Method of manufacturing an electrical plug and connector

Abstract

This invention relates to the field of high-voltage connector technology, and discloses a method for manufacturing an electrical plug and a connector. The method for manufacturing the electrical plug includes the following steps: connecting and fixing multiple power lines to multiple first conductive elements to form a wire bundle; preparing a first body using insulating material, and forming multiple mounting holes within the first body, wherein the mounting holes penetrate the first body along its front-to-back direction, and the inner diameter of the mounting holes is greater than or equal to the outer diameter of the first conductive elements; inserting multiple first conductive elements from the rear end of the mounting holes into corresponding mounting holes, with at least a portion of the power lines exposed outside the mounting holes, thereby forming a preliminary electrical plug component; injection molding a second body using insulating material onto the outside of the preliminary electrical plug component, sealing the rear end of the mounting holes and covering the wire bundle outside the mounting holes, thereby forming an integral structure between the first body and the second body to obtain the electrical plug. This invention can prevent creepage during the use of the electrical plug.

Description

Technical Field

[0001] This invention relates to the field of high-voltage connector technology, and in particular to a method for manufacturing an electrical plug and a connector. Background Technology

[0002] As medical electronic devices evolve towards higher power and precision, the electrical systems within these devices place higher demands on the high-voltage withstand performance and insulation reliability of connectors. Medical connectors are typically used for power transmission or signal connection; their plugs, as critical electrical connection components, need to maintain stable electrical performance during long-term use and meet the withstand voltage test requirements of relevant safety standards.

[0003] Chinese patent document CN204130800U discloses a waterproof plug for the external lead wire of an IC card smart cold water meter. It discloses that the insertion tube assembly consists of an insertion tube fixing block and multiple copper elastic insertion tubes passing through it. The ends of the copper elastic insertion tubes are located inside the lower cavity, and the lower power line extends into the lower cavity and is welded to the copper elastic insertion tubes. The lower cavity is filled with 703 sealant, and the lower power line is pulled down to allow the excess 703 sealant to be discharged from the drain hole, thus removing the excess 703 sealant.

[0004] However, air bubbles are unavoidable during the sealing process in the lower cavity. As the sealant enters from the inlet and exits through the outlet, these air bubbles can easily flow with the sealant and remain between the copper flexible connector and the outlet. Due to the presence of these air bubbles, the insulation material will gradually carbonize under long-term exposure to high voltages of 1500V and above. This can easily create localized conductive paths between the copper flexible connector and the outlet, and these carbonized paths can extend to the surface of the lower cavity, leading to creepage to the outside of the plug. Therefore, the existing structure is still prone to insulation failure. Summary of the Invention

[0005] The primary objective of this invention is to provide a method for manufacturing an electrical plug to prevent creepage during long-term use and ensure safety.

[0006] Another object of the present invention is to provide a connector.

[0007] To address the aforementioned technical problems, the present invention provides the following technical solution: A method for manufacturing an electrical plug includes the following steps: Multiple power lines are connected and fixed to multiple first conductive components to form a wire bundle; The first body is made of insulating material, and a plurality of mounting holes are formed in the first body, wherein the mounting holes penetrate the first body in the front-back direction, and the inner diameter of the mounting holes is greater than or equal to the outer diameter of the first conductive element. The first conductive elements connected to the power cord are inserted into the corresponding mounting holes from the rear end of the mounting holes, and at least a portion of the power cord is exposed outside the mounting holes, thereby forming a pre-assembled plug. The second body is injection molded as an integral structure on the outside of the electrical plug preform using insulating material. The second body seals the rear end of the mounting hole and covers the exposed wire harness portion outside the mounting hole, thereby forming an integral structure between the first body and the second body to obtain the electrical plug.

[0008] In some embodiments, the method for manufacturing an electrical plug further includes the following steps: In the case where multiple first conductive elements connected to the power cord are respectively inserted into the corresponding mounting holes from the rear end of the mounting holes, the connection portion of the first conductive element and the power cord is entirely placed into the corresponding mounting hole. In the case where a second body is injection molded on the outside of the electrical plug preform, the second body blocks the rear end of the mounting hole and covers the power cord exposed outside the mounting hole.

[0009] In some embodiments, the method for manufacturing an electrical plug further includes the following steps: When the connection between the first conductive element and the power cord is inserted entirely into the corresponding mounting hole, the power cord is inserted into the corresponding mounting hole and forms an interference fit with the corresponding mounting hole to seal the rear end of the mounting hole.

[0010] In some embodiments, the method for manufacturing an electrical plug further includes the following steps: In the case where a second body is injection molded on the outside of the electrical plug preform, insulating material is used to cover at least the outer peripheral portion of the rear end of the first body to form the second body.

[0011] In some embodiments, the method for manufacturing an electrical plug further includes the following steps: When a first body is prepared using an insulating material and a plurality of mounting holes are formed within the first body, wherein the mounting holes penetrate the first body along the front-back direction, a concave hole is formed at the front end of the mounting holes in the first body.

[0012] This invention also relates to a connector, including an electrical socket and an electrical plug manufactured by the same method. The electrical plug includes a first body, a second body, a first conductive element, and a power cord. The first body has multiple mounting holes extending through its front and rear sides. Multiple first conductive elements and multiple power cords are provided, with the rear ends of the multiple first conductive elements corresponding to and electrically connected to the multiple power cords. The multiple first conductive elements are correspondingly inserted into the multiple mounting holes. The second body covers the rear ends of the first body. The electrical socket includes a socket body and a second conductive element. The socket body has multiple second conductive elements, which extend through the socket body along its front-rear direction to both sides. The multiple second conductive elements are correspondingly adapted and connected to the multiple first conductive elements.

[0013] In some embodiments, a recessed hole is provided at the front end of the first body corresponding to each of the mounting holes, and a sealing protrusion is provided at the front end of the socket body corresponding to each of the second conductive elements. Each sealing protrusion covers the root of each of the second conductive elements. After the second conductive element passes through the first conductive element, the sealing protrusion is adapted to be inserted into the recessed hole.

[0014] In some embodiments, the socket body is provided with a guide sleeve on the side near the electrical plug, the second conductive element is located inside the guide sleeve, and the first body is adapted to pass through the guide sleeve.

[0015] In some embodiments, the inner wall of the guide sleeve is provided with a guide groove along the front-back direction of the electrical socket, and the outer side of the first body is provided with a guide protrusion along the front-back direction of the electrical plug, the guide protrusion being adapted to enter the guide groove.

[0016] In some embodiments, after the electrical plug and the electrical socket are mated together, the distance between the second body and the guide sleeve is a, in mm, and the overlap between the first body and the guide sleeve in the front-back direction of the electrical plug is b, in mm, where 0.06 ≤ a / b ≤ 0.2.

[0017] In some embodiments, the first conductive element is a conductive sleeve, and the second conductive element is a conductive pin, wherein the conductive pin is adapted to be inserted into the conductive sleeve.

[0018] In some embodiments, the conductive sleeve has a circular cross-section, and the diameter of the conductive sleeve gradually decreases from both ends to the middle along the axial direction of the conductive sleeve, so that a clamping portion for clamping the conductive pin is formed in the middle region of the conductive sleeve.

[0019] In some embodiments, the conductive sleeve has a deformation groove formed along its axial direction in its central region.

[0020] The present invention discloses a method for manufacturing an electrical plug and a connector, which, compared with the prior art, have the following advantages: In this invention, a wire harness formed by the power cord and the first conductive element is inserted into a mounting hole in a first main body made of insulating material. The first conductive element enters the mounting hole from its rear end. Since the inner diameter of the mounting hole is greater than or equal to the outer diameter of the first conductive element, it facilitates the smooth insertion of the first conductive element into the mounting hole. Furthermore, at least a portion of the power cord is exposed outside the mounting hole. Therefore, by using an insulating material to injection mold an integral structure onto the outside of the plug preform, the second main body seals the rear end of the mounting hole and covers the portion of the wire harness exposed outside the mounting hole. Compared to the prior art, this invention... The second body is a single-piece structure without any adhesive drainage holes. Therefore, there is no air bubble path from the first conductive element to the outside of the second body. Consequently, even under long-term high-voltage conditions of 1500V and above, localized conductive paths from the first conductive element to the outside of the second body are less likely to form, thus reducing the likelihood of creepage. Furthermore, this application ensures that the first conductive element is completely sealed within the mounting hole, enhancing the sealing effect and further reducing creepage. It also completely isolates adjacent first conductive elements, preventing creepage and ensuring superior insulation and high-voltage resistance of the plug. Moreover, the first and second bodies form a single-piece structure, ensuring a stable integrated structure and a more secure connection between the first conductive element and the power cord within both bodies, guaranteeing the long-term reliability and safety of the manufactured plug. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of one step of the manufacturing method of the electrical plug of the present invention; Figure 2 This is a schematic diagram of the second step of the manufacturing method of the electrical plug of the present invention; Figure 3 This is a schematic diagram of three steps in the manufacturing method of the electrical plug of the present invention; Figure 4 This is a schematic diagram of four steps in the manufacturing method of the electrical plug of the present invention; Figure 5 This is a schematic diagram of the five steps of the manufacturing method of the electrical plug of the present invention; Figure 6This is a schematic diagram of the overall structure of the connector of the present invention; Figure 7 This is an exploded view of one of the connectors of the present invention; Figure 8 This is another exploded view of the connector of the present invention; Figure 9 This is a schematic diagram of the electrical socket of the present invention; Figure 10 This is a schematic diagram of the electrical plug of the present invention; Figure 11 This is a cross-sectional view of the connector of the present invention; Figure 12 yes Figure 11 Enlarged view of point A in the image; Figure 13 This is a cross-sectional view of the electrical plug of the present invention; Figure 14 This is another cross-sectional view of the electrical plug of the present invention; Figure 15 This is a cross-sectional view of the electrical socket of the present invention; Figure 16 This is a schematic diagram showing the connection relationship between the first conductive element and the power line of the present invention; Figure 17 This is a schematic diagram of the structure of the first conductive element and the power line of the present invention.

[0022] In the figure, 1 is the electrical plug; 11 is the first body; 111 is the mounting hole; 112 is the recessed hole; 12 is the second body; 121 is the recessed part; 122 is the anti-slip structure; 13 is the first conductive element; 131 is the clamping part; 132 is the deformation groove; 14 is the power cord; and 15 is the guide ridge. 2. Electrical socket; 21. Socket body; 22. Second conductive component; 23. Sealing protrusion; 24. Guide sleeve; 25. Guide groove. Detailed Implementation

[0023] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0024] In the description of this invention, it should be understood that the term "comprising" as used in this specification means the presence of the stated features, integers, steps, operations, parts, and / or components, but does not exclude the presence or addition of one or more other features, integers, steps, operations, parts, components, and / or groups thereof. It should be understood that when we say a part is "connected" to another part, it can be directly connected to the other part, or there may be intermediate parts. The term "and / or" as used herein includes all or any unit and all combinations of one or more associated listed items.

[0025] This embodiment provides an electrical plug 1, which is a key interface component for realizing electrical connections between electrical systems. It is mainly used to establish a stable power or signal transmission channel between the internal components of a medical device and an external power / signal terminal. For example... Figure 1 As shown, this embodiment provides a method for manufacturing an electrical plug 1, which specifically includes the following steps: S1. Connect and fix multiple power lines 14 to multiple first conductive elements 13 respectively to form a wire bundle; S2. A first body 11 is prepared using an insulating material, and a plurality of mounting holes 111 are formed in the first body 11, wherein the mounting holes 111 penetrate the first body 11 along the front-back direction of the first body 11, and the inner diameter of the mounting holes 111 is greater than or equal to the outer diameter of the first conductive element 13. S3. The plurality of first conductive elements 13 connected to the power cord 14 are respectively inserted into the corresponding mounting holes 111 from the rear end of the mounting holes 111, and at least a portion of the power cord 14 is exposed outside the mounting holes 111, thereby forming a plug pre-fit. S4. Using insulating material, a second body 12 is injection molded as an integral structure on the outside of the electrical plug preform, so that the second body 12 seals the rear end of the mounting hole 111 and covers the wire harness portion exposed outside the mounting hole 111, thereby forming an integral structure between the first body 11 and the second body 12 to obtain the electrical plug 1.

[0026] It should be noted that there is no specific order between steps S1 and S2. Operators can adjust the order of steps S1 and S2 according to the production environment.

[0027] In this invention, the wire harness formed by the power cord 14 and the first conductive member 13 is inserted into the mounting hole 111 of the first body 11 made of insulating material. The first conductive member 13 is inserted into the mounting hole 111 from the rear end. Since the inner diameter of the mounting hole 111 is greater than or equal to the outer diameter of the first conductive member 13, it is convenient for the first conductive member 13 to be inserted smoothly into the mounting hole 111. At least a portion of the power cord 14 is exposed outside the mounting hole 111. Therefore, the second body 12, which is integrally molded with insulating material on the outside of the plug preform, seals the rear end of the mounting hole 111 and covers the portion of the wire harness exposed outside the mounting hole 111. Compared to... In the prior art, the second body 12 of this application is an integral structure and does not have a glue drainage hole. Therefore, the second body 12 does not have an air bubble path from the first conductive element 13 to the outside of the second body 12. Consequently, even when the plug 1 is in a high-voltage environment of 1500V or above for a long time, it is not easy to generate a local conductive path from the first conductive element 13 to the outside of the second body 12, thus making it less likely to cause creepage. Moreover, this application can ensure that the first conductive element 13 is completely sealed in the mounting hole 111, thereby strengthening the sealing effect of the first conductive element 13 and making it even less likely to cause creepage. Furthermore, it completely blocks the two adjacent first conductive elements 13, so that adjacent first conductive elements 13 will not cause creepage, ensuring the insulation performance of the plug and providing better high-voltage resistance. Furthermore, the first body 11 and the second body 12 form an integral structure, thereby ensuring that the first body 11 and the second body 12 of the electrical plug 1 form a stable integral structure. At the same time, it makes the connection between the first conductive element 13 and the power line 14 in the first body 11 and the second body 12 more stable, ensuring the reliability and safety of the manufactured electrical plug 1 for long-term use.

[0028] It should be noted that by using insulating material to injection mold the second body 12 on the outside of the plug preform, the insulating material of the second body 12 can cover the main terminal of the power cord 14. In this way, during the manufacturing process of the plug 1, the front end and the rear end of the power cord 14 are sealed, thereby completely sealing the area where the power cord 14 is arranged inside the plug 1. This ensures that the area where the power cord 14 is arranged inside the plug 1 is isolated from the outside air. Therefore, even if there are tiny air bubbles between adjacent power cords 14, these air bubbles are surrounded by insulating material, and no creepage phenomenon will occur in the area where the power cord 14 is arranged inside the plug 1. This means that the power cord 14 does not need to be pulled to release air during the manufacturing process of the plug 1, and avoids the power cord 14 and the first conductive element 13 from being pulled, which would affect the stability of the electrical connection.

[0029] Combination Figure 2As shown, in some embodiments, the method for manufacturing the electrical plug 1 further includes the following steps: In step S3, that is, when the plurality of first conductive elements 13 connected to the power cord 14 are respectively inserted into the corresponding mounting holes 111 from the rear end of the mounting holes 111, the connection part of the first conductive element 13 and the power cord 14 is placed entirely into the corresponding mounting holes 111. In step S4, when the second body 12 is injection molded on the outside of the plug preform, the second body 12 blocks the rear end of the mounting hole 111 and covers the power line 14 exposed outside the mounting hole 111, so that the connection part of the first conductive member 13 and the power line 14 is blocked in the corresponding mounting hole 111.

[0030] In other words, by inserting the connection portion of the first conductive element 13 and the power cord 14 entirely into the corresponding mounting hole 111, the insulating material is less likely to flow to the connection portion of the first conductive element 13 and the power cord 14 when the second body 12 is injection molded on the outside of the plug preform, thus not affecting the electrical connection stability of the first conductive element 13 and the power cord 14. Furthermore, the injection-molded second body 12 completely seals the rear end of the mounting hole 111 and covers the power cord 14 exposed outside the mounting hole 111, thereby keeping the electric field sensitive areas of the first conductive element 13 and the power cord 14 away from the external environment, preventing the formation of creepage paths, and ensuring the safety and reliability of the plug 1 under high-voltage operating conditions.

[0031] Combination Figure 3 As shown, in some embodiments, the method for manufacturing the electrical plug 1 further includes the following steps: In step S3, that is, when the connection part of the first conductive element 13 and the power line 14 is inserted into the corresponding mounting hole 111, the power line 14 is inserted into the corresponding mounting hole 111 and forms an interference fit with the corresponding mounting hole 111 to seal the rear end of the mounting hole 111.

[0032] That is, the outer periphery of the end of the power cord 14 that enters the mounting hole 111 contacts and abuts against the inner wall of the mounting hole 111, thereby restricting the movement of the power cord 14 without human intervention. This ensures that the positions of the first conductive element 13 and the power cord 14 will not shift during the injection molding of the second body 12, and the first conductive element 13 and the power cord 14 are not easily separated, thus ensuring the yield rate of the electrical plug 1. Moreover, the insulating material will not flow into the mounting hole 111 due to the obstruction of the power cord 14, and therefore will not flow to the connection part of the first conductive element 13 and the power cord 14, thus not affecting the electrical connection stability of the first conductive element 13 and the power cord 14.

[0033] In some embodiments, after the first conductive element 13 and the power cord 14 are inserted into the mounting hole 111, the outer periphery of the first conductive element 13 contacts and abuts against the inner wall of the mounting hole 111, thereby restricting the first conductive element 13 from moving without human intervention. This ensures that the positions of the first conductive element 13 and the power cord 14 will not shift during the injection molding of the second body 12, and that the first conductive element 13 and the power cord 14 are not easily detached, thus ensuring the yield rate of the electrical plug 1.

[0034] Combination Figure 4 As shown, in some embodiments, the method for manufacturing the electrical plug 1 further includes the following steps: In step S4, that is, when the second body 12 is injection molded on the outside of the plug preform, the insulating material covers at least the outer peripheral portion of the rear end of the first body 11 to form the second body 12.

[0035] That is, after the second body 12 is injection molded, the second body 12 not only completely covers the wire harness portion exposed outside the mounting hole 111, but also covers the rear end portion of the first body 11, thereby increasing the connection area between the first body 11 and the second body 12 and strengthening the stability of the first body 11 and the second body 12 after integral molding. Therefore, when the second body 12 is pulled outward, the force will not be directly transmitted to the first conductive element 13 and the power cord 14, thus not affecting the electrical connection stability of the first conductive element 13 and the power cord 14, ensuring the long-term reliability and safety of the electrical plug 1.

[0036] Combination Figure 5 As shown, in some embodiments, the method for manufacturing the electrical plug 1 further includes the following steps: In step S2, that is, when the first body 11 is prepared using an insulating material and a plurality of mounting holes 111 are formed in the first body 11, wherein the mounting holes 111 penetrate the first body 11 in the front-back direction, a concave hole 112 is formed at the front end of the mounting holes 111 of the first body 11.

[0037] That is, by forming a reserved space at the front end of the mounting hole 111 of the first body 11, the structure of the electrical socket 2 can be inserted when the electrical plug 1 is connected to the electrical socket 2, and the reserved space can be filled. This can help to enhance the sealing performance of the electrical plug 1 after it is connected to the electrical socket 2, prevent moisture from entering the conductive area, and reduce the risk of creepage under high voltage environment.

[0038] Combination Figures 6 to 17 As shown, the present invention also relates to a connector, including an electrical socket 2 and an electrical plug 1 manufactured by the same method as the aforementioned electrical plug 1. The electrical plug 1 includes a first body 11, a second body 12, a first conductive element 13, and a power cord 14. The first body 11 has a plurality of mounting holes 111 extending through its front and rear sides. The first conductive element 13 and the power cord 14 are provided in multiple quantities, and the rear ends of the plurality of first conductive elements 13 are fixed to the plurality of power cords 14, so that one first conductive element 13 is electrically connected to one power cord 14. The plurality of first conductive elements 13 are respectively inserted into the plurality of mounting holes 111. The second body 12 covers the rear ends of the first body 11. The electrical socket 2 includes a socket body 21 and a second conductive element 22. The socket body 21 is provided with a plurality of second conductive elements 22. The second conductive elements 22 extend out of the socket body 21 along the front and rear direction on both sides of the socket body 21 in the front and rear direction. The plurality of second conductive elements 22 are adapted and connected to the plurality of first conductive elements 13.

[0039] The connector includes an electrical plug 1 and an electrical socket 2 for mating and plugging together. When the electrical plug 1 is plugged into and electrically connected to the electrical socket 2, the second conductive element 22 of the electrical socket 2 enters the mounting hole 111 of the electrical plug 1 and is mated and connected with the first conductive element 13, allowing the first conductive element 13, the power cord 14, and the second conductive element 22 to conduct electricity. The first body 11 and the second body 12 of the electrical plug 1 are injection molded as one piece, thereby forming a stable outer shell structure for the electrical plug 1, which can protect the internal components of the electrical plug 1. The first conductive element 13 and the power cord 14 provide better protection. Moreover, they completely isolate and seal the multiple first conductive elements 13 and the multiple power cords 14, that is, they are insulated and sealed between adjacent wire bundles, and there is no creepage path. This allows the plug 1 to be in a highly insulated and sealed structure. When the plug 1 and the socket 2 are plugged in and connected, and the voltage reaches 1500V, no creepage will occur between the wire bundles in the second body 12 of the plug 1, ensuring the reliability and safety of the connector during long-term operation under high voltage.

[0040] In some embodiments, reference Figures 9 to 11 As shown, a recessed hole 112 is provided at the front end of the first main body 11 and corresponding to each of the mounting holes 111. A sealing protrusion 23 is provided at the front end of the socket body 21 and corresponding to each of the second conductive elements 22. Each sealing protrusion 23 covers the root of each second conductive element 22. After the second conductive element 22 passes through the first conductive element 13, the sealing protrusion 23 is adapted to be inserted into the recessed hole 112.

[0041] That is, a recessed hole 112 is provided at the front end of the first main body 11, corresponding to the mounting hole 111. After the plug 1 and the socket 2 are inserted, the sealing protrusion 23 fits into the recessed hole 112, thereby squeezing out the air in the recessed hole 112. After the sealing protrusion 23 is inserted into the recessed hole 112, it can play a waterproof and dustproof role, preventing moisture, dust and other media from entering the first conductive element 13 and the second conductive element 22, so as to avoid creepage and provide better protection. This improves the reliability and safety of the connector under long-term high voltage environment. Moreover, the sealing protrusion 23 and the recessed hole 112 can guide and limit the insertion of the plug 1 and the socket 2, so as to facilitate the insertion of the plug 1 and the socket 2 and ensure the stability of the plug 1 and the socket 2 after insertion.

[0042] Specifically, the recess 112 is circular, and the sealing protrusion 23 is cylindrical, which makes it easier for the sealing protrusion 23 to be inserted into the recess 112, and the connection stability between the two is better, making it less prone to stress concentration problems.

[0043] Furthermore, in combination Figure 13 and Figure 15 As shown, the dimension of the sealing protrusion 23 in the front-rear direction of the socket body 21 is c, in mm, where 2mm ≤ c ≤ 4mm. The depth of the recess 112 in the front-rear direction of the first body 11 is d, in mm, where 2mm ≤ d ≤ 4mm. However, if the dimension of the sealing protrusion 23 in the front-rear direction of the socket body 21 is greater than or equal to the depth of the recess 112 in the front-rear direction of the first body 11, it can ensure that the internal space of the recess 112 is filled, thereby squeezing out the air inside and ensuring a uniform electric field distribution within it, thus reducing the risk of breakdown.

[0044] Combination Figure 9 and Figure 10 As shown, in some embodiments, the socket body 21 is provided with a guide sleeve 24 on the side near the electrical plug 1, the second conductive element 22 is located inside the guide sleeve 24, and the first body 11 is adapted to pass through the guide sleeve 24.

[0045] That is, through the provision of the guide sleeve 24, during the insertion of the electrical plug 1 and the electrical socket 2, the first body 11 slides along the guide sleeve 24 until the first body 11 abuts against the socket body 21. Therefore, it can play a guiding role during the insertion of the electrical plug 1 and the electrical socket 2, so as to facilitate the insertion and removal of the electrical plug 1 and the electrical socket 2. At the same time, it can further enhance the stability of the electrical plug 1 and the electrical socket 2 after insertion, making it less likely for them to detach. Moreover, under the protection of the guide sleeve 24, it can further prevent moisture and dust from entering between the guide sleeve 24 and the first body 11, and prevent moisture and dust from entering the first conductive element 13 and the second conductive element 22.

[0046] In some embodiments, the inner wall of the guide sleeve 24 is provided with a guide groove 25 along the front-back direction of the electrical socket 2, and the outer side of the first body 11 is provided with a guide protrusion 15 along the front-back direction of the electrical plug 1, the guide protrusion 15 being adapted to enter the guide groove 25.

[0047] That is, by providing the guide groove 25 on the inner wall of the guide sleeve 24 and the guide strip on the outer side of the first body 11, the guide strip can slide along the guide groove 25 during the insertion of the plug 1 and the socket 2, thus also serving a guiding function. Therefore, in this invention, the connection between the sealing protrusion 23 and the recess 112, the connection between the first body 11 and the guide sleeve 24, and the connection between the guide strip and the guide groove 25 together constitute multiple guiding and limiting functions, thereby ensuring the convenience of the insertion process of the plug 1 and the socket 2 and the stability after insertion, greatly improving the long-term stability of the connector.

[0048] Combination Figure 11 As shown, in some embodiments, after the electrical plug 1 and the electrical socket 2 are connected, the distance between the second body 12 and the guide sleeve 24 is a, in mm, and the overlap of the first body 11 and the guide sleeve 24 in the front-back direction of the electrical plug 1 is b, in mm, where 0.06≤a / b≤0.2.

[0049] That is, after the plug 1 and the socket 2 are connected, there is still a gap between the second body 12 and the guide sleeve 24, and the gap distance is a. Since the connection between the plug 1 and the socket 2 has multiple guiding and limiting functions, and is in a high voltage environment, in order to prevent moisture and dust from entering the first conductive element 13 and the second conductive element 22 to form a conductive channel, the connection between the plug 1 and the socket 2 needs to be tighter. Therefore, the connection between the plug 1 and the socket 2 is relatively firm. In this regard, the gap between the second body 12 and the guide sleeve 24 makes it easier for the user to pull the plug 1 out of the socket 2.

[0050] Next, since there is a gap between the second body 12 and the guide sleeve 24, moisture and dust may enter the guide sleeve 24 and eventually reach the first conductive element 13 and the second conductive element 22. Therefore, by increasing the overlap dimension b between the first body 11 and the guide sleeve 24 in the front-rear direction of the plug 1, the distance that moisture and dust need to enter the first conductive element 13 and the second conductive element 22 can be increased, thereby reducing the possibility of moisture and dust penetrating into the first conductive element 13 and the second conductive element 22. However, if b is too large, it will undoubtedly increase the size of the connector, making the later installation of the connector more difficult and prone to interference with other components. Therefore, by keeping 0.06≤a / b≤0.2, the risk of moisture and dust entering the first conductive element 13 and the second conductive element 22 can be reduced, and the size of the connector can be avoided from being too large and occupying too much space.

[0051] Specifically, 2mm≤a≤5mm, 25mm≤b≤30mm.

[0052] In some embodiments, the first conductive element 13 is a conductive sleeve, and the second conductive element 22 is a conductive pin, wherein the conductive pin is adapted to be inserted into the conductive sleeve.

[0053] That is, after the electrical plug 1 and the electrical socket 2 are plugged together, the conductive pin is also inserted into the conductive sleeve, and the conductive pin is stably electrically connected to the conductive sleeve.

[0054] Combination Figure 17 As shown, in some embodiments, the conductive sleeve has a circular cross-section, and the diameter of the conductive sleeve gradually decreases from both ends to the middle along the axial direction of the conductive sleeve, so that a clamping portion 131 for clamping the conductive pin is formed in the middle region of the conductive sleeve.

[0055] That is, since the diameter of the conductive sleeve gradually decreases from both ends to the middle, it can guide the conductive pin when it enters the conductive sleeve. Then, when the conductive pin is inserted to the middle position of the conductive sleeve, it can open the conductive sleeve and allow the clamping part 131 in the middle area of ​​the conductive sleeve to clamp the conductive pin, thereby strengthening the stability of the electrical connection between the conductive pin and the conductive sleeve.

[0056] Preferably, the conductive sleeve has a deformation groove 132 formed in the middle region along its axial direction.

[0057] That is, by setting the deformation groove 132, the clamping part 131 in the middle area of ​​the conductive socket can be deformed smoothly, allowing the clamping part 131 to be smoothly opened by the conductive pin, and the clamping part 131 to reset and clamp the conductive pin, further ensuring the stability of the electrical connection between the conductive pin and the conductive socket.

[0058] Combination Figure 12As shown, in some embodiments, a plurality of second conductive elements 22 on the socket body 21 are arranged side by side, and the gap between two adjacent second conductive elements 22 is e, in mm, 2.5mm≤e≤3.5mm, to maintain a reasonable safe distance and not cause the size of the socket body 21 to increase. A plurality of mounting holes 111 on the first body 11 are arranged side by side, and a plurality of second conductive elements 22 correspond one-to-one with a plurality of mounting holes 111, so that two adjacent mounting holes 111 can maintain a sufficient distance to open the recess 112, and the structure of the first body 11 between two adjacent recesses 112 is not too thin so as not to affect the structural strength, so that the structure will not break down due to long-term use and cause two adjacent recesses 112 to connect, ensuring the sealing of each recess 112 and preventing creepage, thus ensuring the structural stability and safety after the plug 1 and the socket 2 are plugged in.

[0059] Combination Figure 10 As shown, in some embodiments, a recess 121 is provided on the outer side of the second body 12 of the plug 1, and an anti-slip structure 122 is provided on the recess 121.

[0060] Because the plug 1 and the socket 2 operate under high voltage conditions, multiple guiding and sealing structures are provided between them to ensure safety and reliability. This makes the connection between the plug 1 and the socket 2 tighter, ensuring safety and reliability during long-term use. However, the tight connection between the plug 1 and the socket 2 also makes them difficult to separate. To address this, the recessed portion 121 and the anti-slip structure 122 are provided so that when the user pulls out the plug 1, they can insert their fingers into the recessed portion 121 and press the anti-slip structure 122 to apply more force to pull out the plug 1.

[0061] Specifically, the anti-slip structure 122 can be an anti-slip texture or an anti-slip protrusion.

[0062] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and substitutions can be made without departing from the technical principles of the present invention, and these improvements and substitutions should also be considered within the scope of protection of the present invention.

Claims

1. A method for manufacturing an electrical plug, characterized in that, Includes the following steps: Multiple power lines (14) are respectively connected and fixed to multiple first conductive parts (13) to form a wire bundle; The first body (11) is made of insulating material and a plurality of mounting holes (111) are formed in the first body (11). The mounting holes (111) penetrate the first body (11) in the front-back direction and the inner diameter of the mounting holes (111) is greater than or equal to the outer diameter of the first conductive element (13). The first conductive elements (13) connected to the power cord (14) are respectively inserted into the corresponding mounting holes (111) from the rear end of the mounting holes (111), and at least a portion of the power cord (14) is exposed outside the mounting holes (111), thereby forming a plug pre-fit. A second body (12) is injection molded as an integral structure on the outside of the electrical plug preform using insulating material. The second body (12) seals the rear end of the mounting hole (111) and covers the wire harness portion exposed outside the mounting hole (111), thereby forming an integral structure between the first body (11) and the second body (12) to obtain the electrical plug (1).

2. The method for manufacturing an electrical plug according to claim 1, characterized in that, It also includes the following steps: In the case where the plurality of first conductive elements (13) connected to the power line (14) are respectively inserted into the corresponding mounting holes (111) from the rear end of the mounting holes (111), the connection part of the first conductive element (13) and the power line (14) is placed entirely into the corresponding mounting holes (111). In the case where the second body (12) is injection molded on the outside of the plug preform, the second body (12) blocks the rear end of the mounting hole (111) and covers the power cord (14) exposed outside the mounting hole (111).

3. The method for manufacturing an electrical plug according to claim 2, characterized in that, It also includes the following steps: When the connection between the first conductive element (13) and the power line (14) is inserted into the corresponding mounting hole (111), the power line (14) is inserted into the corresponding mounting hole (111) and forms an interference fit with the corresponding mounting hole (111) to seal the rear end of the mounting hole (111).

4. The method for manufacturing an electrical plug according to claim 1, characterized in that, It also includes the following steps: In the case where the second body (12) is injection molded on the outside of the plug preform, the insulating material covers at least the outer peripheral portion of the rear end of the first body (11) to form the second body (12).

5. The method for manufacturing an electrical plug according to claim 1, characterized in that, It also includes the following steps: When a first body (11) is prepared using an insulating material and a plurality of mounting holes (111) are formed in the first body (11), wherein the mounting holes (111) penetrate the first body (11) in the front-back direction, a concave hole (112) is formed at the front end of the mounting hole (111) of the first body (11).

6. A connector, characterized in that, The electrical plug (1) is manufactured by the method of manufacturing the electrical socket (2) and the electrical plug (1) according to any one of claims 1-5, wherein, The plug (1) includes a first body (11), a second body (12), a first conductive element (13), and a power cord (14). The first body (11) has a plurality of mounting holes (111) that pass through its front and rear sides. The first conductive element (13) and the power cord (14) are provided in a plurality of ways. The rear ends of the plurality of first conductive elements (13) are fixed and electrically connected to the plurality of power cords (14). The plurality of first conductive elements (13) are respectively inserted into the plurality of mounting holes (111). The second body (12) covers the rear end of the first body (11). The electrical socket (2) includes a socket body (21) and a second conductive element (22). The socket body (21) is provided with a plurality of second conductive elements (22). The second conductive elements (22) extend through the socket body (21) on both sides in the front-back direction. The plurality of second conductive elements (22) are adapted and connected to a plurality of first conductive elements (13).

7. The connector according to claim 6, characterized in that, The front end of the first body (11) is provided with a recess (112) corresponding to each of the mounting holes (111). The front end of the socket body (21) is provided with a sealing protrusion (23) corresponding to each of the second conductive elements (22). Each sealing protrusion (23) covers the root of each second conductive element (22). After the second conductive element (22) passes through the first conductive element (13), the sealing protrusion (23) is adapted to be inserted into the recess (112).

8. The connector according to claim 6, characterized in that, The socket body (21) has a guide sleeve (24) on the side near the plug (1), the second conductive element (22) is located inside the guide sleeve (24), and the first body (11) is adapted to pass through the guide sleeve (24).

9. The connector according to claim 8, characterized in that, The inner wall of the guide sleeve (24) is provided with a guide groove (25) along the front and back direction of the electrical socket (2), and the outer side of the first body (11) is provided with a guide protrusion (15) along the front and back direction of the electrical plug (1), and the guide protrusion (15) is adapted to enter the guide groove (25).

10. The connector according to claim 8, characterized in that, After the plug (1) and the socket (2) are connected, the distance between the second body (12) and the guide sleeve (24) is a, in mm, and the overlap of the first body (11) and the guide sleeve (24) in the front-back direction of the plug (1) is b, in mm, 0.06≤a / b≤0.

2.

11. The connector according to claim 6, characterized in that, The first conductive element (13) is a conductive sleeve, and the second conductive element (22) is a conductive pin, which is adapted to be inserted into the conductive sleeve.

12. The connector according to claim 11, characterized in that, The conductive sleeve has a circular cross-section. Along the axial direction of the conductive sleeve, the diameter of the conductive sleeve gradually decreases from both ends to the middle, so that a clamping part (131) for clamping the conductive pin is formed in the middle region of the conductive sleeve.

13. The connector according to claim 12, characterized in that, The conductive sleeve has a deformation groove (132) in its axial middle region.

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