High-voltage power supply connector with floating function

Abstract

The application relates to the technical field of high-voltage power connectors, in particular to a high-voltage power connector with a floating function, which comprises a male connector and a female connector, and an external first PCB board and an external second PCB board are connected through the male connector and the female connector; one end of the male connector is connected with the first PCB board, the other end is connected with the female connector, and one end of the female connector, which is far away from the male connector, is connected with the second PCB board; the male connector comprises a male shell, a plurality of groups of first terminals arranged in the male shell, the male shell comprises a first main body part and a plurality of groups of convex column parts arranged on the first main body part, the plurality of groups of first terminals are arranged in the plurality of groups of convex column parts one by one, and the first terminals penetrate through the first main body part and the convex column parts; a plurality of groups of hollowed-out perforations are arranged on the first main body part, one group of hollowed-out perforations is arranged between two adjacent groups of convex column parts, and the hollowed-out perforations are used for prolonging the insulation creepage path between adjacent first terminals.

Description

Technical Field

[0001] This invention relates to the field of high-voltage power connector technology, and in particular discloses a high-voltage power connector with a floating function. Background Technology

[0002] As new energy vehicles, energy storage, and industrial high-voltage equipment develop towards higher integration, lighter weight, and miniaturization, the structural dimensions of high-voltage connectors are constantly being compressed, with terminal center distances generally shrinking to 4.0mm or even smaller. This limited installation space places extremely high demands on the connector's insulation performance, assembly compatibility, and contact reliability.

[0003] Existing miniaturized high-voltage connectors mostly rely on adding insulating ribs to improve creepage distance. However, within limited space, the four design requirements of miniaturization, PCB board connection accuracy, high-voltage creepage insulation, and male / female floating compensation are mutually restrictive and difficult to balance, resulting in significant technical bottlenecks. Specifically, miniaturization compresses the space for terminal spacing and insulation layout, which can easily lead to insufficient creepage distance and trigger high-voltage leakage and breakdown risks. PCB board connections require high positioning accuracy, but miniaturized structures have weak positioning references and low assembly tolerance, making them prone to poor contact due to installation deviations. Conventional insulation reinforcement structures occupy a lot of space, conflicting with miniaturization requirements and limiting the arrangement of floating mechanisms. Traditional floating compensation structures not only occupy space but also disrupt the continuity of insulation along the surface, further reducing high-voltage insulation performance.

[0004] In summary, existing technologies cannot simultaneously achieve large tolerance floating compensation, sufficient creepage distance, high-precision board-end assembly, and compact structural design within a limited space. As a result, the products have poor adaptability and reliability, making it difficult to meet the usage requirements of the new generation of miniaturized high-voltage electrical equipment. Summary of the Invention

[0005] In order to overcome the shortcomings and deficiencies of the existing technology, the purpose of this invention is to provide a high-voltage power connector with a floating function.

[0006] To achieve the above objectives, the present invention provides a high-voltage power connector with a floating function, comprising a male connector and a female connector. An external first PCB board and an external second PCB board are connected via the insertion of the male connector and the female connector. One end of the male connector is inserted into the first PCB board and connected, and the other end is inserted into the female connector and connected. The end of the female connector away from the male connector is inserted into the second PCB board and connected. The male connector includes a male housing and multiple sets of first terminals disposed within the male housing. The male housing includes a first main body and multiple sets of protruding pillars disposed on the first main body. The multiple sets of first terminals are housed one-to-one within the multiple sets of protruding pillars, and the first terminals penetrate the first main body and the protruding pillars. The first main body is provided with multiple sets of hollowed-out through holes, and a set of hollowed-out through holes is provided between two adjacent sets of protruding pillars. The hollowed-out through holes are used to extend the insulation creepage path between adjacent first terminals.

[0007] The first terminal of the male connector is housed within each set of protruding parts of the male housing and is conductive to the first PCB board. The female connector is correspondingly aligned and plugged into the second PCB board and the first terminal to achieve overall circuit connectivity. By setting corresponding perforations between adjacent protruding parts, the short linear surface path between adjacent first terminals is no longer a straight path, effectively lengthening the insulation creepage path between terminals. Under the limited space structure of connector miniaturization and significant reduction in terminal spacing, the high voltage insulation capability of the male terminal area can be significantly improved without increasing the overall volume of the housing, avoiding creepage and breakdown between adjacent terminals under high voltage conditions. At the same time, the structure is simple, integrally molded, and has high space utilization, which can adapt to the assembly and use requirements of highly integrated and lightweight high voltage electrical equipment.

[0008] The male shell also includes multiple sets of fasteners, with one set of fasteners between two adjacent sets of protruding pillars. The fasteners are used to increase the structural strength between the two adjacent sets of protruding pillars.

[0009] Fixing members are set between two adjacent sets of protruding pillars on the male shell, so that multiple independent sets of protruding pillars are connected to each other into a whole structure through the fixing members. This effectively improves the overall structural rigidity and integrity of the protruding pillars, and makes up for the problem of reduced shell structural strength caused by opening hollowing holes and receiving slots. It can effectively resist deformation, cracking or displacement caused by assembly insertion and extraction forces, equipment vibration and external extrusion, and ensure the stability of the installation position of the first terminal of each set. While realizing the miniaturized and high creepage distance structural design, it also takes into account the shell structural strength and long-term reliability.

[0010] The protruding post is located between the first main body and the female connector. The protruding post surrounds and covers the outside of the first terminal. The first terminal is floatingly inserted into the female connector. The female connector is provided with a fourth clearance hole that mates with the free end of the protruding post. The first terminal can be inserted into the protruding post, or the protruding post can be injection molded onto the outside of the first terminal.

[0011] The protruding post is provided with an integrally formed extension, and the first terminal passes through the first main body, the protruding post, and the extension; the extension is used to increase the surface creepage distance of the insulation between the terminal and the male housing.

[0012] The structure does not require additional horizontal layout space, and can further improve the overall insulation performance and withstand voltage rating under the constraints of connector miniaturization and narrow terminal spacing. The one-piece molding structure has high strength and good stability, and is suitable for long-term safe use of high-voltage and highly integrated equipment.

[0013] The female connector includes a female housing and multiple sets of second terminals disposed within the female housing. One end of the second terminal is inserted into and connected to the second PCB board, and the other end is inserted into and connected to the first terminal.

[0014] The second terminal includes a second main body, a first conductive part disposed at one end of the second main body, and a second conductive part disposed at the other end of the second main body. The first conductive part is inserted into and connected to the second PCB board, and the second conductive part is inserted into and connected to the first terminal. The second conductive part includes a first elastic clamping arm and a second elastic clamping arm that cooperates with the first elastic clamping arm. The first elastic clamping arm and the second elastic clamping arm form an insertion gap. The end of the first terminal away from the first PCB board is inserted into the insertion gap. The first elastic clamping arm and the second elastic clamping arm clamp the first terminal so that the first terminal and the second terminal are connected.

[0015] During the assembly of the female connector, multiple sets of second terminals are installed inside the female housing. The first conductive part of one end of the second terminal is inserted and connected to the second PCB board. The second conductive part of the other end forms an insertion gap through the parallel first elastic clamping arm and the second elastic clamping arm. The end of the first terminal of the male end is inserted into the insertion gap. Electrical connection is achieved by the two elastic clamping arms clamping and abutting the two sides of the first terminal. The clamping contact method of the elastic clamping arms can ensure reliable contact between the first terminal and the second terminal. It can adapt to certain positional deviations during assembly, reduce the risk of docking failure, and has a compact structure, making it suitable for use in small board-end high-voltage connectors.

[0016] The mother shell includes a shell section and multiple sets of spacer ribs formed inside the shell section. A first chamber is formed inside the shell section, and the multiple sets of spacer ribs divide the first chamber into multiple sets of second chambers. Multiple sets of second terminals are housed in the corresponding second chambers. Multiple sets of first clearance holes are provided at the end of the shell section away from the male shell. After the first guide portion protrudes from the first clearance hole, it is inserted and connected to the second PCB board.

[0017] The female housing has a first chamber inside its housing section. Multiple sets of spacer ribs are arranged inside the chamber, dividing the first chamber into several independent second chambers. Each set of second terminals is housed in its corresponding second chamber for cavity isolation. A first clearance hole is opened at the end of the housing section away from the male housing. The first conductive part of the second terminal extends outward through the first clearance hole and then connects with the second PCB board. The spacer ribs separate the second terminals from each other, which not only limits the installation position of the second terminals and prevents the terminals from shifting or tilting, but also increases the surface creepage path between adjacent second terminals and suppresses surface leakage between terminals. The first clearance hole provides clearance and limit for the first conductive part, facilitating board-end assembly and positioning between the female housing and the second PCB board. The overall structure is compact and adaptable to the installation requirements of miniaturized board-end high-voltage connectors.

[0018] The housing portion is provided with multiple sets of second clearance holes at the end away from the first clearance hole and facing the second PCB board. The first terminal is inserted into the second terminal through the second clearance hole. The hole spacing of the second clearance holes is greater than the thickness of the first terminal. A first gap is provided between one side of the first terminal and the hole wall of the second clearance hole, and a second gap is provided between the other side of the first terminal and the hole wall of the second clearance hole. The first gap and the second gap together provide radial floating compensation for the first terminal, compensate for the positional deviation caused by the PCB board assembly, and realize the floating docking of the connector.

[0019] Multiple sets of second clearance holes are provided on the side of the housing away from the first clearance hole and facing the male end. During insertion, the first terminal passes through the second clearance hole and extends into the female housing to mate with the second terminal. The hole spacing of the second clearance holes is greater than the thickness of the first terminal, so that the first terminal and the hole walls on both sides of the second clearance hole form a first gap and a second gap, respectively. The gaps reserved on both sides provide radial floating compensation for the first terminal. When there is a deviation in the assembly position of the two PCB boards, the first terminal can be radially offset within the gap of the second clearance hole to offset the position error caused by assembly, thereby realizing the floating mating of the male and female ends of the connector. This reduces the risk of terminal jamming and poor contact caused by PCB board assembly misalignment. This floating structure is achieved directly by utilizing the gap of the clearance hole itself, without the need to add additional elastic sliding parts, saving internal space of the housing and facilitating the overall miniaturization design of the connector.

[0020] The first terminal has two clamping surfaces clamped by a first elastic clamping arm and a second elastic clamping arm, and two non-clamping sides; the two non-clamping sides are arranged in parallel, and a third distance is provided between the two non-clamping sides and the inner sidewall of the housing, the third distance being used to allow the first terminal to have radial floating offset space in the second cavity.

[0021] During the docking process, the first terminal is clamped and limited on both sides by the first elastic clamping arm and the second elastic clamping arm to form a stable conductive contact. The two sets of non-clamped sides of the first terminal are reserved with a third gap between them and the inner wall of the second chamber, so that the first terminal as a whole has an independent radial floating offset space inside the second chamber. This structure, while ensuring the stability of terminal clamping and conduction, further increases the range of error tolerance of the first terminal. It works in conjunction with the floating gap of the second clearance hole to compensate for PCB assembly deviations in multiple ways, effectively avoiding the situation of terminal sticking to the shell and causing jamming or offset. It greatly improves the smoothness and assembly compatibility of male and female terminal docking, and further ensures the reliability of connector floating docking.

[0022] The spacer rib is provided with an integrally formed extension strip, and the second PCB board is provided with a first insertion hole. The extension strip is inserted into the first insertion hole. The extension strip is used to block two adjacent second terminals to increase the creepage distance.

[0023] An extension strip is integrally formed on the outer side of the spacer rib. During assembly, the extension strip is inserted into the first insertion hole of the second PCB board, so that the insulation barrier structure between adjacent second terminals extends to the surface of the second PCB board. This effectively blocks the straight leakage path formed by adjacent terminals along the PCB board surface, significantly increasing the surface creepage distance under high voltage conditions. This structure relies on the original spacer rib integrally formed, without the need for additional insulation accessories. The structure is simple and compact. While meeting the miniaturization design of the connector, it effectively solves the problem of easy creepage and breakdown on the PCB board surface under narrow terminal center distance, significantly improving the high voltage insulation safety of the connector.

[0024] The housing part has a snap-fit ​​groove on its side, and the second main body part has a third clearance hole and a spring piece. One end of the spring piece is connected to the second main body part, and the other end of the spring piece extends through the third clearance hole and is snapped into the snap-fit ​​groove. This is used to snap and limit the second terminal in the second cavity of the housing part, and to restrict the second terminal from moving out along the insertion direction.

[0025] The housing has a snap-fit ​​groove on its side, and the second main body of the second terminal has a corresponding third clearance hole and an integrally formed spring piece. During assembly, the spring piece extends outward through the third clearance hole and elastically snaps into the snap-fit ​​groove, so that the second terminal is snapped and limited in the second cavity. Through the elastic snap-fit ​​structure of the spring piece and the snap-fit ​​groove, the movement, loosening or disengagement of the second terminal along the insertion direction can be effectively restricted, so as to achieve axial anti-retraction fixation of the terminal. No additional locking accessories are required. The assembly is convenient and the structure is compact. It can resist the risk of loosening caused by equipment vibration and insertion and pulling for a long time, and ensure the installation stability and docking reliability of the second terminal in the housing.

[0026] The inner side of the housing is provided with a snap-fit ​​part, which is arranged parallel to the snap-fit ​​groove. The snap-fit ​​part includes a stop part arranged along the length direction of the housing part and an insertion limiting member arranged vertically on the stop part. The second main body is provided with a clamping strip hole, which is arranged parallel to the spring piece. The first guide part is provided with multiple sets, and two adjacent sets of first guide parts are located on both sides of the clamping strip hole. When assembling the second terminal, the stop part is used to limit the insertion depth of the second terminal into the housing. The insertion limiting member is located in the clamping strip hole to laterally limit the second terminal and prevent the second terminal from being misaligned during assembly. The spring piece and the snap-fit ​​groove work together to achieve all-round limiting of the second terminal.

[0027] The inner side of the housing is provided with a snap-fit ​​part parallel to the snap-fit ​​groove. The snap-fit ​​part consists of a stop part arranged along the length of the housing and a vertically arranged insertion limiting member. The second main body of the second terminal has a clamping strip hole parallel to the spring piece, and two adjacent sets of first guide parts are arranged on both sides of the clamping strip hole. When assembling the second terminal, the stop part can accurately limit the maximum depth of the second terminal insertion, avoiding structural compression deformation caused by excessive insertion. At the same time, the insertion limiting member is snapped into the clamping strip hole to achieve lateral limiting of the terminal, effectively preventing the second terminal from shifting to the left or right or misaligned assembly. This structure works in conjunction with the axial anti-retraction structure of the spring piece and the snap-fit ​​groove to limit and fix the second terminal in all directions from multiple dimensions such as insertion depth, lateral position, and axial movement, eliminating problems such as terminal assembly skew, movement, and loosening, greatly improving the consistency of terminal assembly and structural stability, and ensuring the reliability of long-term connector connection.

[0028] Both the first and second spacing are 0.05 mm.

[0029] The third spacing is 0.10mm.

[0030] The first and second distances between the first terminal and the wall of the second clearance hole are set to 0.05mm, and the third distance between the non-clamping side of the first terminal and the inner wall of the housing is set to 0.10mm. This configuration provides the first terminal with a moderate radial floating margin, which can compensate for the small positional deviations caused by PCB assembly and realize the floating docking of the male and female ends. It also avoids excessive terminal wobble and unstable contact due to excessive gaps, and at the same time, it will not cause jamming interference when the terminal is offset due to excessive gaps. It balances floating compensation capability and terminal docking stability in the narrow space of the housing, and is suitable for the application scenarios of miniaturized high-voltage connectors with terminal center distance compressed to 4.0mm and below.

[0031] The first main body has a first positioning post on the side away from the protruding post, and a first positioning hole is opened on the first PCB board. The first positioning post is inserted into the first positioning hole to assemble and position the male shell and the first PCB board, and to limit the male shell from shifting relative to the first PCB board.

[0032] A first pad is provided on the side of the first main body away from the protruding post. The first pad is arranged around the circumference of the first main body. After assembly, the first pad abuts against the surface of the first PCB board, forming an isolation gap between the first main body and the first PCB board. This prevents the male shell from directly contacting the surface of the first PCB board, lengthens the insulation path along the board surface, and improves the insulation performance and creepage distance of the connector.

[0033] A first positioning post and a first pad arranged circumferentially are provided on the side of the first main body away from the protruding post. During assembly, the first positioning post is inserted into the first positioning hole of the first PCB board to realize the assembly positioning between the male shell and the first PCB board, restricting the male shell from shifting relative to the PCB board and ensuring the terminal alignment accuracy. After assembly, the first pad abuts against the surface of the first PCB board, forming an isolation gap between the first main body and the first PCB board, preventing the male shell from directly contacting the PCB board surface, lengthening the surface leakage path along the PCB board surface, and increasing the creepage distance. This positioning and insulation structure is integrated and does not occupy additional internal layout space of the connector. It realizes assembly positioning and board surface insulation protection in a miniaturized structure, improving the safety of use under high voltage conditions.

[0034] The housing portion is provided with a second positioning post on the side away from the protruding post portion, and a second positioning hole is provided on the second PCB board. The second positioning post is inserted into the second positioning hole to assemble and position the mother housing and the second PCB board, and to limit the positional displacement of the mother housing relative to the second PCB board.

[0035] A second pad is provided on the side of the housing part away from the protruding post. The second pad is arranged around the circumference of the housing part. After assembly, the second pad abuts against the surface of the second PCB board, forming an isolation gap between the housing part and the second PCB board. This prevents the mother housing from directly contacting the surface of the second PCB board, lengthens the insulation path along the board surface, and improves the insulation performance and creepage distance of the connector.

[0036] A second positioning post and a second pad arranged circumferentially are provided on the side of the housing part away from the protruding post. During assembly, the second positioning post is inserted into the second positioning hole of the second PCB board to achieve the assembly positioning of the mother housing and the second PCB board, restricting the offset of the mother housing relative to the second PCB board and ensuring the docking accuracy between the second terminal and the PCB board. After assembly, the second pad abuts against the surface of the second PCB board, forming an isolation gap between the housing part and the second PCB board, preventing the mother housing from directly contacting the PCB board surface, effectively lengthening the surface creepage path along the PCB board surface, and improving insulation performance. This structure integrates positioning and insulation functions into one, without the need for additional parts, saving internal layout space, adapting to miniaturized high-voltage connectors with small terminal spacing, and taking into account both assembly positioning accuracy and high-voltage insulation safety.

[0037] The housing portion is provided with multiple sets of fourth clearance holes at the end away from the first clearance hole and facing the second PCB board. The fourth clearance holes correspond one-to-one with the second clearance holes and are interconnected. The hole spacing of the fourth clearance holes is greater than the thickness of the first terminal. A fourth spacing is provided between one side of the first terminal and the hole wall of the fourth clearance hole, and a fifth spacing is provided between the other side of the first terminal and the hole wall of the fourth clearance hole. With the help of the fourth and fifth spacing, radial floating margin can be provided for the first terminal. Combined with the floating space of the second clearance hole, it can further accommodate the PCB board assembly position deviation.

[0038] Multiple sets of fourth clearance holes are provided at the end of the housing that is away from the first clearance hole and faces the male end. The fourth clearance holes correspond one-to-one with the second clearance holes and are interconnected. The hole spacing of the fourth clearance holes is greater than the thickness of the first terminal. The first terminal is connected to the fourth clearance hole wall on both sides and the fourth clearance hole wall respectively to form a fourth spacing and a fifth spacing. The fourth spacing and the fifth spacing provide a larger radial floating margin for the first terminal. Together with the floating space provided by the second clearance hole, they form a graded floating structure, which can further compensate for the positional deviation caused by PCB board assembly, improve the connector's compatibility with assembly errors, and reduce the risk of terminal jamming and contact failure. This structure relies on the hole gap itself to achieve floating, without the need to add additional parts, saving internal space of the housing and adapting to the design requirements of miniaturized high-voltage connectors.

[0039] The fourth and fifth spacings are both 1.3mm.

[0040] The fourth and fifth gaps between the first terminal and the wall of the fourth clearance hole are both set to 1.3mm. This gap size is larger than the floating gap of the second clearance hole, and together with the 0.05mm floating gap of the second clearance hole, they form a graded floating structure. The larger gap allows the first terminal to make a large radial offset within the range of the fourth clearance hole, which is used to absorb large assembly misalignment between PCB boards. The small gap of the second clearance hole achieves fine constraint on the terminal mating position. It can accommodate large assembly errors and avoid poor contact caused by excessive terminal wobble. It balances large tolerance compatibility and terminal contact stability in a small housing space, and is suitable for small high-voltage board connectors with terminal center distance compressed to 4.0mm and below.

[0041] The fourth clearance hole corresponds one-to-one with the second clearance hole and is interconnected, together forming a through channel for the first terminal to pass through the housing. The fourth and fifth spacings of the fourth clearance holes are both 1.3mm, which can provide a radial floating margin much larger than that of the second clearance hole. When the two PCB boards have large assembly offsets or installation misalignments, the first terminal can achieve a large range of offset within the range of the fourth clearance hole to achieve large tolerance compatibility. It forms a graded floating fit with the second clearance hole with a floating amount of 0.05mm. The fourth clearance hole absorbs large installation misalignments of the PCB board, and the second clearance hole plays a fine limiting role to prevent the first terminal from swinging too much and causing contact failure with the second terminal. The two work together to tolerate large installation deviations and ensure reliable terminal contact. At the same time, a gap is always maintained between the hole wall and the first terminal, which can increase the creepage distance under high voltage conditions and prevent the terminal from discharging to the housing. This is the key structure for this connector to achieve floating function.

[0042] The fourth clearance hole is coaxially arranged with the second clearance hole, and the fourth clearance hole and the second clearance hole are connected by a smooth transition or a step transition to ensure that there is no jamming or collision during the floating offset of the first terminal.

[0043] The fourth clearance hole corresponds to and connects with the second clearance hole, forming a through channel for the first terminal to pass through the housing. The fourth and fifth spacings of the fourth clearance holes are set to 1.3mm, providing a radial float margin much larger than that of the second clearance hole. When there is a large assembly misalignment between the two PCB boards, the first terminal can be offset within the fourth clearance hole to achieve large tolerance compatibility. This, together with the second clearance hole with a float of 0.05mm, forms a graded floating fit. The fourth clearance hole absorbs the large installation deviation of the PCB board, while the second clearance hole provides precise positioning of the first terminal, suppressing excessive terminal oscillation and avoiding the first terminal's excessive movement. The first terminal fails to make contact with the second terminal; at the same time, a gap is maintained between the terminal and the hole wall to increase the creepage distance under high voltage conditions and prevent the terminal from discharging to the housing; the fourth clearance hole is coaxially arranged with the second clearance hole, and the two are connected by a smooth transition or a stepped transition, so that the first terminal will not get stuck or bump during radial floating offset, ensuring smooth and stable terminal movement. This integrated channel structure does not require additional floating parts, and achieves large tolerance compatibility, fine alignment and high voltage insulation protection in a limited housing space. It is the key structure for this connector to achieve floating function.

[0044] Both the first and second elastic clamping arms have stress relief notches at their roots to reduce stress concentration caused by repeated insertion and removal of the elastic arms, improve the fatigue life and clamping stability of the elastic clamping arms, and prevent loosening or loose connection under long-term vibration conditions.

[0045] Stress relief notches are made at the roots of the first and second elastic clamping arms. When the connector is repeatedly plugged and unplugged or the equipment vibrates for a long time, the stress relief notches can disperse the stress concentration at the roots of the elastic arms, reduce the risk of plastic deformation and fracture at the roots, effectively improve the fatigue life of the elastic clamping arms, maintain the stability of the clamping force of the elastic clamping arms on the first terminal, avoid the problems of clamping force attenuation, terminal loosening and loose connection under vibration conditions, and ensure long-term reliable electrical contact between male and female terminals.

[0046] The entrance of the second clearance hole is provided with a guide slope. The guide slope is set from the outside to the inside to automatically guide and correct the first terminal during insertion, which facilitates blind insertion and assembly, and at the same time avoids the first terminal from being misaligned and hitting the hole wall, causing deformation and damage.

[0047] The entrance of the second clearance hole is equipped with a guide slope that tapers from the outside to the inside. During the mating and insertion process of the male and female ends, the guide slope can automatically guide and correct the first terminal with positional deviation, which is convenient for blind mating assembly of the connector. At the same time, it can prevent the first terminal from directly hitting the hole wall due to insertion misalignment, avoid the terminal from being bent or deformed by impact, protect the integrity of the terminal structure, reduce the assembly difficulty, and improve the fault tolerance and reliability of the connector mating.

[0048] The inner side of the hollowed-out perforation is provided with a wavy insulating wall surface, which extends along the arrangement direction of the first terminal. Compared with a flat wall surface, it significantly extends the creepage path between adjacent first terminals, effectively avoiding creepage and breakdown between adjacent terminals under high voltage conditions.

[0049] The inner side of the perforated hole is provided with a wavy insulating wall extending along the direction of the first terminal arrangement. Compared with a flat planar wall, the undulating contour further lengthens the insulation surface distance between adjacent first terminals. In the miniaturized connector with narrow terminal spacing, the creepage path can be effectively extended without increasing the outer size of the housing, suppressing surface creepage and breakdown between adjacent terminals under high voltage, and improving the withstand voltage insulation performance of the male terminal. The structure is integrated into the inner side of the perforated hole and can be achieved in one piece without occupying additional assembly space, making it suitable for use in highly integrated high-voltage electrical equipment.

[0050] The beneficial effects of this invention are as follows: This invention achieves high-voltage circuit conduction by having male and female connectors respectively inserted into the first and second PCB boards. Utilizing the corrugated insulating wall surface with perforations in the male housing, the extended outer portion of the protruding pillars, the integrally formed extended strip of the spacer ribs in the female housing, and the padding gap structure between the male and female housings and the PCB board, the creepage path between terminals, between terminals and the housing and PCB board surface is extended in multiple dimensions. Under the structural constraints of connector miniaturization and narrow terminal spacing, the high-voltage insulation performance is significantly improved without increasing the overall volume, effectively eliminating creepage, breakdown, and leakage problems under high-voltage conditions. Simultaneously, the fixing components between adjacent protruding pillars in the male housing reinforce the housing structure strength, compensating for the strength loss caused by the perforated structure and improving the overall vibration resistance and resistance to extrusion deformation. Combined with multiple limiting structures in the female housing, through the cooperation of the stop portion, insertion limiting component, spring clip, and snap-fit ​​groove, the second terminal is protected against all-round misalignment. Anti-slip fixation ensures terminal assembly accuracy and long-term stability. The core innovation of this invention employs a graded floating compensation principle. The 1.3mm large gap in the fourth clearance hole accommodates large-sized misalignments in PCB assembly, while the 0.05mm precise floating gap in the second clearance hole and the 0.10mm side floating gap in the chamber achieve multi-level position compensation combining coarse and fine details. Combined with the automatic correction function of the guide slope at the entrance of the second clearance hole, it enables easy blind insertion assembly and eliminates terminal insertion damage from impacts. Simultaneously, the stress release notch at the root of the terminal elastic clamping arm effectively disperses insertion, removal, and vibration stress, improving the fatigue life of the clamping structure and preventing issues like loose connections and disconnections. In summary, this invention integrates advantages such as high-voltage insulation, structural reinforcement, multi-level floating fault tolerance, precise positioning, and wear and vibration resistance. Its compact, one-piece design requires no additional parts, perfectly adapting to the assembly and long-term reliable operation requirements of miniaturized, highly integrated high-voltage electrical equipment. Attached Figure Description

[0051] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the male connector of the present invention; Figure 3 This is a schematic diagram of the female connector of the present invention; Figure 4 This is a schematic diagram of the structure of the mother shell of the present invention; Figure 5 This is a schematic diagram of the structure of the present invention; Figure 6 This is a cross-sectional view of the entire invention; Figure 7 For the present invention Figure 6 An enlarged structural diagram of part A in the diagram; Figure 8 For the present invention Figure 6 An enlarged structural diagram of part B in the diagram; Figure 9 This is a schematic diagram of the structure of the first terminal and the second terminal of the present invention; Figure 10 This is a schematic diagram of the structure of the first terminal and the second terminal of the present invention from another perspective; Figure 11 This is a cross-sectional view from another perspective of the overall invention.

[0052] The reference numerals in the figures include: 1. First PCB board; 2. Second PCB board; 3. Male connector; 4. Female connector; 5. Male housing; 6. First terminal; 7. First main body; 8. Protruding post; 9. Hole; 11. Fixing member; 12. Extension; 13. Female housing; 14. Second terminal; 15. Second main body; 16. First guide; 17. Second guide; 18. First elastic clamping arm; 19. Second elastic clamping arm; 21. Housing; 22. Spacer rib; 23. Second chamber; 24. First clearance hole; 25. Second clearance hole; 26. First 27. Spacing; 28. Second spacing; 29. ​​Clamping surface; 30. Non-clamping side; 31. Third spacing; 32. Extension strip; 33. First insertion hole; 34. Snap-in groove; 35. Third clearance hole; 36. Spring piece; 37. Stop part; 38. Insertion limiting part; 39. Clamping strip hole; 41. First positioning post; 42. First positioning hole; 43. First pad; 44. Second positioning post; 45. Second positioning hole; 46. Second pad; 47. Fourth clearance hole; 48. Fourth spacing; 49. Fifth spacing; 51. Stress relief notch; 52. Guide slope. Detailed Implementation

[0053] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to embodiments and accompanying drawings. The content mentioned in the embodiments is not intended to limit the present invention.

[0054] Please see Figures 1 to 11 As shown, a high-voltage power connector with a floating function according to the present invention includes a male connector 3 and a female connector 4. An external first PCB board 1 and an external second PCB board 2 are connected via the insertion of the male connector 3 and the female connector 4. One end of the male connector 3 is inserted into the first PCB board 1 and connected, and the other end is inserted into the female connector 4 and connected. The end of the female connector 4 away from the male connector 3 is inserted into the second PCB board 2 and connected. The male connector 3 includes a male housing 5 and multiple sets of first terminals 6 disposed within the male housing 5. The male housing 5 includes a first main body 7 and multiple sets of protruding pillars 8 disposed on the first main body 7. The multiple sets of first terminals 6 are housed one-to-one within the multiple sets of protruding pillars 8. The first terminals 6 penetrate the first main body 7 and the protruding pillars 8. The first main body 7 is provided with multiple sets of hollowed-out through holes 9. A set of hollowed-out through holes 9 is provided between two adjacent sets of protruding pillars 8. The hollowed-out through holes 9 are used to extend the insulation creepage path between adjacent first terminals 6.

[0055] The first terminal 6 of the male connector 3 is housed within each set of protruding parts 8 of the male housing 5 and is conductive to the first PCB board 1. The female connector 4 is correspondingly aligned and plugged into the second PCB board 2 and the first terminal 6 to achieve overall circuit connectivity. By setting corresponding perforated holes 9 between adjacent protruding parts 8, the path between adjacent first terminals 6 is no longer a straight short-distance surface path, effectively lengthening the insulation creepage path between terminals. Under the limited space structure of connector miniaturization and significant reduction in terminal spacing, the high voltage insulation capability of the male terminal area can be significantly improved without increasing the overall volume of the housing, avoiding creepage and breakdown phenomena between adjacent terminals under high voltage conditions. At the same time, the structure is simple, integrally molded, and has high space utilization, which can adapt to the assembly and use requirements of highly integrated and lightweight high voltage electrical equipment.

[0056] The male housing 5 also includes multiple sets of fasteners 11. A set of fasteners 11 is provided between two adjacent sets of protruding pillars 8. The fasteners 11 are used to increase the structural strength between two adjacent sets of protruding pillars 8.

[0057] Fixing members 11 are provided between two adjacent sets of protruding pillars 8 of the male housing 5, so that multiple sets of independent protruding pillars 8 are connected to each other as a whole structure through the fixing members 11. This effectively improves the overall structural rigidity and integrity of the protruding pillars 8, and makes up for the problem of reduced housing structural strength caused by the opening of the hollowed-out perforation 9 and the receiving groove. It can effectively resist the deformation, cracking or displacement caused by assembly insertion and extraction force, equipment vibration and external extrusion, and ensure the stable installation position of each set of first terminals 6. While realizing the miniaturized and high creepage distance structural design, it also takes into account the structural strength of the housing and the long-term reliability of use.

[0058] The protruding post 8 is located between the first main body 7 and the female connector 4. The protruding post 8 surrounds and covers the outside of the first terminal 6. The first terminal 6 is floatingly inserted into the female connector 4. The female connector 4 is provided with a fourth clearance hole 47 that mates with the free end of the protruding post 8. The first terminal 6 can be inserted into the protruding post 8, or the protruding post 8 can be injection molded onto the outside of the first terminal 6.

[0059] The protruding post 8 is provided with an integrally formed extension 12, and the first terminal 6 passes through the first main body 7, the protruding post 8 and the extension 12; the extension 12 is used to increase the surface creepage distance of the insulation between the terminal and the male housing 5.

[0060] The structure does not require additional horizontal layout space, and can further improve the overall insulation performance and withstand voltage rating under the constraints of connector miniaturization and narrow terminal spacing. The one-piece molding structure has high strength and good stability, and is suitable for long-term safe use of high-voltage and highly integrated equipment.

[0061] The female connector 4 includes a female housing 13 and multiple sets of second terminals 14 disposed within the female housing 13. One end of the second terminal 14 is inserted and connected to the second PCB board 2, and the other end is inserted and connected to the first terminal 6.

[0062] The second terminal 14 includes a second main body 15, a first conductive part 16 disposed at one end of the second main body 15, and a second conductive part 17 disposed at the other end of the second main body 15. The first conductive part 16 is inserted and connected to the second PCB board 2, and the second conductive part 17 is inserted and connected to the first terminal 6. The second conductive part 17 includes a first elastic clamping arm 18 and a second elastic clamping arm 19 that cooperates with the first elastic clamping arm 18. The first elastic clamping arm 18 and the second elastic clamping arm 19 form an insertion gap. The end of the first terminal 6 away from the first PCB board 1 is inserted into the insertion gap. The first elastic clamping arm 18 and the second elastic clamping arm 19 clamp the first terminal 6 so that the first terminal 6 is connected to the second terminal 14.

[0063] During assembly of the female connector 4, multiple sets of second terminals 14 are installed inside the female housing 13. The first conductive part 16 at one end of the second terminal 14 is inserted and connected to the second PCB board 2. The second conductive part 17 at the other end forms an insertion gap through the parallel first elastic clamping arm 18 and the second elastic clamping arm 19. The end of the first terminal 6 of the male end is inserted into the insertion gap. Electrical connection is achieved by the two elastic clamping arms clamping and abutting the two sides of the first terminal 6. The clamping contact method of the elastic clamping arms can ensure reliable contact between the first terminal 6 and the second terminal 14. It can adapt to certain positional deviations during assembly, reduce the risk of docking failure, and has a compact structure, making it suitable for use in small board-end high-voltage connectors.

[0064] The mother shell 13 includes a shell part 21 and multiple sets of spacer ribs 22 formed in the shell part 21. A first chamber is formed in the shell part 21. The multiple sets of spacer ribs 22 divide the first chamber into multiple sets of second chambers 23. Multiple sets of second terminals 14 are housed in the corresponding second chambers 23. Multiple sets of first clearance holes 24 are provided at the end of the shell part 21 away from the male shell 5. The first guide part 16 protrudes from the first clearance hole 24 and is inserted and connected to the second PCB board 2.

[0065] The housing portion 21 of the mother housing 13 has a first chamber inside, and multiple sets of spacer ribs 22 are arranged in the chamber. The spacer ribs 22 divide the first chamber into multiple independent second chambers 23. Each set of second terminals 14 is housed in the corresponding second chamber 23 to achieve cavity isolation. A first clearance hole 24 is opened at the end of the housing portion 21 away from the male housing 5. The first conductive part 16 of the second terminal 14 extends outward through the first clearance hole 24 and then connects and conducts with the second PCB board 2. The spacer ribs 22 separate each second terminal 14 from each other, which can limit the installation position of the second terminal 14, prevent the terminal from being offset or skewed, and increase the surface creepage path between adjacent second terminals 14 to suppress surface leakage between terminals. The first clearance hole 24 plays a role in giving way and limiting the first conductive part 16, which facilitates the board-end assembly and positioning between the mother housing 13 and the second PCB board 2. The overall structure is compact and adaptable to the installation requirements of miniaturized board-end high-voltage connectors.

[0066] The housing portion 21 is provided with multiple sets of second clearance holes 25 at the end away from the first clearance hole 24 and facing the second PCB board 2. The first terminal 6 is inserted into the second terminal 14 through the second clearance hole 25. The hole spacing of the second clearance hole 25 is greater than the thickness of the first terminal 6. A first gap 26 is provided between one side of the first terminal 6 and the hole wall of the second clearance hole 25, and a second gap 27 is provided between the other side of the first terminal 6 and the hole wall of the second clearance hole 25. The first gap 26 and the second gap 27 together provide radial floating compensation for the first terminal 6, compensate for the positional deviation caused by the PCB board assembly, and realize the floating docking of the connector.

[0067] The housing portion 21, away from the first clearance hole 24 and facing the male end, is provided with multiple sets of second clearance holes 25. During insertion, the first terminal 6 passes through the second clearance holes 25 and extends into the female housing to mate with the second terminal 14. The hole spacing of the second clearance holes 25 is greater than the thickness of the first terminal 6, so that a first gap 26 and a second gap 27 are formed between the first terminal 6 and the hole walls on both sides of the second clearance holes 25, respectively. The gaps reserved on both sides provide radial floating compensation for the first terminal 6. When there is a deviation in the assembly position of the two PCB boards, the first terminal 6 can be radially offset within the gap of the second clearance holes 25 to offset the positional error caused by assembly, thereby realizing the floating mating of the male and female ends of the connector. This reduces the risk of terminal jamming and poor contact caused by PCB board assembly misalignment. This floating structure is achieved directly by utilizing the gap of the clearance holes themselves, without the need to add additional elastic sliding parts, saving internal space of the housing and facilitating the overall miniaturization design of the connector.

[0068] The first terminal 6 has two clamping surfaces 28 clamped by a first elastic clamping arm 18 and a second elastic clamping arm 19, and two non-clamping sides 29. The two non-clamping sides 29 are arranged in parallel, and a third distance 31 is provided between each of the two non-clamping sides 29 and the inner wall of the housing portion 21. The third distance 31 is used to allow the first terminal 6 to have radial floating offset space in the second chamber 23.

[0069] During the docking process, the first terminal 6 is clamped and limited on both sides by the first elastic clamping arm 18 and the second elastic clamping arm 19 to form a stable conductive contact. The two sets of non-clamped sides 29 of the first terminal 6 that are not clamped are reserved with a third gap 31 between them and the inner wall of the second chamber 23, so that the first terminal 6 as a whole has an independent radial floating offset space inside the second chamber 23. This structure, while ensuring the stability of terminal clamping and conduction, further increases the range of error tolerance of the first terminal 6. It works in conjunction with the floating gap of the second clearance hole 25 to compensate for PCB board assembly deviations in multiple ways, effectively avoiding the situation of terminal sticking to the shell and causing jamming or offset. It greatly improves the smoothness and assembly compatibility of male and female terminal docking, and further ensures the reliability of connector floating docking.

[0070] The spacer rib 22 is provided with an integrally formed extension strip 32, and the second PCB board 2 is provided with a first insertion hole 33. The extension strip 32 is inserted into the first insertion hole 33. The extension strip 32 is used to block two adjacent second terminals 14 to increase the creepage distance.

[0071] An extension strip 32 is integrally formed on the outer side of the spacer rib 22. During assembly, the extension strip 32 is inserted into the first insertion hole 33 of the second PCB board 2, so that the insulation barrier structure between adjacent second terminals 14 extends to the surface of the second PCB board 2, effectively blocking the straight leakage path formed by adjacent terminals along the PCB board surface, and significantly lengthening the surface creepage distance under high voltage conditions. This structure relies on the original spacer rib 22 integrally formed, without the need for additional insulation accessories. The structure is simple and compact. While meeting the miniaturization design of the connector, it effectively solves the problem of easy creepage and breakdown on the PCB board surface under narrow terminal center distance, and significantly improves the high voltage insulation safety of the connector.

[0072] The housing portion 21 has a snap-fit ​​groove 34 on its side, and the second main body portion 15 has a third clearance hole 35 and a spring piece 36. One end of the spring piece 36 is connected to the second main body portion 15, and the other end of the spring piece 36 extends through the third clearance hole 35 and is snapped into the snap-fit ​​groove 34 to snap and limit the second terminal 14 in the second chamber 23 of the housing portion 21, thereby restricting the second terminal 14 from moving out along the insertion direction.

[0073] The housing part 21 has a snap-fit ​​groove 34 on its side. The second main body part 15 of the second terminal 14 has a corresponding third clearance hole 35 and an integrally formed spring piece 36. During assembly, the spring piece 36 extends outward through the third clearance hole 35 and elastically snaps into the snap-fit ​​groove 34, so that the second terminal 14 is snapped and limited in the second chamber 23. Through the elastic snap-fit ​​structure of the spring piece 36 and the snap-fit ​​groove 34, the second terminal 14 can be effectively restricted from moving, loosening or falling out along the insertion direction, so as to realize the axial anti-retraction fixation of the terminal. No additional locking accessories are required. The assembly is convenient and the structure is compact. It can resist the risk of loosening caused by equipment vibration and insertion and pulling for a long time, and ensure the installation stability and docking reliability of the second terminal 14 in the mother housing 13.

[0074] The inner side of the housing part 21 is provided with a snap-fit ​​part, which is arranged parallel to the snap-fit ​​groove 34. The snap-fit ​​part includes a stop part 37 arranged along the length direction of the housing part 21 and an insertion limiting member 38 arranged vertically on the stop part 37. The second main body part 15 is provided with a clamping strip hole 39, which is arranged parallel to the spring piece 36. The first guide part 16 is provided with multiple sets, and two adjacent sets of first guide parts 16 are located on both sides of the clamping strip hole 39. When assembling the second terminal 14, the stop part 37 is used to limit the insertion depth of the second terminal 14 into the housing. The insertion limiting member 38 is located in the clamping strip hole 39 to laterally limit the second terminal 14 and prevent the second terminal 14 from being misaligned during assembly. The spring piece 36 and the snap-fit ​​groove 34 work together to achieve omnidirectional limiting of the second terminal 14.

[0075] The inner side of the housing 21 is provided with a snap-fit ​​part parallel to the snap-fit ​​groove 34. The snap-fit ​​part consists of a stop part 37 arranged along the length of the housing and a vertically arranged insertion limiting member 38. The second main body 15 of the second terminal 14 is provided with a clamping strip hole 39 parallel to the spring piece 36, and two adjacent sets of first guide parts 16 are distributed on both sides of the clamping strip hole 39. When assembling the second terminal 14, the stop part 37 can accurately limit the maximum depth of the second terminal 14 to be inserted inward, avoiding structural compression deformation caused by excessive insertion. At the same time, the insertion limiting member 38 is snapped into the clamping strip hole 39 to achieve lateral limiting of the terminal, effectively preventing the second terminal 14 from shifting left and right or misaligned during assembly. This structure cooperates with the axial anti-retraction structure of the spring piece 36 and the snap-fit ​​groove 34 to limit and fix the second terminal 14 in all directions from multiple dimensions such as insertion depth, lateral position, and axial movement, eliminating problems such as terminal assembly skew, movement, and loosening, greatly improving the consistency of terminal assembly and structural stability, and ensuring the reliability of long-term connector connection.

[0076] The first spacing 26 and the second spacing 27 are both 0.05 mm.

[0077] The third spacing 31 is 0.10mm.

[0078] The first distance 26 and the second distance 27 between the first terminal 6 and the wall of the second clearance hole 25 are set to 0.05mm, and the third distance 31 between the non-clamping side 29 of the first terminal 6 and the inner wall of the housing 21 is set to 0.10mm. This configuration provides the first terminal 6 with a moderate radial floating margin, which can compensate for the small positional deviations caused by PCB assembly and realize the floating docking of the male and female ends. It also avoids excessive terminal wobble and unstable contact due to excessive gaps, and at the same time, it will not cause jamming interference when the terminal is offset due to excessive gaps. It balances floating compensation capability and terminal docking stability in the narrow space of the housing, and is suitable for the application scenarios of miniaturized high-voltage connectors with terminal center distance compressed to 4.0mm and below.

[0079] The first main body 7 is provided with a first positioning post 41 on the side away from the protruding post 8. The first PCB board 1 is provided with a first positioning hole 42. The first positioning post 41 is inserted into the first positioning hole 42 to assemble and position the male housing 5 and the first PCB board 1, and to limit the male housing 5 from shifting relative to the first PCB board 1.

[0080] A first pad 43 is provided on the side of the first main body 7 away from the protruding post 8. The first pad 43 is arranged around the first main body 7. After assembly, the first pad 43 abuts against the surface of the first PCB board 1, forming an isolation gap between the first main body 7 and the first PCB board 1. This prevents the male housing 5 from directly contacting the surface of the first PCB board 1, lengthens the insulation path along the board surface, and improves the insulation performance and creepage distance of the connector.

[0081] The first main body 7 is provided with a first positioning post 41 and a first pad 43 arranged circumferentially on the side opposite to the protruding post 8. During assembly, the first positioning post 41 is inserted into the first positioning hole 42 of the first PCB board 1 to realize the assembly positioning between the male shell 5 and the first PCB board 1, restricting the male shell 5 from offset relative to the PCB board and ensuring the terminal alignment accuracy. After assembly, the first pad 43 abuts against the surface of the first PCB board 1, so that an isolation gap is formed between the first main body 7 and the first PCB board 1, preventing the male shell 5 from directly contacting the PCB board surface, lengthening the surface leakage path along the PCB board surface, and increasing the creepage distance. This positioning and insulation structure is integrated and does not occupy additional internal layout space of the connector. It realizes assembly positioning and board surface insulation protection in a miniaturized structure, improving the safety of use under high voltage conditions.

[0082] The housing portion 21 is provided with a second positioning post 44 on the side away from the protruding post portion 8, and the second PCB board 2 is provided with a second positioning hole 45. The second positioning post 44 is inserted into the second positioning hole 45 to assemble and position the mother housing 13 and the second PCB board 2, and to limit the positional displacement of the mother housing 13 relative to the second PCB board 2.

[0083] A second pad 46 is provided on the side of the housing part 21 away from the protruding post part 8. The second pad 46 is arranged around the circumference of the housing part 21. After assembly, the second pad 46 abuts against the surface of the second PCB board 2, forming an isolation gap between the housing part 21 and the second PCB board 2. This prevents the mother housing 13 from directly contacting the surface of the second PCB board 2, lengthens the insulation path along the board surface, and improves the insulation performance and creepage distance of the connector.

[0084] A second positioning post 44 and a second pad 46 arranged circumferentially are provided on the side of the housing part 21 opposite to the protruding post part 8. During assembly, the second positioning post 44 is inserted into the second positioning hole 45 of the second PCB board 2 to realize the assembly positioning of the mother housing 13 and the second PCB board 2, restricting the offset of the mother housing 13 relative to the second PCB board 2, and ensuring the docking accuracy between the second terminal 14 and the PCB board. After assembly, the second pad 46 abuts against the surface of the second PCB board 2, forming an isolation gap between the housing part 21 and the second PCB board 2, preventing the mother housing 13 from directly contacting the PCB board surface, effectively lengthening the surface creepage path along the PCB board surface, and improving insulation performance. This structure integrates the positioning function and the insulation function into one, without the need for additional parts, saving internal layout space, adapting to miniaturized high-voltage connectors with small terminal spacing, and taking into account both assembly positioning accuracy and high-voltage insulation safety.

[0085] The housing portion 21 is provided with multiple sets of fourth clearance holes 47 at the end away from the first clearance hole 24 and facing the second PCB board 2. The fourth clearance holes 47 correspond one-to-one with the second clearance holes 25 and are interconnected. The hole spacing of the fourth clearance holes 47 is greater than the thickness of the first terminal 6. A fourth spacing 48 is provided between one side of the first terminal 6 and the hole wall of the fourth clearance hole 47, and a fifth spacing 49 is provided between the other side of the first terminal 6 and the hole wall of the fourth clearance hole 47. With the help of the fourth spacing 48 and the fifth spacing 49, a radial floating margin can be provided for the first terminal 6. Combined with the floating space of the second clearance hole 25, it can further accommodate the PCB board assembly position deviation.

[0086] Multiple sets of fourth clearance holes 47 are provided at the end of the housing 21 away from the first clearance hole 24 and facing the male end. The fourth clearance holes 47 correspond one-to-one with the second clearance holes 25 and are interconnected. The hole spacing of the fourth clearance holes 47 is greater than the thickness of the first terminal 6. A fourth spacing 48 and a fifth spacing 49 are formed between the two sides of the first terminal 6 and the hole wall of the fourth clearance holes 47, respectively. The fourth spacing 48 and the fifth spacing 49 provide a larger radial floating margin for the first terminal 6. Together with the floating space provided by the second clearance hole 25, they form a graded floating structure, which can further compensate for the positional deviation caused by PCB board assembly, improve the connector's compatibility with assembly errors, and reduce the risk of terminal jamming and contact failure. This structure relies on the gap of the hole itself to achieve floating, without the need to add additional parts, saving internal space of the housing and adapting to the design requirements of miniaturized high-voltage connectors.

[0087] The fourth spacing 48 and the fifth spacing 49 are both 1.3mm.

[0088] The fourth spacing 48 and the fifth spacing 49 between the first terminal 6 and the wall of the fourth clearance hole 47 are both set to 1.3mm. This gap size is larger than the floating gap of the second clearance hole 25, and together with the floating gap of the second clearance hole 25 (0.05mm), they form a graded floating structure. The larger gap allows the first terminal 6 to make a large radial offset within the range of the fourth clearance hole 47, which is used to absorb large assembly misalignment between PCB boards. The small gap of the second clearance hole 25 achieves fine constraint on the terminal mating position. This can accommodate large assembly errors and avoid poor contact caused by excessive terminal wobble. It balances large tolerance compatibility and terminal contact stability in a small housing space, and is suitable for small high-voltage board connectors with terminal center distance compressed to 4.0mm and below.

[0089] The fourth clearance hole 47 corresponds one-to-one with the second clearance hole 25 and is interconnected, together forming a through channel for the first terminal 6 to pass through the mother shell 13. The fourth spacing 48 and the fifth spacing 49 of the fourth clearance hole 47 are both 1.3mm, which can provide a radial floating margin much larger than that of the second clearance hole 25. When the two PCB boards have a large assembly offset or installation misalignment, the first terminal 6 can achieve a large range of offset within the range of the fourth clearance hole 47 to achieve large tolerance compatibility. It forms a graded floating fit with the second clearance hole 25 with a floating amount of 0.05mm. The fourth clearance hole 47 absorbs the large installation misalignment of the PCB board, and the second clearance hole 25 plays a fine limiting role to prevent the first terminal 6 from swinging too much and causing contact failure with the second terminal 14. The two work together to tolerate large installation deviations and ensure reliable terminal contact. At the same time, a gap is always maintained between the hole wall and the first terminal 6, which can increase the creepage distance under high voltage conditions and prevent the terminal from discharging to the shell. This is the key structure for this connector to achieve floating function.

[0090] The fourth clearance hole 47 is coaxially arranged with the second clearance hole 25. The fourth clearance hole 47 and the second clearance hole 25 are connected by a smooth transition or a step transition to ensure that there is no jamming or collision during the floating offset of the first terminal 6.

[0091] The fourth clearance hole 47 and the second clearance hole 25 are connected in a one-to-one correspondence, forming a through channel for the first terminal 6 to pass through the housing 13. The fourth spacing 48 and the fifth spacing 49 of the fourth clearance hole 47 are set to 1.3mm, providing a radial floating allowance much larger than that of the second clearance hole 25. When there is a large assembly misalignment between the two PCB boards, the first terminal 6 can be offset within the fourth clearance hole 47 to achieve large tolerance compatibility. This forms a graded floating fit with the second clearance hole 25, which has a floating amount of 0.05mm. The fourth clearance hole 47 absorbs the large installation deviation of the PCB board, while the second clearance hole 25 completes the fine limiting of the first terminal 6, suppressing the terminal. Excessive oscillation prevents contact failure between the first terminal 6 and the second terminal 14; at the same time, a continuous gap is maintained between the terminal and the hole wall, which can increase the creepage distance under high voltage conditions and prevent the terminal from discharging to the housing; the fourth clearance hole 47 and the second clearance hole 25 are coaxially arranged, and the two are connected by a smooth transition or a stepped transition, so that the first terminal 6 will not get stuck or bump during radial floating offset, ensuring smooth and stable terminal movement. This integrated channel structure does not require the addition of additional floating parts, and achieves large tolerance compatibility, fine alignment and high voltage insulation protection in a limited housing space. It is the key structure for this connector to realize the floating function.

[0092] Both the first elastic clamping arm 18 and the second elastic clamping arm 19 are provided with stress relief notches 51 at their roots to reduce stress concentration caused by repeated insertion and removal of the elastic arms, improve the fatigue life and clamping stability of the elastic clamping arms, and prevent loosening and loose connection under long-term vibration conditions.

[0093] Stress relief notches 51 are provided at the roots of the first elastic clamping arm 18 and the second elastic clamping arm 19. When the connector is repeatedly plugged and unplugged or the equipment vibrates for a long time, the stress relief notches 51 can disperse the stress concentration at the root of the elastic arm, reduce the risk of plastic deformation and fracture at the root, effectively improve the fatigue life of the elastic clamping arm, maintain the stability of the clamping force of the elastic clamping arm on the first terminal 6, avoid the problem of clamping force attenuation, terminal loosening and loose connection under vibration conditions, and ensure long-term reliable electrical contact between the male and female terminals.

[0094] A guide slope 52 is provided at the entrance of the second clearance hole 25. The guide slope 52 is set from the outside to the inside and is used to automatically guide and correct the first terminal 6 during insertion, which facilitates blind insertion and assembly, and at the same time avoids the first terminal 6 from being misaligned and hitting the hole wall, causing deformation and damage.

[0095] The entrance of the second clearance hole 25 is provided with a guide slope 52 that tapers from the outside to the inside. During the mating and insertion process of the male and female ends, the guide slope 52 can automatically guide and correct the first terminal 6 that has a positional deviation, which facilitates blind mating assembly of the connector. At the same time, it can prevent the first terminal 6 from being directly hit by the hole wall due to insertion misalignment, avoid the terminal from being bent or deformed by impact, protect the integrity of the terminal structure, reduce the assembly difficulty, and improve the fault tolerance and reliability of the connector.

[0096] The inner side of the perforated hole 9 is provided with a wavy insulating wall surface. The wavy insulating wall surface extends along the arrangement direction of the first terminal 6. Compared with a flat wall surface, it greatly extends the surface creepage path between adjacent first terminals 6, effectively avoiding creepage and breakdown between adjacent terminals under high voltage conditions.

[0097] The inner side of the perforated hole 9 is provided with a wavy insulating wall extending along the arrangement direction of the first terminal 6. Compared with a flat planar wall, the undulating contour further lengthens the insulation surface distance between adjacent first terminals 6. In the miniaturized connector with narrow terminal spacing, the creepage path can be effectively extended without increasing the outer size of the housing, suppressing surface creepage and breakdown between adjacent terminals under high voltage, and improving the withstand voltage insulation performance of the male terminal. The structure is integrated inside the perforated hole 9 and can be achieved in one piece without occupying additional assembly space, making it suitable for use in highly integrated high-voltage electrical equipment.

[0098] The above description is only a preferred embodiment of the present invention. For those skilled in the art, there will be changes in the specific implementation and application scope based on the ideas of the present invention. The content of this specification should not be construed as a limitation of the present invention.

Claims

1. A high-voltage power connector with a floating function, characterized in that: Includes a male connector (3) and a female connector (4). The first PCB board (1) and the second PCB board (2) are connected to each other via the male connector (3) and the female connector (4). One end of the male connector (3) is connected to the first PCB board (1) and the other end is connected to the female connector (4). The end of the female connector (4) away from the male connector (3) is connected to the second PCB board (2). The male connector (3) includes a male housing (5) and multiple sets of first terminals (6) disposed in the male housing (5). The male housing (5) includes a first main body (7) and multiple sets of protruding pillars (8) disposed on the first main body (7). The multiple sets of first terminals (6) are housed in the multiple sets of protruding pillars (8) in a one-to-one correspondence. The first terminals (6) pass through the first main body (7) and the protruding pillars (8). The first main body (7) is provided with multiple sets of hollowed-out through holes (9). A set of hollowed-out through holes (9) is provided between two adjacent sets of protruding pillars (8). The hollowed-out through holes (9) are used to extend the insulation creepage path between adjacent first terminals (6).

2. A high-voltage power connector with floating function according to claim 1, characterized in that: The protruding part (8) is located between the first main body part (7) and the female connector (4). The protruding part (8) surrounds and covers the outside of the first terminal (6). The first terminal (6) is floatingly inserted into the female connector (4). The female connector (4) is provided with a fourth clearance hole (47) that cooperates with the free end of the protruding part (8) to make way.

3. A high-voltage power connector with floating function according to claim 1, characterized in that: The female connector (4) includes a female housing (13) and multiple sets of second terminals (14) disposed in the female housing (13). One end of the second terminal (14) is connected to the second PCB board (2) and the other end is connected to the first terminal (6).

4. A high-voltage power connector with floating function according to claim 3, characterized in that: The second terminal (14) includes a second main body (15), a first conductive part (16) disposed at one end of the second main body (15), and a second conductive part (17) disposed at the other end of the second main body (15). The first conductive part (16) is inserted and connected to the second PCB board (2), and the second conductive part (17) is inserted and connected to the first terminal (6). The second conductive part (17) includes a first elastic clamping arm (18) and a second elastic clamping arm (19) cooperating with the first elastic clamping arm (18). The first elastic clamping arm (18) and the second elastic clamping arm (19) form an insertion gap. The end of the first terminal (6) away from the first PCB board (1) is inserted into the insertion gap. The first elastic clamping arm (18) and the second elastic clamping arm (19) clamp the first terminal (6) so that the first terminal (6) is connected to the second terminal (14).

5. A high-voltage power connector with floating function according to claim 4, characterized in that: The mother shell (13) includes a shell part (21) and multiple sets of spacer ribs (22) opened in the shell part (21). A first chamber is opened in the shell part (21). The multiple sets of spacer ribs (22) divide the first chamber into multiple sets of second chambers (23). Multiple sets of second terminals (14) are housed in the corresponding second chambers (23). Multiple sets of first clearance holes (24) are provided at the end of the shell part (21) away from the male shell (5). The first guide part (16) protrudes out of the first clearance hole (24) and is inserted and connected to the second PCB board (2).

6. A high-voltage power connector with floating function according to claim 5, characterized in that: The housing part (21) is provided with a plurality of second clearance holes (25) at the end away from the first clearance hole (24) and facing the second PCB board (2). The first terminal (6) is inserted into the second terminal (14) through the second clearance hole (25). The hole spacing of the second clearance hole (25) is greater than the thickness of the first terminal (6). A first gap (26) is provided between one side of the first terminal (6) and the hole wall of the second clearance hole (25). A second gap (27) is provided between the other side of the first terminal (6) and the hole wall of the second clearance hole (25). The first gap (26) and the second gap (27) together provide radial floating compensation for the first terminal (6).

7. A high-voltage power connector with floating function according to claim 5, characterized in that: The first terminal (6) has two clamping surfaces (28) clamped by a first elastic clamping arm (18) and a second elastic clamping arm (19) and two non-clamping sides (29); the two non-clamping sides (29) are arranged in parallel, and a third distance (31) is provided between the two non-clamping sides (29) and the inner wall of the housing part (21). The third distance (31) is used to enable the first terminal (6) to have radial floating offset space in the second chamber (23).

8. A high-voltage power connector with floating function according to claim 5, characterized in that: The spacer rib (22) is provided with an integrally formed extension strip (32), and the second PCB board (2) is provided with a first plug hole (33). The extension strip (32) is inserted into the first plug hole (33). The extension strip (32) is used to block two adjacent second terminals (14) to increase the creepage distance.

9. A high-voltage power connector with floating function according to claim 5, characterized in that: The housing part (21) is provided with a snap-fit ​​groove (34) on its side. The second main body part (15) is provided with a third clearance hole (35) and a spring piece (36). One end of the spring piece (36) is connected to the second main body part (15), and the other end of the spring piece (36) extends out through the third clearance hole (35) and is snapped into the snap-fit ​​groove (34) to snap and limit the second terminal (14) in the second chamber (23) of the housing part (21) and restrict the second terminal (14) from moving out along the insertion direction.

10. A high-voltage power connector with floating function according to claim 9, characterized in that: The inner side of the housing part (21) is provided with a snap-fit ​​part, which is parallel to the snap-fit ​​groove (34). The snap-fit ​​part includes a stop part (37) arranged along the length direction of the housing part (21) and an insertion limiting member (38) arranged vertically on the stop part (37). The second main body part (15) is provided with a clamping strip hole (39), which is parallel to the spring piece (36). The first guide part (16) is provided with multiple sets, and two adjacent sets of first guide parts (16) are located on both sides of the clamping strip hole (39). When assembling the second terminal (14), the stop part (37) is used to limit the insertion depth of the second terminal (14) into the housing. The insertion limiting member (38) is located in the clamping strip hole (39) to laterally limit the second terminal (14) and prevent the second terminal (14) from being misaligned during assembly. The second terminal (14) is limited by the spring piece (36) and the snap-fit ​​groove (34).

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