Plug for connecting copper and aluminum bars and high-voltage connector

Abstract

The utility model discloses a plug for connecting copper and aluminum bars and a high-voltage connector, which comprise a plug shell, two groups of terminal assemblies symmetrically arranged in the far end of the plug shell and two groups of conductive assemblies symmetrically arranged in the near end of the plug shell, and the terminal assemblies are sequentially sleeved with inner core shells, terminal holders and terminals from outside to inside. Each conductive assembly is sequentially provided with a connecting shell and a copper-aluminum bar from outside to inside, the near end of each copper-aluminum bar and the far end of each terminal are welded into a whole, and the terminal assemblies and the conductive assemblies are in one-to-one butt joint. And a first sealing ring and a second sealing ring are respectively arranged in the far end and the near end of the plug shell to seal gaps between the plug shell and the terminal assembly and between the plug shell and the conductive assembly. Compared with a conventional cable, the copper-aluminum row adopted by the utility model is better in current-carrying property, more stable in connection structure and better in heat dissipation effect compared with a cable of the same specification, and can ensure the safety of long-term use and connection stability.

Description

Technical Field

[0001] The utility model relates to the technical field of high-voltage connectors, in particular to a plug for connecting copper-aluminum bars and a high-voltage connector. Background Art

[0002] The power transmission in new energy vehicles is mainly achieved by high-voltage wiring harnesses. Traditional high-voltage wiring harnesses include high-voltage cables and high-voltage connectors. High-voltage connectors usually include components such as housings (combined housings), terminals, shielding rings, waterproof rings, and back covers. The high-voltage cables and high-voltage connectors are joined by crimping or ultrasonic welding, and then assembled and tested on the production line to form a wiring harness.

[0003] As disclosed in the announcement number CN112864670B, the existing high-voltage connectors mostly use cables to crimp with terminals to achieve connection. This connection method is relatively cumbersome, and an anti-rotation component is required to prevent the cable from rotating, which makes the cost high and the assembly cumbersome. At the same time, with the demand for high voltage overcurrent inside the high-voltage connector, the connection between the cable and the terminal is easily damaged due to high temperature, resulting in average conductivity and limited service life. Utility Model Content

[0004] The utility model aims to overcome the shortcomings of the prior art and provide a plug and a high-voltage connector for connecting copper and aluminum bars.

[0005] The purpose of the utility model is achieved through the following technical solutions:

[0006] A plug connected to a copper-aluminum bar comprises a plug housing, two groups of terminal assemblies symmetrically arranged in the distal end of the plug housing, and two groups of conductive assemblies symmetrically arranged in the proximal end of the plug housing. The terminal assemblies are sequentially sleeved with an inner core housing, a terminal retainer and a terminal from the outside to the inside, and the conductive assemblies are sequentially arranged with a connecting housing and a copper-aluminum bar from the outside to the inside. The proximal end of the copper-aluminum bar is welded to the distal end of the terminal as a whole, and the terminal assemblies and the conductive assemblies are butted one by one. A first sealing ring and a second sealing ring are respectively arranged in the distal end and the proximal end of the plug housing to seal the gap between it and the terminal assembly and the conductive assembly.

[0007] Preferably, the inner core shell and the proximal end of the terminal retainer jointly form a first socket, and the copper-aluminum busbar includes a first connecting portion and a second connecting portion, the width of the first connecting portion is adapted to the width of the first socket, the width of the second connecting portion is larger than the width of the first socket and smaller than the proximal width of the terminal retainer, so that when the first connecting portion is inserted into the first socket, the second connecting portion abuts against the proximal end of the terminal retainer.

[0008] Preferably, the axis of the connecting shell has a plug hole, and the second connecting part is covered with an insulating layer, and the two are integrated and passed through the plug hole.

[0009] Preferably, the inner core shell has two first side surfaces and a second side surface, the first side surfaces and the second side surfaces are perpendicular to each other and are connected in sequence by an inclined connecting surface, the inner contour of the connecting shell is adapted to the outer contour of the inner core shell, and the proximal end of the inner core shell is inserted into the distal end of the connecting shell.

[0010] Preferably, the distal end of the terminal retainer is clamped in the distal end of the inner core shell, and the two together form a second socket, a group of first spring sheets are arranged on the first side surface near its proximal end, and the outer wall of the terminal retainer has a recess arranged corresponding to the position of the first spring sheets, a group of the first spring sheets extend inwardly at an angle and are clamped in the recess to confine the terminal retainer in the inner core shell.

[0011] Preferably, a second spring sheet is provided on the second side surface near its distal end, the second spring sheet extends outwardly in an inclined manner, a first clamping block adapted to the second spring sheet is provided on the inner wall of the plug housing, the second spring sheet is clamped with the first clamping block to limit the position of the inner core housing.

[0012] Preferably, a group of outwardly protruding limiting bumps are provided on the first side surface near its distal end, and a second clamping block matching the limiting bumps is provided on the inner wall of the plug housing, and the limiting bumps are clamped with the second clamping block to limit the position of the inner core housing.

[0013] Preferably, the distal port of the plug shell is clamped with a distal limit block, the first sealing ring is sleeved outside the distal port of the plug shell and limited by the distal limit block, the distal end of the inner core shell is evenly distributed with a group of notches, the notches and the inner wall of the distal port of the plug shell together constitute a clamping part, and the inner end edge of the distal limit block is provided with a group of claws, and the claws are clamped in the clamping part.

[0014] Preferably, the proximal port of the plug shell is clamped with a proximal limit block, and buckles are provided on both sides of the proximal limit block. A third clamping block matching the buckle is provided on the outer wall of the plug shell, and the buckle is clamped with the third clamping block and defines the second sealing ring, so that the two ends of the second sealing ring are respectively abutted against the proximal limit block and the end face of the connecting shell.

[0015] The high voltage connector comprises the copper-aluminum bar connected plug and a matching socket as described above, wherein a connecting handle is arranged outside the plug housing of the copper-aluminum bar connected plug.

[0016] The beneficial effects of the utility model are mainly reflected in:

[0017] 1. Use copper-aluminum bars to replace the cables and terminals connected by welding. Compared with cables, copper-aluminum bars have better current carrying capacity and are more suitable for the high current carrying and large current requirements of high-voltage connectors. The connection structure of copper-aluminum bars is more stable. At the same time, the heat dissipation effect of copper-aluminum bars is better than that of cables of the same specifications, ensuring its long-term safety and connection stability.

[0018] 2. A connecting shell is provided to limit the position of the copper-aluminum bar, and the connecting shell plays an effective role in limiting and preventing the copper-aluminum bar from rotating. At the same time, an inner core shell is provided to be clamped with the connecting shell to connect the terminal assembly and the conductive assembly into a whole, thereby ensuring the stability of the two in the plug housing and preventing them from shaking or displacement due to vibration;

[0019] 3. The inner core shell is provided with a first spring sheet and a second spring sheet, which utilize the different extension directions of the spring sheets to respectively establish effective and stable connections with the terminal retaining parts and the plug shell located inside and outside thereof. The elasticity of the first spring sheet and the second spring sheet simultaneously forms reliable soft limits on the inside and outside of the inner core shell to ensure its constant position. At the same time, a limiting protrusion is provided on the inner core shell to further engage with the plug shell to form a hard limit on the four sides of the inner core shell to enhance the accuracy of its position in the plug shell. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The technical solution of the utility model is further described below in conjunction with the accompanying drawings:

[0021] Figure 1 : An exploded schematic diagram of an embodiment of the utility model;

[0022] Figure 2 : A partial structural diagram of an embodiment of the utility model;

[0023] Figure 3 : A cross-sectional view of an embodiment of the utility model;

[0024] Figure 4 : A schematic diagram of a plug housing in an embodiment of the present invention. DETAILED DESCRIPTION

[0025] The present invention will be described in detail below in conjunction with the specific embodiments shown in the accompanying drawings. However, these embodiments are not limited to the present invention, and any structural, methodological, or functional changes made by a person skilled in the art based on these embodiments are all within the scope of protection of the present invention.

[0026] In the description of the scheme, it should be noted that the terms "center", "up", "down", "left", "right", "front", "back", "vertical", "horizontal", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of description and simplified description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present invention. In addition, the terms "first", "second", and "third" are used for descriptive purposes only, and cannot be understood as indicating or implying relative importance. Moreover, in the description of the scheme, with the operator as a reference, the direction close to the operator is the proximal end, and the direction away from the operator is the distal end.

[0027] like Figures 1 to 4 As shown, the utility model discloses a plug for connecting a copper-aluminum bar, comprising a plug housing 1, two groups of terminal assemblies symmetrically arranged in the distal end of the plug housing 1, and two groups of conductive assemblies symmetrically arranged in the proximal end of the plug housing 1, wherein the terminal assemblies are sequentially sleeved with an inner core housing 2, a terminal retainer 3 and a terminal 4 from the outside to the inside, and the conductive assemblies are sequentially arranged with a connecting housing 5 and a copper-aluminum bar 6 from the outside to the inside, the proximal end of the copper-aluminum bar 6 is welded to the distal end of the terminal 4 as a whole, the terminal assemblies and the conductive assemblies are butted one by one, and a first sealing ring 7 and a second sealing ring 10 are respectively arranged in the distal end and the proximal end of the plug housing 1 to seal the gap between it and the terminal assembly and the conductive assembly.

[0028] In this solution, a copper-aluminum bar 6 is used to replace the cable and the terminal 4 connected together by welding. Compared with the cable, the copper-aluminum bar 6 has better current carrying capacity and is more suitable for the high current carrying and large current requirements of the high-voltage connector. The connection structure of the copper-aluminum bar 6 is more stable. At the same time, the heat dissipation effect of the copper-aluminum bar 6 is better than that of the cable of the same specification, so as to ensure its safety and connection stability in long-term use. The connecting shell 5 is set to limit the position of the copper-aluminum bar 6, and the connecting shell 5 plays an effective role in limiting and preventing the copper-aluminum bar 6 from rotating. At the same time, the inner core shell 2 is set to be clamped with the connecting shell 5 to connect the terminal assembly and the conductive assembly into a whole, so as to ensure the stability of the two in the plug housing 1 and prevent them from shaking or displacement due to vibration.

[0029] like Figure 1 and Figure 3As shown, the inner core housing 2 and the proximal end of the terminal retainer 3 jointly form a first socket 8, and the copper-aluminum busbar 6 includes a first connecting portion 601 and a second connecting portion 602, and the width of the second connecting portion 602 is greater than the width of the first connecting portion 601, forming a T-shape. The width of the first connecting portion 601 is adapted to the width of the first socket 8, so that the first connecting portion 601 is inserted into the first socket 8 and welded to the terminal 4. The width of the second connecting portion 602 is greater than the width of the first socket 8 and less than the proximal width of the terminal retainer 3, so that when the first connecting portion 601 is inserted into the first socket 8, the second connecting portion 602 abuts against the proximal end of the terminal retainer 3, and does not affect the connection between the connecting housing 5 and the inner core housing 2.

[0030] The connecting housing 5 has a plug hole 501 at its axis, and the second connecting portion 602 is covered with an insulating layer 603, and the two are integrated and inserted into the plug hole 501. The connecting housing 5 has a limiting and fixing effect on the second connecting portion 602 to prevent it from rotating.

[0031] The inner core shell 2 has two first side surfaces 201 and a second side surface 202. The first side surfaces 201 and the second side surfaces 202 are perpendicular to each other and are connected in sequence via an inclined connecting surface 203. The inner contour of the connecting shell 5 is adapted to the outer contour of the inner core shell 2, and the proximal end of the inner core shell 2 is inserted into the distal end of the connecting shell 5.

[0032] like Figure 2 and Figure 3 As shown, the distal end of the terminal retainer 3 is clamped in the distal end of the inner core housing 2, and the two together form a second socket 9, a group of first elastic pieces 204 are arranged on the first side surface 201 near its proximal end, and the outer wall of the terminal retainer 3 has a recess 301 arranged corresponding to the position of the first elastic piece 204, and a group of the first elastic pieces 204 extend inwardly and are clamped in the recess 301 to limit the terminal retainer 3 in the inner core housing 2. The specific structure of the terminal retainer 3 is prior art, which can be seen in Chinese Patent No. 202321717479.1, and will not be repeated here.

[0033] A second elastic sheet 205 is provided on the second side surface 202 near its far end, and the second elastic sheet 205 extends outwardly at an angle. A first clamping block 101 adapted to the second elastic sheet 205 is provided on the inner wall of the plug housing 1, and the second elastic sheet 205 is clamped with the first clamping block 101 to limit the position of the inner core housing 2.

[0034] The arrangement of the first elastic sheet 204 and the second elastic sheet 205 can enable the inner core housing 2 to maintain its straightness, so that a uniform gap is maintained between its distal end and its proximal end and the terminal retainer 3 and the plug housing 1 .

[0035] Furthermore, a group of outwardly protruding limiting protrusions 206 are provided near the distal end of the first side surface 201, and a second clamping block 102 matching the limiting protrusions 206 is provided on the inner wall of the plug housing 1, and the limiting protrusions 206 are clamped with the second clamping block 102 to limit the position of the inner core housing 2. Compared with the elastic soft limiting function of the first spring sheet 204 and the second spring sheet 205 on the inner core housing 2, the clamping function between the limiting protrusions 206 and the second clamping block 102 provides a hard limiting function for the inner core housing 2, so that it can be stably fixed in the plug housing 1 without shaking, thereby ensuring the position stability of the entire terminal assembly and ensuring the connection effectiveness and stability during use.

[0036] like Figure 1 and Figure 3 As shown, the distal port of the plug housing 1 is clamped with a distal stopper 103, the first sealing ring 7 is sleeved outside the distal port of the plug housing 1 and is limited by the distal stopper 103, the distal end of the inner core housing 2 is evenly distributed with a group of notches 207, the notches 207 and the inner wall of the distal port of the plug housing 1 together constitute a clamping portion, and the inner edge of the distal stopper 103 is provided with a group of claws 104, the claws 104 are clamped in the clamping portion. The distal stopper 103 also limits the first sealing ring 7 and the terminal assembly, and constitutes the distal port of the plug housing 1 to facilitate its sealed plugging with the socket. A signal terminal is also provided in the distal port of the plug for connection.

[0037] Similarly, the proximal port of the plug housing 1 is clamped with a proximal limit block 107, and buckles 105 are provided on both sides of the proximal limit block 107. A third clamping block 106 matching the buckle 105 is provided on the outer wall of the plug housing 1. The buckle 105 is clamped with the third clamping block 106 and limits the second sealing ring 10, so that the two ends of the second sealing ring 10 are respectively abutted against the proximal limit block 107 and the end face of the connecting shell 5.

[0038] In addition, the present solution also discloses a high-voltage connector, including the copper-aluminum busbar-connected plug and the matching socket as described above, wherein the plug housing 1 of the copper-aluminum busbar-connected plug is provided with a connection handle 11 on the outside to facilitate the quick plugging and unplugging of the plug and the socket. The socket (not shown in the figure) is adapted to the copper-aluminum busbar-connected plug, and the two can be removably plugged in. At least a power terminal matching the terminal 4 in the terminal assembly and a signal male terminal matching the signal terminal are provided inside the socket to enable the plug and the socket to perform high-voltage electrical connection and signal control connection, which is a prior art and will not be described in detail here.

[0039] It should be understood that although this specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each implementation mode may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

[0040] The series of detailed descriptions listed above are only specific descriptions of feasible implementation methods of the utility model. They are not intended to limit the protection scope of the utility model. Any equivalent implementation methods or changes that do not deviate from the technical spirit of the utility model should be included in the protection scope of the utility model.

Claims

1. A plug for connecting copper and aluminum busbars, characterized by: The invention comprises a plug housing (1), two groups of terminal assemblies symmetrically arranged in the distal end of the plug housing (1), and two groups of conductive assemblies symmetrically arranged in the proximal end of the plug housing (1), wherein the terminal assembly is provided with an inner core housing (2), a terminal retaining member (3) and a terminal (4) in sequence from the outside to the inside, and the conductive assembly is provided with a connecting housing (5) and a copper-aluminum bar (6) in sequence from the outside to the inside, the proximal end of the copper-aluminum bar (6) is welded to the distal end of the terminal (4) as a whole, the terminal assemblies and the conductive assemblies are butted against each other, and a first sealing ring (7) and a second sealing ring (10) are respectively provided in the distal end and the proximal end of the plug housing (1) to seal the gap between the terminal assembly and the conductive assembly.

2. The plug for connecting copper and aluminum busbars according to claim 1, characterized in that: The inner core shell (2) and the proximal end of the terminal retainer (3) together form a first socket (8); the copper-aluminum busbar (6) comprises a first connecting portion (601) and a second connecting portion (602); the width of the first connecting portion (601) matches the width of the first socket (8); the width of the second connecting portion (602) is greater than the width of the first socket (8) and less than the proximal width of the terminal retainer (3), so that when the first connecting portion (601) is inserted into the first socket (8), the second connecting portion (602) abuts against the proximal end of the terminal retainer (3).

3. The plug for connecting copper and aluminum busbars according to claim 2, characterized in that: The axis of the connection shell (5) has a plug hole (501), and the second connection portion (602) is coated with an insulating layer (603) on the outside, and the two are integrated and inserted into the plug hole (501).

4. The plug for connecting copper and aluminum busbars according to claim 3, characterized in that: The inner core shell (2) has two first side surfaces (201) and a second side surface (202), the first side surfaces (201) and the second side surfaces (202) are perpendicular to each other and are sequentially connected via an inclined connecting surface (203), the inner contour of the connecting shell (5) is adapted to the outer contour of the inner core shell (2), and the proximal end of the inner core shell (2) is inserted into the distal end of the connecting shell (5).

5. The plug for connecting copper and aluminum busbars according to claim 4, characterized in that: The distal end of the terminal retainer (3) is clamped in the distal end of the inner core housing (2), and the two together form a second socket (9); a group of first spring sheets (204) are provided on the first side surface (201) near its proximal end; the outer wall of the terminal retainer (3) has a recess (301) arranged corresponding to the position of the first spring sheets (204); a group of the first spring sheets (204) extend inwardly and are clamped in the recess (301) to confine the terminal retainer (3) in the inner core housing (2).

6. The plug for connecting copper and aluminum busbars according to claim 5, characterized in that: A second spring sheet (205) is provided on the second side surface (202) near its far end, the second spring sheet (205) extending outwardly in an inclined manner, a first clamping block (101) adapted to the second spring sheet (205) is provided on the inner wall of the plug housing (1), the second spring sheet (205) being clamped with the first clamping block (101) to define the position of the inner core housing (2).

7. The plug for connecting copper and aluminum busbars according to claim 6, characterized in that: A group of outwardly protruding limiting bumps (206) are provided on the first side surface (201) near its far end, and a second clamping block (102) matching the limiting bumps (206) is provided on the inner wall of the plug housing (1), and the limiting bumps (206) are clamped with the second clamping block (102) to limit the position of the inner core housing (2).

8. The plug for connecting copper and aluminum busbars according to claim 7, characterized in that: The distal port of the plug housing (1) is clamped with a distal limit block (103); the first sealing ring (7) is sleeved outside the distal port of the plug housing (1) and is limited by the distal limit block (103); a group of notches (207) are evenly distributed at the distal end of the inner core housing (2); the notches (207) and the inner wall of the distal port of the plug housing (1) together form a clamping portion; a group of claws (104) are provided on the inner end edge of the distal limit block (103); the claws (104) are clamped in the clamping portion.

9. The plug for connecting copper and aluminum busbars according to claim 8, characterized in that: The proximal port of the plug housing (1) is clamped with a proximal limit block (107), buckles (105) are arranged on both sides of the proximal limit block (107), and a third clamping block (106) matching the buckle (105) is arranged on the outer wall of the plug housing (1), and the buckle (105) and the third clamping block (106) are clamped and limit the second sealing ring (10), so that the two ends of the second sealing ring (10) are respectively abutted against the proximal limit block (107) and the end surface of the connecting housing (5).

10. High voltage connector, characterized in that: It comprises a copper-aluminum busbar connecting plug as claimed in any one of claims 1 to 9 and a socket matched therewith, wherein a connecting handle (11) is arranged on the outside of a plug housing (1) of the copper-aluminum busbar connecting plug.

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