least 50A, at least 200A, at least 300A, or at least 400A.

[0051] The value of the ratio r can be kept greater than 0.250 to maintain the favorable mechanical properties of the female contact 1, such that r is set as follows: 0.250 <r。

[0052] exist Figures 1 to 3 In the examples, D=8mm L=5mm r=0.625.

[0053] like Figure 3 As shown, adjacent wire assemblies 11 are mounted in the bus electrical contact 1 with a space 19 between them, such that the plurality of wire parts 15 of one wire assembly 11 do not contact the plurality of wire parts 15 of another wire assembly 11.

[0054] As shown in the figure, each conductor assembly 11 includes at least one conductive sleeve 31, which is substantially cylindrical and configured to at least partially accommodate the conductor carrier 13 and a plurality of conductor components 15.

[0055] As shown in the figure, the main electrical contact 1 also includes a conductive socket 33 for receiving at least one conductor assembly 11, the socket 33 including a hollow rod 35 configured to receive a sleeve 31 of each conductor assembly 11.

[0056] As shown in the figure, the female electrical contact 1 also includes a terminal 37 for connecting the female electrical contact 1 to a cable (not shown). The terminal 37 is configured to be crimped, threaded, and / or soldered to the cable. Variations of the terminal 37 are described below regarding... Figures 8 to 11 describe.

[0057] Each wire carrier 13 may include brass and / or copper. The sleeve 31 and / or socket 33 and / or terminal 37 may be made of brass and / or copper.

[0058] This disclosure also relates to a method of manufacturing a female electrical contact for receiving a male electrical contact, comprising at least the step of providing at least one wire assembly of pins for receiving the male electrical contact.

[0059] exist Figure 1 In this process, individual conductor assemblies are provided to the bus contacts. Figure 4A , 4B Figures 5A, 5B, 5C, 6A, 6B, and 6C schematically illustrate the manufacturing process including, for example... Figure 3 An exemplary method 100 for the female electrical contacts of the two conductor assemblies 11 shown.

[0060] exist Figure 4A and Figure 4B In method 100, the steps include: in S1, providing and inserting a first fully-connected wire assembly 11 into a socket 33; and in S2, providing and inserting a second fully-connected wire assembly 11 into a socket 33 to obtain... Figure 3 Contact element 1.

[0061] exist Figure 5A , 5B In method 100, as described in 5C, in S1, providing and inserting a first unsleeved wire assembly 11 into a socket 33, the socket 33 forming a lower sleeve for the first wire assembly 11. Method 100 further includes in S2 providing and inserting an upper sleeve 31 for the first wire assembly 11. Method 100 further includes in S3 providing and inserting a second unsleeved wire assembly 11 into the socket 33, a handle 35 forming a lower sleeve for the second wire assembly 11. Method 100 also includes in S4 providing and inserting the upper sleeve 31 for the first wire assembly 11 to obtain... Figure 3 Contact element 1.

[0062] exist Figure 6A , 6BIn method 100, as described in 6C, in S1, providing and inserting a first unsleeved wire assembly 11 into a socket 33, the socket 33 forming a lower sleeve for the first wire assembly 11. Method 100 further includes: in S2, providing and inserting an upper sleeve 31 for the first wire assembly 11, the sleeve 31 of the first wire assembly 11 further extending to form a socket 33 for receiving a second wire assembly 11, the socket 33 for receiving the second wire assembly 11 also forming a lower sleeve 31 for the second wire assembly 11. Method 100 further includes: in S3, providing and inserting a second unsleeved wire assembly 11 into the socket 33. Method 100 further includes: in S4, providing and inserting the upper sleeve 31 for the first wire assembly 11 to obtain... Figure 3 Contact element 1.

[0063] like Figure 7 As shown, in Figure 6A , 6B In a variation of method 100 of 6C, the contact end ring 39 forms a sleeve 31 of the conductor assembly 11 located at the end of the bus electrical contact 1.

[0064] The above about Figures 1 to 7 The exemplary contacts and methods described generally relate to contacts having two or more wire assemblies. This is not required for all aspects of this disclosure, and contacts with a single wire assembly can also be provided.

[0065] In all examples, the contact does not need to have a ratio of less than 1 between the length of the wire carrier and the diameter of the pin. The improved performance benefits of using CuNiSi are achieved through contacts with a single wire assembly, multiple wire assemblies, and single or multiple wire assemblies with a ratio less than or greater than 1.

[0066] Similarly, performance benefits are obtained when the ratio is less than 1 as described above. These performance benefits can be achieved even without using CuNiSi wire. Therefore, in single-wire or multi-wire assembly examples with a ratio less than 1 as described above, the conductor components do not need to use CuNiSi. For example, each conductor 15 of at least one conductor assembly 11 may be made of the following materials: CuBe, gold-plated; or CuBe, silver-plated; or CuNiSi, silver-plated; or CuNiSi, gold-plated.

[0067] Experiment 1 – Electrical Performance in Low-Cooperation Cyclic Applications The electrical performance of the four female electrical contacts was tested after 100 and 500 mating cycles. A mating cycle refers to a cycle of connecting and disconnecting the male and female electrical contacts. Electrical contacts used in the industrial and rail markets are typically expected to maintain acceptable performance between 100 and 500 mating cycles.

[0068] These four products are all female electrical contacts with a single conductor assembly having a pin for receiving the male electrical contact. The conductor carrier length L of each product is 10 mm, and the diameter D of the contact pin is 8 mm, resulting in a ratio r of 1.25.

[0069] The product differs in the alloy composition of the wires used in the wire assembly.

[0070] Product A – CuBe, gold-plated Product B–CuBe, silver plated Product C–CuNiSi, silver plated. A CuNiSi composition used in composition 1 of Table 1 above.

[0071] Product D – Phosphorus Bronze Alloy (CuSnP), gold-plated. Phosphorus bronze alloy is an alloy containing copper, tin, and phosphorus.

[0072] The electrical performance results of the product AD are provided in Table 2:

[0073] Product C (silver-plated CuNiSi) is the best performing contact in this embodiment, exhibiting the lowest contact resistance, lowest temperature, and highest energy transfer after 100 mating cycles and 500 mating cycles.

[0074] Product D (CuSnP with gold plating) was the worst performing contact in all mating cycles. CuSnP is a beryllium-free copper alloy. The results highlight the benefits of using copper-nickel alloys, especially copper-nickel-silicon alloys, for conductors in bus contacts, superior to established CuBe conductors and other possible beryllium-free alternatives such as CuSnP.

[0075] Comparing products A and B, silver-plated wires were found to have improved electrical properties compared to gold-plated wires. The performance improvement was not significantly achieved by changing the wire's material composition from CuBe to CuNiSi.

[0076] Experiment 2 – Electrical performance in moderately coordinated cycling applications The electrical performance of the four female electrical contacts was tested after 500 and 2000 mating cycles. Electrical contacts used in the defense market are typically expected to maintain acceptable performance between 500 and 2000 mating cycles.

[0077] According to Experiment 1, all four products are female electrical contacts with a single wire assembly for receiving the male electrical contact. As mentioned above, the ratio r is 1.25.

[0078] The product differs in the alloy composition of the wires used in the wire assembly.

[0079] Product A – CuBe, gold-plated Product B–CuBe, silver plated Product C–CuNiSi, silver plated. A CuNiSi composition used in composition 1 of Table 1 above.

[0080] Product D – Phosphorus Bronze Alloy (CuSnP), gold plated.

[0081] The electrical performance results of the product AD are provided in Table 3:

[0082] Product C (silver-plated CuNiSi) is the best-performing contact in this example, exhibiting the lowest contact resistance, lowest temperature, and highest energy transfer after 500 mating cycles and 2000 mating cycles.

[0083] Product D (CuSnP with gold plating) was the worst performing contact in all mating cycles. CuSnP is a beryllium-free copper alloy. The results highlight the benefits of using copper-nickel alloys, especially copper-nickel-silicon alloys, for conductors in busbar contacts, superior to established CuBe conductors and other beryllium-free alternatives such as CuSnP.

[0084] Comparing products A and B, silver-plated wires were found to have improved electrical properties compared to gold-plated wires. The performance improvement was not significantly achieved by changing the wire's material composition from CuBe to CuNiSi.

[0085] Experiment 3 – Electrical Performance in Highly Coordinated Cyclic Applications The electrical performance of the three main electrical contacts was tested after 6,000, 10,000, and 15,000 mating cycles. Electrical contacts used in the electric vehicle market are typically expected to maintain acceptable performance between 6,000 and 15,000 mating cycles.

[0086] According to Experiment 1, all four products are female electrical contacts with a single wire assembly for receiving the male electrical contact. As mentioned above, the ratio r is 1.25.

[0087] The product differs in the alloy composition of the wires used in the wire assembly.

[0088] Product A – CuBe, gold-plated.

[0089] Product B–CuBe, silver plated.

[0090] Product C–CuNiSi, silver plated. A CuNiSi composition used in composition 1 of Table 1 above.

[0091] The electrical performance results of the product AC are provided in Table 4:

[0092] Product C (silver-plated CuNiSi) is the best-performing contact in this embodiment, exhibiting the lowest contact resistance, lowest temperature rise, and highest energy transfer after 6,000, 10,000, and 15,000 mating cycles, respectively.

[0093] Comparing products A and B, silver-plated wires were found to have improved electrical properties compared to gold-plated wires. The performance improvement was not significantly achieved by changing the wire's material composition from CuBe to CuNiSi.

[0094] Experiment 4 – Single-wire assembly and Two wires Electrical performance of component contacts The electrical performance of the six bus contacts was tested after 500 mating cycles. The bus contacts differ in the following aspects: Product A – Single-wire assembly; CuBe, gold-plated Product A1 – Dual-wire assembly; CuBe, gold-plated Product B – Single-wire assembly; CuBe, silver plated. Product B1 – a dual-wire assembly; CuBe, silver-plated. Product C – Single-wire assembly; CuNiSi, silver plated. Product C1 – is a dual-wire assembly; CuNiSi, silver-plated.

[0095] For products A, B, and C, the length L of the conductor carrier is 10mm, the receiving diameter D is 8mm, and the ratio is 1.25. For products A1, B1, and C1, each of the two conductor carriers has a length L of 5mm and a receiving diameter D of 8mm, resulting in a ratio of 0.625.

[0096] The electrical performance results for products A-C1 are provided in Table 5:

[0097] Products A1, B1, and C1 offer improved performance compared to their respective single-wire assembly versions.

[0098] Product C is the best performing single-wire assembly contact. Product C1 is the best performing two-wire assembly contact.

[0099] Female electrical contact with crimp pin Figure 8 A cross-sectional view of another exemplary female electrical contact 100 according to aspects of this disclosure is shown. The female electrical contact 100 may include, as described above... Figures 1 to 7 Any feature of the aforementioned female electrical contact 1.

[0100] The female electrical contact 100 has a machined metal outer body 102 having a generally cylindrical external shape. The body 102 includes a first end 104 and a second end 106. The first end 104 and the second end 106 are generally cylindrical, wherein the diameter of the first end 104 is smaller than the diameter of the second end 106.

[0101] The first end 104 forms a socket 104. The socket 104 defines an internal space in the form of a cylindrical hole / hollow rod 108. The internal space of the socket 104 is defined by an open end 110 and a closed end 112. The diameter of the hole 108 decreases from a first portion near the open end 110 to a second portion near the closed end 112.

[0102] The socket 104 receives at least one wire assembly through an open end 110. The wire assembly includes a wire carrier and a plurality of wire components carried by the wire carrier. The at least one wire assembly may be as described above. Figures 1 to 7 In any of the wire assemblies 11, the socket 104 is configured to receive as described above regarding Figures 1 to 7 The pin of the aforementioned public electrical contact contacts the wire component of any wire assembly housed within the socket 104, as described above regarding... Figures 1 to 7 As stated above.

[0103] The second end 106 forms a wiring end 106 for connecting the female electrical contact 100 to a cable (not shown). The wiring end defines an internal space in the form of a cylindrical hole 114. The internal space of the wiring end is defined by an open end 116 and a closed end 118. The wiring end 106 is arranged to receive one or more exposed conductors (strands) at the end of the cable (not shown) for connecting the female electrical contact 100 to the cable.

[0104] The crimp pin 120 is located within the hole 114 and extends from the closed end 118 of the hole 114 toward the open end 116 of the hole 114. The crimp pin 120 is substantially cylindrical along most of its length and tapers to a point toward the open end 116 of the hole 114.

[0105] The crimp pin 120 is integral with the rest of the body 102 of the female electrical contact 100 and is formed as part of the process of manufacturing the body 102 of the female electrical contact 100. In other examples, the crimp pin 120 is manufactured separately and then attached to the body 102, for example by press fitting, welding or screwing into the closed end 118 of the hole 114.

[0106] The body 102 and the crimp pin 120 are conductive. The body 102 and the crimp pin 120 may include brass and / or copper.

[0107] In use, the exposed conductor (e.g., exposed strands) at the end of the cable (not shown) is inserted through the open end 116 into the hole 114 of the terminal 106. The terminal 106 is then crimped, for example, using a crimping tool, to connect the cable to the female electrical contact 100. This forms an electrical and mechanical connection between the female electrical contact 100 and the cable.

[0108] Figure 9 A cross-sectional view of the wire end 106 after crimping is shown. In this example, a hexagonal crimping tool is used, resulting in the wire end 106 having a hexagonal cross-section after crimping.

[0109] The exposed conductor of the cable is made of Figure 9 Diagonal 122 in the diagram indicates that the exposed conductor of the cable contacts the inner surface wall 124 of the terminal 106. The exposed conductor of the cable also contacts the surface 126 of the crimp pin 120. Therefore, compared to a terminal without a crimp pin, the crimp pin 120 increases the contact surface area between the exposed conductor of the cable and the terminal 106. The larger contact surface area reduces the contact resistance between the cable and the bus contact 100. This reduced contact resistance improves the power transmission capability of the bus contact. In one example, the contact resistance between the terminal 106 and the cable is 13 μΩ when the crimp pin 120 is included, and 20 μΩ when the crimp pin is absent.

[0110] Crimped pins do not necessarily have to be cylindrical. Crimped pins can be in other shapes, such as those with a cross-shaped cross section 120a. Figure 10 ) or hexagonal cross section 120b ( Figure 11 ) Crimp pins of any shape can be used to increase the available surface area for contact with the cable. More than one crimp pin can be provided.

[0111] The aforementioned female electrical contacts 1, 100 may form part of a charger plug for supplying electrical energy to an electric vehicle. The charger plug may include a connector comprising at least one female electrical contact 1, 100. The charger plug is arranged to engage with a charging receiver of the electric vehicle. The charging receiver includes a connector comprising at least one corresponding male electrical contact. Alternatively, the charger plug may include a male electrical contact, and the charging receiver may include female electrical contacts 1, 100.

[0112] Example of numbering: Example 1: A female electrical contact for receiving male electrical contacts, comprising: At least one wire assembly for receiving the pins of the public electrical contact, wherein each wire assembly includes: A conductive, substantially cylindrical conductor carrier, which defines an internal portion and has a length L along its longitudinal axis, and A plurality of wires are arranged within the internal portion of the wire carrier such that the extension direction of each of the wires is inclined relative to the longitudinal axis of the wire carrier. The plurality of wires are configured to surround the pin that receives the male electrical contact with a diameter D. Wherein, the ratio r of length L to diameter D is set as: r<1.

[0113] Example 2: The bus electrical contact according to Example 1 includes at least two wire assemblies installed in the bus electrical contact, such that the longitudinal axes of the wire assemblies are substantially aligned with each other and the longitudinal axes correspond to each other.

[0114] Example 3: The female electrical contact according to Example 1 or 2, wherein r is set as: 0.250 <r≤0.750, Preferably, r is approximately equal to 0.625.

[0115] Example 4: A bus electrical contact according to any one of Examples 1 to 3, wherein: D=8mm, L=5mm.

[0116] Example 5: A bus electrical contact according to any one of Examples 1 to 4, wherein when the bus electrical contact includes at least two wire assemblies, adjacent wire assemblies are installed in the bus electrical contact, wherein there is a space between them such that the plurality of wires of one wire assembly does not contact the plurality of wires of the other wire assembly.

[0117] Example 6: A female electrical contact according to any one of Examples 1 to 5, wherein each conductor assembly includes at least one conductive sleeve, the sleeve being substantially cylindrical and configured to at least partially accommodate the conductor carrier and the plurality of conductors, and The female electrical contact further includes a conductive socket for receiving the at least one conductor assembly, wherein the socket includes a hollow rod configured to receive the sleeve of each conductor assembly, and optionally the material of the sleeve and / or the socket includes brass and / or copper.

[0118] Example 7: A power contact according to any one of Examples 1 to 6, wherein when the power contact includes at least two conductor assemblies, the sleeve of one conductor assembly further extends to form a socket for receiving the other conductor assembly, and the contact end ring forming the sleeve of the conductor assembly is located at the end of the power contact.

[0119] Example 8: A bus contact according to any one of Examples 1 to 7, wherein each wire of the at least one conductor assembly is made of the following: CuBe, gold plating; or CuBe, silver-plated; or CuNiSi, silver-plated; or CuNiSi, gold-plated.

[0120] Example 9: A bus contact according to any one of Examples 1 to 8, wherein each conductor carrier comprises brass and / or copper.

[0121] Example 10: A female electrical contact according to any one of Examples 1 to 9, wherein the angle α of the extension direction of each of the conductors relative to the longitudinal axis of the conductor carrier is set as follows: 3°≤α≤15°.

[0122] Example 11: A bus electrical contact according to any one of Examples 1 to 10, wherein the plurality of wires are arranged hyperbolically in the inner portion of the wire carrier such that the wires are configured to elastically align themselves as contact lines around the pin when the pin is introduced into the bus electrical contact.

[0123] Example 12: The power contact according to any one of Examples 1 to 11 further includes a terminal for connecting the power contact to a cable, wherein the terminal is optionally configured to be crimped, threaded and / or welded to the cable.

[0124] Example 13: The bus contact according to any one of Examples 1 to 12 is configured to conduct a current of 300 to 350 A.

[0125] Example 14: A method for manufacturing a female electrical contact for receiving a male electrical contact, comprising: At least one wire assembly is provided for receiving the pins of the public electrical contact, wherein each wire assembly includes: A conductive, substantially cylindrical conductor carrier, which defines an internal portion and has a length L along its longitudinal axis, and A plurality of wires are arranged within the internal portion of the wire carrier such that the extension direction of each of the wires is inclined relative to the longitudinal axis of the wire carrier. The plurality of wires are configured to surround the pin that receives the male electrical contact with a diameter D. Providing the at least one conductor assembly includes providing the at least one conductor assembly having a ratio r of the length L to the diameter D set as follows: r<1.

[0126] Example 15: The method according to Example 14 includes the step of manufacturing a female electrical contact of any one of Examples 2 to 13.

Claims

1. A female electrical contact for receiving a male electrical contact, the female electrical contact comprising: At least one wire assembly for receiving a pin of the public electrical contact, wherein each wire assembly includes a wire carrier and a plurality of wire components carried by the wire carrier and configured to contact the pin of the public electrical contact, wherein the plurality of wire components comprise a beryllium-free copper-nickel alloy.

2. The bus electrical contact element according to claim 1, wherein, The copper-nickel alloy is a copper-nickel-silicon alloy.

3. The female electrical contact element according to claim 2, wherein, The copper-nickel-silicon alloy comprises 94.0% to 99.1% copper by weight, and optionally 94.6% to 97.6% copper by weight.

4. The female electrical contact according to any one of claims 2 to 3, wherein, The copper-nickel-silicon alloy contains 0.8% to 4.2% nickel, and optionally 2.2% to 4.2% nickel.

5. The female electrical contact according to any one of claims 2 to 4, wherein, The copper-nickel-silicon alloy contains 0.1% to 1.8% silicon by weight, and optionally contains 0.3% to 1.2% silicon by weight.

6. The female electrical contact according to any one of the preceding claims, wherein, The copper-nickel-silicon alloy comprises 94.1% to 97.5% by weight of copper, 2.2% to 4.2% by weight of nickel, and 0.2% to 1.2% by weight of silicon.

7. The power contact element according to any one of the preceding claims, wherein, The plurality of wire components are gold-plated, silver-plated, or nickel-plated.

8. The power contact element according to any one of the preceding claims, wherein, The extension direction of the plurality of conductor components is inclined relative to the longitudinal axis of the conductor carrier.

9. The female electrical contact according to claim 8, wherein, The plurality of conductor components are arranged hyperbolically such that the conductor components are configured such that when the pin is introduced into the female electrical contact, they resiliently align themselves and serve as contact lines surrounding the pin.

10. The female electrical contact according to any one of the preceding claims, wherein, The conductor carrier is substantially cylindrical and defines an internal portion, wherein the plurality of conductor components are arranged in the internal portion of the conductor carrier.

11. The female electrical contact according to claim 10, wherein, The plurality of wire components are formed as a plurality of wires, wherein the opposite ends of the wires are wound around the respective opposite ends of the wire carrier.

12. The power contact according to any one of the preceding claims further includes a conductive socket configured to receive the at least one conductor assembly.

13. The female electrical contact according to claim 12, wherein, The at least one conductor assembly includes at least one conductive sleeve configured to at least partially accommodate the conductor carrier and the plurality of conductor components, and wherein the socket is configured to receive the sleeve of the at least one conductor assembly.

14. The female electrical contact according to any one of the preceding claims, further comprising a terminal for connecting the female electrical contact to a cable, wherein the terminal is optionally configured to be crimped, screwed and / or welded to the cable.

15. The bus contact of claim 14, further comprising a conductive socket configured to receive the at least one wire assembly, wherein the socket and the wiring end are arranged at opposite ends of the bus contact.

16. The female electrical contact according to claim 14 or 15, wherein, The terminal defines an internal space for receiving a cable, and the terminal is configured to be crimped to connect the bus contact and the cable.

17. The power contact element according to claim 16, wherein, The internal space of the terminal is defined by a closed end and an open end, and a crimping pin is located within the internal space and extends from the closed end of the terminal toward the open end.

18. The female electrical contact according to claim 17, wherein, The crimping pin is integrally formed with the closed end of the wiring terminal.

19. The female electrical contact according to claim 17 or 18, wherein, The crimping pin has any one of a cylindrical, cross-shaped, or hexagonal cross-section.

20. The power contact according to any one of the preceding claims, configured to conduct a current of at least 20A, optionally at least 50A, optionally at least 200A, optionally at least 300A, and optionally between 300A and 350A.

21. A female electrical contact according to any one of the preceding claims, comprising at least two conductor assemblies, optionally wherein the at least two conductor assemblies are mounted in the female electrical contact such that the longitudinal axes of the conductor assemblies are substantially aligned with each other and the longitudinal axes correspond to each other.

22. The bus electrical contact according to claim 21, wherein, Adjacent wire assemblies are mounted in the female electrical contact, with space between them such that the plurality of wire parts of one wire assembly do not contact the plurality of wire parts of another wire assembly.

23. The power contact element according to any one of the preceding claims, wherein, Each conductor carrier comprises brass and / or copper.

24. A female electrical contact for receiving a male electrical contact, the female electrical contact comprising: At least one wire assembly for receiving the pins of the public electrical contact, wherein each wire assembly includes: A conductive, substantially cylindrical conductor carrier, defining an internal portion and having a length L along its longitudinal axis; and Multiple wires are configured to contact the pins of the public electrical contact. The plurality of conductors are arranged in the internal portion of the conductor carrier such that the extension direction of each conductor is inclined relative to the longitudinal axis of the conductor carrier. The opposite ends of the conductor are wound around the corresponding opposite ends of the conductor carrier to support the conductor on the conductor carrier. The plurality of wires are hyperbolically arranged inside the wire carrier, such that the wires are configured to elastically align themselves as contact lines around the pin when the pin is introduced into the female electrical contact. The plurality of wires include a beryllium-free copper-nickel-silicon alloy; A conductive socket, configured to receive the at least one wire assembly; and The terminal block is used to connect the female electrical contact to the cable. The socket and the wiring terminal are arranged at opposite ends of the bus electrical contact.

25. A method for manufacturing a female electrical contact for receiving a male electrical contact, comprising: At least one wire assembly is provided for receiving a pin of the male electrical contact, wherein the wire assembly includes: a wire carrier; and a plurality of wire components carried by the wire carrier and configured to contact the pin of the male electrical contact, wherein the plurality of wire components comprise a beryllium-free copper-nickel alloy; Provide conductive sockets; and Insert the at least one wire assembly into the conductive socket.

Images