Novel connector high-voltage terminal with integrated structure and connector using same

Abstract

The utility model discloses a novel connector high pressure terminal of integral structure and the connector of applying it. The connector has novel connector high pressure terminal of integral structure, and high pressure terminal includes: conductive needle, connecting piece and insulating plastic package base body, the conductive needle is the stepped annular of thin wall metal pipe body multistage punch stretch draw -form, and the upper end surface of pipe body is the lead plate of punch bending formation, and the lead plate center is equipped with the upper link hole, and the lower end of pipe body is the small diameter lead ring of stretch formation, the connecting piece upper end surface center has internal thread, and the connecting piece upper end fixed sleeve connects the upper link hole and is located in the conductive needle inner chamber, and forms the intermediate piece, and the plastic package base body and intermediate piece integrative injection molding form high pressure terminal. The utility model has the effect of reducing cost, improving product quality and improving production efficiency.

Description

Technical Field

[0001] This utility model relates to the field of high-voltage electrical connections, and in particular to a novel integrated connector high-voltage terminal and a connector using the same. Background Technology

[0002] In the field of new energy equipment, especially in scenarios such as battery swapping systems for new energy electric vehicles and high-voltage connections for energy storage devices, high-voltage terminals of connectors suitable for high-voltage, high-current fast charging are commonly used. Currently, high-voltage terminals mainly adopt metal rod machining technology and assembly structure. The drawbacks are as follows: First, high material and process costs: rod machining leads to serious waste of raw materials, low processing efficiency, and large investment in precision equipment; Second, complex structure and poor reliability: because it needs to meet the requirements of high conductivity, corrosion resistance, and mechanical strength, the current structure involves the assembly of multiple parts, and multiple sealing rings or adhesives are required to achieve insulation and protection. Relying on manual labor or special tooling, it is easy to introduce tolerance accumulation, resulting in unstable contact resistance and easy degradation of sealing performance after long-term use; Third, long production cycle: machining and multiple assembly processes need to be completed step by step, making it difficult to achieve large-scale and efficient production. Utility Model Content

[0003] To address one or more of the aforementioned problems, this utility model provides a novel integrated connector high-voltage terminal.

[0004] According to one aspect of the present invention, the novel integrated connector high-voltage terminal includes: a conductive pin, a connector, and an insulating encapsulation substrate;

[0005] The conductive needle is a stepped ring formed by multi-stage stamping and stretching of a thin-walled cylindrical tube of conductive metal. The upper end face of the tube is a connecting plate formed by stamping and bending. The center of the connecting plate is provided with an upper connecting hole. The lower end of the tube is a small-diameter connecting ring formed by stretching.

[0006] The upper end face of the connector has an internal thread at the center. The upper end of the connector is fixedly sleeved in the upper connecting hole and the lower end is located in the inner cavity of the conductive needle, forming an intermediate part.

[0007] The high-voltage terminal is formed by integral injection molding of the encapsulated substrate and intermediate component. The inner base post of the encapsulated substrate is integrally connected to the inner wall of the conductive needle. The upper shaft hole of the inner base post is integrally wrapped around the inner end of the connector. The insulating anti-touch finger end of the lower end of the inner base post is attached to the front end face of the lead ring. The outer connector of the encapsulated substrate is integrally connected to the outer wall of the conductive needle. The outer protective ring at the lower end of the outer connector is coaxially sleeved on the outer end of the lead ring, and an annular insertion groove is formed between the two.

[0008] The advantages of this new integrated connector high-voltage terminal structure are as follows: First, reduced costs: replacing the rod-shaped machined contact terminals with conductive pins 1 made of stamped and stretched tubular material reduces material waste and processing costs. Simultaneously, replacing the assembly structure with a plastic-encapsulated structure reduces assembly steps and labor costs. Second, improved product quality: the application of stamping and stretching technology and plastic-encapsulation technology ensures the dimensional accuracy and surface quality of the contact terminals, improving product reliability and stability. Third, increased production efficiency: the optimized process flow and the application of automated production equipment significantly improve production efficiency and shorten the production cycle.

[0009] In some embodiments, the tube body is provided with radial glue passage holes symmetrically at its center, and the glue passage holes are integrally injection molded to connect the bonding arm of the encapsulated substrate. The two ends of the bonding arm are integrally connected to the inner base column and the outer connector.

[0010] In some embodiments, a hollow, rotating surface transition body is formed between the tube body and the lead ring. The rotation axis of the rotating surface transition body is the central axis of the tube body, and its latitudinal circle radius gradually decreases from top to bottom.

[0011] In some embodiments, the revolution surface transition body includes a frustum transition body formed by rotating an upper oblique line and an arcuate surface transition body formed by rotating a lower arc.

[0012] The upper end of the rotating curved transition body and the tube body, as well as the tube body and the guide plate, are provided with rounded corners.

[0013] In some embodiments, the upper end face of the column body of the connector is provided with an internal thread, the upper end of the circumferential wall of the column body is provided with a first positioning shoulder, the outer circumferential wall of the column body is provided with a circumferential array of locking teeth, the locking teeth are integrally connected to the upper surface of the positioning shoulder, when the column body is riveted to the upper connecting hole, the locking teeth are pressed into the lower wall of the guide plate and the first positioning shoulder is in contact with the lower wall of the guide plate.

[0014] Alternatively, the connecting part may be a nut.

[0015] In some embodiments, an outer shell is also included. A positioning end ring is provided in the middle of the outer peripheral wall of the outer connecting seat. The two ends of the positioning end ring are symmetrically and integrally connected to the upper outwardly inclined elastic wing plates. The lower wall of the outer protective ring is connected to the lower end tube of the outer shell with a bushing of equal diameter. The positioning end ring is installed in the upper positioning groove of the outer shell with equal diameter. The elastic wing plates are interference-fitted and connected to the two side slots of the outer shell.

[0016] In some embodiments, a limiting end block is provided at the upper end of the card slot, and a guide slope is provided on the inner side of the limiting end block.

[0017] In some embodiments, the upper positioning groove is an anti-rotation groove with four corner facets, and the positioning end ring is an anti-rotation plate with four corner facets;

[0018] Alternatively, a sealing groove may be provided at the lower end of the upper positioning groove, and a sealing ring in the sealing groove may be used to seal the connection between the outer shell and the outer connecting seat.

[0019] In some implementations, the conductive needle is a copper alloy T2 tubing;

[0020] The molding substrate is PA66 high-temperature resistant engineering plastic.

[0021] According to another aspect of this utility model, a connector includes a housing and a bushing connected within the housing to any of the aforementioned high-voltage terminals. The advantages of this connector are: this design can reduce costs, improve product quality and reliability, and increase production efficiency. Attached Figure Description

[0022] Figure 1 This is a three-dimensional schematic diagram of the high-voltage terminal of the connector with a novel integrated structure according to one embodiment of the present invention.

[0023] Figure 2 for Figure 1 A cross-sectional schematic diagram of the high-voltage terminal of the novel integrated connector structure shown.

[0024] Figure 3 for Figure 2 A 3D schematic diagram of the middleware shown;

[0025] Figure 4 for Figure 3 A three-dimensional schematic diagram of the connector shown;

[0026] Figure 5 for Figure 2 A three-dimensional schematic diagram of the molding substrate shown (I);

[0027] Figure 6 for Figure 2 A three-dimensional schematic diagram (II) of the encapsulated substrate is shown;

[0028] Figure 7 for Figure 1 A three-dimensional schematic diagram of the outer shell shown;

[0029] High-voltage terminal 00, intermediate component 01;

[0030] Conductive needle 1, tube body 10, connecting plate 11, upper connecting hole 12, connecting ring 13, glue through hole 14, rotating curved surface transition body 15, rounded corner 16;

[0031] Connector 2, column body 20, internal thread 21, first positioning shoulder 22, locking tooth 23;

[0032] Plastic-encapsulated substrate 3, outer connector 30, positioning end ring 301, elastic wing plate 302, reinforcing prism 303, inner base column 31, upper shaft hole 311, insulating anti-touch finger end 312, second positioning shaft shoulder 313, outer protective ring 32, insertion groove 33, connecting arm 34.

[0033] Outer shell 4, lower end tube 41, upper positioning groove 42, slot 43, guide slope 44, limiting end block 45, sealing groove 46. Detailed Implementation

[0034] The present invention will now be described in further detail with reference to the accompanying drawings. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to the directions in the accompanying drawings, while the terms "inner" and "outer" refer to the directions toward or away from the geometric center of a specific component, respectively.

[0035] Figures 1 to 7 The diagram schematically illustrates a novel integrated connector high-voltage terminal according to one embodiment of the present invention. As shown, the novel integrated connector high-voltage terminal includes: a conductive pin 1, a connector 2, and an insulating encapsulation substrate 3;

[0036] The conductive pin 1 is a stepped ring directly formed by stamping and stretching a thin-walled cylindrical tube made of conductive metal through more than 10 stages. Its advantages are: stamping and stretching processes the tube material into the conductive pin 1; the work hardening effect of stamping and stretching improves the dimensional stability of the tube material, ensuring the positioning accuracy of the plastic seal and reducing subsequent adjustment processes. The conductive pin 1 is preferably made of copper alloy T2 tubing, which has good conductivity, mechanical strength, and corrosion resistance.

[0037] The upper end face of the tube body 10 is a guide plate 11 formed by stamping and bending, and the center of the guide plate 11 is provided with an upper connection hole 12. The lower end of the tube body 10 is a small diameter guide ring 13 formed by stretching.

[0038] The upper end face of the connector 2 has an internal thread 21 at its center. The upper end of the connector 2 is fixedly sleeved in the upper connecting hole 12 and the lower end is located in the inner cavity of the conductive needle 1, forming an intermediate part 01. The connector 2 can be fixedly connected to the conductive copper busbar by screws.

[0039] The high-voltage terminal 00 is formed by integral injection molding of the molding substrate 3 and the intermediate component 01. The advantages are: an integrated molding process that integrates insulation, sealing, and fixing functions in a single injection molding, eliminating the need for assembly of multiple components such as sealing rings, and reducing accumulated interface tolerances. The molding substrate 3 is preferably PA66 high-temperature resistant engineering plastic.

[0040] The inner base post 31 of the encapsulated substrate 3 is integrally connected to the inner wall of the conductive needle 1. The upper shaft hole 311 of the inner base post 31 integrally wraps the inner end of the connector 2. The insulating anti-touch finger end 312 of the lower end of the inner base post 31 is attached to the front end face of the lead ring 13. The outer connector 30 of the encapsulated substrate 3 is integrally connected to the outer wall of the conductive needle 1. The outer protective ring 32 at the lower end of the outer connector 30 is coaxially sleeved on the outer end of the lead ring 13, and the two form an annular insertion groove 33. The insertion groove 33 can be connected to the power tube.

[0041] The high-voltage terminals of this new integrated connector can be manufactured through a synchronous stamping-molding production line. The mold integrates stamping, stretching and injection stations. After stamping, the tube material is directly transferred to the molding die, reducing the process time. The work hardening effect of stamping and stretching improves the dimensional stability of the tube material, ensuring the positioning accuracy of molding and reducing the need for subsequent adjustment processes.

[0042] The advantages of this new integrated connector high-voltage terminal structure are as follows: First, reduced costs: replacing the rod-shaped machined contact terminals with conductive pins 1 made of stamped and stretched tubular material reduces material waste and processing costs. Simultaneously, replacing the assembly structure with a plastic-encapsulated structure reduces assembly steps and labor costs. Second, improved product quality: the application of stamping and stretching technology and plastic-encapsulation technology ensures the dimensional accuracy and surface quality of the contact terminals, improving product reliability and stability. Third, increased production efficiency: the optimized process flow and the application of automated production equipment significantly improve production efficiency and shorten the production cycle.

[0043] Furthermore, the tube body 10 is centrally symmetrically provided with radially through-holes 14 for adhesive application. An integrally injection-molded connecting arm 34 to the molding substrate 3 is formed within the adhesive application hole 14. Both ends of the connecting arm 34 are integrally connected to the inner base post 31 and the outer connector 30. The beneficial effects are: the adhesive application hole 14 optimizes the flow of adhesive during injection molding, and the formation of the connecting arm 34 integrates the inner base post 31 and the outer connector 30 into a single structure, resulting in higher overall structural strength and achieving better integrated insulation, sealing, and mechanical fixing functions.

[0044] Furthermore, a hollow, rotating surface transition body 15 is formed between the tube body 10 and the connecting ring 13. The upper end of the rotating surface transition body 15 is a large-diameter ring, and the lower end is a small-diameter ring. Its rotation axis is the central axis of the tube body 10, and its radius of curvature gradually decreases from top to bottom. Preferably, the generatrix of the rotating surface transition body 15 includes a connected upper oblique line and a lower arc line. The upper oblique line rotates to form a frustum transition body, and the lower arc line rotates to form an arc-shaped curved surface transition body. The beneficial effects are: the rotating surface transition body 15 makes the overall structure of the conductive needle 1 more reasonable, ensures uniform load-bearing without breakage during tension, and results in a high yield rate.

[0045] Preferably, fillets 16 are provided between the upper end of the rotary curved transition body 15 and the tube body 10, and between the tube body 10 and the guide plate 11. The beneficial effect is that this setting reduces stress load and eliminates abnormal stress.

[0046] Furthermore, the upper end face of the column body 20 of the connector 2 is provided with an internal thread 21, and the upper end of the circumferential wall of the column body 20 is provided with a first positioning shoulder 22. The column body 20 is riveted to the upper connecting hole 12 and the first positioning shoulder 22 is attached to the lower wall of the guide plate 11.

[0047] Preferably, the outer peripheral wall of the column body 20 is provided with a circumferential array of locking teeth 23, which are integrally connected to the upper surface of the positioning shoulder 22 and pressed into the lower wall of the guide plate 11. The beneficial effect is that this setting can improve the connection tightness and maintain good mechanical strength.

[0048] Preferably, the connecting part 2 is a nut.

[0049] Furthermore, a second positioning shoulder 313 is formed at the upper end of the insulated anti-touch fingertip 312, and the second positioning shoulder 313 fits against the lower end face of the connecting tube body 10. The beneficial effects are: this design improves product precision and enhances the anti-touch function.

[0050] Furthermore, it also includes an outer shell 4, with a positioning end ring 301 located in the middle of the outer peripheral wall of the outer connecting seat 30. The two ends of the positioning end ring 301 are symmetrically and integrally connected to elastic wing plates 302 that slope outwards at the upper end. A bushing of equal diameter on the lower wall of the outer protective ring 32 connects to the lower end tube 41 of the outer shell 4. The positioning end ring 301 is installed in the upper positioning groove 42 of the outer shell 4 with equal diameter. The elastic wing plates 302 are interference-fitted and connected to the two side slots 43 of the outer shell 4. Its advantages are: this design ensures good installation performance and quick disassembly.

[0051] Preferably, the inner wall of the elastic wing plate 302 is provided with a plurality of reinforcing prisms 303; the beneficial effect of this arrangement is that it improves the structural strength.

[0052] Preferably, the upper end of the slot 43 is provided with a limiting end block 45, and the inner side of the limiting end block 45 is provided with a guide slope 44; the beneficial effect is that this setting improves the installation accuracy and the ease of installation.

[0053] Preferably, the upper positioning groove 42 is an anti-rotation groove with four corner cut surfaces, and the positioning end ring 301 is an anti-rotation plate with four corner cut surfaces; its beneficial effect is that the structure has high installation accuracy.

[0054] Preferably, the lower end of the upper positioning groove 42 is also provided with a sealing groove 46, and the sealing ring in the sealing groove 46 seals the outer shell 4 and the outer connector 30. Its beneficial effect is that this arrangement improves the terminal's resistance to foreign object interference.

[0055] This utility model also provides a connector, including a housing and a plurality of high-voltage terminals 00 as described above, with bushings connected within the housing. The advantages of this connector are: it can reduce costs, improve product quality and reliability, and increase production efficiency.

[0056] The above descriptions are merely some embodiments of this utility model. For those skilled in the art, various modifications and improvements can be made without departing from the inventive concept of this utility model, and all such modifications and improvements fall within the protection scope of this utility model.

Claims

1. A novel integrated connector high-voltage terminal, characterized in that, Includes: conductive pin (1), connector (2), and insulating encapsulation substrate (3); The conductive needle (1) is a stepped ring formed by multi-stage stamping and stretching of a thin-walled conductive metal tube (10). The upper end face of the tube (10) is a connecting plate (11) formed by stamping and bending. The center of the connecting plate (11) is provided with an upper connecting hole (12). The lower end of the tube (10) is a small-diameter connecting ring (13) formed by stretching. The upper end face of the connector (2) has an internal thread (21) at the center. The upper end of the connector (2) is fixedly sleeved in the upper connecting hole (12) and the lower end is located in the inner cavity of the conductive needle (1), forming an intermediate part (01). The encapsulated substrate (3) and the intermediate component (01) are integrally injection molded to form a high-voltage terminal (00). The inner base post (31) of the encapsulated substrate (3) is integrally connected to the inner wall of the conductive needle (1). The upper shaft hole (311) of the inner base post (31) is integrally wrapped around the inner end of the connector (2). The insulating anti-touch finger end (312) at the lower end of the inner base post (31) is attached to the front end face of the guide ring (13). The outer connector (30) of the encapsulated substrate (3) is integrally connected to the outer wall of the conductive needle (1). The outer protective ring (32) at the lower end of the outer connector (30) is coaxially sleeved on the outer end of the guide ring (13) and an annular insertion groove (33) is formed between the two.

2. The novel integrated connector high-voltage terminal according to claim 1, characterized in that, The tube body (10) is provided with radial glue passage holes (14) symmetrically arranged at the center. The glue passage holes (14) are integrally injection molded to the connecting arm (34) of the sealing substrate (3). The two ends of the connecting arm (34) are integrally connected to the inner base column (31) and the outer connecting seat (30).

3. The novel integrated connector high-voltage terminal according to claim 1, characterized in that, A hollow rotating surface transition body (15) is formed between the tube body (10) and the connecting ring (13). The rotation axis of the rotating surface transition body (15) is the central axis of the tube body (10), and its latitudinal circle family radius gradually decreases from top to bottom.

4. The novel integrated connector high-voltage terminal according to claim 3, characterized in that, The rotating surface transition body (15) includes a frustum transition body formed by rotating an upper oblique line and an arc-shaped surface transition body formed by rotating a lower arc. Alternatively, rounded corners (16) may be provided between the upper end of the rotating curved transition body (15) and the tube body (10), and between the tube body (10) and the guide plate (11).

5. The novel integrated connector high-voltage terminal according to claim 1, characterized in that, The upper end face of the column body (20) of the connector (2) is provided with an internal thread (21), the upper end of the circumferential wall of the column body (20) is provided with a first positioning shoulder (22), the outer circumferential wall of the column body (20) is provided with a locking tooth (23) in a circumferential array, the locking tooth (23) is integrally connected to the upper surface of the positioning shoulder (22), when the column body (20) is riveted to the upper connecting hole (12), the locking tooth (23) is pressed into the lower wall of the guide plate (11) and the first positioning shoulder (22) fits against the lower wall of the guide plate (11); Alternatively, the connecting part (2) may be a nut.

6. The novel integrated connector high-voltage terminal according to claim 1, characterized in that, It also includes an outer shell (4), and the outer connecting seat (30) has a positioning end ring (301) in the middle of its outer peripheral wall. The two ends of the positioning end ring (301) are symmetrically and integrally connected to the upper outwardly inclined elastic wing plate (302). The lower wall of the outer protective ring (32) is connected to the lower end tube (41) of the outer shell (4) by a bushing of equal diameter. The positioning end ring (301) is installed in the upper positioning groove (42) of the outer shell (4) with equal diameter. The elastic wing plate (302) is interference-fitted and connected to the two side slots (43) of the outer shell (4).

7. The novel integrated connector high-voltage terminal according to claim 6, characterized in that, The upper end of the slot (43) is provided with a limiting end block (45), and the inner side of the limiting end block (45) is provided with a guide slope (44).

8. The novel integrated connector high-voltage terminal according to claim 6, characterized in that, The upper positioning groove (42) is an anti-rotation groove with four corner cut surfaces, and the positioning end ring (301) is an anti-rotation plate with four corner cut surfaces; Alternatively, a sealing groove (46) may be provided at the lower end of the upper positioning groove (42), and the sealing ring in the sealing groove (46) seals and connects the outer shell (4) and the outer connecting seat (30).

9. The novel integrated connector high-voltage terminal according to any one of claims 1 to 8, characterized in that, The conductive needle (1) is a copper alloy T2 tube; The encapsulation substrate (3) is PA66 high-temperature resistant engineering plastic.

10. A connector, characterized in that, Includes a housing and a plurality of high-voltage terminals (00) as described in claim 9, which are connected within the housing by bushings.

Images