An electrical connector device with dual over-temperature protection

Abstract

This utility model relates to an electrical connector device with dual overheat protection, comprising an insulating shell and two external PTC thermal protection wiring mechanisms. Each external PTC thermal protection wiring mechanism includes a base, a heat-induced power-off component, a first terminal and a second terminal, and a PTC chip disposed outside the base. The PTC chip is electrically connected to the first terminal and the second terminal, respectively. By placing the PTC chip outside the base, the size of the PTC chip is not limited by the base, allowing the use of larger PTC chips with sufficiently high resistance values ​​to intercept large currents and prevent current from passing through the PTC chip, thus avoiding equipment damage or safety accidents. Simultaneously, it eliminates the need to embed the PTC chip in the base, allowing for a more compact base design and reduced base size. This enables the electrical connector device to accommodate large PTC chips while maintaining an overall compact size, making it compatible with various electrical devices.

Description

Technical Field

[0001] This utility model relates to the field of electrical connector technology, and in particular to an electrical connector device with dual overheat protection. Background Technology

[0002] Currently, electrical connectors or plugs often incorporate a built-in thermal protector to provide overload and overheat protection, ensuring that the device will not operate under abnormal conditions, thereby preventing equipment damage or safety accidents. Among existing electrical connectors or plugs, the applicant previously filed a patent application with the China National Intellectual Property Administration on March 8, 2023, with patent number 202320417761.1, entitled "A Double-Insurance Safety Plug Device." This solution mainly includes an insulating shell, two thermal protectors housed within the insulating shell, and two pins connected to the two thermal protectors, both of which are PTC thermal protectors. In use, regardless of whether the neutral or live wire overheats, the circuit can be quickly disconnected, providing double protection and high safety. However, in practical applications, this solution still has the following shortcomings:

[0003] First, both thermal protectors are PTC thermal protectors. Existing PTC thermal protectors consist of a traditional thermal protector and a PTC chip embedded within it. The PTC chip is electrically connected to the two terminals of the traditional thermal protector (see Chinese patent application number 201821584049.6, entitled "A Power-Off Reset Temperature Controller"). Using this type of thermal protector with an embedded PTC chip results in an even smaller PTC chip due to the already small size of the thermal protector itself. During manufacturing, holes need to be made in the small thermal protector to embed the PTC chip, which not only complicates the structure of the thermal protector but also increases the difficulty of manufacturing. Furthermore, it increases the difficulty of assembling the PTC chip with the thermal protector.

[0004] Secondly, the use of this type of built-in PTC thermal protector limits the size of the PTC chip, resulting in a very small size and relatively low resistance. This leads to poor overcurrent protection performance. When the current is too large, it will pass directly through the PTC chip, causing the device to be powered on, which in turn causes the device to overheat, be damaged, or even cause a fire.

[0005] Therefore, given the aforementioned shortcomings of existing electrical connectors or plugs with dual overheat protection, it is essential to further improve their structure in order to better meet people's application needs. Utility Model Content

[0006] The purpose of this invention is to solve the aforementioned problems and shortcomings by providing an electrical connector device with dual overheat protection. This device places the PTC chip outside the base, freeing the PTC chip from the limitations of the base size. This allows for the use of larger PTC chips with sufficiently high resistance values ​​to intercept large currents, preventing current from passing through the PTC chip and avoiding equipment damage or safety accidents. Simultaneously, it eliminates the need to embed the PTC chip in the base, allowing for a more compact base design and reduced overall size. This enables the electrical connector device to accommodate large PTC chips while maintaining a consistent overall size, making it compatible with various electrical devices.

[0007] The technical solution of this utility model is implemented as follows: an electrical connector device with dual overheat protection, characterized in that it includes an insulating shell and two external PTC thermal protection wiring mechanisms disposed in the insulating shell. The two external PTC thermal protection wiring mechanisms each include a base, a heat-induced power-off component disposed on the base, a first terminal and a second terminal connected to the input and output ends of the heat-induced power-off component, and a PTC chip disposed outside the base. The PTC chip is electrically connected to the first terminal and the second terminal respectively.

[0008] Preferably, the PTC chip and the heat-induced power-off component are separated by a base.

[0009] Preferably, the PTC chip is electrically connected to the first terminal and the second terminal directly; the PTC chip is also provided with an elastic clamping member to keep it in close contact with the first terminal and the second terminal.

[0010] Preferably, the first terminal and the second terminal are respectively provided with a power connector, and the outer ends of the two power connectors extend out of the insulating shell; the two power connectors are both wire terminals, or one of the power connectors is an electrical plug and the other is a wire terminal.

[0011] Preferably, the insulating shell is provided with two open composite chambers extending through its front and rear ends. The two open composite chambers respectively include a thermal protection nested chamber, two electrical connection nested chambers connected to the front and rear ends of the thermal protection nested chamber, a power-off movable cavity and a PTC nested chamber connected to the left and right ends of the thermal protection nested chamber, and a clamping member nested chamber connected to the PTC nested chamber. The base, the heat-induced power-off component, the first terminal and the second terminal are respectively fitted in the thermal protection nested chamber, the PTC chip is fitted in the PTC nested chamber, the elastic clamping member is fitted in the clamping member nested chamber, and the two electrical connections are respectively fitted in the two electrical connection nested chambers.

[0012] Preferably, the insulating outer shell includes a shell and a cover assembled together, the two open composite chambers are respectively disposed on the shell, and the cover is disposed to cover the two open composite chambers; the cover and the shell are also provided with nested positioning posts and positioning grooves; the cover and the shell are also provided with nested reinforcing protrusions and reinforcing grooves on their four sides.

[0013] Preferably, the present invention further includes two locking rivets, and the two electrical connectors are respectively fixed to the first terminal and the second terminal by the two locking rivets; the thermal protection nesting cavity is also provided with a rivet limiting and unloading cavity for the nesting installation of the two locking rivets.

[0014] Preferably, one of the electrical connector nesting cavities and the thermal protection nesting cavity are arranged in a transverse manner; the other electrical connector nesting cavity and the thermal protection nesting cavity are arranged in a longitudinal manner.

[0015] Preferably, the electrical connector and the electrical connector nesting cavity are further provided with a limiting protrusion and a limiting groove that are nested together.

[0016] Preferably, the heat-induced power-off assembly includes a bimetallic strip, a movable contact with a flanged clamping part and a movable contact, a first conductive rivet, and a second conductive rivet with a fixed contact. The second conductive rivet is locked to the base. One end of the bimetallic strip and one end of the movable contact are locked to the base by the first conductive rivet. The other end of the bimetallic strip is clamped between the flanged clamping part and the movable contact, and the movable contact is in contact with the fixed contact. The first terminal is riveted to the base by the first conductive rivet, and the second terminal is riveted to the base by the second conductive rivet. The base is also provided with a support pad, and one end of the movable contact and one end of the bimetallic strip are sequentially stacked on the support pad.

[0017] The beneficial effects of this utility model are as follows: By placing the PTC chip outside the base, the size of the PTC chip is no longer limited by the base. This allows for the use of larger PTC chips according to actual application needs, ensuring the PTC chip has a sufficiently high resistance value, improving overcurrent protection performance, and more reliably intercepting large currents to prevent current from passing through the PTC chip, thus avoiding equipment damage or safety accidents. Furthermore, placing the PTC chip outside the base eliminates the need for a dedicated hole in the base for embedding the PTC chip, greatly reducing the difficulty of base processing and manufacturing. It also eliminates the need to embed the PTC chip within the base, allowing for a more compact base design. This reduces the base's size and the space it occupies inside the insulating shell, freeing up more space within the insulating shell for the PTC chip. Thus, the electrical connector device can accommodate large PTC chips while maintaining its overall size, making it compatible with various electrical devices. Attached Figure Description

[0018] Figure 1 This is a three-dimensional structural diagram of the present invention.

[0019] Figure 2 This is a schematic diagram of the disassembled structure of this utility model.

[0020] Figure 3 This is a top view of the housing and two external PTC thermal protection wiring mechanisms in this utility model.

[0021] Figure 4 This is a schematic diagram showing the disassembled structure of the insulating shell in this utility model.

[0022] Figure 5 This is a three-dimensional structural diagram of the shell in this utility model.

[0023] Figure 6 This is a top view of the shell structure in this utility model.

[0024] Figure 7 This is one of the three-dimensional structural diagrams of the external PTC thermal protection wiring mechanism in this utility model.

[0025] Figure 8 This is the second three-dimensional structural diagram of the external PTC thermal protection wiring mechanism in this utility model.

[0026] Figure 9 This is a partial cross-sectional structural diagram of the external PTC thermal protection wiring mechanism in this utility model.

[0027] Figure 10 This is a partial cross-sectional structural diagram of an extended scheme for the external PTC thermal protection wiring mechanism in this utility model. Detailed Implementation

[0028] like Figure 1 and Figure 2 As shown, the electrical connector device with dual overheat protection according to this utility model includes an insulating housing 10 and two external PTC thermal protection wiring mechanisms 200 disposed in the insulating housing 10. To achieve the purpose proposed by this utility model, as... Figure 7 As shown, the two external PTC thermal protection wiring mechanisms 200 each include a base 3, a heat-sensitive power-off component 2 mounted on the base 3, a first terminal 4 and a second terminal 5 connected to the input and output ends of the heat-sensitive power-off component 2, and a PTC chip 1 mounted outside the base 3. The PTC chip 1 is electrically connected to the first terminal 4 and the second terminal 5, respectively. This invention, by placing the PTC chip 1 outside the base 3, eliminates the size limitation of the base 3, allowing for the use of larger PTC chips with sufficiently high resistance values ​​to intercept large currents and prevent current from passing through the PTC chip 1, thus avoiding equipment damage or safety accidents. Simultaneously, it eliminates the need to embed the PTC chip 1 within the base 3, allowing for a more compact base 3, reducing its overall size. This enables the electrical connector device to accommodate large PTC chips while maintaining a consistent overall size, making it suitable for various electrical devices.

[0029] To ensure that PTC chip 1 does not affect the power-off action of the heat-induced power-off component 2, such as Figure 9 As shown, the PTC chip 1 and the heat-induced power-off component 2 are separated by the base 3. This allows the heat generated by the PTC chip 1 to be conducted to the heat-induced power-off component 2 without the PTC chip 1 affecting the power-off action of the heat-induced power-off component 2.

[0030] In practical applications, the electrical connection between PTC chip 1 and the first terminal 4 and the second terminal 5 can be achieved through the following two methods:

[0031] The first option, such as Figure 9 As shown, the PTC chip 1 is electrically connected by direct contact with the first terminal 4 and the second terminal 5. This makes electrical connection very easy to achieve and simplifies the structure. To ensure a tight contact and prevent loosening, as shown... Figure 9 As shown, the PTC chip 1 is also provided with an elastic clamping member 7 to keep it in close contact with the first terminal 4 and the second terminal 5.

[0032] The second option, such as Figure 10As shown, this utility model also includes two conductive components 6, through which the PTC chip 1 is electrically connected to the first terminal 4 and the second terminal 5 respectively. This design ensures stable electrical connection. Specifically, the conductive component 6 can be a conductive part such as a wire or a metal spring.

[0033] To facilitate connection with wires in electrical equipment, such as Figure 8 As shown, the first terminal 4 and the second terminal 5 are respectively provided with electrical connectors 8, and the outer ends of the two electrical connectors 8 extend out of the insulating shell 10.

[0034] When this product is used as an electrical connector in the wiring of electrical equipment, both of the connecting parts 8 are wire clamp terminals. This allows for clamping and connecting the wires of the electrical plug and the electrical equipment to achieve power transmission.

[0035] Of course, this product can also be used as an electrical plug, and its connecting parts are as follows: Figure 7 As shown, one of the electrical connectors 8 is an electrical plug, and the other electrical connector 8 is a wire terminal.

[0036] To further improve the assembly structure of the insulating shell 10 and the external PTC thermal protection wiring mechanism 200, such as Figure 3 , Figure 6 and Figure 8As shown, the insulating shell 10 is provided with two open composite chambers 100 extending through its front and rear ends. The two open composite chambers 100 respectively include a thermal protection nested chamber 11, two electrical connection nested chambers 12 connected to the front and rear ends of the thermal protection nested chamber 11, a power-off movable cavity 13 and a PTC nested chamber 14 connected to the left and right ends of the thermal protection nested chamber 11, and a clamping member nested chamber 15 connected to the PTC nested chamber 14. The base 3, the heat-induced power-off component 2, the first terminal 4 and the second terminal 5 are respectively fitted in the thermal protection nested chamber 11, the PTC chip 1 is fitted in the PTC nested chamber 14, the elastic clamping member 7 is fitted in the clamping member nested chamber 15, and the two electrical connection members 8 are respectively fitted in the two electrical connection nested chambers 12. By setting up an open composite chamber 100 formed by interconnected cavities, when the circuit overheats abnormally, the heat received by the connector 8 and the heat generated by the PTC chip 1 can quickly fill the entire open composite chamber 100, which is very conducive to the introduction and dissipation of heat. This allows the external PTC thermal protection wiring mechanism 200 to sense the temperature immediately and quickly perform power-off and power-on actions, ensuring the reliability of the external PTC thermal protection wiring mechanism 200 and eliminating safety hazards. By setting up a power-off movable cavity 13, sufficient space is provided for the heated power-off component 2 to complete the power-off and power-on actions, ensuring that the heated power-off component 2 can operate normally. By setting up a clamping member nested cavity 15, the pressing direction of the elastic clamping member 7 can be limited, ensuring that the PTC chip 1 can always be tightly attached to the first terminal 4 and the second terminal 5. Specifically, the clamping member nested cavity 15, the PTC nested cavity 14, the thermal protection nested cavity 11, and the power-off movable cavity 13 are arranged horizontally in sequence. In practical applications, the two open composite chambers 100 are arranged symmetrically on the left and right.

[0037] To further improve the structure of the insulating shell 10, such as Figure 4 As shown, the insulating outer shell 10 includes a housing 17 and a cover 18 assembled together. Two open composite chambers 100 are respectively disposed on the housing 17, and the cover 18 is disposed to cover the two open composite chambers 100. By dividing the insulating outer shell 10 into a housing 17 and a cover 18, the manufacturing of the open composite chambers 100 becomes easier. In practical applications, open composite chambers 100 can also be disposed on the cover 18, and the open composite chambers 100 of the cover 18 correspond to the open composite chambers 100 of the housing 17. This allows for the manufacture of a cover 18 and a housing 17 that are separated in half.

[0038] like Figure 4 and Figure 5As shown, the bottom of the PTC nesting cavity 14, the bottom of the clamping member nesting cavity 15, and the cover shell 18 are respectively provided with limiting protrusions 105. This can limit the upper and lower ends of the PTC chip 1 and the elastic clamping member 7 installed in the insulating shell 10, so that the PTC chip 1 and the elastic clamping member 7 can only move towards the thermal protection nesting cavity 11, ensuring that the PTC chip 1 can always be tightly attached to the first terminal 4 and the second terminal 5, thereby improving the structural reliability of the insulating shell 10.

[0039] In order to allow the cover 18 and the housing 17 to be quickly positioned together, such as Figure 4 As shown, a positioning post 101 and a positioning groove 102 are nested together between the cover shell 18 and the shell 17. When the shell 17 is provided with a positioning post 101, the cover shell 18 is provided with a positioning groove 102. Of course, the positioning post 101 and the positioning groove 102 can also be interchanged to achieve the same positioning function. In practical applications, the number of positioning posts 101 and positioning grooves 102 can be multiple to enhance their positioning effect.

[0040] To enhance the structural strength of the perimeter of the cover 18 and the housing 17, such as Figure 4 As shown, the cover 18 and the housing 17 are further provided with nested reinforcing protrusions 103 and reinforcing grooves 104. This prevents the edges of the cover 18 and the housing 17 from bending or warping, resulting in a tighter and more secure fit. It also prevents the external PTC thermal protection wiring mechanism 200 from being exposed, making it safer and more reliable to use. When the housing 17 is provided with the reinforcing protrusion 103, the cover 18 is provided with the reinforcing groove 104. Of course, the reinforcing protrusion 103 and the reinforcing groove 104 can also be interchanged, achieving the same effect of strengthening the structure.

[0041] like Figure 8 and Figure 3 As shown, this utility model also includes two locking rivets 9. The two electrical connectors 8 are respectively fixed to the first terminal 4 and the second terminal 5 by the two locking rivets 9. The thermal protection nesting cavity 11 is also provided with a rivet limiting and unloading cavity 16 for the nesting installation of the two locking rivets 9. The fixed connection by locking rivets 9 makes assembly easier. And by setting the rivet limiting and unloading cavity 16, when plugging and unplugging the electrical connector, the pulling force can be unloaded through the rivet and the rivet limiting and unloading cavity 16, which can play a role in dispersing the pulling force. This can prevent the pulling force from concentrating on the two electrical connectors 8 and the first terminal 4 and the second terminal 5, and prevent them from loosening.

[0042] like Figure 6As shown, one of the electrical connector nesting cavities 12 and the thermal protection nesting cavity 11 are arranged laterally; the other electrical connector nesting cavity 12 and the thermal protection nesting cavity 11 are arranged longitudinally. The longitudinal through-hole design improves installation convenience. The lateral through-hole design allows the electrical connector nesting cavity 12 and the thermal protection nesting cavity 11 to form a Z-shaped structure, which limits the connection between the external PTC thermal protection wiring mechanism 200 and the electrical connector 8, preventing them from being pulled out during insertion, removal, or pulling, thus ensuring installation stability.

[0043] To further prevent the electrical connector 8 installed in the electrical connector nesting cavity 12 from becoming loose, such as Figure 6 and Figure 7 As shown, a limiting protrusion 122 and a limiting groove 121 are nested together between the electrical connector 8 and the electrical connector nesting cavity 12. When the electrical connector 8 is provided with a limiting groove 121, the electrical connector nesting cavity 12 is provided with a limiting protrusion 122. Of course, the limiting protrusion 122 and the limiting groove 121 can also be interchanged, and can still play a limiting role. In practical applications, the number of limiting protrusions 122 and limiting grooves 121 can be multiple to enhance their limiting and anti-loosening functions. In practical applications, a limiting protrusion 122 and a limiting groove 121 nested together are also provided between the electrical connector 8 and the cover shell 18.

[0044] To further improve the structure of the heat-induced power-off component 2, such as Figure 3 As shown, the heat-induced power-off assembly 2 includes a bimetallic strip 21, a movable contact 22 with a flanged clamping part 221 and a movable contact 222, a first conductive rivet 23, and a second conductive rivet 24 with a fixed contact 241. The second conductive rivet 24 is locked onto the base 3. One end of the bimetallic strip 21 and one end of the movable contact 22 are locked onto the base 3 by the first conductive rivet 23. The other end of the bimetallic strip 21 is clamped between the flanged clamping part 221 and the movable contact 22, and the movable contact 222 is in contact with the fixed contact 241. The first terminal 4 is riveted to the base 3 by the first conductive rivet 23, and the second terminal 5 is riveted to the base 3 by the second conductive rivet 24. When conducting electricity, the first terminal 4 is energized to the moving contact 22 through the first conductive rivet 23. The moving contact 22 is energized to the fixed contact 241 through the moving contact 222. The fixed contact 241 is energized to the second terminal 5 through the second conductive rivet 24. More specifically, the base 3 is also provided with a countersunk groove 32 for storing the fixed contact 241, which can further reduce the overall volume of the external PTC thermal protection wiring mechanism 200 and further reduce space occupation.

[0045] like Figure 9As shown, the base 3 is also provided with a support pad 31, and one end of the movable contact piece 22 and one end of the bimetallic strip 21 are sequentially stacked on the support pad 31. By setting the support pad 31, the bimetallic strip 21 can be raised, thereby providing better movement space for the bimetallic strip 21, which helps to improve the reliability of the bimetallic strip 21's operation and further ensures that the heat-induced power-off component 2 can operate normally. In practical applications, the support pad 31 can be made of either a non-insulating material (e.g., copper or steel) or an insulating material (e.g., plastic). The base 3 is made of an insulating material (e.g., plastic).

Claims

1. An electrical connector device with dual overheat protection, characterized in that: The device includes an insulating housing (10) and two external PTC thermal protection wiring mechanisms (200) disposed in the insulating housing (10). The two external PTC thermal protection wiring mechanisms (200) each include a base (3), a heat-induced power-off component (2) disposed on the base (3), a first terminal (4) and a second terminal (5) connected to the input and output terminals of the heat-induced power-off component (2), and a PTC chip (1) disposed outside the base (3). The PTC chip (1) is electrically connected to the first terminal (4) and the second terminal (5) respectively.

2. The electrical connector device with dual overheat protection according to claim 1, characterized in that: The PTC chip (1) and the heat-dissipated power-off component (2) are separated by a base (3).

3. The electrical connector device with dual overheat protection according to claim 1, characterized in that: The PTC chip (1) is in direct contact with the first terminal (4) and the second terminal (5) to achieve electrical connection; the PTC chip (1) is also provided with an elastic clamping member (7) to keep it in close contact with the first terminal (4) and the second terminal (5).

4. The electrical connector device with dual overheat protection according to claim 3, characterized in that: The first terminal (4) and the second terminal (5) are respectively provided with electrical connectors (8), and the outer ends of the two electrical connectors (8) extend out of the insulating shell (10); the two electrical connectors (8) are both wire terminals, or one of the electrical connectors (8) is an electrical plug and the other electrical connector (8) is a wire terminal.

5. The electrical connector device with dual overheat protection according to claim 4, characterized in that: The insulating shell (10) is provided with two open composite chambers (100) that run through its front and rear ends. The two open composite chambers (100) respectively include a thermal protection nested chamber (11), two electrical connection nested chambers (12) connected to the front and rear ends of the thermal protection nested chamber (11), a power-off movable cavity (13) and a PTC nested chamber (14) connected to the left and right ends of the thermal protection nested chamber (11), and a clamping member nested chamber (15) connected to the PTC nested chamber (14). The base (3), the heat-induced power-off component (2), the first terminal (4) and the second terminal (5) are respectively fitted in the thermal protection nested chamber (11), the PTC chip (1) is fitted in the PTC nested chamber (14), the elastic clamping member (7) is fitted in the clamping member nested chamber (15), and the two electrical connection members (8) are respectively fitted in the two electrical connection nested chambers (12).

6. The electrical connector device with dual overheat protection according to claim 5, characterized in that: The insulating outer shell (10) includes a shell (17) and a cover (18) assembled together. The two open composite chambers (100) are respectively disposed on the shell (17), and the cover (18) is disposed to cover the two open composite chambers (100). The cover (18) and the shell (17) are also provided with a positioning post (101) and a positioning groove (102) nested together. The cover (18) and the shell (17) are also provided with a reinforcing protrusion (103) and a reinforcing groove (104) nested together.

7. The electrical connector device with dual overheat protection according to claim 5, characterized in that: It also includes two locking rivets (9), and the two electrical connectors (8) are fixed to the first terminal (4) and the second terminal (5) respectively by the two locking rivets (9); the thermal protection nesting cavity (11) is also provided with a rivet limiting and unloading cavity (16) for the nesting installation of the two locking rivets (9).

8. The electrical connector device with dual overheat protection according to claim 5, characterized in that: One of the electrical connection nesting cavities (12) and the thermal protection nesting cavity (11) are arranged in a transverse manner; the other electrical connection nesting cavity (12) and the thermal protection nesting cavity (11) are arranged in a longitudinal manner.

9. The electrical connector device with dual overheat protection according to claim 5, characterized in that: The electrical connector (8) and the electrical connector nesting cavity (12) are further provided with a limiting protrusion (122) and a limiting groove (121) nested together.

10. The electrical connector device with dual overheat protection according to claim 1, characterized in that: The heat-induced power-off assembly (2) includes a bimetallic strip (21), a movable contact (22) with a flanged clamping part (221) and a movable contact (222), a first conductive rivet (23), and a second conductive rivet (24) with a fixed contact (241). The second conductive rivet (24) is locked on the base (3). One end of the bimetallic strip (21) and one end of the movable contact (22) are locked on the base (3) by the first conductive rivet (23). The other end of the bimetallic strip (21) is clamped. Between the flange clamping part (221) and the moving contact piece (22), and the moving contact (222) is in contact with the fixed contact (241); the first terminal (4) is riveted to the base (3) by the first conductive rivet (23), and the second terminal (5) is riveted to the base (3) by the second conductive rivet (24); the base (3) is also provided with a support pad (31), and one end of the moving contact piece (22) and one end of the bimetallic strip (21) are successively stacked on the support pad (31).

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