A reliable high current capability plug-in pin

Abstract

The application discloses a reliable high-current-capable plug-in pin, and belongs to the technical field of electric connectors. The pin body is a square pin structure, and sequentially comprises, along the axial direction, an umbrella-shaped supporting part, a contact conductive part and a locking anti-retreating part. The umbrella-shaped supporting part is located at the insertion end of the pin body, and its cross-sectional size is larger than that of the main body rod part, so as to limit and guide the insertion structure. The contact conductive part is located behind the umbrella-shaped supporting part, so as to increase the contact area and current carrying capacity with the mating terminal. The locking anti-retreating part is located behind the contact conductive part, so as to be clamped with the elastic buckle in the socket after insertion, and physical locking is realized. The square pin structure is adopted, extrusion process is matched, the service life of the mold is long, the complex umbrella-shaped head can be directly extruded, additional welding or multiple processing is not needed, the production cost is greatly reduced, and the application is suitable for mass production.

Description

Technical Field

[0001] This invention belongs to the field of electrical connector technology, and more specifically, relates to a reliable, high-current-capable, easy-to-plug pin. Background Technology

[0002] In modern industrial systems where electronic technology is highly integrated, printed circuit boards (PCBs) serve as the core carrier for interconnecting electronic systems. The reliability of their electrical connections with external components directly determines the performance boundaries of the entire equipment under extreme operating conditions.

[0003] Currently, terminals are widely used in power conversion modules to connect the DBC substrate at the bottom of the module and the PCB circuit board at the top. These terminals typically use square straight pins or stamped connectors. In the square straight pin design, one end of the pin is inserted into the slotted cylindrical pad on the bottom DBC substrate for a tight fit, while the other end is inserted into the pad on the top PCB circuit board for soldering. Additionally, existing technologies also use an interference fit to connect the square pins to the plug's insulating mounting plate, or a fisheye pin crimping process, achieving a solderless connection through the interference fit between the fisheye structure of the pin and the crimping hole.

[0004] However, the aforementioned existing technologies have the following objective drawbacks: First, there is a risk of detachment. Existing pin structures mainly rely on interference fits to fix the pins to the PCB board. Due to fluctuations in manufacturing dimensions, the clamping force between the pins and the PCB board may be insufficient, making them prone to detachment under harsh conditions such as high temperature and vibration. In particular, when the PCB board operates in a high-temperature environment, the thermal expansion and contraction effect may cause changes in the interference of the interference fit, further exacerbating the risk of detachment.

[0005] Secondly, the contact area is too small. Because the manufacturing process cannot guarantee that the pins are perfectly round, the actual cross-section of the processed pins has shape errors, resulting in the actual contact area between the pin and the PCB hole wall being much smaller than the theoretical value. An insufficient contact area leads to increased contact resistance and heat generation, which not only affects current carrying capacity but may also accelerate material aging due to localized overheating, reducing the product's lifespan.

[0006] Third, inconsistent pin heights; the processed pin end faces cannot be guaranteed to be perfectly flat, and will have a certain degree of curvature or unevenness, causing the pin tips to be at different heights after insertion. This will lead to poor contact of some pins or failure to make effective contact simultaneously, affecting the reliability of the overall electrical connection.

[0007] Fourth, it has poor resistance to environmental disturbances. Under operating conditions, the PCB board will deform or vibrate due to environmental factors such as high temperature and vibration. The existing pin structure that relies on interference fit is prone to gradually loosening under long-term vibration environment, eventually leading to detachment.

[0008] Therefore, there is an urgent need in this field for a pin structure that can ensure high current carrying capacity, reliable anti-dislodgement, and easy insertion and removal. Summary of the Invention

[0009] To achieve the above objectives, the present invention adopts the following technical solution: A reliable, high-current-capable, easy-to-plug pin, wherein the pin body has a square lead structure and comprises, in sequence along its axial direction: An umbrella-shaped support portion is located at the insertion end of the pin body, and its cross-sectional dimension is larger than that of the main body rod, which is used to limit and guide the insertion structure. The conductive contact portion is located behind the umbrella-shaped support portion and is used to increase the contact area with the mating terminal and the current carrying capacity. A locking anti-retraction part is located behind the contact conductive part and is used to engage with the elastic buckle inside the socket after insertion to achieve physical locking.

[0010] Furthermore, the umbrella-shaped support is a copper part formed by extrusion.

[0011] Furthermore, the contact conductive part has four symmetrically or evenly distributed contact protrusions on its sides to form four contact areas.

[0012] Furthermore, the locking anti-retraction part is provided with annular or semi-annular protrusions extending along the axial direction of the pin, and the cross-sectional width of the protrusion forms a step difference with the main body of the pin, thereby enhancing the vibration resistance and anti-fall-off capability under harsh working conditions through interference fit.

[0013] Furthermore, the overall axial length of the pin body is 14.30mm, the axial length of the locking anti-retraction part is 0.50mm, and a 2mm installation positioning area is provided at a preset distance from the tail end.

[0014] Furthermore, the insert body is a one-piece molded knot.

[0015] The beneficial effects of this invention are: This invention adopts a square pin structure, combined with an extrusion process, resulting in a long mold life and the ability to directly extrude complex umbrella-shaped heads without additional welding or multiple processing steps, which greatly reduces production costs and is suitable for mass production.

[0016] This invention, through a distributed design of four contact areas, significantly reduces contact resistance, enabling it to withstand greater current and solving the heat dissipation and current carrying bottlenecks of high-power semiconductor modules.

[0017] The invention's umbrella-shaped support and locking structure provide double protection, ensuring that the pins maintain stable electrical contact even under severe vibration and impact, as well as harsh environments (such as high temperature and high humidity), thus avoiding safety hazards such as signal interruption or power interruption. Attached Figure Description

[0018] Figure 1 A schematic diagram of a reliable, high-current-capable, easy-to-plug pin provided for this invention; Figure 2 A side view of a reliable, high-current-capable, easy-to-plug pin provided for the present invention; In the diagram: 1. Umbrella-shaped support; 2. Contact conductive part; 3. Locking anti-retraction part. Detailed Implementation

[0019] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0020] Example 1

[0021] refer to Figures 1-2 A reliable, high-current-capable, easy-pluggable pin, the pin body having a square lead structure, comprising, along its axial direction: Umbrella-shaped support 1, located at the insertion end of the pin body, has a cross-sectional dimension larger than that of the main rod, and is used to limit and guide the insertion structure; The conductive contact part 2 is located behind the umbrella-shaped support part and is used to increase the contact area with the mating terminal and the current carrying capacity. The locking anti-reverse part 3 is located behind the contact conductive part and is used to engage with the elastic buckle inside the socket after insertion to achieve physical locking.

[0022] The square pin structure not only facilitates extrusion molding, but its edge features also provide an additional scraping effect during insertion, which helps remove oxide layers or dirt from the mating terminal surfaces, ensuring the cleanliness of the contact interface and thus reducing initial contact resistance.

[0023] Preferably, the umbrella-shaped support 1 is a copper part formed by extrusion. The extrusion process can make the internal grain direction of the copper material continuous, avoid stress concentration and microcracks caused by stamping and shearing, and significantly improve the mechanical strength and fatigue resistance of the pin.

[0024] Preferably, the conductive contact portion 2 has four symmetrically or evenly distributed contact protrusions to form four contact areas. The four contact areas are evenly distributed along the circumference of the pin, so that the insertion force is evenly distributed on the four edges, avoiding terminal deformation caused by unilateral load. At the same time, the multi-point parallel conductive path effectively reduces the overall contact resistance, and the Joule heat generated under high current conditions is much less than that of single-point or two-point contact structures. Moreover, the four contact areas are redundant, so even if individual contact points are momentarily separated due to vibration, the remaining points can still maintain electrical connection, which greatly improves the reliability of the system.

[0025] Preferably, the locking anti-retraction part 3 has an annular or semi-annular protrusion extending along the axial direction of the insert pin. The cross-sectional width of the protrusion forms a step difference with the main body of the insert pin, which enhances the vibration resistance and anti-dislodgement capability under harsh working conditions through interference fit. This locking anti-retraction part and the umbrella-shaped support part constitute a two-way limiting mechanism—the umbrella-shaped support part limits the maximum insertion depth to prevent excessive insertion from damaging the internal elastic buckle; the locking anti-retraction part provides a reverse locking force. The two work together to ensure that the insert pin hardly shifts under axial vibration. This is an active anti-dislodgement effect that a simple interference fit structure cannot achieve.

[0026] Preferably, the overall axial length of the pin body is 14.30mm, the axial length of the locking anti-retraction part 3 is 0.50mm, and a 2mm installation positioning area is provided at a preset distance from the tail end.

[0027] Preferably, the pin body is a one-piece molded structure. One-piece molding avoids the additional contact resistance and potential fracture interface caused by welding or riveting, and the overall structure has no stress concentration inflection points, resulting in higher durability under thermal cycling and mechanical shock.

[0028] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention are included within the scope of protection of the present invention.

Claims

1. A reliable, high-current-capable, easy-pluggable pin, characterized in that, The pin body has a square pin structure, and includes, along its axial direction, the following components: An umbrella-shaped support portion is located at the insertion end of the pin body, and its cross-sectional dimension is larger than that of the main body rod, which is used to limit and guide the insertion structure. The conductive contact portion is located behind the umbrella-shaped support portion and is used to increase the contact area with the mating terminal and the current carrying capacity. A locking anti-retraction part is located behind the contact conductive part and is used to engage with the elastic buckle inside the socket after insertion to achieve physical locking.

2. The reliable, high-current-capacity, easy-plug pin according to claim 1, characterized in that, The umbrella-shaped support is a copper part formed by extrusion.

3. The reliable, high-current-capacity, easy-plug pin according to claim 1, characterized in that, The contact conductive part has four symmetrically or evenly distributed contact protrusions on the sides to form four contact areas.

4. A reliable, high-current-capacity, easy-plug pin according to claim 3, characterized in that, The locking anti-retraction part is provided with annular or semi-annular protrusions extending along the axial direction of the pin. The cross-sectional width of the protrusion forms a step difference with the main body of the pin, which enhances the anti-vibration and anti-fall-off ability under harsh working conditions through interference fit.

5. A reliable, high-current-capacity, easy-plug pin according to claim 1, characterized in that, The overall axial length of the pin body is 14.30mm, the axial length of the locking anti-retraction part is 0.50mm, and a 2mm installation positioning area is provided at a preset distance from the tail end.

6. A reliable, high-current-capacity, easy-plug pin according to claim 1, characterized in that, The insert body is a one-piece molded knot.

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