A high-current connector plug, connector and battery energy storage switching module

Abstract

The application discloses a plug-in connector, a connector and a battery energy storage switching module, and belongs to the technical field of connectors. The plug-in connector comprises a front end shaft, a connecting shaft terminal coaxially sleeved in a rear end cylinder, and a filling cavity formed by the three. The cavity is filled with conductor nodules formed by solidification of molten solder after resistance heating. The conductor nodules are connected with the front end shaft, the rear end cylinder and the connecting shaft terminal respectively. When a pulling force is applied in the axial direction, the conductor nodules are broken at the body or the connecting interface, so that the front end shaft is separated from the connecting terminal shaft, and the connection between the conductor nodules and the inner wall of the rear end cylinder is disconnected. The conductor nodules ensure reliable conduction during normal use. When the terminal is damaged, the plug-in connector can be quickly separated by axial pulling, so that on-site maintenance and replacement are facilitated, and the whole module does not need to be scrapped. The application has the advantages of compact structure, convenient maintenance and significantly reduced maintenance cost of the connector terminal.

Description

Technical Field

[0001] This invention relates to the field of electrical connector technology, and in particular to a high-current connector plug, connector, and battery energy storage adapter module. Background Technology

[0002] Connectors, as key components in electrical systems for transmitting current and signals, are widely used in new energy storage, charging piles, photovoltaic inverters, industrial automation, and high-power power supply equipment. The signal cores of connectors are typically small in diameter. In multi-core, high-density connectors, the terminals are subjected to repeated insertion and removal, mechanical vibration, and axial tension over long periods, making them highly susceptible to bending or even breakage. Once a signal terminal breaks, on-site repair is extremely difficult due to the precious metal plating (such as gold or silver) typically on the terminal surface. Currently, the industry standard practice is to replace the entire connector module.

[0003] Existing technologies have yielded several connector solutions with partially detachable and replaceable terminals. For example, some solutions use a detachable connection between the front and rear ends of a male module, allowing replacement of only the front module after terminal wear. Others utilize threaded structures for individual terminal replacement by unscrewing. Still others employ a pluggable fit between a flexible conductive component and a bushing for component replacement. However, all of these solutions suffer from the following drawbacks: detachable structures typically rely on mechanical connections such as threads, snap-fits, or elastic contacts. These structures are prone to wear and loosening after repeated disassembly and assembly, leading to increased contact resistance and unstable signal transmission (the most serious problem). Furthermore, detachable connections often occupy additional axial or radial space, hindering connector miniaturization and high-density integration. Additionally, when a terminal breaks due to external force (such as accidental cable pulling), the broken fragment often becomes stuck inside the insulating housing, making removal difficult. Repair personnel still need to disassemble the entire module for repair, preventing rapid on-site repair.

[0004] To address the aforementioned issues, this application provides a connector that solves the technical problem of high costs associated with replacing the entire connector after its terminals are damaged. Summary of the Invention

[0005] The purpose of this invention is to provide a high-current connector, connector, and battery energy storage adapter module to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a high-current connector insert, comprising a front end shaft, a rear end cylinder coaxially sleeved at the rear end of the front end shaft, and a connecting shaft terminal coaxially fixed within the rear end cylinder; the connecting shaft terminal, the rear end cylinder, and the front end shaft enclose a filling cavity, the filling cavity being filled with conductor nodules formed by melting and solidifying solder through resistance heating, the conductor nodules being connected to the front end shaft, the rear end cylinder, and the connecting shaft terminal respectively; when a tensile force is applied to the front end shaft and the rear end cylinder along the axial direction, the conductor nodules break at their bodies or at the connection interface with the front end shaft and the connecting shaft terminal, causing the front end shaft to separate from the connecting shaft terminal, and the connection between the conductor nodules and the inner wall of the rear end cylinder to break.

[0007] The high-current connector assembly of the present invention has clamping pieces integrally provided on the rear end face of the front end shaft and the front end face of the connecting terminal shaft, facing each other. When assembled, the clamping pieces on the front end shaft and the clamping pieces on the connecting terminal shaft are radially opposite to each other and form a filling air gap, which is filled by the conductor knot.

[0008] The high-current connector assembly of the present invention has microstructure arrays on the surfaces of the two clamps facing each other. After the conductor nodule is melted and solidified, it is embedded in the microstructure array and forms a mechanical interlock with the two clamps. During maintenance, the solidified conductor nodule can be removed from the filling gap between the two clamps and from the filling cavity using a tool.

[0009] In the high-current connector assembly of the present invention, the microstructure array is one or more of microgrooves, microholes or microprotrusions disposed on the surface of the clip, and the conductor nodules fill the microgrooves or microholes and solidify to form the mechanical interlock.

[0010] In the high-current connector plug-in component of the present invention, the depth of the microgroove or microhole is 0.05mm to 0.5mm, and the spacing between two adjacent microgrooves or microholes is 0.1mm to 1.0mm.

[0011] The high-current connector of the present invention includes a metallurgical bonding layer formed between the conductor joint and the two clips, and the mechanical interlock provides a separable interface between the conductor joint and the clips.

[0012] The high-current connector assembly of the present invention includes a clamping piece on the front end shaft and two radially opposing clamping pieces on the connecting terminal shaft; when assembled, the clamping piece on the front end shaft extends between the two clamping pieces on the connecting terminal shaft.

[0013] The high-current connector plug-in component of the present invention further includes an outer sleeve that is radially detachably sleeved on the outside of the overlapping portion of the rear end cylinder and the front end shaft. The outer side wall of the rear end cylinder is provided with a coaxial annular positioning groove, and the inner side wall of the outer sleeve is provided with an annular rib that matches the annular positioning groove.

[0014] In addition, the present invention also provides a connector, which includes an insulating base body and the aforementioned plug-in component; The connector is integrally injection molded onto the insulating base body, with both ends exposed within the end connectors of the insulating base body, and is used to interface with the connectors of external devices to achieve signal transmission. The insulating base body is also provided with power plug-in terminals.

[0015] In addition, the present invention also provides a battery energy storage adapter module, including the connector described above.

[0016] Compared with existing technologies, the advantages of this invention are as follows: Under normal use, the conductor joint acts as a conductive medium to achieve a reliable electrical connection between the front end shaft and the connecting terminal shaft; when a terminal is damaged and needs to be replaced, only axial tension needs to be applied to cause the joint to break at a preset weak point, achieving rapid separation without disassembling the entire module; simultaneously, the connection between the joint and the inner wall of the rear end cylinder is disconnected, facilitating the cleaning of residues and creating conditions for subsequent refilling with solder for repair. The entire repair process can be completed on-site, significantly reducing maintenance and time costs. Attached Figure Description

[0017] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0018] Figure 1 This is a diagram of the internal structure of the connector of the present invention.

[0019] Figure 2 for Figure 1 A magnified view of a portion of the image.

[0020] Figure 3 This is a top view of the connector of the present invention.

[0021] Figure 4 for Figure 3 AA sectional view.

[0022] Figure 5 This is a perspective view of the connector of the present invention.

[0023] Figure 6 This is a scanning electron microscope (SEM) microstructure of the conductor nodule of the present invention. Detailed Implementation

[0024] The terms "first," "second," "third," and "fourth," etc., used in the specification, claims, and accompanying drawings of this invention are used to distinguish different objects, not to describe a specific order. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or apparatus that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or apparatuses.

[0025] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of the invention. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0026] "Multiple" refers to two or more. "And / or" describes the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A alone, A and B simultaneously, or B alone. The character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0027] Furthermore, the terms indicating orientation, such as "up," "down," "left," "right," "upper end," "lower end," and "longitudinal," are all based on the posture and position of the device or equipment described in this solution during normal use.

[0028] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, a clear and complete description will be provided below in conjunction with the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the protection scope of the present invention.

[0029] This embodiment discloses, as follows: Figures 1 to 6The high-current connector 100 shown mainly includes a front shaft 1, a rear cylinder 2, and a connecting shaft terminal 3. The rear cylinder 2 is coaxially sleeved outside the rear end of the front shaft 1, and the connecting shaft terminal 3 is coaxially fixed inside the rear cylinder 2, with the front end of the connecting shaft terminal 3 axially spaced from the rear end of the front shaft 1. The front shaft 1, rear cylinder 2, and connecting shaft terminal 3 together form an annular filling cavity 200, located between the rear end face of the front shaft 1 and the front end face of the connecting shaft terminal 3, and radially constrained by the inner wall of the rear cylinder 2. Conductor nodules 4 are filled within the filling cavity 200. These conductor nodules 4 are formed by melting solder through resistance heating and then cooling and solidifying it, and they achieve physical contact and conductive connection with the front shaft 1, rear cylinder 2, and connecting shaft terminal 3, respectively. The conductor nodule 4 has a columnar solid structure within the filling cavity 200. Its axial ends abut against the rear end face of the front shaft 1 and the front end face of the connecting shaft terminal 3, respectively, while its radial exterior is tightly fitted to the inner wall of the rear cylinder 2. When opposite tensile forces are applied to the front shaft 1 and the rear cylinder 2 along the axial direction, the conductor nodule 4 can undergo brittle fracture at its weakest section, either at its connection interface with the front shaft 1 or with the connecting shaft terminal 3. This completely separates the front shaft 1 and the connecting shaft terminal 3 axially. Simultaneously, the connection between the conductor nodule 4 and the inner wall of the rear cylinder 2 is also broken, preventing the residue of the fractured conductor nodule 4 from adhering to the inner wall of the rear cylinder 2, facilitating subsequent cleaning and refilling repair.

[0030] More specifically, a clip 5 extending toward the connecting shaft terminal 3 is integrally protruded on the rear end face of the front end shaft 1, while at least one clip 6 extending toward the front end shaft 1 is integrally protruded on the front end face of the connecting shaft terminal 3. When the connector 100 is assembled in place, that is, when the front end shaft 1 and the connecting shaft terminal 3 are in the axial pre-assembly position, the clip 5 on the front end shaft 1 and the clip 6 on the connecting shaft terminal 3 are arranged radially spaced apart, and a certain filling air gap 300 is formed between them in the axial direction. This filling air gap 300 is interconnected with the aforementioned filling cavity 200 and is completely filled by the cured conductor nodule 4.

[0031] In a preferred embodiment, the front shaft 1 is provided with a clamping piece 5, while the connecting shaft terminal 3 is provided with two radially opposing clamping pieces 61 and 62, i.e., clamping pieces 61 and 62 are 180 degrees apart in the circumferential direction. When assembled, the clamping piece 5 on the front shaft 1 extends axially between the two clamping pieces 61 and 62 on the connecting shaft terminal 3, so that the clamping piece 5 is located in the middle position of clamping pieces 61 and 62 in the circumferential direction, thereby forming two filling air gaps 300 between clamping pieces 5 and 61 and between clamping pieces 5 and 62, respectively. Both of these filling air gaps 300 are connected to the filling cavity 200 and filled by the conductor knot 4. Through this three-piece staggered clamping structure, the conductor knot 4 forms a three-dimensional wrapping around the clamping piece 5 after curing, which significantly increases the contact area and bonding strength between the conductor knot 4 and the front shaft 1 and the connecting shaft terminal 3. At the same time, this structure can evenly transmit the tensile force to the interior of the conductor knot 4 when subjected to axial force, which is beneficial to achieving the preset brittle fracture mode. At the same time, it also facilitates the breakdown of the solder during resistance welding.

[0032] Based on the above structure, in order to further improve the bonding reliability between the conductor junction 4 and the clips and to provide a separable maintenance interface, microstructure arrays are respectively provided on the surfaces of clips 5, 61 and 62 facing each other. Specifically, the microstructure array can be one or more combinations of microgrooves, micropores or microprotrusions provided on the surface of the clips.

[0033] In this embodiment, it is preferable to provide a mixed array of multiple microgrooves and micropores on both sides of the clip 5 and on the opposite surfaces of the clips 61 and 62. The depth of these microgrooves and micropores is 0.05 mm to 0.5 mm, and the spacing between two adjacent microgrooves or two adjacent micropores is 0.1 mm to 1.0 mm. The specific depth and spacing can be selected within the range according to the actual current carrying requirements and process conditions.

[0034] After the solder melts in the filling cavity 200, the molten solder can automatically flow into and fill the interior of the aforementioned microgrooves and micropores under the action of capillary effect. After the solder cools and solidifies to form conductor nodules 4, the material of conductor nodules 4 is embedded in the interior of the microgrooves and micropores to form a mechanical interlocking structure. At the same time, at the contact interface between conductor nodules 4 and clips 5, 61 and 62, due to the mutual diffusion and reaction between the solder and the clip base metal, a metallurgical bonding layer 9 is naturally formed. This metallurgical bonding layer 9 further reduces the contact resistance, ensuring the stability and low loss of signal transmission.

[0035] However, since the pull-out force of the mechanical interlocking structure provided by the microgrooves and micropores is greater than the shear strength of the metallurgical bonding layer 9, and the mechanical interlocking structure itself has a clear weak pull-out interface under axial tensile force, during maintenance, when a predetermined tensile force is applied along the axial direction, the metallurgical bonding layer 9 is destroyed first. Subsequently, the mechanical interlocking structure undergoes plastic deformation or fracture under axial shear force, so that the solidified conductor nodule 4 can be removed from the surface of the clips 5, 61 and 62 and from the interior of the air gap 300 by tools (such as flathead screwdrivers or special scrapers). The separable interface provided by the mechanical interlocking structure ensures that no irreparable damage is caused to the clip body during the removal process.

[0036] In this embodiment, considering the distribution characteristics of the current path during resistance heating—that is, current tends to preferentially follow the path of lower resistance in a metal conductor—and the rear end cylinder 2 in this connector is a continuous and complete metal cylindrical structure, its radial cross-sectional area is much larger than the cross-sectional area of ​​the solder layer inside the filling cavity 200. Therefore, the resistance of the rear end cylinder 2 is much smaller than the resistance of the molten solder. If current is applied directly, most of the current will flow along the cylinder wall of the rear end cylinder 2 and hardly flow through the solder, resulting in the solder not being effectively heated and melted. To solve this technical problem, this embodiment adopts the following process measures during resistance heating.

[0037] Specifically, the first electrode of the resistance heating device is clamped to the exposed front section of the front end shaft 1, and the second electrode is clamped to the exposed rear section of the rear end cylinder 2. This ensures that the first and second electrodes are located on the axial front and rear sides of the filling cavity 200, respectively, guaranteeing that the current flows axially across the section of the filling cavity 200, rather than conducting radially to the nearest point. Simultaneously, in the axially overlapping area between the outer peripheral wall of the front end shaft 1 and the inner peripheral wall of the rear end cylinder 2, except for the section corresponding to the filling cavity 200, the remaining sections located on the axial front and rear sides of the filling cavity 200 are provided with an electrical insulation layer. This electrical insulation layer is a ceramic coating (e.g., an alumina ceramic coating) or a high-temperature resistant polyimide insulation layer coated on the outer surface of the front end shaft 1, with a thickness of 0.01 mm to 0.05 mm, capable of withstanding heating temperatures above 150°C without breakdown or detachment. By setting this electrical insulation layer, the low-resistance bypass channel for current to be directly radially conducted from the outer wall of the front shaft 1 to the inner wall of the rear cylinder 2, and then axially transmitted along the cylinder wall of the rear cylinder 2 to the second electrode is completely cut off. On this basis, since the overlapping area of ​​the front shaft 1 and the rear cylinder 2 outside the filling cavity 200 is separated by the electrical insulation layer, and the area where the filling cavity 200 is located is not provided with this insulation layer, after the current flows into the front shaft 1 from the first electrode, when it travels axially to the position of the filling cavity 200, it cannot directly radially pass through the outer wall of the front shaft 1 to the inner wall of the rear cylinder 2, nor can it continue to be axially conducted along the outer wall of the front shaft 1 to the rear (because the overlapping area on the rear side is also blocked by the insulation layer 18). Therefore, the only feasible conduction path for the current is: the body of the front shaft 1 → the clip 5 at the rear end of the front shaft 1 → the solder in the filling cavity 200 → the clips 61 and 62 at the front end of the connecting shaft terminal 3 → the body of the connecting shaft terminal 3 → the cylinder wall of the rear cylinder 2 → the second electrode.

[0038] Therefore, the current must pass through the clamp 5, the solder layer, and clamps 61 and 62 in series. The resistivity of the solder layer at room temperature is much higher than that of the copper alloy clamp and the substrate of the rear cylinder 2 (the resistivity of the copper alloy is about 0.02 μΩ·m, while the resistivity of the solder in the solid phase in this embodiment is about 0.3 to 0.5 μΩ·m, a difference of more than 15 times). Moreover, the resistivity of the solid phase solder is even higher in the early stage of melting, making the solder layer the section with the highest resistance in this series circuit. According to Joule's law Q=I²Rt, most of the Joule heat will be concentrated in the solder itself and at the interface with the clamp, realizing the rapid and uniform melting of the solder from the inside out, while effectively avoiding the overheating damage of the cylinder wall of the rear cylinder 2 due to the large amount of current flowing through it.

[0039] Furthermore, due to the forced current passing through the solder in the air gap 300 between clips 5 and 61, 62, the current density in this region is significantly increased (up to 10³~10⁻⁶). 4The strong Joule heat generated by the solder (A / cm²) further promotes the wetting and filling of the roots of the microgrooves 71 and microholes 72, ensuring that the conductor nodule 4 forms a complete and reliable mechanical interlock 8 with the microstructure array 7 after curing.

[0040] Regarding the internal structure of the conductor nodule 4, the conductor nodule 4 formed by the process of this embodiment has unique microstructure characteristics. The conductor nodule 4 has a dense metallic crystalline structure with fine and uniformly distributed grains, with an average grain size between 5 μm and 15 μm. In the region near the surfaces of clips 5, 61, and 62 and the inner wall of the rear cylinder 2, an intermetallic compound layer 11 with a thickness of 2 μm to 8 μm is formed between the conductor nodule 4 and each metal substrate. This intermetallic compound layer 11 mainly includes Cu6Sn5 phase and Ag3Sn phase. These two compound phases grow into the solder in a continuous toothed or scalloped morphology, providing reliable metallurgical bonding force. Due to the difference in thermal expansion coefficients between them and the solder substrate, a small residual stress field is formed at the interface. This residual stress field can serve as a preferential path for crack initiation and propagation during subsequent axial pull-out, which is beneficial for achieving brittle fracture.

[0041] The internal structure of conductor nodule 4 is a fine eutectic or near-eutectic structure, in which the bismuth-rich phase is uniformly distributed in a dispersed granular form within the tin-rich matrix. The presence of bismuth significantly reduces the plasticity and toughness of the solder, giving conductor nodule 4 intrinsic brittleness. At the same time, the porosity inside conductor nodule 4 is controlled to below 1%, with almost no macroscopic voids, ensuring the integrity of the conductive cross-section.

[0042] It is worth noting that although the intermetallic compound layer 11 and mechanical bond are formed between the conductor nodule 4 and the inner wall of the rear end cylinder 2, the inner wall of the rear end cylinder 2 has been pre-smoothed in the filling cavity 200 area (surface roughness Ra not greater than 0.4 μm) and no microstructure array is set. Therefore, the bonding strength between the conductor nodule 4 and the inner wall of the rear end cylinder 2 is designed to be less than the bonding strength between the conductor nodule 4 and the clips 5, 61 and 62. This ensures that the connection between the conductor nodule 4 and the inner wall of the rear end cylinder 2 is preferentially broken during axial pull-out, avoiding the adhesion of nodule residue after fracture to the inner wall of the rear end cylinder 2 and affecting subsequent repair.

[0043] To achieve precise configuration and filling of the solder as described above, this embodiment provides an optimized solder formulation and a corresponding solder paste form.

[0044] The solder uses Sn-Bi-In low-temperature lead-free alloy as the base and adds a variety of strengthening and modifying elements. The whole is processed into spherical alloy powder, and then the alloy powder is uniformly mixed with a special flux medium to make solder paste, so that it can be accurately filled into the filling cavity 200 by dispensing or printing.

[0045] Specifically, the chemical composition of the alloy powder, by mass percentage, is as follows: The alloy comprises 17% to 22% tin, 48% to 54% bismuth, 24% to 28% indium, 2% to 5% silver, 0.5% to 1.2% copper, 0.05% to 0.15% germanium, and 0.5% to 1.5% zinc, with the balance being unavoidable impurity elements, and the sum of all components is 100%. In the preferred formulation of this embodiment, the alloy powder comprises 18.5% tin, 26% indium, 50% bismuth, 3% silver, 0.8% copper, 0.1% germanium, and 1.6% zinc, with the balance being tin to make up to 100%. The alloy of this preferred formulation has a melting point of approximately 78°C to 85°C, which falls within the category of cryogenic solders.

[0046] The alloy powder is prepared by gas atomization, with a particle size distribution satisfying D50 = 15μm to 25μm. The particle morphology is spherical or near-spherical, and the oxygen content of the powder does not exceed 200ppm. The addition of germanium effectively inhibits surface oxidation of the powder during storage and use, ensuring long-term stability. The above alloy powder is mixed with a special low-temperature flux medium at a mass ratio of 88% to 92% (alloy powder) to 8% to 12% (flux medium) to form a solder paste, wherein the flux medium includes, by mass percentage: The solder paste contains 40% to 55% modified rosin resin (softening point 80℃), 20% to 35% butyl carbitol (solvent), 5% to 12% adipic acid (activator), 3% to 8% hydrogenated castor oil (thixotropic agent), and 0.1% to 0.5% benzotriazole (corrosion inhibitor), with the total components comprising 100%. The Brookfield viscosity at 25℃ is 80 Pa·s to 120 Pa·s, the thixotropic index is 4.5 to 6.0, and the halogen content is zero, fully complying with halogen-free environmental protection requirements.

[0047] In the specific process of forming conductor nodules 4 using the above-mentioned solder paste, firstly, a pneumatic precision dispensing machine or a screw dispensing pump is used to apply the solder paste to the bottom position of the filling cavity 200 inside the rear cylinder 2 according to the calculated amount of 90% to 95% of the volume of the filling cavity 200. Care should be taken to control the dispensing trajectory so that it is evenly distributed around the clips 5, 61 and 62.

[0048] Then, the assembled components with the adhesive applied are placed on a preheating platform at 60°C to 80°C and kept at that temperature for 15 to 30 seconds. This allows the butyl carbitol solvent in the solder paste to slowly evaporate, reducing the viscosity of the paste. At the same time, the solder paste flows naturally under gravity and wets the microgrooves and micropores on the surface of the clips, thus achieving the pre-placement of solder powder in the microstructure.

[0049] After preheating, the above-mentioned resistance heating equipment is used to heat the material according to a stepped temperature rise curve: First, slowly heat the temperature to 80°C using a low power of 20W to 50W for 3 to 5 seconds to completely evaporate any residual solvent and prevent boiling and splashing. Then, heat to 100°C to 110°C at a medium power of 80W to 150W and maintain for 2 to 4 seconds to fully decompose the adipic acid activator to remove the solder powder and oxide film on the surface of the clips, thus obtaining a clean interface. Then, the temperature is rapidly increased to 130°C to 150°C at full power of 200W to 400W for 2 to 5 seconds, so that the solder powder is completely melted. The molten solder instantly fills the microgrooves, micropores and air gaps 300 under the capillary effect. Finally, the power was reduced to 100W and held at 120°C to 130°C for 1 to 3 seconds to maintain the liquid phase state and ensure that the molten solder fully penetrated to the root of the microstructure array.

[0050] Throughout the heating process, a low-frequency mechanical vibration of 20Hz to 50Hz with an amplitude of 0.05mm is simultaneously applied to the rear cylinder 2 via a piezoelectric vibrator. This promotes the upward movement and expulsion of air bubbles in the molten solder, while volatile gases escape outward through a 0.02mm to 0.05mm axial micro-gap at the tail end of the filling cavity 200 between the inner wall of the rear cylinder 2 and the outer wall of the front shaft 1. After heating is completed, the current is cut off, and the component is first allowed to cool naturally for 5 to 8 seconds, allowing the temperature to drop from the melting peak to approximately 100°C to release thermal stress. Then, room-temperature compressed air is used to force-cool the outer wall of the rear cylinder 2, rapidly cooling it to room temperature within 10 to 15 seconds. This segmented cooling method yields a refined grain structure, and the conductor nodules 4 eventually solidify to form a dense conductive structure. The entire process cycle is approximately 40 to 60 seconds per piece, suitable for automated mass production.

[0051] In this embodiment, the connector 100 further includes an outer sleeve 12, which is radially detachably fitted onto the outer side of the axially overlapping portion of the rear end cylinder 2 and the front end shaft 1. Specifically, the outer sleeve 12 consists of two radially opposing metal half-shells 121 and 122, namely the first half-shell 121 and the second half-shell 122, which are radially joined to form a complete cylindrical body, which covers the outside of the overlapping area of ​​the rear end cylinder 2 and the front end shaft 1. A coaxial annular positioning groove 13 is provided on the outer side wall of the rear end cylinder 2, while an annular rib 14 that radially matches the annular positioning groove 13 is provided on the inner side wall of the outer sleeve 12. When the first half-shell 121 and the second half-shell 122 are joined and fitted onto the outside of the rear end cylinder 2, the annular rib 14 engages with the annular positioning groove 13, thereby achieving axial positioning of the outer sleeve 12 relative to the rear end cylinder 2 and preventing axial movement between the two.

[0052] Meanwhile, the outer wall of the outer sleeve 12 is provided with external threads, which are used for integral injection molding with the insulating base body 16 of the connector. During the injection molding process, the closed outer sleeve 12 (including the front shaft 1 and rear sleeve 2 assembly inside) is placed into the injection mold as an insert. Molten plastic material (such as LCP liquid crystal polymer or PA66 nylon) wraps around the outer wall of the outer sleeve 12 and fills the thread root and crest of the external thread. After solidification, the outer sleeve 12 and the insulating base body 16 form a strong integral whole. The external thread provides reliable mechanical anchoring force, ensuring that the connector 100 will not come out of the insulating base body 16 when subjected to repeated insertion and extraction forces. When maintenance or replacement is required, since the outer sleeve 12 and the insulating base body 16 are integrally injection molded, there is no need to disassemble the outer sleeve 12. Separation can be achieved by directly applying axial tensile force from the exposed end of the front shaft 1 and the exposed end of the rear sleeve 2.

[0053] This embodiment also provides a connector, which includes the aforementioned insulating base body 16 and at least one plug-in member 100 as described above. The plug-in member 100 is integrally injection molded onto the insulating base body 16 via the external thread of the outer sleeve 12, and the front end of the front end shaft 1 and the rear end of the rear end sleeve 2 of the plug-in member 100 are both exposed within the two end plug-in interfaces 161 of the insulating base body 16, for interlocking with the corresponding plug-in interfaces of external devices to achieve signal transmission.

[0054] Meanwhile, the insulating base body 16 is also provided with a power plug-in terminal 17, which is used to transmit high current power signals. Its current carrying capacity is selected according to different specifications of terminals according to actual needs. Through the above structure, the plug-in component 100 for signal transmission realizes the function of being replaceable individually. When a signal terminal is damaged due to long-term plugging and unplugging, it is only necessary to axially pull the front end shaft 1 and the rear end cylinder 2 of the plug-in component 100 apart, remove the residual conductor joint 4, reassemble a new front end shaft 1 or rear end cylinder 2 assembly, and refill with solder paste to form a new conductor joint 4 to complete the repair without scrapping the entire connector module.

[0055] Furthermore, this embodiment also provides a battery energy storage adapter module, which includes the aforementioned connector. This battery energy storage adapter module is specifically designed for use in energy storage module power supplies, internal power modules of charging piles, photovoltaic inverter power modules, and high-power industrial automation equipment. By integrating a connector with replaceable signal terminals into the adapter module, it effectively solves the technical problem of needing to replace the entire module due to signal core terminal breakage during long-term service. This significantly reduces the operation and maintenance costs of energy storage systems and equipment downtime, and is particularly suitable for high-power applications with stringent requirements for power supply stability and reliability.

[0056] The above description is merely a preferred embodiment of this application and is not intended to limit the scope of protection of this application. Any modifications, equivalent substitutions, improvements, etc., made within the technical concept and principles of this application should be included within the scope of protection of the claims of this application.

Claims

1. A connector, characterized in that, The device includes a front shaft, a rear cylinder coaxially sleeved at the rear end of the front shaft, and a connecting shaft terminal coaxially fixed inside the rear cylinder. The connecting shaft terminal, the rear cylinder, and the front shaft enclose a filling cavity, which is filled with conductive nodules formed by melting and solidifying solder through resistance heating. The conductive nodules are connected to the front shaft, the rear cylinder, and the connecting shaft terminal, respectively. When a tensile force is applied to the front shaft and the rear cylinder along the axial direction, the conductive nodules break at their bodies or at the connection interface with the front shaft and the connecting shaft terminal, causing the front shaft to separate from the connecting shaft terminal, and the connection between the conductive nodules and the inner wall of the rear cylinder to break.

2. The connector according to claim 1, characterized in that, Both the rear end face of the front end shaft and the front end face of the connecting terminal shaft are integrally provided with clamping pieces facing each other. When assembled, the clamping pieces on the front end shaft and the clamping pieces on the connecting terminal shaft are radially opposite to each other and form a filling air gap, which is filled by the conductor knot.

3. The connector according to claim 2, characterized in that, The two clamps have microstructure arrays on their surfaces facing each other. After the conductor nodule melts and solidifies, it is embedded in the microstructure array and mechanically interlocked with the two clamps. During maintenance, the solidified conductor nodule can be removed from the filling gap between the two clamps and from the filling cavity using a tool.

4. The connector according to claim 3, characterized in that, The microstructure array is one or more of microgrooves, micropores, or microbumps disposed on the surface of the clip, and the conductor nodules fill the microgrooves or micropores and solidify to form the mechanical interlock.

5. The connector according to claim 4, characterized in that, The depth of the microgroove or micropore is 0.05mm to 0.5mm, and the distance between two adjacent microgrooves or micropores is 0.1mm to 1.0mm.

6. The connector according to claim 3, characterized in that, The metallurgical bonding layer is formed between the conductor nodule and the two clamps, and the mechanical interlock provides a separable interface between the conductor nodule and the clamps.

7. The connector according to claim 2, characterized in that, The front end shaft is provided with a clamping piece, and the connecting terminal shaft is provided with two radially opposite clamping pieces; when assembled, the clamping piece on the front end shaft extends into the space between the two clamping pieces on the connecting terminal shaft.

8. The connector according to claim 1, characterized in that, The connector further includes an outer sleeve that is radially detachably sleeved on the outside of the overlapping part of the rear end cylinder and the front end shaft. The outer side wall of the rear end cylinder is provided with a coaxial annular positioning groove, and the inner side wall of the outer sleeve is provided with an annular rib that matches the annular positioning groove.

9. A connector, characterized in that, Includes an insulating base body and a connector as described in any one of claims 1 to 7; The connector is integrally injection molded onto the insulating base body, with both ends exposed within the end connectors of the insulating base body, and is used to interface with the connectors of external devices to achieve signal transmission. The insulating base body is also provided with power plug-in terminals.

10. A battery energy storage adapter module, comprising the connector described in claim 9.

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