A quick plug-in aluminum bar connector

Abstract

The utility model discloses a kind of fast-inserted aluminium bar connectors, including plug and socket;At least one copper bar is provided in the socket, the copper bar includes slot, the slot is made of several opposite copper spring, the copper connector is connected with slot;Aluminium bar is provided on the plug, the aluminium bar includes the aluminium terminal of one end protruding the plug and the copper terminal being provided at the other end of the plug;When the plug and socket are connected together, the copper terminal is inserted into the slot to form electrical connection.The beneficial effects of the utility model are that copper-aluminium adapter, using stir friction welding, diffusion welding or other copper-aluminium composite method, copper and aluminium bar are combined at molecular level, to avoid electrochemical corrosion when aluminium bar and copper mechanical connection;When aluminium bar and socket copper terminal are connected, socket terminal uses slot structure, to realize the function of fast insertion and quick assembly.

Description

Technical Field

[0001] This utility model relates to electrical connectors, and more particularly to a quick-connect aluminum busbar connector for use in new energy vehicles. Background Technology

[0002] Chinese Patent CN 115084876 A discloses a wiring connector. This structure belongs to the field of electrical connectors. The wiring connector also includes multiple rigid conductors corresponding to each connecting conductor. Each rigid conductor has an integrally formed conductive connecting plate at its end. The outer shell has conductor through holes for the conductive connecting plates of each rigid conductor to pass through the shell and overlap the top surface of the connecting conductor. The rigid conductors are arranged vertically at intervals. Each conductive connecting plate has bolt through holes for bolts to pass through and corresponding to the bolt mounting holes. This technology is mainly used in electrical connectors for aluminum busbars or copper busbars in the market.

[0003] Chinese Patent CN 218586365 U discloses a high-voltage aluminum busbar connector. This structure belongs to the field of electrical connectors. The system includes a wire harness end, a device end, and an aluminum busbar. A copper post is provided on the device end. The wire harness end is connected and fixed to the device end. The connector further includes a copper bushing, a copper busbar, fasteners, and a PCB board. The aluminum busbar is welded to the copper bushing. The copper bushing is mounted on the copper busbar. The copper busbar is mounted on the wire harness end and connected to the copper post via fasteners to achieve current transfer. This technology is mainly used in the market for electrical connectors with aluminum busbars.

[0004] The aforementioned product structures all employ a relatively conventional screw-locking installation between rigid conductors. This screw-locking assembly method is inefficient and cumbersome. Furthermore, with an aluminum conductor on one side and a copper conductor on the other, ordinary mechanical connections easily lead to the formation of a galvanic cell, causing electrochemical corrosion. In high-current connections, the different coefficients of linear expansion between copper and aluminum generate heat, causing the conductor temperature to rise. The different degrees of thermal expansion and contraction between copper and aluminum conductors reduce the contact area at the connection point, increasing resistance and further raising the temperature, creating a vicious cycle that can lead to severe damage such as ablation. Moreover, the aforementioned and related technologies generally only allow for 90° cable exits, failing to meet the needs for cable exits at different angles, especially 180°. Utility Model Content

[0005] The purpose of this utility model is to provide a quick-connect aluminum busbar connector that solves or partially solves the above-mentioned technical problems.

[0006] To achieve the above objectives, this utility model provides the following technical solution:

[0007] A quick-connect aluminum busbar connector includes a plug and a socket; the socket has at least one copper busbar, the copper busbar including a copper connector extending out of the socket at one end and a slot at the other end, the slot being composed of a plurality of opposing copper spring contacts, the copper connector being connected to the slot; the plug has at least one aluminum busbar correspondingly provided, the aluminum busbar including an aluminum terminal extending out of the plug at one end and a copper terminal at the other end of the plug, the copper terminal and the aluminum terminal being fixedly connected by welding; when the plug and the socket are connected together, the copper terminal is inserted into the slot to form an electrical connection.

[0008] Preferably, the plug includes a connecting end for connecting to the socket and an output end, wherein the axes of the connecting end and the output end form an angle of 90°, 120°, 135°, 165° or 180°; when the axes of the connecting end and the output end form an angle of 120°, 135°, 165° or 180°, the copper terminal is correspondingly provided with an oblique angle to be flush with the slot.

[0009] Preferably, the plug is pivotally provided with a rotatable latch handle for fixing the socket, and the socket is correspondingly provided with a latch post for engaging the latch handle.

[0010] Preferably, the buckle handle is provided with an arc-shaped groove around the pivot point, and the edge of the arc-shaped groove is provided with a sliding groove for the buckle post to enter the arc-shaped groove.

[0011] Preferably, the plug is provided with at least one wedge-shaped locking block for fixing the buckle handle, and the buckle handle is provided with a square window corresponding to the position of the wedge-shaped locking block. The square window is provided with an unlocking spring, which includes a locking part for locking with the wedge-shaped locking block and a pressing part. The locking part and the pressing part are connected to the buckle handle by a pivot shaft.

[0012] Preferably, a connecting post is provided on each side of the socket, and a screw hole is provided on the connecting post. The plug is connected to the screw hole by a screw to connect the plug and the socket.

[0013] Preferably, both the copper terminal and the aluminum terminal include a thickened connecting end, and the connecting ends of the copper terminal and the aluminum terminal are connected together by friction stir welding, diffusion welding or laser welding.

[0014] Preferably, the outlet end is provided with a sealing ring made of insulating material and a front cover for fixing the sealing ring.

[0015] Preferably, the socket is provided with an aluminum busbar made of insulating material.

[0016] Preferably, the socket is provided with two copper busbars and the plug is provided with two aluminum busbars; the copper busbar is formed by folding a copper plate in half, with the front part forming the copper connector, and the rear part being split and having an elongated hole to form the spring contact, the spring contact being bent inward to form a contact point.

[0017] The beneficial effects of this invention are as follows: At the copper-aluminum junction, friction stir welding, diffusion welding, or other copper-aluminum composite methods are used to achieve a molecular-level bond between the copper and aluminum busbars, avoiding electrochemical corrosion during mechanical connection. When connecting the aluminum busbar to the copper terminals of the socket, the socket terminals employ a slot structure, enabling quick insertion and rapid assembly. No screws are required when connecting the aluminum busbar on the plug to the socket terminals, significantly reducing assembly steps and time, and avoiding the risk of missing or improperly installed screws. Furthermore, this invention allows for cable exit at different angles, greatly satisfying the needs of diverse customers. Attached Figure Description

[0018] Figure 1 This is a three-dimensional structural schematic diagram of the first embodiment;

[0019] Figure 2 This is an exploded structural diagram of the first embodiment;

[0020] Figure 3 This is a three-dimensional structural schematic diagram of the second embodiment;

[0021] Figure 4 This is a front view structural diagram of the second embodiment;

[0022] Figure 5 yes Figure 4 A schematic diagram of the AA-direction cross-section structure;

[0023] Figure 6 This is an exploded structural diagram of the second embodiment;

[0024] Figure 7 This is a top view of the structure of the second embodiment;

[0025] Figure 8 These are comparative structural diagrams of five embodiments;

[0026] Figure 9 These are comparative structural diagrams of five other embodiments;

[0027] Figure 10 This is a partial structural diagram of one embodiment;

[0028] Figure 11 This is a three-dimensional structural schematic diagram of one embodiment;

[0029] Figure 12 This is a schematic diagram of an aluminum busbar structure according to a certain embodiment. Detailed Implementation

[0030] The technical solution of this utility model will be further described in detail below with reference to specific embodiments.

[0031] In the description of this utility model, it should be noted that the terms "inner", "outer", "upper", "lower", "horizontal", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0032] like Figures 1 to 12 As shown, this utility model discloses a quick-connect aluminum busbar connector including a plug 10 and a socket 12. The plug 10 and socket 12 are separate, and when connected, they can be fixed together in two ways:

[0033] 1) A rotatable latching handle 14 for securing the socket 12 is pivotally mounted on the plug 10. A corresponding latching post 16 is mounted on the socket 12 to engage the latching handle 14. The latching handle 14 has an arc-shaped groove 18 around the pivot point, and its edge has a sliding groove 20 for the latching post 16 to enter. When the plug 10 is inserted into the socket 12, the position of the latching handle 14 is adjusted so that the latching post 16 enters the arc-shaped groove 18 along the sliding groove 20. After the plug 10 is in place, rotating the latching handle 14 causes the latching post 16 to move along the arc-shaped groove 18, thereby preventing the plug 10 from moving away from the socket 12 in the opposite direction of entry, thus achieving a secure connection. The plug 10 and socket 12 are shaped to match, allowing them to be inserted from only one direction; this is common industry practice and therefore not described in detail.

[0034] 2) A connecting post 22 is provided on each side of the socket 12. The connecting post 22 is provided with a screw hole (not shown). The plug 10 is connected to the screw hole by a screw 23 to connect the plug 10 and the socket 12.

[0035] The socket 12 has two copper busbars, each including a copper connector 24 extending out of the socket 12 at one end and a slot 26 at the other end. The slot 26 consists of several opposing copper spring contacts 28. The copper connector 24 connects to the slot 26. The plug 10 has two corresponding aluminum busbars, each including an aluminum terminal 30 extending out of the plug 10 at one end and a copper terminal 32 at the other end. The copper terminal 32 and the aluminum terminal 30 are fixedly connected by welding. When the plug 10 and socket 12 are connected, the copper terminal 32 inserts into the slot 26 to form an electrical connection. This structure allows the plug 10 and socket 12 to be properly engaged and secured, forming a standard connector consisting of two aluminum terminals 30 and a copper connector 24. Because the copper terminal 32 and slot 26 are plug-in, quick-connect and rapid assembly are achieved without the need for additional screws.

[0036] Furthermore, the plug 10 includes a connecting end 34 for connecting to the socket 12 and a wire outlet end 36. The axes of the connecting end 34 and the wire outlet end 36 form an angle of 90°, 120°, 135°, 165°, or 180°. When the axes of the connecting end 34 and the wire outlet end 36 form an angle of 120°, 135°, 165°, or 180°, the copper terminal 32 is correspondingly provided with an oblique angle 38 to be flush with the slot 26. Therefore, by using plugs 10 with different structures, multiple wire outlet directions of the aluminum terminal 30 and the copper connector 24 can be achieved to meet diverse needs.

[0037] Furthermore, the plug 10 is provided with at least one wedge-shaped locking block (not shown) for fixing the latch handle 14. A square window 40 is provided on the latch handle 14 corresponding to the position of the wedge-shaped locking block. An unlocking spring is provided within the square window 40. The unlocking spring includes a locking part 42 for engaging with the wedge-shaped locking block and a pressing part 44. The locking part 42 and the pressing part 44 are connected to the latch handle 14 via a pivot shaft 46. The method of use is as follows: when locking, the locking part 42 is lifted by the pressure of the wedge-shaped locking block, and the wedge-shaped locking block enters, thus achieving locking; when unlocking, the pressing part 44 is manually pressed, the locking part 42 is lifted, and the wedge-shaped locking block disengages, thus achieving unlocking. Since the wedge-shaped locking block itself is well-known in the industry, its structure is not shown in detail.

[0038] Both the copper terminal 32 and the aluminum terminal 30 include a thickened connecting end 34, and the connecting ends 34 of the copper terminal 32 and the aluminum terminal 30 are connected together by friction stir welding, diffusion welding or laser welding.

[0039] The outlet terminal 36 is provided with a sealing ring 48 made of insulating material and a front cover 50 for fixing the sealing ring 48. The socket 12 is provided with an aluminum busbar 52 made of insulating material. This is to prevent fingers or foreign objects from entering.

[0040] There are many ways to implement a copper busbar. This utility model adopts the following structure: the copper busbar is formed by folding a copper plate in half, with a copper connector 24 formed at the front and a long strip hole opened at the rear to form a spring piece 28. The spring piece 28 is bent inward to form a contact point.

[0041] The above description is merely an embodiment of this utility model and does not limit the patent scope of this utility model. Any equivalent structural or procedural transformations made based on the content of this utility model specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this utility model.

Claims

1. A quick-connect aluminum busbar connector, comprising a plug and a socket; characterized in that: The socket is provided with at least one copper busbar, which includes a copper connector extending out of the socket at one end and a slot at the other end. The slot is composed of several opposing copper spring contacts, and the copper connector is connected to the slot. The plug is provided with at least one aluminum busbar, which includes an aluminum terminal extending out of the plug at one end and a copper terminal at the other end of the plug. The copper terminal and the aluminum terminal are fixedly connected by welding. When the plug and the socket are connected together, the copper terminal is inserted into the slot to form an electrical connection.

2. The quick-connect aluminum busbar connector according to claim 1, characterized in that, The plug includes a connecting end for connecting to the socket and an output end. The axes of the connecting end and the output end form an angle of 90°, 120°, 135°, 165° or 180°. When the axes of the connecting end and the output end form an angle of 120°, 135°, 165° or 180°, the copper terminal is correspondingly provided with an oblique angle to be flush with the slot.

3. A quick-connect aluminum busbar connector according to claim 1, characterized in that, The plug is pivotally provided with a rotatable latch handle for fixing the socket, and the socket is provided with a corresponding latch post for engaging the latch handle.

4. A quick-connect aluminum busbar connector according to claim 3, characterized in that, The buckle handle is provided with an arc-shaped groove around the pivot point, and the edge of the arc-shaped groove is provided with a sliding groove for the buckle post to enter the arc-shaped groove.

5. A quick-connect aluminum busbar connector according to claim 4, characterized in that, The plug is provided with at least one wedge-shaped locking block for fixing the buckle handle. The buckle handle is provided with a square window corresponding to the position of the wedge-shaped locking block. The square window is provided with an unlocking spring. The unlocking spring includes a locking part for locking with the wedge-shaped locking block and a pressing part. The locking part and the pressing part are connected to the buckle handle by a pivot shaft.

6. A quick-connect aluminum busbar connector according to claim 1, characterized in that, A connecting post is provided on each side of the socket, and a screw hole is provided on the connecting post. The plug is connected to the screw hole by a screw to connect the plug and the socket.

7. A quick-connect aluminum busbar connector according to claim 1, characterized in that, Both the copper and aluminum terminals include thickened connecting ends, and the connecting ends of the copper and aluminum terminals are connected together by friction stir welding, diffusion welding, or laser welding.

8. A quick-connect aluminum busbar connector according to claim 2, characterized in that, The outlet end is provided with a sealing ring made of insulating material and a front cover for fixing the sealing ring.

9. A quick-connect aluminum busbar connector according to claim 1, characterized in that, An aluminum busbar made of insulating material is installed at the socket.

10. A quick-connect aluminum busbar connector according to claim 1, characterized in that, The socket is provided with two copper busbars, and the plug is provided with two aluminum busbars; the copper busbar is formed by folding a copper plate in half, with the front part forming the copper connector, and the rear part being split and having an elongated hole to form the spring contact, the spring contact being bent inward to form a contact point.

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