A large-current double-contact spring structure for a new energy vehicle charging socket

Abstract

The utility model discloses a big current -carrying double contact spring piece structure for new energy automobile charging socket, including installation bottom plate, a pair of elastic cantilever, installation bottom plate is composed of the conductive metal sheet material, and a pair of elastic cantilever is integrally connected to the both sides of installation bottom plate along the length direction symmetry, and with bottom plate common constitution U type structure, and elastic cantilever includes the support portion that installation bottom plate extends upwards in proper order, the elastic portion that support portion extends and the contact portion that sets up in the free end of elastic portion, wherein, the contact portion of a pair of elastic cantilever is arranged in the direction of perpendicular to installation bottom plate plane dislocation, for with corresponding plug pin forms double contact point. The utility model discloses through the U type symmetrical structure and double elastic cantilever design of integral forming, realized the vertical dislocation double contact point layout of contact point, has improved the anti -vibration reliability and current -carrying capacity significantly, and also satisfied the rigorous requirement of high density integration and mechanical durability.

Description

Technical Field

[0001] This invention relates to the field of current-carrying spring technology, and in particular to a high-current-carrying dual-contact spring structure for charging sockets of new energy vehicles. Background Technology

[0002] With the rapid development of the new energy vehicle market, the performance requirements of on-board charging sockets, as the core charging interface, are increasing. Especially with the trend of high integration between low-voltage signal terminals and PCBA functions, traditional charging socket solutions are no longer sufficient to meet current demands. On the one hand, integration requires high-density layout of terminal devices within a limited space, while traditional spring contacts occupy a large area and lack structural stability, making them unsuitable for compact spaces. On the other hand, the widespread adoption of fast charging technology and the increase in on-board electrical equipment have significantly increased the current that signal terminals need to carry. Traditional spring contacts, due to their small cross-sectional area and high resistance, are prone to overheating under high current conditions, posing a risk of overheating. Furthermore, the operating environment of new energy vehicles is complex and subject to frequent vibrations. Traditional single-contact spring contacts are prone to unstable contact resistance due to fluctuations in contact pressure or slight tilting, affecting the continuity and reliability of signal transmission and failing to meet the high reliability requirements of automotive-grade connectors. Therefore, existing technologies have significant shortcomings in terms of high current carrying capacity, high integration, and high contact reliability, urgently requiring an innovative spring contact structure to overcome these technical bottlenecks. Summary of the Invention

[0003] To address the aforementioned shortcomings, this invention proposes a high-current-carrying dual-contact spring structure for charging sockets of new energy vehicles. Through an integrally molded U-shaped symmetrical structure and a double elastic cantilever design, a vertically staggered dual-contact layout of the contact points is achieved, which significantly improves vibration resistance reliability and current-carrying capacity, while also meeting the stringent requirements of high-density integration and mechanical durability.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a high-current-carrying dual-contact spring structure for a charging socket for new energy vehicles, comprising: The mounting base plate is made of conductive metal sheet. A pair of flexible cantilever arms are symmetrically and integrally connected to both sides of the mounting base plate along the length direction, and together with the mounting base plate, they form a U-shaped structure. The flexible cantilever includes, in sequence, a support portion extending upward from the mounting base plate, an elastic portion extending from the support portion, and a contact portion disposed at the free end of the elastic portion. Among them, the contact parts of a pair of flexible cantilever arms are staggered in a direction perpendicular to the plane of the mounting base plate to form a double contact point with the corresponding plug pins.

[0005] Compared with the prior art, the advantages of the present invention are as follows: By employing a one-piece molded U-shaped symmetrical structure and a double elastic cantilever design, the two contact points are staggered in the vertical direction, forming two independent physical contact points with the pins. This significantly improves contact reliability and effectively avoids signal transmission interruptions caused by momentary disconnection of a single contact point in complex vibration environments. The dual contact point design also forms multiple current paths in parallel, significantly increasing the current-carrying cross-sectional area and reducing contact resistance and heat generation, thus meeting the stringent requirements of new energy vehicle charging sockets for high current carrying capacity. Simultaneously, the compact U-shaped layout and cantilever structure achieve excellent elastic travel and contact positive pressure while occupying minimal installation space, perfectly adapting to the trend of high-density integration in automotive connectors. The structure has good overall rigidity and uniform stress distribution, ensuring mechanical durability and performance stability during frequent plugging and unplugging operations.

[0006] As an improvement, at least a portion of the support and elastic parts together form an arc-shaped structure that bends inward toward the mounting base plate. This arc-shaped structure significantly optimizes the mechanical properties of the spring. Its smooth transition bending shape can effectively disperse and absorb the stress generated during insertion and removal, avoiding stress concentration at the root bend, thereby greatly improving the fatigue strength and mechanical life of the spring and ensuring long-term reliability under frequent insertion and removal conditions. At the same time, the inwardly bending arc path naturally guides the contact part to move along a more stable trajectory when under pressure, effectively suppressing lateral offset or torsional deformation, so that the contact part can always maintain good alignment with the pin, and the contact pressure is more stable, further enhancing the stability and consistency of the electrical connection. This structure achieves maximum elastic deformation within a limited space, taking into account both miniaturization and high performance requirements.

[0007] As an improvement, the contact portion is a protrusion formed by bending the free end of the elastic part downwards. By bending the contact portion downwards to form a protrusion, the pin can be smoothly inserted along the inclined surface of the protrusion during insertion, significantly reducing the insertion force, improving the insertion and removal feel, and reducing the risk of plastic deformation of the spring due to rough insertion and removal. When subjected to pin pressure, this downward protrusion structure can more effectively convert the vertical downward pressure into the inward horizontal displacement of the elastic part, reducing the relative sliding between the contact portion and the pin surface, thereby reducing wear on the contact surface and improving wear resistance and service life. More importantly, this structure ensures that the contact point is located below the overall spring structure, forming a stable support point, effectively preventing the contact portion from jumping upwards in a vibration environment, and greatly enhancing the stability and reliability of the contact. At the same time, this protrusion structure increases the local rigidity of the contact portion and accumulates higher contact normal pressure near the contact point, thereby reducing contact resistance and facilitating the stable transmission of large currents.

[0008] As an improvement, the support section includes a vertical section perpendicularly connected to the mounting base plate and a horizontal section perpendicularly connected to the vertical section. The elastic section extends upward from the horizontal section and tilts inward. The connections between the mounting base plate, the vertical section, and the horizontal section are all transitioned by rounded arcs. The combined design of the vertical and horizontal sections greatly enhances the lateral stiffness and torsional resistance of the support section, ensuring that the spring will not shift as a whole when subjected to lateral forces, thus providing a stable foundation for the precise movement of the elastic section. The rounded arc transitions at each connection effectively eliminate stress concentration, evenly distributing the stress generated during the insertion and removal cycle to the entire structure, significantly improving the fatigue limit of the material, and thus greatly extending the service life of the spring. The configuration of the elastic section extending upward from the horizontal section and tilting inward achieves a longer effective elastic stroke within a limited height, resulting in less internal stress when subjected to the same displacement, while providing a softer and more stable contact force. This composite structure has a compact layout in three-dimensional space, achieving high-performance elastic contact with minimal footprint, perfectly meeting the development requirements of high-density and high-reliability connectors for new energy vehicle charging interfaces.

[0009] As an improvement, symmetrical U-shaped stress relief grooves are provided on both sides of the mounting base plate at the root of the vertical section. These grooves precisely interrupt the stress transmission path to the mounting base plate, guiding the most concentrated stress generated by repeated bending of the spring to the groove and dispersing it. This fundamentally avoids the risk of cracks or breakage at the root due to stress concentration, greatly improving the mechanical life and reliability of the spring under long-term frequent insertion and removal conditions. This structure also takes into account the ease of processing. The smooth U-shaped contour avoids sharp corners, making it less prone to micro-cracks during stamping and ensuring product yield. The symmetrical arrangement further ensures the consistency of the force and deformation of the two springs, enabling the two contact points to maintain synchronous and stable contact performance, enhancing the reliability of the entire electrical connection system.

[0010] As an improvement, the mounting base plate has at least two symmetrically arranged mounting holes at the front and rear ends. The cooperation of these two mounting holes effectively prevents the spring from rotating or shifting during welding or fastening, ensuring the consistency of installation position accuracy in mass production and facilitating automated assembly. The symmetrical layout ensures even distribution of installation force, avoiding deformation of the base plate caused by uneven force on one side, and guaranteeing a flat and secure fit between the spring and the circuit board, thereby improving the reliability of welding quality. This design also enhances the overall structure of the spring's resistance to mechanical vibration and impact, enabling it to maintain a stable connection under the complex operating conditions of new energy vehicles, further ensuring the long-term stability of the electrical connection.

[0011] As an improvement, the length-to-width ratio of the horizontal segment is 1:1, forming an approximately square structure in space. This allows the horizontal segment to achieve an optimal balance between its resistance to bending and torsional deformation when subjected to multidimensional forces from the elastic part, providing an extremely stable support foundation for the elastic part and ensuring the accuracy and consistency of the contact part's movement trajectory. This ratio avoids excessive stress concentration caused by insufficient rigidity due to an excessively long segment or excessively short segment, allowing for a smoother transition and more uniform distribution of stress from the vertical segment to the elastic part, significantly improving the fatigue life of the structure. At the same time, this regular geometry is also most conducive to the stamping layout of materials, greatly improving the utilization rate of metal strip, reducing manufacturing costs, and ensuring the uniformity of material flow during stamping, thereby improving the dimensional accuracy and forming quality of the parts.

[0012] As an improvement, the bending angle between the contact part and the elastic part is an obtuse angle, forming a smooth and open guiding slope, which significantly reduces the resistance when inserting the pins, greatly improves the insertion and removal feel, and reduces scratches and wear on the pin surface. This angle design optimizes the force transmission path, converting the vertical pressure on the contact part into inward elastic deformation of the elastic part more efficiently, rather than stress concentration at the root, thereby significantly improving the mechanical durability and fatigue strength of the spring. The obtuse angle structure also increases the material volume at the connection between the contact part and the elastic part, enhancing the rigidity of this critical node and effectively preventing plastic deformation or angle collapse after repeated stress, ensuring the long-term stability of the contact normal pressure. At the same time, this specific angle provides the contact part with additional degrees of freedom, enabling it to fine-tune alignment when subjected to forces in different directions, further enhancing the reliability and consistency of the contact. This design also facilitates stamping during manufacturing, reduces stress concentration in the mold, and improves production yield.

[0013] As an improvement, the bending angle is 135° to 155°. The slope of the guide ramp formed by this angle range is most suitable, which can ensure smooth insertion of the pin, significantly reduce the insertion force, improve the user experience, and provide sufficient structural support to prevent the contact part from weakening due to excessive angle.

[0014] As an improvement, the conductive metal plate is a copper alloy plate with a thickness of 0.2-0.3 mm. Attached Figure Description

[0015] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments: Figure 1 A schematic diagram of a high-current-carrying dual-contact spring structure for a charging socket for new energy vehicles; Figure 2 A front view of a high-current-carrying dual-contact spring structure for a charging socket for new energy vehicles; Figure 3 A bottom view of a high-current-carrying dual-contact spring structure for a charging socket for new energy vehicles; Figure 4 This is a schematic diagram showing the interaction between the spring structure and the circuit board, plug, and pin structure.

[0016] The markings in the above figures are as follows: 1. Mounting base plate; 1.1. Stress relief groove; 1.2. Mounting hole; 2. Elastic cantilever; 2.1. Support part; 2.1.1. Vertical section; 2.1.2. Horizontal section; 2.2. Elastic part; 2.3. Contact part. Detailed Implementation

[0017] In this utility model, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "planar direction", "circumferential", etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0018] like Figures 1 to 3 As shown, a high-current-carrying dual-contact spring structure for a charging socket for new energy vehicles includes a mounting base plate 1 and a pair of elastic cantilever arms 2. The mounting base plate 1 is made of conductive metal sheet. The pair of elastic cantilever arms 2 are symmetrically and integrally connected to both sides of the mounting base plate 1 along the length direction, and together with the mounting base plate 1, they form a U-shaped structure. The elastic cantilever arms 2 sequentially include a support portion 2.1 extending upward from the mounting base plate 1, an elastic portion 2.2 extending from the support portion 2.1, and a contact portion 2.3 disposed at the free end of the elastic portion 2.3. The contact portions 2.3 of the pair of elastic cantilever arms 2 are staggered in a direction perpendicular to the plane of the mounting base plate 1 to form dual contact points with the corresponding plug pins.

[0019] At least a portion of the support portion 2.1 and the elastic portion 2.2 together form an arc-shaped structure that bends toward the inside of the mounting base plate 1.

[0020] The contact portion 2.3 is a protrusion formed by bending downward from the free end of the elastic portion 2.2. The bending angle between the contact portion 2.3 and the elastic portion 2.2 is an obtuse angle, ranging from 135° to 155°, preferably 145°.

[0021] The support part 2.1 includes a vertical section 2.1.1 that is perpendicularly connected to the mounting base plate 1 and a horizontal section 2.1.2 that is perpendicularly connected to the vertical section 2.1.1. The elastic part 2.2 extends upward from the horizontal section 2.1.2 and tilts inward. The connection between the mounting base plate 1, the vertical section 2.1.1 and the horizontal section 2.1.2 is all transitioned by a rounded arc.

[0022] Stress relief grooves 1.1 in a U-shape are symmetrically provided on both sides of the mounting base plate 1 at the root of the vertical section 2.1.1.

[0023] The mounting base plate 1 has at least two symmetrically arranged mounting holes 1.2 at its front and rear ends.

[0024] The length-to-width ratio of the horizontal segment 2.1.2 is 1:1. Preferably, the length and width of the horizontal segment 2.1.2 are both 1mm, which meets the requirements for SMT chuck to pick up and solder.

[0025] The conductive metal plate is a copper alloy plate with a thickness of 0.2-0.3mm.

[0026] like Figure 4 As shown, the lower end face of the mounting base plate 1 of the spring-loaded structure is fixedly connected to the upper end face of the circuit board. When the plug pin is inserted into the spring-loaded structure, the pin end first contacts the misaligned contact portion 2.3. During the continued insertion, the pin applies downward pressure to the contact portion 2.3, which is transmitted to the support portion 2.1 through the elastic portion 2.2 connected to it. During this process, the two elastic cantilever arms 2 work independently and cooperate with each other, and the two contact points share the load. Then, the elastic portion 2.2 begins to produce elastic deformation toward the inner side of the mounting base plate 1. At the same time, the vertical section 2.1.1 and the horizontal section 2.1.2 of the support portion 2.1 undergo slight elastic bending at the arc transition, absorbing displacement energy together. This allows the contact portion 2.3 to move downward and slightly inward while maintaining good alignment. After the pin is finally pressed into place, the two contact portions 2.3, under the restoring force provided by their respective elastic cantilever arms 2, tightly abut against the pin, forming two independent and stable electrical connection points. Throughout the insertion process, the U-shaped stress relief groove 1.1 effectively releases the concentrated stress at the root of the vertical section 2.1.1, the mounting hole 1.2 ensures the stability of the entire spring mounting base without displacement, and the specific 145° bending angle and the proportion of the horizontal section 2.1.2, which has a length and width of 1mm, optimize the transmission and conversion of force, ensuring smooth operation and uniform stress distribution, ultimately achieving a low insertion and extraction force, high contact reliability and long mechanical life of the insertion process.

[0027] The above description only illustrates the preferred embodiments of the present invention and should not be construed as limiting the scope of the claims. The present invention is not limited to the above embodiments, and variations in its specific structure are permitted. All modifications made within the scope of the independent claims of this invention are also within the scope of protection of this invention.

Claims

1. A high-current-carrying dual-contact spring structure for a charging socket for new energy vehicles, characterized in that, include: The mounting base plate is made of conductive metal sheet. A pair of flexible cantilever arms are symmetrically and integrally connected to both sides of the mounting base plate along the length direction, and together with the mounting base plate, they form a U-shaped structure; The elastic cantilever sequentially includes a support portion extending upward from the mounting base plate, an elastic portion extending from the support portion, and a contact portion disposed at the free end of the elastic portion. The contact portions of the pair of elastic cantilever arms are staggered in a direction perpendicular to the plane of the mounting base plate to form a double contact point with the corresponding plug pins.

2. The high-current-carrying dual-contact spring structure for a new energy vehicle charging socket according to claim 1, characterized in that, The support portion and at least a portion of the elastic portion together form an arc-shaped structure that bends toward the inside of the mounting base plate.

3. The high-current-carrying dual-contact spring structure for a new energy vehicle charging socket according to claim 1, characterized in that, The contact portion is a protrusion formed by bending the free end of the elastic portion downwards.

4. The high-current-carrying dual-contact spring structure for a new energy vehicle charging socket according to claim 1, characterized in that, The support includes a vertical section that is perpendicularly connected to the mounting base plate and a horizontal section that is perpendicularly connected to the vertical section. The elastic part extends upward from the horizontal section and tilts inward. The connection between the mounting base plate, the vertical section, and the horizontal section is a rounded transition.

5. A high-current-carrying dual-contact spring structure for a new energy vehicle charging socket according to claim 4, characterized in that, The mounting base plate has symmetrically arranged U-shaped stress relief grooves on both sides corresponding to the root of the vertical section.

6. The high-current-carrying dual-contact spring structure for a new energy vehicle charging socket according to claim 1, characterized in that, The mounting base plate has at least two symmetrically arranged mounting holes at its front and rear ends.

7. A high-current-carrying dual-contact spring structure for a new energy vehicle charging socket according to claim 4, characterized in that, The length to width ratio of the horizontal segment is 1:

1.

8. The high-current-carrying dual-contact spring structure for a new energy vehicle charging socket according to claim 3, characterized in that, The bending angle between the contact portion and the elastic portion is an obtuse angle.

9. A high-current-carrying dual-contact spring structure for a new energy vehicle charging socket according to claim 8, characterized in that, The bending angle is between 135° and 155°.

10. A high-current-carrying dual-contact spring structure for a new energy vehicle charging socket according to claim 1, characterized in that, The conductive metal plate is a copper alloy plate with a thickness of 0.2-0.3 mm.

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