Power connector

Abstract

The utility model provides a power supply connector, which comprises an insulating body and a plurality of power supply terminals arranged in the insulating body, and is characterized in that the insulating body is provided with a butt joint part with a butt joint cavity and a terminal groove communicated with the butt joint cavity; each power supply terminal is provided with a base body part fixed in the terminal groove and a contact arm which extends forwards from the base body part so as to protrude into the butt joint cavity; the range of the ratio of the material thickness of the power supply terminal to the height of the butt joint part is 4.44%-9.85%. According to the power supply connector, the current bearing capability of the power supply terminals can be improved, and meanwhile, the mechanical strength and the structural stability are ensured, so that the reliability and the market applicability of products are improved.

Description

Technical Field

[0001] This utility model relates to a power connector. Background Technology

[0002] Traditional power connectors have an insulating body and several power terminals fixed within the insulating body. Each power terminal has a base portion and at least one elastic contact arm extending forward from the base portion. The material thickness (t) of the power terminals and the mating height (H) of the insulating body have a significant impact on the electrical and mechanical performance of high-current applications. The ratio of the power terminal material thickness to the mating height is a key factor determining the balance between the connector's current carrying capacity and mechanical strength. However, current technology has not yet optimized this ratio. When the t / H value is too large, meaning the power terminal material thickness is relatively thick, the power terminal has a high current carrying capacity but insufficient mechanical strength, affecting its durability and structural stability. When the t / H value is too small, meaning the power terminal material thickness is relatively thin, the power terminal has high mechanical strength, but the cross-sectional area of ​​the power terminal is small, resulting in a decrease in its current carrying capacity and failing to meet the miniaturization requirements of high power density applications. Since different application scenarios have different requirements for the current carrying capacity and mechanical strength of the power terminals, existing designs struggle to balance reliability and industry demands.

[0003] In view of this, it is necessary to improve the existing power connectors to solve the above problems. Utility Model Content

[0004] The purpose of this invention is to provide a power connector that can improve overall performance and market applicability.

[0005] To achieve the above-mentioned utility model objectives, this utility model provides a power connector, which includes an insulating body and a plurality of power terminals disposed within the insulating body. The insulating body has a mating portion forming a mating cavity and a terminal groove communicating with the mating cavity. Each power terminal has a base portion fixed within the terminal groove and a contact arm extending forward from the base portion to protrude into the mating cavity. The ratio of the material thickness of the power terminal to the height of the mating portion ranges from 4.44% to 9.85%.

[0006] As a further improvement of this utility model, the ratio of the material thickness of the power terminal to the height of the mating portion ranges from 4.71% to 9.14%.

[0007] As a further improvement of this utility model, the ratio of the material thickness of the power terminal to the height of the mating portion ranges from 5.00% to 8.53%.

[0008] As a further improvement of this utility model, the ratio of the material thickness of the power terminal to the height of the mating portion ranges from 5.33% to 8.00%.

[0009] As a further improvement of this utility model, the contact arms of the power terminals are arranged in a row along the transverse direction of the insulating body, and the power terminals corresponding to the same row of contact arms are formed with at least one terminal assembly. Each terminal assembly includes at least two power terminals, and the base portions of the two power terminals are arranged in the height direction of the insulating body.

[0010] As a further improvement of this utility model, the terminal assembly includes an upper row of terminal assemblies and a lower row of terminal assemblies with contact arms arranged opposite each other in the height direction. The contact arms of each terminal assembly are arranged in at least two groups arranged side by side in the transverse direction, and the distance between two adjacent groups of contact arms is greater than the distance between two adjacent contact arms in the same group.

[0011] As a further improvement of this utility model, the contact arms of each power terminal are arranged in at least two groups side by side in the lateral direction, and the distance between two adjacent groups of contact arms in the lateral direction is greater than the distance between two adjacent contact arms in the same group.

[0012] As a further improvement of this utility model, each of the terminal slots is provided with at least one partition wall, which separates two adjacent sets of contact arms in the lateral direction.

[0013] As a further improvement of this utility model, the insulating body has a transverse wall extending in the transverse direction, which divides the terminal slot into two groups corresponding to the upper row of terminal assemblies and the lower row of terminal assemblies respectively. Each of the partition walls extends in the front-back direction and has a connecting portion connected to the transverse wall.

[0014] As a further improvement of this utility model, in the same terminal assembly, at least a portion of the contact arm of the second terminal extends into the gap between two adjacent contact arms of the first terminal.

[0015] The beneficial effects of this utility model are as follows: By optimizing the ratio of the material thickness of the power terminal to the height H of the mating part, the power connector of this utility model achieves a ratio of 4.44% to 9.85%, thereby improving the current carrying capacity while ensuring mechanical strength and structural stability to meet the miniaturization requirements of high power density applications. Attached Figure Description

[0016] Figure 1 This is a three-dimensional assembly diagram of the power connector of this utility model.

[0017] Figure 2 yes Figure 1 Another view of the power connector shown.

[0018] Figure 3 yes Figure 1 An exploded 3D view of the power connector shown.

[0019] Figure 4 yes Figure 3 An exploded view of a terminal assembly of the power connector shown.

[0020] Figure 5 yes Figure 4 A further exploded view of the terminal assembly shown.

[0021] Figure 6 yes Figure 3 A top view of one terminal assembly of the power connector shown.

[0022] Figure 7 yes Figure 3 Top view of the first terminal in the upper terminal assembly of the power connector shown.

[0023] Figure 8 yes Figure 3 A partial enlarged view of the insulating body of the power connector shown.

[0024] Figure 9 yes Figure 3 A cross-sectional view of the insulating body of the power connector shown.

[0025] Figures 10 to 12 yes Figure 1 The power connector shown is a cross-sectional view. Detailed Implementation

[0026] The present invention will now be described in detail with reference to the embodiments shown in the accompanying drawings. However, these embodiments do not limit the present invention, and any structural, methodological, or functional modifications made by those skilled in the art based on these embodiments are included within the protection scope of the present invention.

[0027] Please refer to Figures 1 to 12 The present invention is shown as a preferred embodiment of the power connector 100. In some embodiments of the present invention, the power connector 100 includes an insulating body 1 and a plurality of power terminals 2 disposed within the insulating body 1.

[0028] For ease of explanation, when describing the power connector 100 below, we will consider the mating direction of the power connector 100 as the front-back direction, one direction perpendicular to the front-back direction as the lateral direction, and another direction perpendicular to the front-back direction as the height direction.

[0029] Please refer to Figures 1 to 3 As shown, the insulating body 1 has a mating portion 10 with a mating cavity 101 and a terminal slot 103 communicating with the mating cavity 101. The mating portion 10 is located on the front side of the insulating body 1. The terminal slot 103 extends in the front-rear direction, and the power terminal 2 is fixed in the corresponding terminal slot 103 of the insulating body 1.

[0030] like Figure 8 and Figure 9 As shown, in this utility model, each terminal slot 103 is provided with at least one partition wall 102 to divide each terminal slot 103 into at least two terminal channels 1031. In the embodiment shown in this application, each terminal slot 103 is provided with two partition walls 102 to divide one terminal slot 103 into three terminal channels 1031. In other embodiments, each terminal slot 103 may also be divided into two, four or more terminal channels 1031 by partition walls 102.

[0031] The insulating body 1 has a transverse wall 104 extending in the transverse direction, which divides the terminal slot 103 into upper and lower groups. Each of the spacer walls 102 extends in the front-back direction and has a connecting portion 1021 connected to the transverse wall 104.

[0032] Each of the spacers 102 includes a first spacer 1022 located in front of the connecting portion 1021 and a second spacer 1023 located behind the connecting portion 1021. The first spacer 1022 is integrally connected to the top wall 105 or the bottom wall 106 of the insulating body 1.

[0033] Furthermore, the front end of the second spacing portion 1023 is connected to the connecting portion 1021 and has a rearwardly extending cantilever structure. The second spacing portion 1023 has a vertically placed flat plate structure, that is, its width in the lateral direction is smaller than its height in the vertical direction.

[0034] like Figure 9 and Figure 11 As shown, the first spacer 1022 has a guide surface 1024 on the front side and an extension surface 1025 on the rear side. The guide surface 1024 is inclined at an angle to the horizontal plane, and the extension surface 1025 is parallel to the horizontal plane. The extension length of the guide surface 1024 in the front-rear direction is greater than the extension length of the extension surface 1025 in the front-rear direction, so as to achieve a better guiding effect on the front side, thereby adapting to the increase in the width of the base portion 202.

[0035] In the height direction, the distance between the extension surface 1025 and the transverse wall 104 is smaller than the distance between the corresponding second interval 1023 and the transverse wall 104, thereby increasing the arc creep distance at the corresponding position of the contact arm 201 of the power terminal and ensuring the safety and reliability of the electrical connection.

[0036] The rear end face of the first spacing portion 1022 is located between the front end face and the rear end face of the connecting portion 1021 in the front-back direction. The second spacing portion 1023 located on the upper side extends rearward to be flush with the top wall 105. The rear end face of the transverse wall 104 is flush with the rear end face of the top wall 105. The second spacing portion 1023 located on the lower side extends rearward to be flush with the bottom wall 106.

[0037] The transverse wall 104 has a notch 1041 located on its lower side. The notch 1041 is recessed from the rear end of the transverse wall 104 and is located on the rear side of the bottom wall 106 in the front-rear direction.

[0038] Please refer to Figures 1 to 7 and Figures 10 to 12 As shown, each power terminal 2 has a base portion 202 fixed within the terminal slot 103 and a contact arm 201 extending forward from the base portion 202 to protrude into the mating cavity 101. The front section of the contact arm 201 is bent to be elastic. In this example, the base portion 202 has an interference portion 2021 fixed to the insulating body 1, and the interference portion 2021 is disposed on both sides of the base portion 202 in the lateral direction.

[0039] like Figure 12 As shown, the ratio of the material thickness t of the power terminal 2 to the height H of the mating portion 10 ranges from 4.44% to 9.85%. In this invention, the thickness of the base portion 202 of the power terminal 2 in the height direction is the material thickness t of the power terminal 2. By controlling the ratio t / H of the material thickness t of the power terminal to the height H of the mating portion 10 within the range of 4.44% to 9.85%, this invention ensures a balance between the current carrying capacity and mechanical strength of the power terminal 2, making the power connector 100 suitable for general high-power applications, improving overall reliability and durability, and ensuring optimal performance.

[0040] Furthermore, the ratio of the material thickness of the power terminal 2 to the height of the mating portion 10 is in the range of 4.71% to 9.14%. Thus, by controlling the range of t / H to 4.71% to 9.14%, the structural rigidity of the power terminal 2 can be further optimized, the mechanical strength can be improved, and better current transmission performance can be maintained.

[0041] Furthermore, the ratio of the material thickness t of the power terminal 2 to the height H of the mating portion 10 is in the range of 5.00% to 8.53%. Thus, by controlling the range of t / H to 5.00% to 8.53%, the holding force and insertion / removal force of the power terminal 2 can be optimized while taking into account high power transmission capability, making it suitable for industrial and server power supply applications with high reliability requirements.

[0042] More preferably, the ratio of the material thickness t of the power terminal 2 to the height H of the mating portion 10 is in the range of 5.33% to 8.00%. Thus, by controlling the range of t / H to 5.33% to 8.00%, the optimal mechanical and electrical performance of the power terminal 2 in high power density applications can be ensured, further reducing contact resistance and heat generation, and conforming to the trend of industrial miniaturization, making it optimally suitable for high-density power modules or high-performance computing (HPC) devices.

[0043] In addition, such as Figure 4 and Figure 10 As shown, the width W1 of the base portion 202 of each power terminal 2 in the lateral direction is not less than 10% of the width W2 of the insulating body 1 in the lateral direction. By making the width of the base portion 202 of the power terminal 2 in the lateral direction wider, the conductor area is increased, thereby effectively increasing the conductive path of the terminal assembly and suppressing the heating of the power terminal.

[0044] Furthermore, the width W1 of the base portion 202 of the first and second terminals 21 and 22 in the lateral direction is not less than 20% of the width W2 of the insulating body 1 in the lateral direction, thereby increasing the cross-sectional area of ​​the power terminal, reducing resistance, reducing heat generation, and effectively improving the current carrying capacity of the power terminal.

[0045] Furthermore, in a preferred embodiment of this utility model, the width W1 of the base portion 202 of each power terminal 2 in the lateral direction is not less than 30% of the width W2 of the insulating body 1 in the lateral direction. By maximizing the width of the power terminal 2 in the lateral direction, the conductive path is increased, effectively suppressing the overheating of the power terminal.

[0046] In this embodiment, the contact arms 201 of the power terminals 2 are arranged in a row along the transverse direction of the insulating body 1. The power terminals 2 corresponding to the same row of contact arms 201 are formed with at least one terminal assembly. Each terminal assembly includes at least two power terminals 2, and the base portions 202 of the two power terminals 2 are arranged in the height direction of the insulating body 1.

[0047] Specifically, the terminal assembly includes an upper row terminal assembly 2a and a lower row terminal assembly 2b with contact arms 201 arranged oppositely in the height direction. The upper row terminal assembly 2a and the lower row terminal assembly 2b arranged oppositely in the height direction form a power terminal pair. The transverse wall 104 divides the terminal slot 103 into two groups corresponding to the upper row terminal assembly 2a and the lower row terminal assembly 2b respectively.

[0048] As shown in Figures 3 to 6 , the contact arms 201 of each terminal assembly are arranged in at least two groups side by side in the transverse direction. As shown in Figure 6 , each group of contact arms 201 is marked as G in Figure 6 . The spacing between adjacent two groups of contact arms 201 is greater than the spacing between two adjacent contact arms 201 in the same group.

[0049] Each of the upper row terminal assembly 2a and the lower row terminal assembly 2b includes a first terminal 21 and a second terminal 22. Each of the first terminal 21 and the second terminal 22 has a base portion 202 and at least one of the contact arms 201 extending forward from the base portion 202.

[0050] Each of the upper row terminal assembly 2a and the lower row terminal assembly 2b is called a terminal assembly. Each of the first and second terminals 21 and 22 is called a power terminal 2, and each power terminal 2 is integrally in a sheet-like structure extending in the transverse direction. In the present utility model, the base portion 202 is the part with the largest width of each power terminal 2 in the transverse direction.

[0051] In the present utility model, in each terminal assembly, the base portion 202 of the first terminal 21 is arranged close to the transverse wall 104 in the height direction, and the base portion 202 of the second terminal 22 is arranged away from the transverse wall 104 in the height direction.

[0052] In this embodiment, the power terminal 2 further has an extension portion 203 bent and extending from the base portion 202, and the extension portion 203 is located at the rear side of the base portion 202. In addition, the power terminal 2 further has a welding leg 204 extending downward from the extension portion 203, and the extending direction of the welding leg 204 is perpendicular to the extending direction of the contact arm 201.

[0053] In this embodiment, the partition wall 102 separates two adjacent sets of contact arms 201 in the same terminal assembly in the lateral direction. Specifically, the first partition portion 1022 separates two adjacent sets of contact arms 201 in the same terminal assembly in the lateral direction. The notch 1041 is provided at a position corresponding to the bent portion of the second terminal 22 of the lower row terminal assembly 2b, thereby making the assembly process smoother and preventing the bent portion from interfering with the lateral wall 104.

[0054] Please refer to Figure 5 and Figure 7 As shown, the contact arms 201 of each power terminal 2 are arranged in at least two groups side by side in the lateral direction, and each group of contact portions 201 in each power terminal is... Figure 7 In, it is marked as g, such as Figure 7 As shown, the distance D1 between two adjacent sets of contact arms 201 in the lateral direction is greater than the distance D2 between two adjacent contact arms 201 in the same set, so that after the terminal assembly is formed, the contact arms 201 of the first and second terminals 21 and 22 can be arranged into at least two sets and can be cross-arranged to achieve balanced insertion and extraction forces.

[0055] In this embodiment, each power terminal 2 is configured to have a base portion 202 and at least two sets of contact arms 201 extending forward from the front end of the base portion 202, thereby increasing the conductor area of ​​each power terminal 2 in the lateral direction, thereby effectively increasing the conductive path of the terminal assembly and suppressing the overheating of the power terminal.

[0056] In addition, in some embodiments of this utility model, the second terminal 22 is provided with a recessed groove 205, which is formed by recessing backward from the front end of the base portion 202, and the connecting portion 1021 is inserted into the groove 205.

[0057] In the embodiment shown in this utility model, the first terminal 21 also has a groove 205 formed by recessing from the front end of its base portion 202 to the rear, and the first spacer portion 1022 is inserted rearward into the groove 205 of the first terminal 21 to further limit the power terminal in the lateral direction.

[0058] The second spacer 1023 is inserted rearward into the space between the base portions 202 of the corresponding first and second terminals 21 and 22 in the height direction, so that the base portions 202 are clamped in the height direction by two adjacent of the second spacer 1023, the transverse wall 104, the top wall 105 of the insulating body 1, and the bottom wall 106 of the insulating body 1, thereby further limiting the power terminals in the height direction.

[0059] In the upper terminal assembly 2a, the base portion 202 of the first terminal 21 is sandwiched between the top wall 105 of the insulating body 1 and the second spacer portion 1023 in the height direction, and the base portion 202 of the second terminal 22 in the upper terminal assembly 2a is sandwiched between the second spacer portion 1023 and the transverse wall 104 in the height direction.

[0060] In the lower terminal assembly 2b, the base portion 202 of the first terminal 21 is sandwiched between the second spacer portion 1023 and the bottom wall 106 of the insulating body 1 in the height direction, and the base portion 202 of the second terminal 22 in the lower terminal assembly 2b is sandwiched between the second spacer portion 1023 and the transverse wall 104 in the height direction.

[0061] Furthermore, in this invention, the docking cavity 101 is a space for accommodating the contact arm 201 of the power terminal 2, such as... Figure 10 As shown, the width W1 of the base portion 202 of the first and second terminals 21 and 22 in the lateral direction is not less than 15% of the width W3 of the mating cavity 101 in the lateral direction.

[0062] Thus, by setting the width W1 of the base portion 202 of the power terminal 2 in the lateral direction to be no less than 15% of the width W3 of the mating cavity 101 in the lateral direction, the power connector 100 of this utility model can provide a single power terminal as wide as possible within the limited width range of the mating cavity 101, thereby increasing the conductive path and suppressing the heating of the power terminal.

[0063] Furthermore, the width W1 of the base portion 202 of the first and second terminals 21 and 22 in the lateral direction is not less than 30% of the width W3 of the mating cavity 101 in the lateral direction, thereby providing a wider range of single power terminals within the limited width range of the mating cavity 101, and thus more effectively improving the current carrying capacity of the power terminals.

[0064] Furthermore, the width W1 of the base portion 202 of the first and second terminals 21 and 22 in the lateral direction is not less than 45% of the width W3 of the mating cavity 101 in the lateral direction, so that the single power terminal can be arranged as wide as possible within the limited width range of the mating cavity 101, thereby more effectively improving the current carrying capacity of the power terminal.

[0065] In this embodiment, in the same terminal assembly, at least a portion of the contact arm 201 of the second terminal 22 extends into the gap between two adjacent contact arms 201 of the first terminal 21.

[0066] Specifically, such as Figure 3 and Figure 4As shown, in some embodiments, the contact arms 201 of the first and second terminals 21 and 22 are arranged alternately in the same terminal assembly; in other embodiments, the contact arms 201 of the second terminal 22 may be divided into two groups spaced apart in the lateral direction, and the contact arms 201 of the first terminal 21 may be arranged between the two groups of contact arms 201 of the second terminal 22 in the lateral direction; in other embodiments, in the same terminal assembly, the contact arms 201 of the first terminal 21 may be arranged adjacent to each other, and the contact arms 201 of the second terminal 22 may be arranged adjacent to each other, with the contact arms 201 of the first terminal 21 located on one side of the contact arms 201 of the second terminal 22 in the lateral direction.

[0067] In some embodiments of this utility model, the insulating body 1 also has a plurality of heat dissipation channels 107 formed on its top wall 105. The heat dissipation channels 107 penetrate the top wall 105 along the height direction to dissipate the heat generated by the power terminal 2 when it is powered on as quickly as possible.

[0068] In this utility model, the power connector 100 also has a plurality of signal terminals 3 located on one side of the power terminal 2 in the lateral direction, and each signal terminal 3 has a mating arm 31 and a soldering part 32.

[0069] In addition, in a modified embodiment of the power connector 100 of this utility model, similar to the aforementioned embodiment, the power connector 100 includes an insulating body 1 and at least one power terminal pair. The insulating body 1 has a terminal groove 103 extending in the front-back direction. The power terminal pair is fixed in the terminal groove 103 of the insulating body 1. Each power terminal pair includes an upper row terminal assembly 2a and a lower row terminal assembly 2b arranged opposite each other in the height direction with contact arms 201. Each of the upper row terminal assembly 2a and the lower row terminal assembly 2b includes a first terminal 21 and a second terminal 22. Each of the first terminal 21 and the second terminal 22 has a base portion 202 and at least one contact arm 201 extending forward from the base portion 202.

[0070] The difference is that in this modified embodiment, in the same terminal assembly 2a, 2b, each of the first and second terminals 21, 22 has only one set of contact arms 201, that is, each contact arm 201 is evenly arranged in the lateral direction, that is, in the lateral direction, the distance between two adjacent contact arms 201 is equal; instead of having at least two sets of contact arms 201 as in the first embodiment of the first and second terminals 21, 22.

[0071] In summary, the power connector 100 of this utility model optimizes the ratio (t / H) of the material thickness t of the power terminal 2 to the height H of the mating portion 10, so that the ratio ranges from 4.44% to 9.85%. This improves the current carrying capacity while ensuring mechanical strength and structural stability, so as to meet the miniaturization requirements of high power density applications.

[0072] It should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This way of describing the specification is only for clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

[0073] The above embodiments are only used to illustrate the technical solutions of this application and are not intended to limit it. Although this application has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of this application without departing from the spirit and scope of the technical solutions of this application.

Claims

1. A power connector comprising an insulating body and a plurality of power terminals disposed in the insulating body, the insulating body having a mating portion formed with a mating cavity and a terminal slot communicating with the mating cavity, each of the power terminals having a base portion fixed in the terminal slot and a contact arm extending forwardly from the base portion to protrude into the mating cavity; characterized in that: The ratio of the material thickness of the power terminal to the height of the docking portion is in the range of 4.44% to 9.85%.

2. The power connector of claim 1, wherein: The ratio of the material thickness of the power terminal to the height of the docking portion is in the range of 4.71% to 9.14%.

3. The power connector of claim 1, wherein: The ratio of the material thickness of the power terminal to the height of the docking portion is in the range of 5.00% to 8.53%.

4. The power connector of claim 1, wherein: The ratio of the material thickness of the power terminal to the height of the docking portion is in the range of 5.33% to 8.00%.

5. The power connector of any one of claims 1 to 4, wherein: The contact arms of the power terminal are arranged in rows along the transverse direction of the insulating body, and the power terminals corresponding to the contact arms in the same row form at least one terminal assembly, each terminal assembly including at least two pieces of power terminals, and the base portions of the two pieces of power terminals are arranged in the height direction of the insulating body.

6. The power connector of claim 5, wherein: The terminal assembly includes an upper row of terminal assemblies and a lower row of terminal assemblies, which are oppositely arranged in the height direction of the contact arms, and the contact arms of each terminal assembly are arranged in at least two groups in the transverse direction, and the spacing between the two adjacent groups of contact arms is greater than the spacing between the two adjacent contact arms in the same group.

7. The power connector of claim 6, wherein: The contact arms of each power terminal are arranged in at least two groups in the transverse direction, and the spacing between the two adjacent groups of contact arms in the transverse direction is greater than the spacing between the two adjacent contact arms in the same group.

8. The power connector of claim 6, wherein: Each of the terminal grooves is provided with at least one partition wall, which separates the two adjacent groups of contact arms in the transverse direction.

9. The power connector of claim 8, wherein: The insulating body has a transverse wall extending in the transverse direction, which separates the terminal grooves into two groups corresponding to the upper row of terminal assemblies and the lower row of terminal assemblies, respectively, and each of the partition walls extends in the front-rear direction and has a connecting portion connected to the transverse wall.

10. The power connector of claim 5, wherein: Each of the terminal assemblies includes a first terminal and a second terminal, and in the same terminal assembly, at least part of the contact arms of the second terminal extend into the gap between the two adjacent contact arms of the first terminal.

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