Power connector

Abstract

An electric power connector comprises an insulation body and two electric power assemblies, the insulation body is provided with a butt joint groove penetrating forwards, the butt joint groove penetrates in the vertical direction at the same time, and the two electric power assemblies are arranged on the left side and the right side of the butt joint groove respectively; each power assembly comprises a terminal group, a conductive block and a power extension line, and the terminal group at least comprises a plurality of first conductive sheets; each first conducting strip is arranged in the vertical direction and comprises a first attachment part and a first elastic arm extending forwards from the first attachment part, and each first elastic arm is provided with a first contact part protruding into the butt joint groove; the plurality of first conductive sheets are arranged along the vertical direction, and the plurality of first attachment parts are attached to the conductive block and are fixed on the conductive block one by one; the electric power extension cord is fixed on the conductive block. The mutually independent conductive sheets form mutually independent elastic arms, so that the elastic deformation height and the bending size of the elastic arms can be precisely controlled, meanwhile, the mold structure can be simplified, and the cost can be reduced.

Description

Technical Field

[0001] This relates to an electrical connector capable of transmitting large currents. Background Technology

[0002] Existing technology, Chinese invention patent CN116137395A, discloses a power connector for contacting slender DC power distribution busbars and a method for monitoring such a connection. Its power terminals consist of first and second spring contact assemblies. Due to the transmission of large currents, temperature rise is inevitable. To record the temperature rise in the very early stages of electrical contact deterioration, a temperature sensor is added. However, this does not truly solve the temperature rise problem.

[0003] With the increasing demand for larger power transmission capabilities, power terminals are becoming larger to form more flexible contact arms, and are increasingly constructed from stacked metal plates. This significantly increases design complexity. Therefore, an improved power connector is desired. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a power connector that improves the terminal structure.

[0005] To solve the above problems, the present invention can adopt the following technical solution: a power connector, including an insulating body and two power components, wherein the insulating body is provided with a forward-through mating groove, the mating groove also extending in the vertical direction, and the two power components are respectively disposed on the left and right sides of the mating groove; each power component includes a terminal group, a conductive block and a power extension line, the terminal group including at least a plurality of first conductive pieces; each first conductive piece is placed in the vertical direction and includes a first attachment portion and a first elastic arm extending forward from the first attachment portion, each first elastic arm having a first contact portion protruding into the mating groove; the plurality of first conductive pieces are arranged in the vertical direction, the plurality of first attachment portions are attached to the conductive block and fixed to the conductive block one by one; the power extension line is fixed to the conductive block.

[0006] To solve the above problems, the present invention can adopt the following technical solution: a power connector, including an insulating body and two power components, wherein the insulating body is provided with a forward-through mating groove, the mating groove also extending in the vertical direction, and the two power components are respectively disposed on the left and right sides of the mating groove; each power component includes a terminal group and a conductive block, the terminal group including at least a plurality of first conductive pieces; each first conductive piece includes a first attachment portion and a first elastic arm extending forward from the first attachment portion, each first elastic arm having a first contact portion protruding into the mating groove; the plurality of first attachment portions are arranged side by side abutting each other in the vertical direction, the plurality of first elastic arms are arranged side by side with a gap between adjacent first elastic arms; the first attachment portions are attached one by one to the conductive block.

[0007] Compared with the prior art, the present invention forms independent elastic arms from independent conductive sheets, which can precisely control the height and bending size of the elastic deformation of the elastic arm, while simplifying the mold structure and reducing costs. Attached Figure Description

[0008] Figure 1 This is a perspective view of the power connector according to the first embodiment of the present invention.

[0009] Figure 2 yes Figure 1 A three-dimensional view from another angle.

[0010] Figure 3 yes Figure 2 A three-dimensional view of the insulating body.

[0011] Figure 4 yes Figure 2 A 3D view of a power component.

[0012] Figure 5 yes Figure 4 A top view of an electrical component.

[0013] Figure 6 yes Figure 4 A more detailed 3D disassembly.

[0014] Figure 7 yes Figure 6 A more detailed 3D disassembly.

[0015] Figure 8 yes Figure 7 3D exploded view of the intermediate terminal group and conductive block.

[0016] Figure 9 yes Figure 8 A three-dimensional view of the middle terminal assembly from another angle.

[0017] Figure 10 yes Figure 9 An exploded 3D view of the five conductive sheets.

[0018] Figure 11 yes Figure 9 A 3D view of the first conductive sheet in the middle row.

[0019] Figure 12 yes Figure 9 A perspective view of a row of first conductive sheets and a row of second conductive sheets, with one of the first conductive sheets and one of the second conductive sheets disassembled to clearly show their structure.

[0020] Figure 13 This is a perspective view of a power component according to the second embodiment of the present invention.

[0021] Figure 14 yes Figure 13 Further disassembly and 3D view, in which some structures are not shown.

[0022] Figure 15 yes Figure 14 A three-dimensional view of the middle terminal assembly from another angle.

[0023] Component symbol explanation: Power connector 100 Insulating body 10 mating groove 11 terminal groove 12 spacer wall 13 positioning hole 14 mounting wing 15 Power Components 20A and 20B Terminal groups 20, 20a Attachment 201, Inner surface 2011, Outer surface 2012, Contact part 202 First conductive sheet 21, first attachment portion 211, first elastic arm 212, first contact portion 213 First feeding gap 2131 First sub-contact part 2132 Slit 2133 Gap 215 Second conductive sheet 22, second attachment portion 221, second elastic arm 222, second contact portion 223 Third conductive sheet 23; Third attachment part 231; Third elastic arm 232; Third contact part 233 Second feeding gap 2331 Third sub-contact part 2332 Fourth conductive sheet 24, fourth attachment 241, fourth elastic arm 242, fourth contact 243 Fifth conductive sheet 25, fifth attachment portion 251, fifth elastic arm 252, fifth contact portion 253 Third feeding gap 2531 Fifth sub-contact part 2532 Concave hole 261, convex bulge 262, through hole 27 Conductive block 30 inner side 311 outer side 312 Depression 32, attachment surface 321, abutment surface 322, rear depression 33, fixing hole 34 Power extension cord 40 Pressing piece 51, concave hole 512 First bolt assembly 52 First backing plate 53, second backing plate 54 Second bolt assembly 55, pressing member 56, pressing lug 561 Positioning member 64, grounding member 65 Specific implementation manner

[0024] Next, the technical solutions in the embodiments of the present application will be described in conjunction with the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments.

[0025] The present invention is a power connector that can transmit large currents. In a specific embodiment, the direct current converted and output by a power supply unit (PSU) is transmitted to a rack busbar through the power connector; alternatively, the direct current of the rack busbar is transmitted to an arithmetic server through the power connector. Currently, the rack busbar defined by the OCP Association includes positive and negative conductors and an insulating strip supporting the positive and negative conductors. The positive and negative conductors are respectively embedded in two opposite side surfaces of the insulating strip. When the rack busbar is inserted into the docking slot 11 provided in the power connector 100, the terminal groups 20 on both sides of the docking slot are respectively in contact with the positive and negative conductors, and the large-current transmission is completed through the power extension cord 40 at the rear end thereof. For the convenience of description, it is defined that the slender rack busbar extends in the up and down directions. The docking slot 11 not only penetrates forward but also penetrates in the up and down directions to facilitate the slender rack busbar. The terminal groups 20 are located on the left and right sides of the docking slot.

[0026] Refer Figure 1-4 As shown, the power connector 100 of the present invention includes an insulating body 10 and two power components 20A. The insulating body 10 is provided with a docking slot 11 that penetrates forward and also penetrates in the up and down directions. The two power components 20A are respectively arranged on the left and right sides of the docking slot 11. Each power component 20A includes a terminal group 20, a conductive block 30, and a power extension cord 40. The terminal group 20 and the power extension cord 40 are respectively fixed to the conductive block 30 to form a current path.

[0027] The insulating body 10 includes terminal slots 12 located on the left and right sides of the docking groove 11. The two terminal slots extend rearward and are separated by a partition wall 13 in the left-right direction. The partition wall 13 is located behind the docking groove 11. The power assembly 20A is inserted into the corresponding terminal slot 12 from back to front, and the multiple contact portions 202 of its terminal group protrude into the docking groove 12, thereby contacting the power distribution bus inserted therein to achieve current conduction.

[0028] The electrical connector 100 includes multiple limiting members 64. The upper and lower surfaces of the conductive block 30 are respectively provided with fixing holes 34, and the insulating body is provided with positioning holes 14 at corresponding fixing holes 34. The limiting member 64 passes through the positioning hole 14 and is fixed in the fixing hole 34, with a portion of the limiting member 64 housed within the positioning hole 14 to restrict the power assembly 20A from detaching from the insulating body 10 in the front-back direction. After the power assembly 20A is installed and fixed in the terminal slot 12, the limiting member 64 is assembled into the fixing hole 34 and the positioning hole 14, thereby restricting the movement of the power assembly in the front-back direction. In a specific embodiment, the limiting member 64 can be a screw made of stainless steel, such as an M2 screw. In other embodiments, the limiting member 64 can also adopt other structures, such as a riveting pin.

[0029] The insulating body 10 is further provided with two mounting wings 15 extending in the left-right direction. A grounding member 65 is fixed to the front end face of the mounting wing 15 and extends with several elastic long arms, which are located on the left and right outer sides of the insulating body and in front of the mounting wings.

[0030] In this embodiment, the terminal group 20 and the conductive block 30 are located within the terminal slot 12. The terminal slot 12 extends outward in the left-right direction at the rear end of the mounting wing 14. Thus, the power extension line 40 is located outside the insulating body 10, particularly the portion where the power extension line 40 is attached to the conductive block 30, which is exposed outside the insulating body 10. This increases the area of ​​the conductive material exposed to the air, facilitating heat dissipation. In this embodiment, the power extension line 40 and the conductive block 30 are fixed by multiple second bolt assemblies 55 extending in the left-right direction. The exposed second bolt assemblies 55 facilitate heat dissipation and reduce the volume of the insulating body. In this embodiment, the first bolt assembly 55 includes an M4 screw, a washer, and a spring washer M4.

[0031] The power extension cord 40 of this invention can be made of copper busbars, aluminum busbars, or copper cables with multiple copper fibers. For transmitting large currents, such as those up to thousands of amperes, copper busbars or aluminum busbars are preferred, as are combinations of both. In this embodiment, a cold-pressed soft copper busbar structure is used.

[0032] In this invention, each terminal group 20 includes at least a plurality of first conductive sheets 21, which are arranged side-by-side in a vertical direction. Each first conductive sheet 21, placed in the vertical direction, includes a first attachment portion 211 and a first elastic arm 212 extending forward from the first attachment portion 211. Each first elastic arm has a first contact portion 213 protruding into the mating groove 11. The plurality of first attachment portions 211 are attached to and fixed to the conductive block 30.

[0033] In this embodiment, eight first conductive sheets 21 are arranged side-by-side in the vertical direction, thus eight first elastic arms 212 are arranged in a row in the vertical direction, and eight first attachment portions 211 are arranged in a row in the vertical direction. Figure 13 In the second embodiment shown, five first conductive sheets 21 are arranged side-by-side in a row. In other embodiments, other numbers can be arranged, and the number of first conductive sheets can be appropriately selected according to the required current transmission magnitude. The independent conductive sheets forming independent elastic arms allow for precise control of the height and bending dimensions of the elastic arm's elastic deformation, while also simplifying the mold structure and reducing costs.

[0034] Furthermore, adjacent first attachment portions 211 abut against each other in the vertical direction, which not only reduces the size of multiple first attachment portions 211 in the vertical direction, but also allows adjacent first conductive pieces 21 to be electrically connected to each other, shortening the parallel current transmission path. Adjacent first elastic arms 212 have a small gap 215 to avoid interference, especially during deformation after the power distribution busbar is inserted. In other embodiments, adjacent first conductive pieces can be spaced a certain distance apart according to some special needs. In a specific embodiment, the first attachment portions 211 are formed by stamping and cutting metal plates, with their cut surfaces perpendicular to the vertical direction abutting against each other, i.e., arranged side-by-side to form electrical conductivity. This allows for the increase or decrease of adjacent first conductive pieces to meet different current requirements.

[0035] In this embodiment, each terminal group 20 further includes four sets of conductive sheets, which are stacked one on top of the other on the outside of the corresponding conductive sheet. That is, each terminal group consists of multiple first conductive sheets 21, multiple second conductive sheets 22, multiple third conductive sheets 23, multiple fourth conductive sheets 24, and multiple fifth conductive sheets 25 from the inside out. It should be noted that the first to fifth are not in any particular order, but are only used to distinguish different component names. In fact, the prefixes such as first and second can be omitted when the description is clear. For ease of description, the side adjacent to the mating groove 11 is positioned as the inside, and the opposite side is the outside.

[0036] Each second conductive sheet 22 includes a second attachment portion 221 and a second elastic arm 222 extending forward from the second attachment portion. Each second elastic arm has a second contact portion 223 protruding into the mating groove 11. Each second conductive sheet 22 is stacked on the outside of the corresponding first conductive sheet 21. The second attachment portion 221 is attached to the outside of the first attachment portion 211.

[0037] Each third conductive sheet 23 includes a third attachment portion 231 and a third elastic arm 232 extending forward from the third attachment portion. Each third elastic arm has a third contact portion 233 protruding into the mating groove 11. Each third conductive sheet is stacked one on top of the corresponding second conductive sheet.

[0038] Each fourth conductive sheet 24 includes a fourth attachment portion 241 and a fourth elastic arm 242 extending forward from the fourth attachment portion. Each fourth elastic arm has a fourth contact portion 243 protruding into the mating groove 11. Each fourth conductive sheet 24 is stacked one on top of the corresponding third conductive sheet 23 on the outside.

[0039] Each fifth conductive sheet 25 includes a fifth attachment portion 251 and a fifth elastic arm 252 extending forward from the fifth attachment portion. Each fifth elastic arm has a fifth contact portion 253 protruding into the mating groove 11. Each fifth conductive sheet 25 is stacked one on top of the corresponding fourth conductive sheet 24.

[0040] As described above, the terminal group consists of five conductive layers, each layer comprising eight conductive layers, thus enabling the transmission of high currents up to 1000A. In the second embodiment, refer to... Figure 15 The terminal group consists of five conductive sheets, each layer comprising five conductive sheets, thus enabling the transmission of high currents up to 550A. In other embodiments, for transmitting smaller currents, the terminal group may consist of only one conductive sheet, i.e., only a plurality of first conductive sheets 21. Alternatively, the terminal group may consist of only two conductive sheets, i.e., only a plurality of first conductive sheets 21 and a plurality of second conductive sheets 22. Alternatively, the terminal group may consist of only three conductive sheets, i.e., only a plurality of first conductive sheets 21, a plurality of second conductive sheets 22, and a plurality of third conductive sheets 23. Or, other numbers of layers and other numbers of conductive sheets in each layer. When multiple conductive sheets are stacked, the independent conductive sheets are more effective in controlling the elastic height of each elastic arm, avoiding mutual interference.

[0041] In summary, after the conductive sheets are stacked together, the above-mentioned attachment portion constitutes the attachment portion 201 of the terminal group 20, and the above-mentioned contact portion constitutes the contact portion 202 of the terminal group. The attachment portion 201 is provided with opposing inner surface 2011 and outer surface 2012.

[0042] In the above-mentioned multilayer conductive sheet arrangement, the contact portions are further designed to avoid interference between them during deformation. Each first contact portion 213 is divided into two first sub-contact portions 2132 arranged in the vertical direction by a first feeding gap 2131. The second contact portion 223 at least partially passes through the first feeding gap 2131. Each third contact portion 23 is divided into two third sub-contact portions 2332 arranged in the vertical direction by a second feeding gap 2331. The front end of the second contact portion 223 is accommodated within the second feeding gap 2331, and the fourth contact portion 243 at least partially passes through the second feeding gap 2331. Of course, other designs are also possible. The first feeding gap 2131 extends further rearward to form a slit 2133, which advantageously increases the elastic deformation of the first sub-contact portions 2132. Similarly, each fifth contact portion 25 is separated by a third feeding gap 2531 into two fifth sub-contact portions 2532 arranged in the vertical direction, and the front end of the fourth contact portion is accommodated within the third feeding gap 2531.

[0043] In this embodiment, the conductive block 30 is provided with a recessed portion 32, which has an attachment surface 321 and abutment surface 322. The first attachment surface 321 is arranged in the left-right direction, and the first abutment surface 322 is arranged facing forward. In this way, multiple attachment portions are attached to the attachment surface 321 and abut against the abutment surface 322. This facilitates the setting of the attachment portions of the terminal group and also allows for better positioning of the attachment portions of the terminal group.

[0044] Each power assembly 20A includes a clamping plate 51, which is attached to one side of both the conductive block 30 and the attachment portion 201, for better fixing the attachment portion 201 of the terminal group to the conductive block 30.

[0045] The conductive block 30 has opposing inner surfaces 311 and outer surfaces 312. An attachment surface 321 is located on the outer surface 312, and a clamping piece is attached to the attachment portion 201 and the outer surface 312 of the conductive block. Multiple first bolt assemblies 52 pass through through holes 27 provided in the conductive block 30 and the attachment portion 201 to fix the terminal group 20 to the conductive block 30. In this embodiment, the first bolt assembly 52 includes an M2 screw, a washer, and a spring washer. In other embodiments, the attachment portion of the terminal group can be fixed to the conductive block by other methods, such as laser spot welding, laser welding, or even adhesive bonding.

[0046] In this embodiment, a first pad 53 is disposed between the clamping plate 51 and the outer surface 2012 of the attachment portion 201, and a second pad 54 is disposed between the first bolt assembly 52 and the inner surface 2011 of the attachment portion 201, which can better position the multiple independent conductive sheets. The first bolt assembly 52 passes through the through hole 511 of the clamping plate 51, the through hole 27 of the terminal group, the through hole 531 of the first pad 53, and the through hole 541 of the second pad 54, thereby fixing its terminal group 20 to the conductive block 30. The second bolt assembly 55 passes through the through holes of the clamping plate 51, the conductive block, and the power extension wire to fix them to each other, thus forming the electronic component 20A.

[0047] Each conductive sheet has a recessed hole 261 on its inner side 2011 of the attachment portion, and a protrusion 262 is provided on the corresponding outer side 2012. When multiple conductive sheets are stacked on top of each other, the protrusion 262 is positioned in the recessed hole 262, which can better position the attachment portion. The clamping plate 51 also has a recessed hole 512 for accommodating the protrusion 262 of the attachment portion.

[0048] As shown in Figures 13-15, this is the power assembly 20B of the second embodiment. Each layer of conductive sheets in the terminal group 20a consists of five conductive sheets. The conductive block 30 has a rear recess 33 on its inner side. The front ends of the two power extension lines are placed in the rear recess 33 and abut forward. The four power extension lines 40 are placed on the outer side of the conductive block and fixed by the second bolt assembly. In this embodiment, no limiting member is provided. Two pressing members 56 are fixed to the inner side 311 of the conductive block. They extend rearward and inwardly inclined pressing lugs 561, which press against the spacer wall 13 of the insulating body to prevent the power assembly 20B from detaching rearward.

[0049] In summary, the above are merely preferred embodiments of the present invention and should not be construed as limiting the scope of the present invention. Any simple equivalent changes and modifications made in accordance with the claims and description of the present invention should still fall within the scope of the patent of the present invention.

Claims

1. A power connector, comprising an insulating body and two power components, wherein the insulating body has a forward-through mating groove that extends vertically, and the two power components are respectively disposed on the left and right sides of the mating groove; Its features are: Each of the aforementioned power components includes a terminal group, a conductive block, and a power extension line, wherein the terminal group includes at least a plurality of first conductive plates; Each of the first conductive sheets is placed along the vertical direction and includes a first attachment portion and a first elastic arm extending forward from the first attachment portion. Each of the first elastic arms is provided with a first contact portion protruding into the docking groove. Multiple first conductive sheets are arranged along the vertical direction, and multiple first attachment portions are attached to the conductive block and fixed to the conductive block one by one. The power extension cable is fixed to the conductive block.

2. The power connector as described in claim 1, characterized in that: Each of the power components includes a plurality of second conductive sheets, each second conductive sheet includes a second attachment portion and a second elastic arm extending forward from the second attachment portion, and each second elastic arm is provided with a second contact portion protruding into the mating groove; Each of the second conductive sheets is stacked on the outside of the corresponding first conductive sheet; The second attachment is attached to the outside of the first attachment and fixed to the conductive block.

3. The power connector as described in claim 1, characterized in that: The conductive block has a recessed portion, the recessed portion has a first attachment surface and a first abutting surface, the first attachment surface is arranged along the left and right direction, and the first abutting surface is arranged facing forward; a plurality of the first attachment portions are attached to the first attachment surface and abut against the first abutting surface backward.

4. The power connector as described in claim 3, characterized in that: The power assembly includes a clamping plate that is attached to both the conductive block and the terminal group.

5. The power connector as described in claim 4, characterized in that: The conductive block has opposing inner and outer surfaces, the first attachment surface is disposed on the outer surface of the conductive block, and the clamping sheet is attached to the outer surface of the conductive block and the terminal group.

6. The power connector as described in claim 1, characterized in that: Multiple bolt assemblies pass through the conductive block and the first attachment portion to secure the terminal group to the conductive block.

7. The power connector as described in claim 1, characterized in that: Each of the aforementioned power components includes multiple limiting elements; The upper and lower surfaces of the conductive block are respectively provided with fixing holes, and the insulating body is provided with positioning holes at the corresponding fixing holes; The limiting member passes through the positioning hole and is fixed in the fixing hole, and a portion of the limiting member is accommodated in the positioning hole to restrict the power assembly from disengaging from the insulating body in the front-back direction.

8. The power connector as described in claim 2, characterized in that: Each of the first contact portions is divided into two first sub-contact portions arranged along the vertical direction by a first feeding gap, and the second contact portion at least partially passes through the first feeding gap.

9. The power connector as described in claim 8, characterized in that: Each of the terminal groups includes a plurality of third conductive sheets and a plurality of fourth conductive sheets; Each of the third conductive sheets includes a third attachment portion and a third elastic arm extending forward from the third attachment portion, and each of the third elastic arms is provided with a third contact portion protruding into the mating groove; Each of the fourth conductive sheets includes a fourth attachment portion and a fourth elastic arm extending forward from the fourth attachment portion, and each of the fourth elastic arms is provided with a fourth contact portion protruding into the mating groove; Each of the third conductive sheets is stacked on the outside of the corresponding second conductive sheet; Each of the fourth conductive sheets is stacked on the outside of the corresponding third conductive sheet.

10. The power connector as claimed in claim 9, characterized in that: Each of the third contact portions is divided into two third sub-contact portions arranged along the vertical direction by a second feeding gap, the front end of the second contact portion being accommodated within the second feeding gap, and the fourth contact portion at least partially passing through the second feeding gap.

11. The power connector as claimed in claim 9, characterized in that: Each of the terminal groups includes a plurality of fifth conductive sheets; Each of the fifth conductive sheets includes a fifth attachment portion and a fifth elastic arm extending forward from the fifth attachment portion, and each of the fifth elastic arms is provided with a fifth contact portion protruding into the mating groove; Each of the fifth contact portions is divided into two fifth sub-contact portions arranged along the vertical direction by a third feeding gap, and the front end of the fourth contact portion is accommodated within the third feeding gap.

12. The power connector as claimed in claim 1, characterized in that: Each of the power components includes multiple pressing members, which are fixed to the inner side of the conductive block; the pressing members are provided with rearward and inwardly inclined pressing lugs, which press against the insulating body to prevent the power component from detaching from the insulating body.

13. A power connector, comprising an insulating body and two power components, wherein the insulating body is provided with a forward-through mating groove, the mating groove also extending in a vertical direction, and the two power components are respectively disposed on the left and right sides of the mating groove; Its features are: Each of the power components includes a terminal group and a conductive block, wherein the terminal group includes at least a plurality of first conductive sheets; Each of the first conductive sheets includes a first attachment portion and a first elastic arm extending forward from the first attachment portion, and each of the first elastic arms is provided with a first contact portion protruding into the mating groove; Multiple first attachment portions are arranged side by side abutting each other along the vertical direction, and multiple first elastic arms are arranged side by side with gaps between adjacent first elastic arms; The first attachment portion is attached to each of the conductive blocks.

14. The power connector as claimed in claim 13, characterized in that: The terminal group includes a plurality of second conductive sheets, each of which is stacked on the outside of a corresponding first conductive sheet; each of the second conductive sheets includes a second attachment portion and a second elastic arm extending forward from the second attachment portion, and each of the second elastic arms is provided with a second contact portion protruding into the mating groove.

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