Composite integrated wiring board capable of carrying large current

Abstract

This invention discloses a composite integrated terminal block capable of carrying high current, belonging to the field of electrical equipment technology. The terminal block includes a board body with a composite layered board structure, comprising, from bottom to top, an insulating substrate layer, a high-current copper foil layer, and a signal circuit layer. The board surface is divided into a power circuit connection area and a signal circuit connection area, each equipped with high-power pluggable terminals and small pluggable signal terminals. The two types of terminals employ differentiated shapes to form a physically misaligned anti-misinsertion structure. The board circuitry and terminal base are covered with a potting compound protective layer, forming an integrated seal. This terminal block replaces manual wiring with onboard terminal connections, can carry a high current of 380V / 100A, provides physical isolation between strong and weak currents, and features anti-misinsertion, self-locking, and modular splicing functions. It has a high protection level, is suitable for automated mass production, and effectively solves the problems of low efficiency, poor reliability, and weak environmental adaptability associated with manual wiring in traditional low-voltage control cabinets.

Description

Technical Field

[0001] This invention belongs to the field of electrical equipment technology, and specifically relates to a composite integrated terminal block that can carry large currents. Background Technology

[0002] Low-voltage electrical control cabinets are core infrastructure equipment in fields such as industrial automation, water treatment, photovoltaics, HVAC, and hoisting machinery, undertaking functions such as power distribution, equipment start-up and shutdown control, operational status monitoring, and fault protection. Currently, the vast majority of low-voltage control cabinet manufacturers in China still use the traditional manual wiring method. This method is becoming increasingly problematic in the face of the industry's trend towards miniaturization, standardization, intelligence, and mass production.

[0003] Traditional low-voltage electrical control cabinets rely entirely on manual labor for wiring operations, including wire cutting, stripping, crimping, routing, and labeling. This process is highly unpredictable; according to domestic industry surveys, the overall error rate of traditional manual wiring can reach 10%-15%, with frequent occurrences of incorrect, missing, and loose connections, directly impacting equipment stability and safety. Furthermore, the disorganized wiring, with its tangled and intertwined wires, causes electromagnetic interference between strong and weak current circuits. Inconsistent wire diameters and crimping techniques result in uneven current carrying capacity and withstand voltage distribution throughout the cabinet, making it prone to localized overheating and abnormal voltage drops under 380V industrial high-current conditions. Modular cabling and integrated wiring harnesses, while improved solutions, still rely on wires as the core carrier, making them incompatible with automated production and failing to address these fundamental problems.

[0004] Conventional conductors and ordinary low-voltage PCB circuit boards have weak protective performance and are only suitable for normal indoor environments. In harsh working conditions such as water treatment, photovoltaics, construction machinery, chemicals, and mining, where there is a lot of dust, high humidity, corrosive gases, and high-frequency vibration of equipment, the insulation layer of the conductors is prone to aging and damage, the terminals are prone to oxidation and loosening, the equipment failure rate increases significantly, and the service life is greatly shortened.

[0005] Existing wiring structures lack standardized interfaces and anti-misconnection designs. The visual distinction between strong and weak current terminals is low, making them prone to misconnection during on-site installation and maintenance, potentially leading to short circuits, equipment burnout, electric shocks, and other safety accidents. Ordinary terminals lack self-locking mechanisms and are easily loosened under vibration. Furthermore, traditional wiring structures are fixed and lack modular expansion capabilities. Adding or removing circuits or upgrading equipment requires rewiring, resulting in high modification costs, poor versatility, and difficulty in adapting to the mass production of control cabinets of various specifications.

[0006] In summary, the existing technologies mainly suffer from the following core problems:

[0007] First, the production model is outdated. It mainly relies on manual operation, which has a high error rate, cannot be adapted to automated production, and results in low production efficiency and high labor costs.

[0008] Secondly, the electrical performance is poor. The interweaving of strong and weak currents leads to severe electromagnetic interference, uneven current carrying capacity of the conductors, and easy overheating under high current conditions, failing to meet the stable transmission requirements of high current in industrial applications.

[0009] Third, it has poor environmental adaptability. Its protective capabilities are insufficient, making it prone to aging and damage under harsh working conditions such as dust, humidity, corrosion, and vibration, resulting in a short service life. It lacks standardized anti-misinsertion and self-locking structures, posing a risk of misconnection and loosening; its fixed structure also prevents flexible expansion and modification. Summary of the Invention

[0010] This invention provides a composite integrated terminal block for carrying high current. The terminal block includes a board body with a composite layered board structure, comprising, from bottom to top, an insulating substrate layer, a high-current copper foil layer, and a signal circuit layer. The surface of the board body is divided into a power circuit connection area and a signal circuit connection area, which are respectively provided with high-power pluggable terminals and small pluggable signal terminals. The two types of terminals adopt a differentiated shape design to form a physical misalignment to prevent mis-insertion, thereby solving the problems mentioned in the background art.

[0011] To achieve the above objectives, the present invention provides the following technical solution:

[0012] A composite integrated terminal block for carrying high current includes:

[0013] plate body;

[0014] The board body adopts a composite layered board structure, which consists of an insulating substrate layer, a high-current copper foil power conductor layer, an insulating isolation dielectric layer, and a signal line conductor layer from bottom to top. The insulating isolation dielectric layer completely covers and separates the power conductor layer and the signal conductor layer, and the two conductors have no direct contact area.

[0015] The surface of the board is divided into a power circuit docking area and a signal circuit docking area according to function. The power circuit docking area is provided with power docking terminals, and the signal circuit docking area is provided with signal docking terminals.

[0016] The terminals in the power circuit docking area and the terminals in the signal circuit docking area are designed with different shapes to prevent the power terminals and signal terminals from being interlocked.

[0017] At least a portion of the circuit and terminal base of the board is covered with a potting protective layer, which is a sealing layer formed by curing insulating resin material.

[0018] As a further option, the conductor layer for transmitting high-current power signals is a high-current copper foil layer, and the conductor layer for transmitting control signals is a signal line layer; the composite layered board structure is a four-layer composite integrated structure, consisting of an insulating substrate layer, a high-current copper foil layer, an insulating dielectric layer, and a signal line layer from bottom to top, with each layer being pressed and cured into one piece by a vacuum hot pressing process.

[0019] As a further option, the high-power pluggable terminals in the power circuit docking area are electrically connected to the high-current copper foil layer through conductive vias, and the small pluggable signal terminals in the signal circuit docking area are electrically connected to the signal line layer through conductive vias; the power circuit docking area is also provided with a high-power aviation connector, and the signal circuit docking area is also provided with a low-power aviation connector, and the high-power aviation connector and the low-power aviation connector are respectively electrically connected to the corresponding copper foil layer through conductive vias.

[0020] As a further option, both the power connection terminal and the signal connection terminal are provided with anti-misinsertion structure and self-locking structure;

[0021] The anti-misinsertion structure is set around the entrance of the terminal plug interface. The plug interfaces of the power terminal and the signal terminal are respectively provided with anti-misinsertion structures of different shapes. The inner wall of the plug sleeve is provided with matching grooves of corresponding shapes. Different shapes cannot be interchanged for insertion.

[0022] The self-locking structure is set in the internal cavity of the terminal plug interface, including an elastic self-locking spring piece installed in the mounting groove on the side wall of the plug channel. When the plug is inserted to a predetermined depth, the self-locking spring piece automatically engages with the locking slot on the plug housing to prevent the plug from coming out. The terminal housing is also provided with an unlocking button, which can be pressed to allow the self-locking spring piece to exit the locking slot.

[0023] As a further alternative, in the foolproof structure, the foolproof structure of the power terminal is a rectangular boss structure, with a rectangular groove provided on the inner wall of the power plug sheath; the foolproof structure of the signal terminal is a circular boss structure, with a circular groove provided on the inner wall of the signal plug sheath; the rectangular boss and the circular boss have different cross-sectional shapes and sizes.

[0024] As a further option, the potting protective layer is a selective area potting structure that covers the upper surface of the board and fills the internal gaps of the board and the bottom cavity of the terminal base, keeping the internal cavity of each terminal plug-in unobstructed, and keeping the welding pin area on the bottom surface of the board exposed.

[0025] As a further option, the edge of the plate is provided with a splicing slot, which is a cavity structure formed by recessing from the side edge of the plate. A guide slope is provided at the entrance of the cavity, and an elastic metal contact and a metal hook are provided inside the cavity.

[0026] When multiple junction boxes are spliced ​​together, the edges of adjacent boards are pushed into the splicing slots, the metal hooks automatically lock, and the elastic metal contacts are elastically pressed against the conductive pads on the edges of adjacent boards, thus realizing the electrical connection between the common power circuit and the common signal circuit.

[0027] As a further option, the splicing slots are located on the left and right sides and the top and bottom sides of the board; a single board can be used independently, or multiple boards can be spliced ​​side by side horizontally, stacked vertically, or combined into a matrix multi-board array through the splicing slots.

[0028] As a further option, the insulating substrate layer is made of industrial-grade high-temperature resistant insulating PCB board; the high-current copper foil layer is made of thickened copper foil and configured to carry AC220V or AC380V industrial AC power, with a maximum continuous current carrying capacity of 100A.

[0029] A low-voltage electrical control cabinet includes a cabinet body and a composite integrated terminal block for carrying high current, as described above, installed inside the cabinet body.

[0030] Compared with the prior art, the beneficial effects of the present invention are:

[0031] 1. Replacing manual cutting, stripping, crimping, wiring, and labeling with onboard terminal connections significantly reduces human error such as incorrect connections, missing connections, and loose connections caused by manual wiring, thereby significantly improving the operational safety of electrical systems.

[0032] 2. The layered composite isolation structure is adopted, which physically isolates the strong and weak current circuits. The high current copper foil layer can stably carry a 380V / 100A load with uniform impedance. The layered physical isolation structure of strong and weak current can reduce electromagnetic crosstalk between the strong and weak current circuits. The thickened copper foil can evenly distribute the current and alleviate the problem of local heating under high current conditions.

[0033] 3. Standardized board structure and unified interface terminals allow for direct connection to automated production lines to complete the entire process of assembly, insertion, and testing, ensuring batch consistency and reducing labor and management costs.

[0034] 4. Selective epoxy resin potting and sealing, the upper surface and interior of the board are fully sealed, and the plug and solder pins are exposed. It can operate stably for a long time under harsh conditions such as dust, humidity, acid and alkali corrosion, high and low temperature, and strong vibration, without affecting terminal plugging and soldering testing. Compared with the traditional discrete wire wiring structure, the service life under dust, humidity and vibration conditions is significantly improved.

[0035] 5. The physical misalignment anti-misconnection structure prevents incorrect connection of strong and weak currents, and the built-in spring self-locking structure ensures that the terminals will not loosen under vibration, reducing the failure rate of operation and maintenance.

[0036] 6. Standard splicing slots enable synchronous interconnection of mechanical and electrical components across multiple boards. The power contacts adopt a multi-contact parallel redundant design to ensure that the current carrying capacity is not reduced. They can be flexibly combined according to the number of circuits, adapting to various control cabinet specifications and reducing modification costs. Attached Figure Description

[0037] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. Obviously, the drawings described below are merely some embodiments of the present invention, and those skilled in the art can obtain other drawings based on these drawings without any creative effort.

[0038] In the attached diagram:

[0039] Figure 1 This is a schematic diagram of the overall structure of an embodiment of the present invention;

[0040] Figure 2 This is a schematic diagram of the composite layered board structure according to an embodiment of the present invention;

[0041] Figure 3 This is a schematic diagram of the overall architecture of the present invention;

[0042] Figure 4 This is a schematic diagram of the wiring board manufacturing process according to an embodiment of the present invention.

[0043] Explanation of markings in the diagram:

[0044] 1. Board body; 2. Insulating substrate layer; 3. High current copper foil layer; 4. Signal line layer; 5. Insulating isolation material; 6. Power circuit docking area; 7. Signal circuit docking area; 8. High power plug-in terminal; 801. Foolproof structure; 9. High power aviation plug socket; 10. Small plug-in signal terminal; 1001. Second foolproof structure; 11. Low voltage aviation plug socket; 12. Splicing slot; 13. Potting protective layer. Detailed Implementation

[0045] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0046] Example 1: Overall Structure of the Terminal Block

[0047] like Figure 1As shown, the composite integrated terminal block for carrying high current in this embodiment has a rectangular rigid flat plate structure as its body 1. The conductive circuit is integrated inside the body 1, and there is no need to lay discrete wires outside. It can be directly embedded in the low-voltage control cabinet to replace traditional insulated wires, wire troughs and independent terminal blocks.

[0048] The upper surface of board 1 is functionally divided into two independent areas: a power circuit docking area 6 and a signal circuit docking area 7. The power circuit docking area 6 houses all high-voltage terminals, while the signal circuit docking area 7 houses all low-voltage terminals. These two areas are located on the left and right sides of the upper surface of board 1, respectively, with sufficient physical spacing between them to achieve strong and weak current isolation. Standardized splicing slots 12 are pre-installed on all four side edges of board 1, and the entire board undergoes selective area potting and sealing treatment.

[0049] Example 2: Composite Layered Panel Structure

[0050] like Figure 2 As shown, the core structure of plate 1 is a four-layer composite integrated structure, which is stacked and pressed together from bottom to top:

[0051] The bottom layer is the insulating substrate layer 2, which uses industrial-grade high-temperature resistant insulating board (such as FR-4 epoxy fiberglass cloth substrate). This layer is a whole flat insulating rigid base plate, and its lower surface forms the bottom surface of the plate body 1, which is used to provide mechanical support and bottom insulation.

[0052] The second layer is a high-current copper foil layer 3, which is attached to the upper surface of the insulating substrate layer 2. The thickened copper foil is patterned and etched to form a power circuit line to carry industrial AC power (such as AC220V or AC380V), with a maximum continuous current carrying capacity of 100A.

[0053] The third layer is an insulating dielectric layer (i.e., insulating isolation material 5), which is an insulating material layer (e.g., a prepreg) uniformly coated or laid on the upper surface of the high current copper foil layer 3, used to provide high voltage insulation between adjacent copper foil layers.

[0054] The top layer is the signal line layer 4, which is attached to the upper surface of the insulating dielectric layer. It uses copper foil of conventional thickness to form signal control lines after patterning and etching. The upper surface of this layer constitutes the upper surface of the board 1.

[0055] After the above layers are stacked, they are pressed and cured by vacuum hot pressing process, so that the insulating dielectric layer melts and flows and the layers are bonded together. Then, the high current copper foil layer 3 and the signal line layer 4 are patterned and etched to form the required line layout.

[0056] Example 3: Terminal Integration and Automated Welding Structure

[0057] like Figure 1 As shown, multiple high-power pluggable terminals 8 and a high-power aviation connector 9 are embedded on the surface of the plate 1 in the power circuit docking area 6; multiple small pluggable signal terminals 10 and a low-voltage aviation connector 11 are embedded on the surface of the plate 1 in the signal circuit docking area 7.

[0058] Metallized conductive vias are provided on board 1 corresponding to the positions of each terminal pin. The pins of the high-power pluggable terminal 8 are inserted into the corresponding conductive vias and electrically connected to the copper layer of the via wall and the high-current copper foil layer 3 by soldering. The pins of the small pluggable signal terminal 10 are inserted into the corresponding conductive vias and electrically connected to the copper layer of the via wall and the signal line layer 4 by soldering. The mounting flanges of the high-power aviation connector 9 and the low-power aviation connector 11 are fixed to the surface of board 1 with screws, and their pins also pass downwards through the conductive vias on board 1 and are soldered to the corresponding copper foil layers.

[0059] All terminals are batch-fixed to board 1 using automated welding processes (e.g., through-hole reflow soldering or wave soldering). The terminal base is preferably mechanically locked to the mounting holes of board 1 by means of built-in hooks, and can be reinforced with adhesive.

[0060] Example 4: Anti-misinsertion and self-locking structure

[0061] like Figure 1 As shown, this embodiment incorporates both an anti-misinsertion structure and a self-locking structure on both the outside and inside of the terminal connector.

[0062] A mis-insertion prevention structure is installed around the entrance of the terminal connector. The power terminal connector has a ring of rectangular bosses around its perimeter, forming a mis-insertion prevention structure 801. These bosses protrude outwards from the terminal base and have a rectangular cross-section. Correspondingly, the inner wall of the power plug sheath has a rectangular groove matching the shape of these bosses. The plug can only be fully inserted when the rectangular bosses are aligned with the rectangular grooves. The signal terminal connector has a second mis-insertion prevention structure 1001 with rectangular bosses of different sizes around its perimeter. Correspondingly, the inner wall of the signal plug sheath has a groove matching the shape of these bosses. Due to the different cross-sectional shapes and sizes of the rectangular bosses, the power plug cannot be inserted into the signal terminal, and vice versa, achieving physical misalignment to prevent mis-insertion.

[0063] In a preferred embodiment, the self-locking structure is disposed within the internal cavity of the terminal connector. The internal cavity of the terminal connector serves as a insertion channel, with a mounting groove on its side wall. A bent, elastic metal sheet (self-locking spring) is embedded within this mounting groove. The root of the self-locking spring is fixed within the mounting groove, while its free end bends and protrudes into the insertion channel, forming a cantilevered elastic hook. When the plug is inserted along the insertion channel, the plug housing compresses the free end of the self-locking spring, causing it to retract into the mounting groove. When the plug is fully inserted to a predetermined depth, the locking groove on the plug housing moves to a position opposite to the free end of the self-locking spring. Under the action of elastic restoring force, the self-locking spring pops outward, its free end locking into the locking groove, preventing the plug from dislodging. An unlocking button is provided on the outer wall of the terminal housing, corresponding to the mounting groove position. Pressing this unlocking button pushes the self-locking spring back out of the groove, allowing the plug to be removed. The self-locking structure is conventional technology and will not be described in detail with accompanying drawings.

[0064] Example 5: Selective Area Potting Protective Structure

[0065] like Figure 1 As shown, after all circuits and terminal bases on the upper surface of board 1 are assembled, selective area potting is performed. Industrial-grade flame-retardant epoxy resin is preferred as the potting material.

[0066] Before potting, a removable elastic silicone mask is installed at the entrance of the internal insertion channel of each terminal connector. The mask fits tightly against the inner wall of the connector, completely filling and sealing the internal cavity of the insertion channel to prevent liquid potting material from seeping in. At the same time, high-temperature resistant protective tape is affixed to the bottom surface of board 1 to completely cover all solder pin areas extending from the bottom surface of board 1, preventing potting material from covering the pins.

[0067] The board 1 is placed in a potting mold, and liquid epoxy resin is injected under vacuum conditions, allowing the resin to fully penetrate all gaps inside the board 1, the gaps between each layer of circuits, and the bottom cavity of the terminal base. After the potting is completed, it is heated and cured.

[0068] After curing, the silicone mask and bottom protective tape are removed sequentially. The cured potting protective layer 13 covers the entire upper surface of the board 1 (except for the interface inlet area), fills all gaps inside the board 1, and wraps the sidewalls of the terminal base, forming an integrated sealing layer. The internal insertion channels of each terminal interface remain unobstructed and free of potting material, and all solder pins on the bottom surface of the board 1 remain clean and exposed. After the above treatment, the overall protection level of the board can reach IP67 or higher.

[0069] Example 6: Modular splicing structure and electrical connection method

[0070] like Figure 1As shown, splicing slots 12 are provided on the four side edges of the plate 1, and multiple splicing slots 12 are provided on each side edge.

[0071] Each splicing slot 12 is an open cavity structure formed by recessing inward from the side edge of the plate 1. The cavity entrance has an outwardly expanding chamfered slope, forming a guiding structure. The upper and lower walls inside the cavity are respectively fitted with elastic metal contacts (preferably crown spring type or elastic pin type structure), with their elastic contact portions protruding into the cavity. The power circuit contacts employ a multi-contact parallel redundant design (e.g., two positive contacts and two negative contacts on each of the upper and lower walls) to ensure that the current-carrying capacity of the common power circuit is not derated after splicing; the signal circuit contacts employ a multi-pin parallel arrangement structure. A cantilevered metal hook is also provided on the rear side wall inside the cavity, with a hook-shaped protrusion at its free end facing into the cavity.

[0072] During assembly, align the side of the first board with the corresponding side of the second board, and push the edge of the second board into the splicing slot 12 of the first board along the board surface direction. During the pushing process, the guide ramp guides the alignment; the edge of the second board presses against the metal hook to make it elastically open. After being fully pushed in, the hook resets, and the hook-shaped protrusion engages with the corresponding groove on the inner side of the edge of the second board, achieving mechanical locking. At the same time, the elastic metal contact in the cavity elastically presses against the conductive pad on the edge surface of the second board, achieving electrical conduction. The high-current copper foil layer 3 of the two boards is connected in parallel through the power contact, and the common power circuit is connected. During separation, use a tool to press the hook to open it, and then pull it out along the board surface direction.

[0073] Depending on actual needs, a single terminal block can be used independently, or multiple terminal blocks can be spliced ​​horizontally side by side, stacked vertically, or combined into a matrix-style multi-board array through the splicing slots 12 mentioned above.

[0074] Example 7: Working Principle and Application

[0075] like Figures 3-4 As shown, the external main power supply is connected to the terminal block through a high-power aviation connector 9. Electrical energy is distributed to each high-power pluggable terminal 8 via a pre-defined circuit through the high-current copper foil layer 3, powering external high-power actuators. The signal line layer 4 interacts with external sensors, communication modules, and control units via small pluggable signal terminals 10 and low-voltage aviation connectors 11. All external components connect to the board terminals via prefabricated standard plugs. An anti-misinsertion structure ensures that power and signal plugs are not incorrectly inserted, self-locking springs prevent plugs from loosening under vibration, and a potting protective layer 13 protects the internal circuitry from dust, moisture, and corrosive gases in harsh environments. The entire process eliminates the need for manual laying of discrete wires and can be automated for batch assembly and testing.

[0076] Example 8: Fabrication-free connection method for external prefabricated wire harnesses

[0077] In this embodiment, all external components that interface with the terminal block (such as circuit breakers, contactors, relays, PLC controllers, sensors, etc.) use factory-prefabricated standard plug wire harnesses. One end of the wire harness has a pre-crimped anti-misinsertion plug that matches the board terminals. The other end, depending on the component interface type, is crimped to the component pin using an insulation displacement connection method, or pre-crimped with cold-pressed terminals at the factory and then fixed to the component terminals with screws. The wire harness has undergone continuity testing before leaving the factory. During on-site installation, operators only need to quickly plug the plugs at both ends of the prefabricated wire harness to the terminal block terminals and component ports or fix them with screws; no cutting, stripping, crimping, or soldering operations are required on-site.

[0078] Example 9: Control Cabinet Application

[0079] The low-voltage electrical control cabinet of the present invention includes a cabinet body and the aforementioned terminal block installed inside the cabinet body. The terminal block is fixed to the cabinet mounting back plate with screws through its mounting holes, or fixed to the guide rail by standard rail clips. All external components are directly plugged into the corresponding terminals of the terminal block via the prefabricated standard plug harness described in Embodiment 8, with no exposed discrete wires inside the cabinet. When it is necessary to add control circuits, the extension terminal block can be spliced ​​through the splicing slot 12 without redesigning and rewiring.

[0080] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A composite integrated terminal block for carrying high current, characterized in that, include: Plate(1); The plate (1) adopts a composite layered plate structure, which includes at least an insulating substrate layer (2), a conductor layer for transmitting high current power signals and a conductor layer for transmitting control signals from bottom to top, and an insulating isolation material (5) is provided between each layer. The surface of the plate (1) is divided into a power circuit docking area (6) and a signal circuit docking area (7) according to function. The power circuit docking area (6) is provided with power docking terminals, and the signal circuit docking area (7) is provided with signal docking terminals. The terminals of the power circuit docking area (6) and the terminals of the signal circuit docking area (7) are designed with different shapes so that the power terminals and signal terminals cannot be interlocked. At least a portion of the circuit and terminal base of the board (1) is covered with a potting protective layer (13), which is a sealing layer formed by curing insulating resin material.

2. The composite integrated terminal block for carrying high current according to claim 1, characterized in that, The conductor layer for transmitting high current power signals is a high current copper foil layer (3), and the conductor layer for transmitting control signals is a signal line layer (4). The composite layered board structure is a four-layer composite integrated structure, consisting of an insulating substrate layer (2), a high current copper foil layer (3), an insulating dielectric layer (5), and a signal line layer (4) from bottom to top. Each layer is pressed and cured into an integrated structure by a vacuum hot pressing process.

3. The composite integrated terminal block for carrying high current according to claim 2, characterized in that, The high-power plug-in terminal (8) provided in the power circuit docking area (6) is electrically connected to the high-current copper foil layer (3) through conductive vias. The small plug-in signal terminal (10) provided in the signal circuit docking area (7) is electrically connected to the signal line layer (4) through conductive vias. The power circuit docking area (6) is also provided with a high-power aviation plug socket (9), and the signal circuit docking area (7) is also provided with a low-power aviation plug socket (11). The high-power aviation plug socket (9) and the low-power aviation plug socket (11) are electrically connected to the corresponding copper foil layer through conductive vias.

4. The composite integrated terminal block for carrying high current according to claim 1, characterized in that, Both the power connection terminal and the signal connection terminal are equipped with anti-misinsertion structure and self-locking structure; The anti-misinsertion structure is set around the entrance of the terminal plug interface. The plug interfaces of the power terminal and the signal terminal are respectively provided with different shapes of anti-misinsertion structure (801) and second anti-misinsertion structure (1001). The inner wall of the plug sleeve is provided with a matching groove of the corresponding shape. Different shapes cannot be interchanged for insertion. The self-locking structure is set in the internal cavity of the terminal plug interface, including an elastic self-locking spring piece installed in the mounting groove on the side wall of the plug channel. When the plug is inserted to a predetermined depth, the self-locking spring piece automatically engages with the locking slot on the plug housing to prevent the plug from coming out. The terminal housing is also provided with an unlocking button, which can be pressed to allow the self-locking spring piece to exit the locking slot.

5. A composite integrated terminal block for carrying high current according to claim 4, characterized in that, In the aforementioned foolproof structure, the foolproof structure for the power terminal is a rectangular boss structure, with a rectangular groove on the inner wall of the power plug sheath; the foolproof structure for the signal terminal is a circular boss structure, with a circular groove on the inner wall of the signal plug sheath; the rectangular boss and the circular boss have different cross-sectional shapes and sizes.

6. A composite integrated terminal block for carrying high current according to claim 1, characterized in that, The potting protective layer (13) is a selective area potting structure that covers the upper surface of the board (1) and fills the internal gaps of the board (1) and the bottom cavity of the terminal base. The internal cavity of each terminal plug-in interface remains unobstructed, and the welding pin area on the bottom surface of the board (1) remains exposed.

7. A composite integrated terminal block for carrying high current according to claim 1, characterized in that, The edge of the plate (1) is provided with a splicing slot (12). The splicing slot (12) is a concave cavity structure formed by recessing from the side edge of the plate (1). A guide slope is provided at the entrance of the concave cavity. An elastic metal contact and a metal hook are provided inside the concave cavity. When multiple terminal blocks are spliced ​​together, the edges of adjacent boards are pushed into the splicing slot (12), the metal hooks are automatically locked, and the elastic metal contacts are elastically pressed against the conductive pads on the edges of adjacent boards to achieve electrical connection between the common power circuit and the common signal circuit.

8. A composite integrated terminal block for carrying high current according to claim 7, characterized in that, The splicing slots (12) are located on the left and right sides and the top and bottom sides of the board (1); a single board (1) can be used independently, or multiple boards (1) can be spliced ​​horizontally side by side, stacked vertically, or combined into a matrix multi-board array through the splicing slots (12).

9. A composite integrated terminal block for carrying high current according to claim 1, characterized in that, The insulating substrate layer (2) is made of industrial-grade high-temperature resistant insulating PCB board; the high-current copper foil layer (3) is made of thickened copper foil and is configured to carry AC220V or AC380V industrial AC power, with a maximum continuous current carrying capacity of 100A.

10. A low-voltage electrical control cabinet, characterized in that, The invention includes a cabinet and a composite integrated terminal block for carrying high current, as described in any one of claims 1 to 9, installed inside the cabinet.

Images