A high current connector terminal

Abstract

The utility model provides a kind of high current-carrying connector terminal, including joint, main row, the joint both ends are with hole, and the joint between fixedly connected with main row;The two sides of the main row are fixedly connected with a plurality of connecting pieces, and every two of the connecting piece is a group;The connecting piece is hollow and the connecting piece of same group is connected.The utility model has the advantages of: it can maximize contact area: conical surface extrusion forces metal material to produce plastic deformation, so that external connection line and terminal guide table are closely fitted, significantly increase effective conductive contact area, which is the key to reduce contact resistance and temperature rise.Reduce contact resistance: high contact pressure and large contact surface directly lead to significant reduction in contact resistance, meet high current-carrying requirement.Can realize very low contact resistance: through maximum contact area and very high contact pressure realization.Can realize low operating temperature rise: low resistance leads to reduced heat loss, reduce temperature rise risk, improve long-term reliability and safety current-carrying capacity.

Description

Technical Field

[0001] This utility model relates to the field of connector technology, and in particular to a high current-carrying connector terminal. Background Technology

[0002] In the field of electrical connections, high-current connector terminals are widely used in high-current scenarios such as power distribution, new energy vehicles, and industrial equipment. Traditional connector terminals typically use screw crimping or plug-in structures to achieve cable fixing and conductivity, but they have the following significant drawbacks: High contact resistance: Existing terminals mostly rely on bolts to vertically tighten cables or simple surface contact, resulting in a limited effective conductive area. Microscopic irregularities on the metal surface lead to sparse contact points, causing current to concentrate in localized areas, making it difficult to effectively reduce contact resistance. High contact resistance triggers the Joule heating effect, resulting in a significant temperature rise, which not only causes energy loss but may also lead to aging of insulation materials and even the risk of fire.

[0003] Limited current-carrying capacity: Screw-type crimp terminals typically rely solely on the thread to provide pressure, making it difficult to achieve uniform and continuous clamping force. Under high current conditions (such as those above 100 amperes), cables are prone to loosening due to thermal expansion or mechanical vibration, leading to a drop in contact pressure and a sharp decrease in current-carrying capacity, which cannot meet the long-term stable operation requirements of high-power equipment. Therefore, a high current-carrying connector terminal is proposed to solve the above problems. Utility Model Content

[0004] The purpose of this invention is to at least solve one of the aforementioned technical defects.

[0005] Therefore, one objective of this utility model is to provide a high current-carrying connector terminal to solve the problems mentioned in the background art and overcome the shortcomings of the prior art.

[0006] To achieve the above objectives, one embodiment of the present invention provides a high current-carrying connector terminal, including a connector and a main bar, wherein the connector has holes at both ends and the main bar is fixedly connected between the connectors; Several connectors are fixedly connected to both sides of the main row, and the connectors are in groups of two. The connector is hollow and the connectors in the same group are connected to each other, and the connector has a terminal fixedly connected inside; The terminal is hollow; The top of the connector is fixedly connected to a cylinder, and the cylinder is internally threaded with fasteners. A cone head is fixedly connected to the bottom end of the fastener, and a guide platform is fixedly connected to the inner side of the terminal near the opening. The surface of the guide platform is a smooth slope, and the guide platform is located below the cone head.

[0007] Preferably, in any of the above schemes, the joint is heat-fused to the main drain, and the hole of the joint is opened horizontally.

[0008] The above technical solution is adopted: In this connector connection method, the main busbar is fixed to the base by the connector and screws. The end of the input line is inserted into the terminal of a connector. The corresponding fastener is tightened with a tool. The cone at the bottom of the fastener presses the end of the input line onto the guide platform. The end of the output line is inserted into the other end of the terminal of the same group of connectors and tightened.

[0009] Preferably, in any of the above solutions, the joint and the connector are bonded together, and the joint and the connector are made of plastic.

[0010] The hollow channel of the terminal is improved by fixing an angled guide platform at the terminal opening. The surface of the guide platform is a smooth slope, and this area is the core conductive contact area. The fastener is improved by adding a cone at the bottom of the fastener. The angle of the cone surface is the same as the angle of the guide platform. After the fastener is tightened, the cone presses the cable end onto the guide platform, maximizing the contact area. The cone surface compression forces the metal material to undergo plastic deformation, ensuring a tight fit between the external wire and the terminal guide platform, significantly increasing the effective conductive contact area. This is key to reducing contact resistance and temperature rise. Reduced contact resistance: High contact pressure and a large contact area directly lead to a significant reduction in contact resistance, meeting high current carrying capacity requirements. Extremely low contact resistance can be achieved: This is achieved by maximizing the contact area and extremely high contact pressure. Low operating temperature rise can be achieved: Low resistance reduces heat loss, lowers the risk of temperature rise, and improves long-term reliability and safe current carrying capacity.

[0011] Preferably, in any of the above embodiments, the terminal is bonded inside the connector, the terminal has a cylindrical channel inside, and the front and rear ends of the terminal are connected.

[0012] The above technical solution employs the following: The connector has holes at both ends for external screw fixing; a main row is fixedly connected between the connectors. Several connectors are fixedly connected to both sides of the main row, with each pair of connectors forming a group, and the connectors within the same group are interconnected. Each connector is hollow, with a terminal fixedly connected inside; the terminal is hollow, with a through-type connection at both ends, and has a cylindrical channel inside. A cylindrical body is fixedly connected to the top of the connector, and a fastener is threaded into the inside of the cylindrical body. A conical head is fixedly connected to the bottom of the fastener. A guide platform is fixedly connected to the inner side of the terminal near the opening; the surface of the guide platform is a smooth slope, and the guide platform is located below the conical head.

[0013] In terms of materials: the connectors and fittings are made of plastic to ensure insulation and lightweight design; the terminals and guides are made of copper to provide high conductivity; and the fasteners are made of PVC to ensure chemical stability and low friction. Furthermore, the cone angle of the cone head is the same as the tilt angle of the guides to achieve uniform pressing.

[0014] The coordinated design of the guide platform and the cone: The guide platform forms a smooth slope in the terminal entry area, serving as the core conductive contact area; the cone angle matches the guide platform tilt angle. After fastening, the cone can forcefully press the cable end against the guide platform, inducing plastic deformation of the metal material, thereby maximizing the contact area and achieving ultra-low contact resistance. This not only reduces heat loss but also increases rated current carrying capacity.

[0015] Preferably, in any of the above embodiments, the terminal is made of copper, and the upper part of the terminal is connected to the cylinder.

[0016] The connector consists of the following components: Connector: Both ends of the connector have horizontal holes for securing the entire connector to an external base (such as a circuit board or housing) using screws. The connector and main busbar are fixed together via heat fusion, ensuring overall stability and mechanical strength. The plastic material of the connector provides electrical insulation.

[0017] Main busbar: The main busbar is fixedly connected between the connectors and serves as the main load-bearing structure. Several sets of connectors are distributed on both sides of the main busbar; each set of connectors consists of two independent connectors that are interconnected through internal channels. The main busbar serves to shunt current and provide support.

[0018] Connectors: The connectors are fixed to the main bar by adhesive bonding. Two connectors in each group share a common communication space for easy current transmission. The connectors are hollow plastic parts with terminals bonded inside. The top of the connector is welded to or snapped onto the cylinder.

[0019] Terminals: The terminals are bonded inside the connector and are hollow copper components, forming a cylindrical channel that runs through both ends. The top of the terminal connects to the cylinder, allowing for the insertion of fasteners. A guide platform is fixedly connected to the inside of the terminal near the inlet (approximately 5-10mm from the terminal opening). The guide platform is a smooth copper ramp with an angle of approximately 30-45 degrees (the specific angle is adjusted according to the design), guiding the cable insertion and serving as the main conductive contact area.

[0020] Cylinder: The cylinder is fixedly connected to the top of the connector and has standard threads machined inside for thread engagement with fasteners.

[0021] Fasteners: The fasteners are PVC screw-shaped components with a conical head embedded at the bottom. The inclination angle of the conical head's conical surface is precisely matched with the inclination angle of the guide platform's slope (error ±2 degrees) to ensure uniform force distribution during pressing.

[0022] Guide platform: The guide platform is fixed inside the terminal. The copper bevel surface is polished to achieve low friction and high conductivity. Its position is directly opposite the cone head to receive the compressed surface of the cable end.

[0023] Preferably, the fastener is made of PVC, and the cone angle of the cone head is the same as the tilt angle of the guide platform.

[0024] Preferably, the guide platform is made of copper, as described in any of the above schemes.

[0025] Compared with the prior art, the advantages and beneficial effects of this utility model are as follows: This high-current-carrying connector terminal features an improved hollow channel. A sloping guide platform is fixedly connected to the terminal opening, with a smooth, beveled surface. This area forms the core conductive contact zone. The fastener has been improved with a conical tip at its bottom. The conical tip's angle matches the guide platform's angle. When tightened, the conical tip presses the cable end against the guide platform, maximizing the contact area. The conical surface compression forces plastic deformation in the metal material, ensuring a tight fit between the external cable and the terminal guide platform, significantly increasing the effective conductive contact area. This is crucial for reducing contact resistance and temperature rise. Reduced contact resistance: High contact pressure and a large contact area directly lead to a significant reduction in contact resistance, meeting high current-carrying requirements. Extremely low contact resistance can be achieved: This is achieved by maximizing the contact area and using extremely high contact pressure. Low operating temperature rise can be achieved: Low resistance reduces heat loss, lowers the risk of temperature rise, and improves long-term reliability and safe current carrying capacity.

[0026] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0027] The above and / or additional aspects and advantages of this utility model will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 This is a first-view structural schematic diagram of the present invention; Figure 2 This is a structural schematic diagram of the present invention from a second perspective; Figure 3 This is a front view structural diagram of the present utility model; Figure 4 This is a schematic diagram of a partial internal structure of the present invention.

[0028] In the diagram: 1-Connector, 2-Main row, 3-Connector, 4-Terminal, 5-Cylinder, 6-Fastener, 7-Cone, 8-Guide platform. Detailed Implementation

[0029] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this utility model, and should not be construed as limiting this utility model.

[0030] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0031] like Figure 1-4 As shown, the high current-carrying connector terminal includes a connector 1 and a main row 2. The connector 1 has holes at both ends, and the main row 2 is fixedly connected between the connectors 1. Several connectors 3 are fixedly connected to both sides of the main row 2, with each pair of connectors 3 forming a group; Connector 3 is hollow and connected to each other in the same group. Terminal 4 is fixedly connected inside connector 3. Terminal 4 is hollow; The top of the connector 3 is fixedly connected to the cylinder 5, and the cylinder 5 is internally threaded with fasteners 6; A cone head 7 is fixedly connected to the bottom end of the fastener 6, and a guide platform 8 is fixedly connected to the inner side of the terminal 4 near the opening. The surface of the guide platform 8 is a smooth slope, and the guide platform 8 is located below the cone head 7.

[0032] Example 1: The connector 1 and main busbar 2 are heat-fused together. The hole in connector 1 is horizontally opened. Connector 1 is bonded to connector 3. Both connector 1 and connector 3 are made of plastic. Terminal 4 is bonded inside connector 3. Terminal 4 has a cylindrical channel inside, and its front and rear ends are connected. Terminal 4 is made of copper, and its upper part connects to cylinder 5. Fastener 6 is made of PVC, and the cone angle of the cone head 7 is the same as the tilt angle of guide platform 8. Guide platform 8 is made of copper.

[0033] Example 2: In this connector connection method, the main busbar 2 is fixed to the base by the connector 2 and screws. The end of the input line is inserted into the terminal 4 of a connector 3. The corresponding fastener 6 is tightened using a tool. The cone 7 at the bottom of the fastener 6 presses the end of the input line onto the guide platform 8. The end of the output line is inserted into the other end of the terminal 4 of the same connector 3 and tightened.

[0034] The connector 1 has holes at both ends for external screw fixing; a main row 2 is fixedly connected between the connectors 1. Several connectors 3 are fixedly connected to both sides of the main row 2, with each pair of connectors 3 forming a group, and the connectors 3 in the same group are connected. The connector 3 is hollow, and a terminal 4 is fixedly connected inside; the terminal 4 is hollow, with its front and rear ends connected, and has a cylindrical channel inside. A cylinder 5 is fixedly connected to the top of the connector 3, and a fastener 6 is threaded inside the cylinder 5. A cone 7 is fixedly connected to the bottom end of the fastener 6. A guide platform 8 is fixedly connected to the inner side of the terminal 4 near the opening. The surface of the guide platform 8 is a smooth slope, and the guide platform 8 is located below the cone 7.

[0035] In terms of materials: the connector 1 and the connecting piece 3 are made of plastic to ensure insulation and lightweight; the terminal 4 and the guide platform 8 are made of copper to provide high conductivity; the fastener 6 is made of PVC to ensure chemical stability and low friction. In addition, the cone angle of the cone head 7 is the same as the tilt angle of the guide platform 8 to achieve uniform pressing.

[0036] The coordinated design of the guide platform 8 and the cone head 7: The guide platform 8 forms a smooth slope in the entrance area of ​​the terminal 4, serving as the core conductive contact area; the cone angle of the cone head 7 matches the tilt angle of the guide platform 8. After the fastener 6 is tightened, the cone head 7 can forcefully press the cable end onto the guide platform 8, inducing plastic deformation of the metal material, thereby maximizing the contact area and achieving ultra-low contact resistance. This not only reduces heat loss but also improves the rated current carrying capacity.

[0037] The working principle of this utility model is as follows: Connection method: During installation, first fix the main busbar 2 to the base through the hole of connector 1 and the external screw. Insert the end of the input line (such as a power cord) into one end of terminal 4 in a set of connectors 3. Insert the end of the output line (such as a load line) into the other end of terminal 4 of another connector 3 in the same set. Then, use a standard tool to tighten the fastener 6 corresponding to terminal 4: the fastener 6 rotates and moves downward inside the cylinder 5, driving the cone 7 to press against the exposed end of the input or output line.

[0038] Initial insertion stage: When the end of the input or output line is inserted into the hollow channel of terminal 4, the smooth slope of guide platform 8 guides the cable smoothly into the channel, preventing jamming or damage. Guide platform 8 serves as the initial contact point, providing a temporary conductive connection.

[0039] Tightening Stage: The operator rotates the upper fastener 6, which moves downward along the thread of the cylinder 5. As it moves downward, the cone 7 at the bottom contacts the cable end. The cone angle of the cone 7 (matching the tilt angle of the guide platform 8) applies a combined vertical and radial force. Under the pressure of the cone 7, the cable end (copper or aluminum wire) is forced against the slope of the guide platform 8.

[0040] The contact area maximization stage: The high pressure of the cone 7 (10-50 N·m of torque can be applied via a tool) causes plastic deformation of the cable's metal material. The deformed cable surface completely conforms to the slope of the guide platform 8, forming a large-area surface-to-surface contact. Traditional point contact or tiny contact surfaces are completely eliminated, increasing the contact area by 50-100%. This process benefits from the precise matching of the cone angles: the cone 7 and the guide platform 8 have the same inclination angle, ensuring uniform force distribution and no stress concentration points.

[0041] Conductivity and Thermal Management Phase: With the contact surface maximized, current is transferred from the cable through guide plate 8 to the copper body of terminal 4. Low contact resistance (typically below 0.5mΩ) significantly reduces ohmic losses, thereby reducing heat generation. For example, at 100A current, the contact resistance of a conventional connector may cause a local temperature rise of over 50K, while this device can control the temperature rise to within 20K. Simultaneously, the "cold soldering" effect formed after plastic deformation further enhances electrical continuity, preventing loosening due to vibration or thermal cycling.

[0042] Cyclic operation and high current carrying capacity: Under continuous high current carrying conditions (e.g., 200-1000A), low resistance and low heat loss ensure stable temperature in the terminal 4 area. The copper material of the guide platform 8 provides rapid heat dissipation, preventing hot spots from forming. The interconnected design of the same group of connectors 3 allows current to be distributed among multiple connection points, further improving the safe current carrying capacity.

[0043] Compared with the prior art, the present invention has the following advantages: This high-current-carrying connector terminal improves upon the hollow channel of terminal 4 by fixing an angled guide platform 8 at the opening of terminal 4. The surface of guide platform 8 is a smooth slope, and this area is the core conductive contact area. The fastener 6 is also improved by adding a cone 7 at its bottom. The angle of the cone 7 is the same as the angle of the guide platform 8. When fastener 6 is tightened, the cone 7 presses the cable end against the guide platform 8, maximizing the contact area. The cone surface compression forces the metal material to undergo plastic deformation, ensuring a tight fit between the external wire and the terminal 4 guide platform 8, significantly increasing the effective conductive contact area. This is key to reducing contact resistance and temperature rise. Reduced contact resistance: High contact pressure and a large contact area directly lead to a significant reduction in contact resistance, meeting high current-carrying requirements. Extremely low contact resistance can be achieved: This is achieved by maximizing the contact area and using extremely high contact pressure. Low operating temperature rise can be achieved: Low resistance reduces heat loss, lowers the risk of temperature rise, and improves long-term reliability and safe current carrying capacity.

Claims

1. A high current connector terminal characterized by, Includes a connector (1) and a main row (2). The connector (1) has holes at both ends, and the main row (2) is fixedly connected between the connectors (1). Several connectors (3) are fixedly connected to both sides of the main row (2), and the connectors (3) are in groups of two; The connector (3) is hollow and the connectors (3) in the same group are connected to each other. The connector (3) has a terminal (4) fixedly connected inside. The terminal (4) is hollow; The top of the connector (3) is fixedly connected to the cylinder (5), and the cylinder (5) is threadedly connected to the fastener (6). The bottom end of the fastener (6) is fixedly connected to a cone head (7), and the inner side of the terminal (4) near the opening is fixedly connected to a guide platform (8). The surface of the guide platform (8) is a smooth slope, and the guide platform (8) is located below the cone head (7).

2. A high current-carrying connector terminal as described in claim 1, characterized in that: The joint (1) is heat-fused to the main row (2), and the hole of the joint (1) is horizontally opened.

3. A high current-carrying connector terminal as described in claim 2, characterized in that: The connector (1) is bonded to the connector (3), and the connector (1) and connector (3) are made of plastic.

4. A high current-carrying connector terminal as described in claim 3, characterized in that: The terminal (4) is bonded inside the connector (3), and the terminal (4) has a cylindrical channel inside, with the front and rear ends of the terminal (4) connected.

5. A high current-carrying connector terminal as described in claim 4, characterized in that: The terminal (4) is made of copper, and the upper part of the terminal (4) is connected to the cylinder (5).

6. A high current-carrying connector terminal as described in claim 5, characterized in that: The fastener (6) is made of PVC, and the cone angle of the cone head (7) is the same as the tilt angle of the guide platform (8).

7. A high current-carrying connector terminal as described in claim 6, characterized in that: The guide platform (8) is made of copper.

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