Electrical connector and electrical system
By using copper conductive connectors welded to an aluminum substrate in electrical connectors, the high resistance problem caused by the aluminum oxide layer was solved, thereby improving the stability and safety of the electrical system.
Patent Information
- Application Number
- CN202423089602.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-13
- Publication Date
- 2025-12-26
- Estimated Expiration
- 2034-12-13
AI Technical Summary
In electrical systems, aluminum surfaces are prone to forming oxide layers with poor conductivity, which leads to high lap resistance at electrical connections, increases power loss, and causes local temperature rise, affecting the safe and stable operation of the system.
Copper conductive connectors are used to connect to the aluminum substrate. Stable electrical connections are formed through welding or ultrasonic welding, avoiding direct contact, reducing the impact of oxide layer, and using guide bevels and flange structures to ensure stable contact.
It reduces the lap resistance at electrical connections, reduces power loss, improves the stability and safety of electrical systems, and avoids poor contact problems caused by oxide layers.
Smart Images
Figure CN223729051U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] Embodiments of the present disclosure generally relate to the field of electrical equipment, and in particular, to an electrical connector and an electrical system. BACKGROUND
[0002] In an electrical system, in order to realize electrical connection between two busbar groups, an electrical connector is usually arranged between them. In some conventional electrical connectors, aluminum plates are sometimes used as conductor materials inside the electrical connectors, so as to reduce material cost. However, aluminum materials are prone to form an oxide layer with poor conductivity on the surface during use, so that a high lap joint resistance occurs at the electrical connection, which not only causes more electrical energy to be converted into heat energy and lost, but also causes local temperature rise, which brings potential risks to the safe and stable operation of the entire circuit system. CONTENT OF THE UTILITY MODEL
[0003] Embodiments of the present disclosure aim to provide an electrical connector and an electrical system to at least partially solve the above problems and other potential problems.
[0004] In a first aspect of the present disclosure, an electrical connector is provided. The electrical connector comprises: a pair of covers; a plurality of insulating pieces arranged between the pair of covers and spaced apart to define a connection area between adjacent insulating pieces of the plurality of insulating pieces for insertion of a busbar; and a plurality of conductive assemblies, each conductive assembly being arranged between corresponding adjacent insulating pieces of the plurality of insulating pieces and coupled to one of the corresponding adjacent insulating pieces, and each conductive assembly comprising: a metal substrate; and a conductive connecting piece comprising a contact plate arranged on a side of the metal substrate facing the connection area and coupled to the metal substrate.
[0005] In some embodiments, the contact plate and the metal substrate are connected by welding.
[0006] In some embodiments, the contact plate and the metal substrate are connected by ultrasonic welding, the contact plate is made of copper material, and the metal substrate is made of aluminum material.
[0007] In some embodiments, the contact plate and the metal substrate are connected by a plurality of welding points, and a ratio of a total coverage area of the plurality of welding points to a contact area between the contact plate and the metal substrate is greater than or equal to 10%.
[0008] In some embodiments, the contact plate and the metal substrate are connected by point-shaped welding points or by a strip-shaped welding seam.
[0009] In some embodiments, the metal substrate is respectively provided with a guide inclined surface at opposite ends thereof in a busbar insertion direction, and the contact plate is provided with a guide portion at opposite ends thereof in the busbar insertion direction, the guide portion being fitted with the corresponding guide inclined surface to guide the busbar to be inserted into the corresponding connection area along the guide portion.
[0010] In some embodiments, the conductive connector further includes: a pair of first flanges respectively arranged at opposite ends of the contact plate in the busbar insertion direction, the pair of first flanges being structures bent from edges of the contact plate, and each first flange being inserted between the metal substrate and a corresponding insulating member.
[0011] In some embodiments, the conductive connector further includes: a pair of second flanges respectively arranged at opposite ends of the contact plate in a direction perpendicular to the busbar insertion direction, the pair of second flanges being structures bent from edges of the contact plate, and an end of each second flange away from the contact plate being inserted between the metal substrate and a corresponding insulating member.
[0012] In some embodiments, a side of the insulating member facing the connection region is provided with a limiting groove, the conductive assembly is arranged in the limiting groove, and the conductive connector protrudes out of the limiting groove and can be in contact with the corresponding busbar.
[0013] In some embodiments, the electrical connector further includes: a pair of elastic members arranged between each cover of the pair of covers and the plurality of insulating members, the pair of elastic members being configured to apply a force to the plurality of insulating members to make the plurality of insulating members abut against the corresponding conductive assembly.
[0014] In some embodiments, the electrical connector further includes: a plurality of mounting members respectively arranged in the plurality of connection regions and coupled to the corresponding insulating members.
[0015] In some embodiments, the contact plate is of an integral structure; or the contact plate includes: a pair of contact portions spaced apart from each other along the busbar insertion direction and respectively corresponding to one or more regions of the side of the metal substrate facing the connection region.
[0016] In some embodiments, each contact portion of the pair of contact portions includes: a single contact portion; or a plurality of sub-contact portions spaced apart from each other.
[0017] In a second aspect of the present disclosure, an electrical system is provided. The electrical system includes the electrical connector of the first aspect of the present disclosure; and a busbar group including a plurality of busbars, the plurality of busbars being respectively inserted into corresponding connection regions of the plurality of connection regions along the busbar insertion direction, and each contact plate being in contact with two busbars.
[0018] In embodiments of the present disclosure, the electrical connector includes a pair of covers, a plurality of insulating pieces, and a plurality of conductive assemblies. The plurality of insulating pieces are arranged between the pair of covers and are spaced apart to define a connection region between adjacent insulating pieces of the plurality of insulating pieces for insertion of a busbar. Each conductive assembly is arranged between corresponding adjacent insulating pieces of the plurality of insulating pieces and is coupled to one of the corresponding adjacent insulating pieces. Each conductive assembly includes a metal substrate and a conductive connecting piece. The conductive connecting piece includes a contact plate. The contact plate is arranged on a side of the metal substrate facing the connection region and is coupled to the metal substrate. With this arrangement, the anti-oxidation performance of the part of the metal substrate connected to the contact plate of the conductive connecting piece is improved, and the influence of oxidation generated during use on the electrical connection performance between the metal substrate and the contact plate can be reduced. During use, the current flows from the metal substrate to the busbar or from the busbar to the metal substrate via the contact plate, and the busbar is not in direct contact with the metal substrate, which reduces the lapping resistance at the electrical connection and helps to reduce the electrical energy loss and lower the system temperature, thereby improving the stability of the electrical system.
[0019] It should be understood that the content described in this section is not intended to limit the key features or important features of the embodiments of the present disclosure, nor is it used to limit the scope of the present disclosure. Other features of the present disclosure will become apparent through the following description. BRIEF DESCRIPTION OF DRAWINGS
[0020] The above and other features, advantages, and aspects of embodiments of the present disclosure will become more apparent by describing in detail the following embodiments with reference to the accompanying drawings. In the drawings, the same or similar reference numerals refer to the same or similar elements, in which:
[0021] Figure 1 A perspective view of an electrical connector of an embodiment of the present disclosure is shown;
[0022] Figure 2 A schematic view of an electrical connector of an embodiment of the present disclosure is shown;
[0023] Figure 3 An exploded view of a conductive assembly of one embodiment of the present disclosure is shown, in which a guide bevel is shown;
[0024] Figure 4 An exploded view of a conductive assembly of one embodiment of the present disclosure is shown, in which a first flange and a second flange are shown; and
[0025] Figure 5 A perspective view of a conductive assembly of another embodiment of the present disclosure is shown, in which a pair of contact portions are shown.
[0026] BRIEF DESCRIPTION OF DRAWINGS
[0027] X, busbar insertion direction; Y, direction perpendicular to the busbar insertion direction;
[0028] 11. cover body;
[0029] 12. insulating member; 120, limiting groove;
[0030] 13. connecting area;
[0031] 14. conductive assembly; 141, metal substrate; 1410, guide inclined surface; 142, conductive connecting member; 1420, contact plate; 1420a, contact portion; 1421, first flange; 1422, second flange; 1423, guide portion; 1424, welding point;
[0032] 15. elastic member;
[0033] 16. mounting member;
[0034] 17. connecting assembly. DETAILED DESCRIPTION
[0035] Preferred embodiments of the present disclosure will be described in more detail with reference to the drawings. Although preferred embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. Rather, these embodiments are provided so that the present disclosure is more thoroughly and completely conveyed to those skilled in the art, and the scope of the present disclosure is fully conveyed to those skilled in the art.
[0036] The term "comprising" and variations thereof as used herein are intended to mean "including but not limited to". The term "or" as used herein is intended to mean "and / or". The term "based on" means "based, at least in part, on". The terms "one example embodiment" and "an embodiment" mean "at least one example embodiment". The term "another embodiment" means "at least one additional embodiment". The terms "first", "second", etc. can refer to different or same objects.
[0037] As described above, in some conventional electrical connectors, aluminum plates are sometimes used as conductor materials inside the electrical connectors to reduce material costs. However, aluminum materials are prone to form an oxide layer with poor electrical conductivity on the surface during use, resulting in high lap joint resistance at the electrical connection, which not only causes more electrical energy to be converted into heat energy and lost, but also causes local temperature rise, which poses potential risks to the safe and stable operation of the entire circuit system.
[0038] Embodiments of the present disclosure provide an electrical connector and an electrical system. The electrical connector includes a pair of covers, a plurality of insulating pieces, and a plurality of conductive assemblies. The plurality of insulating pieces are arranged between the pair of covers and are spaced apart to define a plurality of connection regions between adjacent insulating pieces of the plurality of insulating pieces for insertion of busbars. Each conductive assembly is arranged between corresponding adjacent insulating pieces of the plurality of insulating pieces and is coupled to one of the corresponding adjacent insulating pieces. Each conductive assembly includes a metal substrate and a conductive connecting piece. The conductive connecting piece includes a contact plate. The contact plate is arranged on a side of the metal substrate facing the connection region and is coupled to the metal substrate. With this arrangement, the anti-oxidation performance of the part of the metal substrate connected to the contact plate of the conductive connecting piece is improved, and the effect of oxidation generated during use on the electrical connection performance between the metal substrate and the contact plate is reduced. During use, the current flows from the metal substrate to the busbar or from the busbar to the metal substrate via the contact plate, and the busbar is not in direct contact with the metal substrate, which reduces the lap joint resistance at the electrical connection and helps to reduce the electrical energy loss and lower the system temperature, thereby improving the stability of the electrical system. The principles of the present disclosure will be described in detail below with reference to the drawings. Figures 1 to 5
[0039] As shown in Figure 1 and Figure 2 , the electrical connector includes a pair of covers 11, a plurality of insulating pieces 12, and a plurality of conductive assemblies 14. The pair of covers 11 can protect the plurality of components inside the electrical connector and can fix the plurality of components. Between the pair of covers 11, the plurality of insulating pieces 12 can be arranged at a predetermined interval, and the plurality of insulating pieces 12 can provide electrical isolation to prevent short circuits between different busbars. Between adjacent insulating pieces 12 of the plurality of insulating pieces 12, a connection region 13 can be formed, for example, between 5 insulating pieces 12, 4 connection regions 13 can be formed, and each connection region 13 can be inserted with a busbar. When the electrical connector is connected with a busbar group, the plurality of busbars of the busbar group can be inserted into the plurality of connection regions 13, respectively. In addition, the electrical connector can be connected with a plurality of busbar groups at the same time to achieve electrical connection between the plurality of busbar groups.
[0040] As shown in Figure 1 and Figure 2 , the electrical connector further includes a plurality of conductive assemblies 14. Each conductive assembly 14 is arranged between corresponding adjacent insulating pieces 12 of the plurality of insulating pieces 12 and is coupled to one of the corresponding adjacent insulating pieces 12. As an example, between 5 insulating pieces 12, 4 connection regions 13 can be formed, and one conductive assembly 14 can be arranged in each of the 4 connection regions. When four busbars are inserted into the corresponding connection regions 13, the busbars can be in contact with the corresponding conductive assemblies 14.
[0041] As another example, as shown in Figure 2 As shown, two conductive components 14 can be provided in each connection area 13, so the conductive components 14 can be connected to the corresponding insulator 12 on the side of each insulator 12 facing the connection area 13. With this arrangement, when the busbar is inserted into the connection area 13, both sides of the busbar are in contact with the conductive components 14, which can improve the conductivity between the busbar and the conductive components 14.
[0042] like Figure 3 and Figure 4 As shown, each conductive component 14 includes a metal substrate 141 and a conductive connector 142. The metal substrate 141 serves as the primary current carrier, transmitting electrical energy from one busbar to another. The conductive connector 142 includes a contact plate 1420. The contact plate 1420 is disposed on the side of the metal substrate 141 facing the connection area 13. During the fabrication of the conductive component 14, the oxide layer on the surface of the metal substrate 141 can be removed, and then the contact plate 1420 is connected to the metal substrate 141. In some embodiments, the oxide layer on the surface of the metal substrate 141 can also be removed during the connection process between the contact plate 1420 and the metal substrate 141. During later use, the metal substrate 141 and the contact plate 1420 maintain good contact, and no loosening occurs at the contact points, thereby reducing oxidation.
[0043] This arrangement improves the oxidation resistance of the portion where the metal substrate 141 connects to the contact plate 1420 of the conductive connector 142, reducing the impact of oxidation during use on the electrical connection performance between the metal substrate 141 and the contact plate 1420. During use, current can flow from the metal substrate 141 to the busbar or vice versa via the contact plate 1420. The busbar and metal substrate 141 are not in direct contact, reducing lap resistance at the electrical connection point, which helps reduce power loss and lower system temperature, thereby improving the stability of the electrical system.
[0044] It should be understood that the surface of the metal substrate 141 in the embodiments of the present disclosure is provided with the conductive connecting piece 142, which is obviously different from the scheme of providing a plating layer on the surface of the metal substrate 141. Regarding the plating layer scheme, taking an aluminum substrate as an example, in order to ensure that the aluminum substrate has good electrical connection and corrosion resistance, a layer of copper needs to be plated on the aluminum substrate first, and then tin is plated. Copper as an intermediate layer can improve the quality and adhesion of the tin layer to solve the problem of poor direct combination of tin and aluminum. However, this double-layer plating increases the complexity of the process, and it is difficult to ensure the compatibility and uniformity between the layers. In addition, the cost of multi-layer plating is relatively high, and the related costs such as plating solution maintenance and waste liquid treatment also need to be considered. Most importantly, although the tin layer can provide certain corrosion resistance, its current carrying capacity depends on the quality of the copper layer. If the quality of the copper layer is not good, the final electrical performance will be affected. In contrast, in the embodiments of the present disclosure, the surface of the metal substrate 141 is provided with the conductive connecting piece 142, which not only has a simple manufacturing process and relatively low cost, but also has good electrical conductivity.
[0045] In some examples, the surface of the metal substrate 141 in the present disclosure is provided with the conductive connecting piece 142, which is different from the structure presented by the plating layer provided on the surface of the metal substrate 141, including but not limited to: for example, the surface of the metal substrate 141 in the present disclosure is provided with the conductive connecting piece 142, which is a phase-separated and independent structure with the metal substrate 141 and can be connected with the metal substrate 141 (such as welding as described below); for another example, the conductive connecting piece 142 (or the contact plate 1420 of the conductive connecting piece 142) in the present disclosure can be a sheet body (such as a copper sheet structure) or a plate body, etc., which is different from the layer body of the plating layer scheme (such as the film layer formed by plating). This is only an example and is not a limitation of the embodiments of the present disclosure.
[0046] In some embodiments, an aluminum plate can be used as the metal substrate 141, and a copper material that is not easy to oxidize can be used to make the conductive connecting piece 142. The aluminum plate is widely used because of its good electrical conductivity and thermal conductivity and relatively low cost, but its surface is easy to form a high-resistance aluminum oxide film. The surface of the aluminum substrate is provided with a copper conductive connecting piece 142, which can overcome the problem of high resistance of the aluminum oxide film. Copper has a lower resistivity and excellent oxidation resistance, and can maintain stable electrical contact for a long time. The copper contact plate 1420 is combined with the aluminum substrate, and when the aluminum substrate surface appears an oxide layer, the current can also be transmitted to the inside of the aluminum substrate through the copper part, thereby reducing the electrical energy loss caused by the aluminum oxide layer.
[0047] It should be understood that in other embodiments, the metal substrate 141 may also be made of other materials that are prone to forming high-resistivity oxide layers on their surfaces, while the conductive connector 142 needs to have good oxidation resistance. Since the materials of the metal substrate 141 and the conductive connector 142 are different, this disclosure is not intended to limit the specific materials.
[0048] In some embodiments, the contact plate 1420 is welded to the metal substrate 141. By welding the contact plate 1420 to the metal substrate 141 together, loosening caused by factors such as vibration and temperature changes during use can be avoided, thereby reducing oxidation at the connection point between the contact plate 1420 and the metal substrate 141 and helping to maintain good conductivity.
[0049] In some embodiments, such as Figure 3 and Figure 4 As shown, the contact plate 1420 and the metal substrate 141 can be connected by a dotted arrangement of solder points 1424, for example, arranged in an array. In this way, the dotted arrangement of solder points 1424 can provide a stable mechanical and electrical connection, while dispersing stress and avoiding fatigue or failure problems that may occur at a single connection point.
[0050] It should be understood that, in other embodiments, the contact plate 1420 and the metal substrate 141 may also be connected by a strip weld, for example, by roll welding or dense zero-pitch spot welding. Using this arrangement, the strip weld not only provides a large contact area but also improves mechanical strength and electrical conductivity.
[0051] In some embodiments, ultrasonic welding technology can be used to connect the contact plate 1420 and the metal substrate 141. The energy generated by high-frequency vibration locally heats the material to a molten state, and then rapidly cools and solidifies it under pressure, thereby forming a strong and electrically conductive solder joint 1424. Furthermore, aluminum conductors readily form an oxide film on their surface under natural conditions. Ultrasonic welding technology can remove this oxide film at the solder joint 1424 during the welding process, forming a good electrical connection and reducing the impact of the oxide layer on the electrical connection performance.
[0052] In some embodiments, the contact plate 1420 is connected to the metal substrate 141 via a plurality of solder joints 1424. The ratio of the total coverage area of the plurality of solder joints 1424 to the actual contact area between them is greater than or equal to a preset ratio, for example, a ratio ≥ 10%. When the total coverage area of the plurality of solder joints 1424 is large, more surface area can participate in the current transmission process, thereby reducing resistance and helping to improve the electrical performance of the system. In addition, a large total coverage area of the plurality of solder joints 1424 can also enhance the strength of the structure, enabling the conductive connector 142 and the contact plate 1420 to maintain a stable electrical connection.
[0053] In some embodiments, the electrical connector employs a copper conductive connector 142 with a hardness close to that of the aluminum substrate. The Vickers hardness of the copper conductive connector 142 can be between 50-60, for example. In this way, the problem of poor welding or virtual welding during the welding process can be solved.
[0054] In some embodiments, as shown in FIG. 1A, the metal substrate 141 is provided with a guide slope 1410 at each of the opposite ends thereof in the busbar insertion direction X. The contact plate 1420 is provided with a guide portion 1423 at each of the opposite ends thereof in the busbar insertion direction X, which is in abutment with the corresponding guide slope 1410. The angle and shape of the guide portion 1423 help the busbar to correct its position when the busbar enters the corresponding connection region 13 along the guide portion 1423, so that the busbar can be smoothly inserted into the corresponding connection region 13 even if the insertion position is slightly deviated, thereby improving the efficiency of the busbar and the electrical connector when they are mated. Figure 3 In some embodiments, as shown in FIG. 1A, the metal substrate 141 is provided with a guide slope 1410 at each of the opposite ends thereof in the busbar insertion direction X. The contact plate 1420 is provided with a guide portion 1423 at each of the opposite ends thereof in the busbar insertion direction X, which is in abutment with the corresponding guide slope 1410. The angle and shape of the guide portion 1423 help the busbar to correct its position when the busbar enters the corresponding connection region 13 along the guide portion 1423, so that the busbar can be smoothly inserted into the corresponding connection region 13 even if the insertion position is slightly deviated, thereby improving the efficiency of the busbar and the electrical connector when they are mated.
[0055] In some embodiments, as shown in FIG. 1A, the metal substrate 141 is provided with a guide slope 1410 at each of the opposite ends thereof in the busbar insertion direction X. The contact plate 1420 is provided with a guide portion 1423 at each of the opposite ends thereof in the busbar insertion direction X, which is in abutment with the corresponding guide slope 1410. The angle and shape of the guide portion 1423 help the busbar to correct its position when the busbar enters the corresponding connection region 13 along the guide portion 1423, so that the busbar can be smoothly inserted into the corresponding connection region 13 even if the insertion position is slightly deviated, thereby improving the efficiency of the busbar and the electrical connector when they are mated. Figure 3 Figure 4 In some embodiments, as shown in FIG. 1A, the metal substrate 141 is provided with a guide slope 1410 at each of the opposite ends thereof in the busbar insertion direction X. The contact plate 1420 is provided with a guide portion 1423 at each of the opposite ends thereof in the busbar insertion direction X, which is in abutment with the corresponding guide slope 1410. The angle and shape of the guide portion 1423 help the busbar to correct its position when the busbar enters the corresponding connection region 13 along the guide portion 1423, so that the busbar can be smoothly inserted into the corresponding connection region 13 even if the insertion position is slightly deviated, thereby improving the efficiency of the busbar and the electrical connector when they are mated.
[0056] In some embodiments, as shown in FIG. 1A, the metal substrate 141 is provided with a guide slope 1410 at each of the opposite ends thereof in the busbar insertion direction X. The contact plate 1420 is provided with a guide portion 1423 at each of the opposite ends thereof in the busbar insertion direction X, which is in abutment with the corresponding guide slope 1410. The angle and shape of the guide portion 1423 help the busbar to correct its position when the busbar enters the corresponding connection region 13 along the guide portion 1423, so that the busbar can be smoothly inserted into the corresponding connection region 13 even if the insertion position is slightly deviated, thereby improving the efficiency of the busbar and the electrical connector when they are mated. Figure 3 Figure 4 In some embodiments, as shown in FIG. 1A, the metal substrate 141 is provided with a guide slope 1410 at each of the opposite ends thereof in the busbar insertion direction X. The contact plate 1420 is provided with a guide portion 1423 at each of the opposite ends thereof in the busbar insertion direction X, which is in abutment with the corresponding guide slope 1410. The angle and shape of the guide portion 1423 help the busbar to correct its position when the busbar enters the corresponding connection region 13 along the guide portion 1423, so that the busbar can be smoothly inserted into the corresponding connection region 13 even if the insertion position is slightly deviated, thereby improving the efficiency of the busbar and the electrical connector when they are mated.
[0057] In some embodiments, as shown in FIG. 1A, the metal substrate 141 is provided with a guide slope 1410 at each of the opposite ends thereof in the busbar insertion direction X. The contact plate 1420 is provided with a guide portion 1423 at each of the opposite ends thereof in the busbar insertion direction X, which is in abutment with the corresponding guide slope 1410. The angle and shape of the guide portion 1423 help the busbar to correct its position when the busbar enters the corresponding connection region 13 along the guide portion 1423, so that the busbar can be smoothly inserted into the corresponding connection region 13 even if the insertion position is slightly deviated, thereby improving the efficiency of the busbar and the electrical connector when they are mated. Figure 3 Figure 4 As shown, the side of the insulating member 12 facing the connecting region 13 is provided with a limiting groove 120. The conductive assembly 14 is arranged in the limiting groove 120, and the conductive connecting member 142 of the conductive assembly 14 protrudes out of the limiting groove 120 and can contact the inserted busbar. In this way, the contact plate 1420 of the conductive connecting member 142 can stably contact the busbar, and the physical constraint of the limiting groove 120 can prevent the conductive connecting member 142 from unnecessary movement or deformation during use.
[0058] In some embodiments, as shown in Figure 2 As shown, the electrical connector further comprises a pair of elastic members 15. The pair of elastic members 15 is arranged between each of the pair of cover bodies 11 and the plurality of insulating members 12. The elastic member 15 can apply a constant pressure to the insulating member 12, so that the insulating member 12 can be tightly abutted on the corresponding conductive assembly 14. When the busbar is inserted into the connecting region 13 between the insulating members 12, the insulating members 12 will be close to each other due to the action of the elastic member 15, thereby pushing the conductive assembly 14 (including the metal substrate 141 and the conductive connecting member 142) to form a tight contact with the busbar. In this way, the stability of the connection between the busbar and the conductive assembly 14 can be improved. In addition, the presence of the elastic member 15 can also compensate for the dimensional changes caused by temperature changes, material aging, etc.
[0059] In some embodiments, as shown in Figure 2 As shown, the electrical connector further comprises a plurality of mounting members 16. The plurality of mounting members 16 is arranged in each of the connecting regions 13 and coupled with the corresponding insulating member 12. Each mounting member 16 is located between two adjacent insulating members 12 and plays a supporting and separating role, so that the necessary distance between the two adjacent insulating members 12 can be maintained, thereby forming the connecting region 13 to facilitate the insertion and positioning of the busbar. In addition, the mounting member 16 can also fix the insulating member 12 and the conductive assembly 14. During use, the insulating member 12 and the conductive assembly 14 can not be displaced or loosened.
[0060] In some embodiments, as shown in Figure 1 and Figure 2 As shown, the electrical connector further comprises a connecting assembly 17. The connecting assembly 17 is coupled to the pair of cover bodies 11, the plurality of insulating members 12, the plurality of conductive assemblies 14, and the plurality of mounting members 16. The connecting assembly 17 fixes the pair of cover bodies 11 together and can form an external frame of the electrical connector. In addition, the connecting assembly 17 is also connected with the internal insulating members 12, conductive assemblies 14, and mounting members 16, and can fix all the components together. When facing external forces or environmental changes, the relative positions between the components can be maintained unchanged.
[0061] In some embodiments, as shown in Figure 3 andFigure 4 As shown, the contact plate 1420 can be a single, integral metal plate. The contact plate 1420 is a one-piece structure made of a single material, without segments or connection points. The contact plate 1420 can cover all or most of the side surface of the metal substrate 141, thereby providing a uniform electrical connection.
[0062] In other embodiments, such as Figure 5 As shown, the contact plate 1420 may include a pair of contact portions 1420a. The pair of contact portions 1420a are spaced apart from each other along the busbar insertion direction X, and each corresponds to one or more regions on the side of the metal substrate 141 facing the busbar.
[0063] As an example, such as Figure 5 As shown, the contact plate 1420 includes two contact portions 1420a. The two contact portions 1420a correspond to two regions on the side of the metal substrate 141 facing the busbars. During use, the paired contact portions 1420a contact the two busbars. Current flows from one of the busbars into one of the contact portions 1420a, then to the metal substrate 141, and then through the other contact portion 1420a to the other busbar. This ensures efficient and stable current transmission while reducing energy loss due to poor contact or excessive resistance.
[0064] As another example, each of the paired contact portions 1420a may also include a plurality of sub-contact portions spaced apart from each other. For example, the paired contact portions 1420a may include four sub-contact portions. The four sub-contact portions are divided into two pairs, with each contact portion 1420a including two sub-contact portions, for example, two sub-contact portions are arranged in the left region and two sub-contact portions are arranged in the right region. Here, the four sub-contact portions correspond to four regions on the side of the metal substrate 141 facing the connection region 13, respectively. During use, current flows from one busbar into two of the four sub-contact portions, then to the metal substrate 141, and then flows to the other busbar via the other two sub-contact portions. In this way, high efficiency and stability of current transmission can be ensured, while reducing energy loss due to poor contact or excessive resistance.
[0065] It should be understood that in other embodiments, each contact portion 1420a may also include three or four sub-contact portions, etc., and this disclosure is not intended to limit the specific number.
[0066] In some embodiments, such as Figure 5 As shown, each pair of contact portions 1420a is provided with a guide portion 1423. When the busbar slides into the corresponding position along the guide portion 1423, the guide portion 1423 can correct the insertion angle of the busbar.
[0067] In a second aspect of the present disclosure, an electrical system is provided. The electrical system includes any of the electrical connectors described above and a plurality of busbar groups. Each busbar group includes a plurality of busbars. The plurality of busbars are respectively inserted into corresponding connection areas 13 of the electrical connector along a busbar insertion direction X. When the busbars are inserted into the connection areas 13, each contact plate 1420 can be in contact with two busbars respectively. With this arrangement, the plurality of busbar groups can be connected together through the same electrical connector, thereby achieving the transmission and distribution of electrical power.
[0068] In the electrical system, the anti-oxidation performance of the part of the metal substrate 141 that is connected with the contact plate 1420 of the conductive connecting member 142 is improved, and the influence of oxidation generated during use on the electrical connection performance between the metal substrate 141 and the contact plate 1420 can be reduced. During use, the current flows from the metal substrate 141 to the busbar or from the busbar to the metal substrate 141 via the contact plate 1420, and the busbar is not in direct contact with the metal substrate 141, which reduces the lapping resistance at the electrical connection and helps to reduce the power loss and lower the system temperature, thereby improving the stability of the electrical system.
[0069] The above has described embodiments of the present disclosure, and the above description is exemplary and is not exhaustive, and is also not limited to the disclosed embodiments. Many modifications and changes are obvious to those skilled in the art without departing from the scope and spirit of the described embodiments. The selection of the terms used herein is intended to best explain the principles of the embodiments, practical application, or improvement of the technology in the market, or to enable other ordinary skilled in the art to understand the embodiments disclosed herein.
Claims
1. An electrical connector, characterized by, The utility model relates to a busbar connecting device, comprising: a pair of covers (11); a plurality of insulating pieces (12) arranged between the pair of covers (11) and spaced apart to define a connecting area (13) for inserting a busbar between adjacent insulating pieces (12) among the plurality of insulating pieces (12); and a plurality of conductive assemblies (14), each conductive assembly (14) being arranged between corresponding adjacent insulating pieces (12) among the plurality of insulating pieces (12) and coupled to one insulating piece (12) among the corresponding adjacent insulating pieces (12), and each conductive assembly (14) comprising: a metal substrate (141); and a conductive connecting piece (142) comprising a contact plate (1420) arranged on a side of the metal substrate (141) facing the connecting area (13) and coupled to the metal substrate (141). The contact plate (1420) and the metal substrate (141) are connected by welding.
2. The electrical connector of claim 1, wherein, The contact plate (1420) and the metal substrate (141) are connected by ultrasonic welding, the contact plate (1420) is made of copper material, and the metal substrate (141) is made of aluminum material.
3. The electrical connector of claim 1, wherein, The contact plate (1420) and the metal substrate (141) are connected by a plurality of welding spots (1424), and a ratio of a total coverage area of the plurality of welding spots (1424) to a contact area between the contact plate (1420) and the metal substrate (141) is greater than or equal to 10%.
4. The electrical connector of claim 2, wherein, The contact plate (1420) and the metal substrate (141) are connected by point-shaped welding spots (1424) or by a strip-shaped welding seam.
5. The electrical connector of claim 2, wherein, Opposite ends of the metal substrate (141) in a busbar insertion direction (X) are respectively provided with guide inclined surfaces (1410), and opposite ends of the contact plate (1420) in the busbar insertion direction (X) are provided with guide portions (1423) abutting the corresponding guide inclined surfaces (1410) to guide the busbar to be inserted into the corresponding connecting area (13) along the guide portions (1423).
6. The electrical connector of any one of claims 1 to 5, wherein, The conductive connecting piece (142) further comprises:
7. The electrical connector of claim 6, wherein, a pair of first flanges (1421) respectively arranged at opposite ends of the contact plate (1420) in the busbar insertion direction (X), the pair of first flanges (1421) are structures bent from edges of the contact plate (1420), and each first flange (1421) is inserted between the metal substrate (141) and the corresponding insulating piece (12). The conductive connecting piece (142) further comprises:
8. The electrical connector of claim 6, wherein, a pair of second flanges (1422) respectively arranged at opposite ends of the contact plate (1420) in a direction (Y) perpendicular to the busbar insertion direction (X), the pair of second flanges (1422) are structures bent from edges of the contact plate (1420), and a distal end of each second flange (1422) away from the contact plate (1420) is inserted between the metal substrate (141) and the corresponding insulating piece (12). 9. The electrical connector of any one of claims 1 to 5, wherein, A limiting groove (120) is arranged on a side of the insulating member (12) facing the connecting region (13), the conductive assembly (14) is arranged in the limiting groove (120), and the conductive connecting member (142) protrudes out of the limiting groove (120) and can contact the corresponding busbar.
10. The electrical connector of any one of claims 1 to 5, wherein, Further comprising: A pair of elastic members (15) arranged between each cover (11) of the pair of covers (11) and the plurality of insulating members (12), the pair of elastic members (15) configured to apply a force to the plurality of insulating members (12) to make the plurality of insulating members (12) abut against the corresponding conductive assembly (14); And / or A plurality of mounting members (16) respectively arranged in the plurality of connecting regions (13) and coupled to the corresponding insulating members (12).
11. The electrical connector according to any one of claims 1 to 5, wherein: The contact plate (1420) is of an integral structure; or The contact plate (1420) comprises: A pair of contact portions (1420a) spaced apart from each other along a busbar insertion direction (X) and respectively corresponding to one or more regions of a side of the metal substrate (141) facing the connecting region (13).
12. The electrical connector of claim 11, wherein, Each contact portion (1420a) of the pair of contact portions (1420a) comprises: A single contact portion; or A plurality of sub-contact portions spaced apart from each other.
13. An electrical system, characterized by Comprise: The electrical connector according to any one of claims 1 to 12; And A busbar group comprising a plurality of busbars, the plurality of busbars respectively inserted into corresponding connecting regions of the plurality of connecting regions (13) along a busbar insertion direction (X), and each contact plate (1420) respectively in contact with two busbars.