Multi-contact progressive spark-resistant high current connector and method

Abstract

This invention relates to the field of electrical connection technology, and in particular to a multi-contact progressive anti-arc high-current connector and method, comprising a male connector and a female connector that mate with each other. At least one of the male and female connectors includes an insulating shell, a conductive terminal assembly, and an insulating support. The conductive terminal assembly includes a pre-conducting contact group and a main conducting contact group that sequentially participate in conduction along the insertion and removal direction. The pre-conducting contact group is electrically connected to an anti-arc resistor, and the main conducting contact group is electrically connected to a main current circuit. The pre-conducting contact group and the main conducting contact group are each composed of multiple conductive protrusions or elastic fingers, and the pre-conducting contact group and the main conducting contact group have a length difference in the insertion and removal direction. This invention avoids direct conduction or disconnection of the main contact area under a high potential difference, thereby effectively preventing arcing and sparking.

Description

Technical Field

[0001] This invention relates to the field of electrical connection technology, and in particular to a multi-contact progressive anti-sparking high-current connector and method. Background Technology

[0002] With the development of new energy vehicles, energy storage equipment, industrial power supplies, charging equipment, and high-power electronic systems, high-current connectors are widely used in high-voltage, high-current power transmission scenarios. These connectors typically need to achieve stable electrical connections within a small volume and withstand high operating currents and frequent mating operations. Therefore, their contact reliability and mating safety have a significant impact on the stable operation of the entire system.

[0003] During the insertion and removal of high-current connectors, especially when hot-plugging or when there is a potential difference between the two ends of the connector, sudden current changes can easily occur at the moment of contact or separation between the male and female terminals. When the terminals are not yet fully in contact or are about to separate, the gap in the contact area is small and the electric field strength is high, which can easily generate arcs or sparks. Such arcing or sparking can cause ablation and oxidation of the terminal surface, increased contact resistance, and localized temperature rise. In severe cases, it may also lead to damage to the insulation material, connection failure, or even safety accidents.

[0004] Existing high-current connectors typically employ a single-stage main contact direct contact structure. This means that the male and female terminals directly form the main current loop after mating to a certain position, and the main contact directly disconnects the circuit upon removal. While this structure is simple, in high-voltage, high-current scenarios, the current changes are drastic during the initial mating and final removal phases, making the main contacts susceptible to instantaneous surge currents and arcing. To mitigate these issues, some connectors employ external pre-charging circuits, relay control, or separately designed pre-contact terminals for buffering. However, these methods often require additional circuitry or space, resulting in complex structures, and the conduction sequence between the pre-contact and main contact cannot be fully guaranteed by mechanical stability.

[0005] Furthermore, in existing connectors, the main contacts typically handle the entire conduction and disconnection process, making it difficult to simultaneously meet the requirements of arc resistance and low contact resistance in terms of contact material, contact pressure, and contact area. Simply increasing the contact pressure or contact area would increase insertion and extraction forces and structural dimensions; simply adding a current-limiting resistor would not meet the high current carrying capacity requirements under normal operating conditions. Therefore, how to achieve a process in the connector body structure where current-limiting pre-conduction occurs during mating, followed by high-current main conduction, and during removal, main conduction is disconnected first, followed by pre-conduction disconnection, while maintaining a stable mechanical timing sequence, is a pressing issue to be addressed in the arc-proof design of high-current connectors. Summary of the Invention

[0006] To solve the above problems, the present invention divides the contact structure into a pre-conducting contact group and a main-conducting contact group, and makes the two have a length difference in the insertion and removal direction, so that the connector first forms a pre-conducting circuit through the anti-sparking resistor during the insertion process, and then forms the main current circuit; during the removal process, the main current circuit is first disconnected, and then completely disconnected after passing through the pre-conducting circuit. This is a multi-contact progressive anti-sparking high-current connector and method.

[0007] The technical solution adopted in this invention is: a multi-contact progressive anti-arcing high-current connector, including a male connector and a female connector that are mutually inserted. At least one of the male connector and the female connector includes an insulating shell, a conductive terminal assembly and an insulating support. The conductive terminal assembly includes a pre-conducting contact group and a main conducting contact group that participate in conduction sequentially along the insertion and removal direction.

[0008] The pre-conducting contact group is electrically connected to the anti-sparking resistor, and the main conducting contact group is electrically connected to the main current circuit. The pre-conducting contact group and the main conducting contact group are each composed of multiple conductive protrusions or elastic contact fingers. The pre-conducting contact group and the main conducting contact group have a length difference in the insertion and removal direction. This allows the pre-conducting contact group to first contact and conduct with the main conducting contact group during the insertion process of the male connector and the female connector, forming a current-limiting pre-conducting circuit through the anti-sparking resistor. Subsequently, the main conducting contact group contacts and conducts and carries the working current. During the removal process, the main conducting contact group first separates from the pre-conducting contact group, allowing the current to pass through the anti-sparking resistor before being disconnected, thereby reducing the risk of arcing and sparking during insertion and removal.

[0009] A further improvement to the above scheme is that the pre-conducting contact group and the main conducting contact group are arranged in a stepped manner along the insertion and extraction direction. The free end of the conductive protrusion in the pre-conducting contact group is located close to the insertion front end, and the free end of the conductive protrusion in the main conducting contact group is located after the pre-conducting contact group, so as to form at least two levels of contact sequence. An insulating gap is provided between the pre-conducting contact group and the main conducting contact group to reduce the risk of partial discharge between adjacent contact levels.

[0010] A further improvement to the above solution is that the anti-sparking resistor is one of a resistor ring, resistor sheet, resistor block, resistor film layer or wire-wound resistor. The anti-sparking resistor is disposed in the circuit where the pre-conducting contact group is located and is connected in series with the pre-conducting contact group to limit surge current and contact transient current in the initial stage of insertion.

[0011] A further improvement to the above solution is that the anti-sparking resistor is disposed inside the terminal block, on the insulating support, or in the peripheral positioning groove of the conductive terminal assembly, and is electrically connected to the pre-conducting contact group by means of crimping, welding, snap-fitting, embedding, or conductive adhesive connection; the insulating support forms an insulating isolation between the anti-sparking resistor and the main conductive contact group.

[0012] A further improvement to the above scheme is that the number of conductive protrusions in the pre-conduction contact group is less than the number of conductive protrusions in the main conduction contact group, and / or the conduction cross-sectional area of ​​the pre-conduction contact group is less than the conduction cross-sectional area of ​​the main conduction contact group, so that the conduction capability in the pre-conduction stage is less than the conduction capability in the main conduction stage; the main conduction contact group is composed of multiple circumferentially distributed or parallelly distributed elastic contact fingers to share the main current and reduce single-point heating.

[0013] A further improvement to the above scheme is that the pre-conducting contact group and the main conducting contact group adopt different conductive materials or surface treatment layers. Specifically, the pre-conducting contact group adopts a conductive material or plating with high resistance to arc erosion, and the main conducting contact group adopts a conductive material or plating with high conductivity and low contact resistance. The conductive material is one of copper alloy, beryllium copper, phosphor bronze, or silver-copper composite material, and the plating is one or more combinations of silver layer, tin layer, nickel layer, or gold layer.

[0014] A further improvement to the above scheme is that the conductive terminal assembly includes a terminal base and a plurality of elastic contact fingers extending from the terminal base. The plurality of elastic contact fingers are divided into a first contact level and a second contact level according to the contact sequence. The first contact level corresponds to the pre-conduction contact group, and the second contact level corresponds to the main conduction contact group. The first contact level and the second contact level are offset in the axial direction and have differences in radial elastic deformation and contact pressure, so that the contact pressure in the initial stage of insertion is less than the contact pressure in the main conduction stage.

[0015] A further improvement to the above solution is that the insulating housing is provided with a positioning structure for limiting the mating depth and a guide structure for guiding the axial alignment of the male and female connectors. The positioning structure matches the stepped contact stroke of the pre-conducting contact group and the main-conducting contact group to ensure that the pre-conducting circuit is formed first and the main-conducting circuit is formed later during the mating process. The guide structure includes one or more of the following: guide slope, guide groove, guide post or guide hole.

[0016] An anti-sparking terminal assembly for a multi-contact progressive anti-sparking high-current connector includes a terminal base, a pre-conducting contact group, a main-conducting contact group, an anti-sparking resistor, and an insulating support. The pre-conducting contact group and the main-conducting contact group are both disposed on the terminal base and form a stepped length difference along the insertion / removal direction. The anti-sparking resistor is connected in series with the pre-conducting contact group. The insulating support is used to fix the anti-sparking resistor and isolate the pre-conducting contact group from the main-conducting contact group. When the terminal assembly is inserted with a mating terminal, a pre-conducting circuit is first established through the pre-conducting contact group and the anti-sparking resistor, and then a main current circuit is established through the main-conducting contact group.

[0017] A method for preventing arcing during insertion and removal of a multi-contact progressive anti-arson high-current connector, applied to high-current connectors, includes the following steps: S1. When the male connector and female connector approach each other axially and begin to engage, the pre-conducting contact group makes contact first, and the current forms a pre-conducting circuit through the anti-sparking resistor connected in series with it. S2. As the insertion depth increases, the main contact group is made to conduct after the pre-conducting circuit is established, and the main current is carried by the main contact group. S3. During the pulling process, the main contact group is disconnected first, and the current returns to the pre-conducting circuit through the anti-sparking resistor. S4. Continue pulling out to separate the pre-conducting contact group from the mating contact, thereby completing the disconnection; In particular, by making the pre-conducting contact group and the main conducting contact group in stages and disconnecting them in stages, the risk of sudden current changes and arcing at the moment of insertion and removal is reduced.

[0018] The beneficial effects of this invention are: The high-current connector of this invention divides the contact structure into a pre-conducting contact group and a main-conducting contact group, creating a length difference between the two in the insertion and removal directions. This allows the connector to first form a pre-conducting circuit via an anti-sparking resistor during insertion, followed by the main current circuit. During removal, the main current circuit is first disconnected, then completely disconnected via the pre-conducting circuit. This results in smoother current changes during insertion and removal, preventing direct conduction or disconnection of the main contact area under high potential differences, thus effectively reducing arcing and sparking.

[0019] This invention incorporates an anti-arc resistor in series within the circuit containing the pre-conducting contact group. This prevents the connector from directly conducting full current during the initial mating phase; instead, it establishes an initial electrical connection via a pre-conducting path with current-limiting properties. This method reduces surge current and transient contact current at the moment of mating, lowers the probability of arcing, and mitigates the risk of main contact ablation.

[0020] This invention does not rely solely on resistive components to carry the operating current. Instead, after pre-conduction, the main conduction contact group takes over to carry the main current. The main conduction contact group consists of multiple conductive protrusions or elastic fingers, which can share the current and reduce single-point heating. Thus, while ensuring anti-sparking effect, it also meets the requirements of low contact resistance and high current carrying capacity for high-current connectors.

[0021] In this invention, the pre-conduction contact group and the main conduction contact group not only differ in length in the insertion and extraction directions, but also can be differentiated in terms of the number of contacts, conduction cross-sectional area, materials, and contact pressure, so that the pre-conduction stage and the main conduction stage have different conduction capabilities and contact characteristics. This makes the functional division of the two-stage circuit clearer, which is beneficial to improving the conduction control effect and structural adaptability.

[0022] This invention incorporates guiding and positioning structures within the connector's insulating housing, ensuring that the male and female connectors align along a predetermined path and reach a predetermined mating depth during insertion. This guarantees that the pre-conducting contact group and the main conducting contact group contact sequentially according to the design sequence. This helps reduce the impact of assembly errors or insertion / removal posture deviations on the conduction sequence and improves the consistency of anti-sparking performance.

[0023] The connector structure of this invention is particularly suitable for use in high-voltage connection systems for new energy vehicles, connection systems for energy storage devices, high-power power supply systems, and other electrical connection applications with high requirements for insertion and removal safety. By achieving a coordinated design of pre-conduction current limiting and main conduction carrying at the connector body structure level, the reliability of high-current connectors under frequent insertion and removal or hot-plugging conditions can be significantly improved.

[0024] The anti-arc terminal of this invention includes a main terminal, a contact front cover, and a resistive element disposed between the two. The contact front cover contacts the target connector first during connector mating and conducts electricity to the main terminal through the resistive element, introducing resistance into the contact circuit during the initial mating phase. This mitigates instantaneous current surges and reduces the risk of arcing and sparking during mating. This structure is particularly suitable for high-voltage, high-speed connector applications, improving connector mating safety and reliability. Attached Figure Description

[0025] Figure 1 This is a three-dimensional schematic diagram of the anti-sparking high-current connector of the present invention; Figure 2 for Figure 1 Schematic diagram of a high-current anti-sparking connector; Figure 3 This is a three-dimensional schematic diagram of an embodiment of the anti-sparking high-current connector of the present invention; Figure 4 for Figure 3 Schematic diagram of a high-current anti-sparking connector; Figure 5 This is a perspective view of one embodiment of the conductive terminal assembly of the present invention; Figure 6 This is a perspective view of one embodiment of the conductive terminal assembly of the present invention; Figure 7 This is a schematic diagram of the insertion of a conductive terminal assembly according to an embodiment of the present invention; Figure 8 This is a schematic diagram of the insertion of a conductive terminal assembly according to an embodiment of the present invention.

[0026] Explanation of reference numerals in the attached drawings: Male connector 1, Female connector 2, Insulating housing 3, Guide structure 31, Positioning structure 32, Conductive terminal assembly 4, Pre-conducting contact group 41, Conductive protrusion 411, Main conducting contact group 42, Resilient contact finger 421, Anti-sparking resistor 43, Terminal base 44, Resilient contact finger 45, Insulating support 5. Detailed Implementation

[0027] To facilitate understanding of the present invention, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of the invention are shown in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a thorough and complete understanding of the disclosure of the invention.

[0028] It should be noted that when a component is said to be "fixed to" another component, it can be directly attached to the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component.

[0029] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0030] See Figures 1-8 As shown, the present invention provides a multi-contact progressive anti-sparking high-current connector, including a male connector 1 and a female connector 2 that can be mated together. At least one of the male connector 1 and the female connector 2 includes an insulating shell 3, a conductive terminal assembly 4, and an insulating support 5. The conductive terminal assembly 4 includes a pre-conducting contact group 41 and a main conducting contact group 42 that participate in conduction sequentially along the insertion and removal direction, wherein the pre-conducting contact group 41 is electrically connected to an anti-sparking resistor 43, and the main conducting contact group 42 is electrically connected to the main current circuit.

[0031] Example 1: In this example, the male connector 1 and the female connector 2 adopt a plug-in mating structure. The insulating housing 3 is used to accommodate and fix the conductive terminal assembly 4, while insulating and isolating different conductive parts. The conductive terminal assembly 4 includes a terminal base 44, a plurality of elastic contact fingers 45 extending from the terminal base 44, and an anti-sparking resistor 43 connected in series with the pre-conducting contact group 41.

[0032] The plurality of resilient contact fingers 45 are divided into two levels along the insertion and removal direction: the first level is a pre-conduction contact group 41, and the second level is a main conduction contact group 42. The free end of the pre-conduction contact group 41 protrudes beyond the main conduction contact group 42 in the insertion and removal direction, so that when the connector is inserted, the pre-conduction contact group 41 makes priority contact with the mating terminal, while the main conduction contact group 42 only makes contact and conduction after being inserted to a deeper position.

[0033] In this embodiment, the pre-conduction contact group 41 and the main conduction contact group 42 are respectively disposed on the same terminal base 44, or they can be disposed on two mutually insulated but electrically connected controlled terminal portions. For the female terminal structure, multiple elastic contact fingers 45 distributed around the central hole can be used; for the male terminal structure, correspondingly inserted pins, blade terminals, or cylindrical contacts can be used. As long as a hierarchical contact sequence of pre-conduction and main conduction can be formed, it falls within the protection scope of this invention.

[0034] See Figures 5-6 As shown in Embodiment 2: In this embodiment, the pre-conduction contact group 41 consists of multiple conductive protrusions 411 that are shorter in length or have lower conductivity, and is connected in series with the anti-sparking resistor 43. The anti-sparking resistor 43 can be one of a resistor ring, resistor sheet, resistor block, resistor film layer, or wire-wound resistor. The anti-sparking resistor 43 is disposed inside the terminal assembly, preferably in a mounting position on the insulating support 5, and forms a series circuit with the pre-conduction contact group 41 by welding, crimping, snap-fitting, or conductive adhesive connection.

[0035] When the connector begins to engage, the pre-conducting contact group 41 preferentially contacts the mating terminals, and the current forms an initial conduction circuit through the pre-conducting contact group 41 and the anti-arc resistor 43. Because a resistor is introduced into the circuit, the current surge can be reduced at the moment of contact, avoiding the formation of a strong arc directly in the main contact area.

[0036] In this embodiment, the insulating support 5 is located between the pre-conducting contact group 41 and the main conducting contact group 42. It is used to fix the anti-sparking resistor 43 and to provide insulation between different conduction stages to reduce the risk of short circuit and partial discharge.

[0037] Example 3: In this example, the main conductive contact group 42 is composed of multiple main conductive protrusions or elastic contact fingers 421, preferably more than the number of pre-conductive contact groups 41, and the conductive cross-sectional area is also preferably larger than that of the pre-conductive contact groups 41. The main conductive contact group 42 is directly connected to the main current circuit of the connector and is used to carry the full operating current after the connector has completed further mating.

[0038] When the connector reaches the designed engagement depth, the main conductive contact group 42 makes contact with the mating terminal and conducts electricity, at which point the main current flows through the main conductive contact group 42. Because the main conductive contact group 42 adopts a multi-contact parallel contact structure, it can effectively distribute the current, reduce the temperature rise of a single contact point, and improve the overall conductivity reliability.

[0039] In this embodiment, the main contact group 42 can be made of a high conductivity material, such as copper alloy, silver-copper composite material, etc., and a silver plating layer, tin plating layer or other low contact resistance plating layer can be formed on the contact surface to further improve the current carrying performance.

[0040] Example 4: In this example, the pre-conducting contact group 41 and the main conducting contact group 42 are made of different materials or have different surface treatments. The pre-conducting contact group 41 may be made of a material or surface layer with high resistance to arc erosion to improve the tolerance to partial discharge during repeated pre-contact processes; the main conducting contact group 42 is made of a material with higher conductivity and lower contact resistance to meet the needs of high current operation.

[0041] Furthermore, the pre-conducting contact group 41 and the main-conducting contact group 42 can also be designed differently in terms of contact pressure. Preferably, the contact pressure of the pre-conducting contact group 41 is lower than that of the main-conducting contact group 42 to reduce friction and local wear during the initial engagement; while the main-conducting contact group 42 provides a greater contact pressure to ensure stable carrying of the main current.

[0042] Example 5: In this example, the insulating housing 3 is provided with a guide structure 31 and a positioning structure 32. The guide structure 31 is used to provide axial guidance and position correction when the male connector 1 and the female connector 2 are mated, so as to avoid contact misalignment caused by insertion deviation. The guide structure 31 may include a guide slope, a guide groove, a guide post, or a guide hole, etc.

[0043] The positioning structure 32 is used to limit the mating depth of the connector and to ensure that the pre-conduction contact group 41 and the main conduction contact group 42 make contact sequentially at a predetermined travel position. By matching the positioning structure 32 with the stepped conduction travel, the stability of the pre-conduction and main conduction contact sequence can be improved, thereby ensuring the anti-sparking effect.

[0044] Example 6: This example also provides a spark-proof terminal assembly for the above-described connector. The terminal assembly includes a terminal base 44, a pre-conducting contact group 41, a main conducting contact group 42, a spark-proof resistor 43, and an insulating support 5. The pre-conducting contact group 41 and the main conducting contact group 42 are both disposed on the terminal base 44 and have a length difference along the insertion / removal direction. The spark-proof resistor 43 is connected in series with the pre-conducting contact group 41, and the insulating support 5 is used to fix the spark-proof resistor 43 and isolate contacts of different levels.

[0045] In actual assembly, the pre-conducting contact group 41 and the main conducting contact group 42 can be formed by integral stamping and bending, or they can be assembled and fixed as separate structures. The anti-sparking resistor 43 can be pre-installed on the insulating support 5 before the terminal assembly is assembled, and then assembled as a whole with the terminal base 44, thereby improving manufacturing efficiency.

[0046] Anti-sparking process during insertion and removal: In this embodiment, the insertion and removal process of the connector is as follows: When the male connector 1 and the female connector 2 approach each other axially and begin to engage, the pre-conducting contact group 41 preferentially contacts the mating contact. At this time, a pre-conducting circuit is established through the anti-sparking resistor 43 connected in series with it, completing the current-limiting pre-charge. As the insertion depth continues to increase, the main conducting contact group 42 contacts the mating contact and conducts, and the main current is carried by the main conducting contact group 42.

[0047] During the pull-out process, the main conducting contact group 42 is first disconnected, then the current returns to the pre-conducting circuit through the anti-sparking resistor 43, and finally the pre-conducting contact group 41 separates from the mating contact to complete the final disconnection.

[0048] Since the conduction and disconnection throughout the process do not occur abruptly, but rather through a transition between the pre-conducting circuit and the main conduction circuit, the risk of current surges and arcing during insertion and removal can be significantly reduced.

[0049] In summary, by incorporating a pre-conduction contact group 41, a main conduction contact group 42, and an anti-sparking resistor 43 into the connector, and by establishing a stepped, hierarchical contact relationship between the two in the structure, the present invention achieves progressive conduction and disconnection during the insertion and removal process, thereby effectively improving the anti-sparking performance and safety of high-current connectors.

[0050] The above embodiments merely illustrate several implementation methods of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this patent should be determined by the appended claims.

Claims

1. A multi-contact progressive anti-arcing high-current connector, characterized in that, The device includes a male connector and a female connector that are mutually mated, at least one of the male connector and the female connector including an insulating housing, a conductive terminal assembly and an insulating support, wherein the conductive terminal assembly includes a pre-conducting contact group and a main conducting contact group that participate in conduction sequentially along the insertion and removal direction; The pre-conducting contact group is electrically connected to the anti-sparking resistor, and the main conducting contact group is electrically connected to the main current circuit. The pre-conducting contact group and the main conducting contact group are each composed of multiple conductive protrusions or elastic contact fingers. The pre-conducting contact group and the main conducting contact group have a length difference in the insertion and removal direction. This allows the pre-conducting contact group to first contact and conduct with the main conducting contact group during the insertion process of the male connector and the female connector, forming a current-limiting pre-conducting circuit through the anti-sparking resistor. Subsequently, the main conducting contact group contacts and conducts and carries the working current. During the removal process, the main conducting contact group first separates from the pre-conducting contact group, allowing the current to pass through the anti-sparking resistor before being disconnected, thereby reducing the risk of arcing and sparking during insertion and removal.

2. The multi-contact progressive anti-arcing high-current connector according to claim 1, characterized in that: The pre-conducting contact group and the main conducting contact group are arranged in a stepped manner along the insertion and extraction direction. The free end of the conductive protrusion in the pre-conducting contact group is located close to the insertion front end, and the free end of the conductive protrusion in the main conducting contact group is located after the pre-conducting contact group, so as to form at least two levels of contact sequence. An insulating gap is provided between the pre-conducting contact group and the main conducting contact group to reduce the risk of partial discharge between adjacent contact levels.

3. The multi-contact progressive anti-arcing high-current connector according to claim 1, characterized in that: The anti-sparking resistor is one of a resistor ring, resistor sheet, resistor block, resistor film layer or wire-wound resistor. The anti-sparking resistor is disposed in the circuit where the pre-conducting contact group is located and is connected in series with the pre-conducting contact group to limit surge current and contact transient current in the initial stage of insertion.

4. The multi-contact progressive anti-arcing high-current connector according to claim 3, characterized in that: The anti-sparking resistor is disposed inside the terminal block, on the insulating support, or in the positioning groove on the periphery of the conductive terminal assembly, and is electrically connected to the pre-conducting contact group by means of crimping, welding, snap-fitting, embedding, or conductive adhesive connection; the insulating support forms an insulating isolation between the anti-sparking resistor and the main conductive contact group.

5. The multi-contact progressive anti-arcing high-current connector according to claim 1, characterized in that: The number of conductive protrusions in the pre-conduction contact group is less than the number of conductive protrusions in the main conduction contact group, and / or the conduction cross-sectional area of ​​the pre-conduction contact group is less than the conduction cross-sectional area of ​​the main conduction contact group, so that the conduction capability in the pre-conduction stage is less than the conduction capability in the main conduction stage; the main conduction contact group is composed of multiple circumferentially distributed or parallelly distributed elastic contact fingers to share the main current and reduce single-point heating.

6. The multi-contact progressive anti-arcing high-current connector according to claim 1, characterized in that: The pre-conducting contact group and the main conducting contact group use different conductive materials or surface treatment layers. The pre-conducting contact group uses a conductive material or plating with high resistance to arc erosion, while the main conducting contact group uses a conductive material or plating with high conductivity and low contact resistance. The conductive material is one of copper alloy, beryllium copper, phosphor bronze, or silver-copper composite material, and the plating is one or more combinations of silver layer, tin layer, nickel layer, or gold layer.

7. The multi-contact progressive anti-arcing high-current connector according to claim 1, characterized in that: The conductive terminal assembly includes a terminal base and a plurality of elastic contact fingers extending from the terminal base. The plurality of elastic contact fingers are divided into a first contact level and a second contact level according to the contact sequence. The first contact level corresponds to the pre-conduction contact group, and the second contact level corresponds to the main conduction contact group. The first contact level and the second contact level are offset in the axial direction and have differences in radial elastic deformation and contact pressure, so that the contact pressure in the initial stage of insertion is less than the contact pressure in the main conduction stage.

8. The multi-contact progressive anti-arcing high-current connector according to claim 1, characterized in that: The insulating housing is provided with a positioning structure for limiting the mating depth and a guide structure for guiding the axial alignment of the male and female connectors. The positioning structure matches the stepped contact stroke of the pre-conducting contact group and the main-conducting contact group to ensure that the pre-conducting circuit is formed first and the main-conducting circuit is formed later during the mating process. The guide structure includes one or more of the following: guide slope, guide groove, guide post or guide hole.

9. A spark-proof terminal assembly for a multi-contact progressive spark-proof high-current connector according to any one of claims 1 to 8, characterized in that, The device includes a terminal base, a pre-conducting contact group, a main-conducting contact group, an anti-sparking resistor, and an insulating support. The pre-conducting contact group and the main-conducting contact group are both disposed on the terminal base and form a stepped length difference along the insertion and removal direction. The anti-sparking resistor is connected in series with the pre-conducting contact group. The insulating support is used to fix the anti-sparking resistor and isolate the pre-conducting contact group from the main-conducting contact group. When the terminal assembly is inserted with the mating terminal, a pre-conducting circuit is first established through the pre-conducting contact group and the anti-sparking resistor, and then a main current circuit is established through the main-conducting contact group.

10. A method for preventing arcing during insertion and removal of a multi-contact progressive anti-arcing high-current connector, characterized in that, The application of the high-current connector according to any one of claims 1 to 8 includes the following steps: Step S1: When the male connector and the female connector approach each other axially and begin to engage, the pre-conducting contact group makes contact first, and the current passes through the anti-sparking resistor connected in series with it to form a pre-conducting circuit. Step S2: As the insertion depth increases, the main contact group is made to make contact and conduct after the pre-conducting circuit is established, and the main current is carried by the main contact group. Step S3: During the pulling process, the main contact group is disconnected first, and the current returns to the pre-conducting circuit through the anti-sparking resistor. Step S4: Continue pulling out to separate the pre-conducting contact group from the mating contact, thereby completing the disconnection; In particular, by making the pre-conducting contact group and the main conducting contact group in stages and disconnecting them in stages, the risk of sudden current changes and arcing at the moment of insertion and removal is reduced.

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