Electrical connector

Abstract

The utility model provides a kind of electric connector, including cable and terminal, cable includes at least one conductor, and the conductor is connected with terminal by composite welding part, and composite welding part includes: first welding part, at least partially formed between conductor and terminal;And second welding part, at least partially surrounded by first welding part, and second welding part is connected with first welding part by metallurgical combination.Accordingly, the connection strength between conductor and terminal, the stability of conduction and the anti-vibration performance can be significantly enhanced.

Description

Technical Field

[0001] This utility model generally relates to the field of electrical equipment, and more specifically to an electrical connector. Background Technology

[0002] Existing cables (such as flat cables) and terminals are typically connected by resistance welding, with the two joined only by a weld joint formed by resistance welding. However, with the development of electrical connectors, connector sizes have gradually decreased, and terminal pad sizes have also become smaller (e.g., approximately 1.2 mm). In such cases, relying solely on a weld joint formed by resistance welding can easily lead to microcracks and brittle fracture, insufficient fatigue resistance, and other issues, resulting in a high product defect rate. Utility Model Content

[0003] To overcome the aforementioned deficiencies in the prior art, this utility model proposes an electrical connector comprising a cable and terminals. The cable includes at least one conductor, which is connected to the terminals via a composite welding portion. The composite welding portion includes: a first welding portion, at least partially formed between the conductor and the terminal; and a second welding portion, at least partially surrounded by the first welding portion, and the second welding portion and the first welding portion are connected by a metallurgical bonding. Accordingly, the connection strength between the conductor and the terminal can be significantly enhanced, thereby improving conductivity stability and vibration resistance.

[0004] Furthermore, the first welded portion is formed by resistance welding, laser welding, or ultrasonic welding, and the second welded portion is formed by resistance welding, laser welding, or ultrasonic welding. Specifically, the first welded portion is formed by resistance welding, and the second welded portion is formed by laser welding. This improves ease of operation.

[0005] Furthermore, the composite welded portion includes a plurality of second welded portions separated from each other, wherein at least a portion of the plurality of second welded portions is arranged in a straight line along the extension direction of the conductor; and / or at least three of the second welded portions are arranged in a triangular arrangement. Accordingly, the connection strength between the conductor and the terminal can be further enhanced.

[0006] Furthermore, the longitudinal section of the second welded portion is trapezoidal, inverted conical, rectangular, square, or irregular in shape. Accordingly, the connection strength between the conductor and the terminal can be further enhanced in various ways.

[0007] Furthermore, a fusion interface is formed between the second welded portion and the first welded portion, and the thickness of the fusion interface is greater than or equal to 0.005 mm. This further enhances the connection strength between the conductor and the terminal.

[0008] Furthermore, the second weld portion passes through the conductor or the terminal and is fused to the first weld portion. The second weld portion includes a first embedding portion, which is disposed within and surrounded by the first weld portion, and the height of the first embedding portion is greater than or equal to 0.02 mm. Accordingly, the connection strength between the conductor and the terminal can be further enhanced.

[0009] Furthermore, the first end of the second welded portion is fused to the first welded portion, and the second end of the second welded portion opposite to the first end is recessed relative to the surface of the conductor to form a first recess, the depth of the first recess being less than or equal to 0.02 mm; or the second end of the second welded portion opposite to the first end is recessed relative to the surface of the terminal to form a second recess, the depth of the second recess being less than or equal to 0.02 mm. Accordingly, the connection strength between the conductor and the terminal can be further enhanced.

[0010] Furthermore, the second weld portion passes sequentially through the conductor and the first weld portion and is fused to the terminal. The second weld portion includes a second embedding portion at its first end, which is placed within and surrounded by the terminal. The height of the second embedding portion is greater than or equal to 0.02 mm. Furthermore, the second end of the second weld portion, opposite to the first end, is recessed relative to the surface of the conductor to form a third recess, the depth of which is less than or equal to 0.02 mm. This further enhances the connection strength between the conductor and the terminal.

[0011] Furthermore, the second weld portion passes sequentially through the terminal and the first weld portion and is fused to the conductor. The second weld portion includes a third embedded portion at its first end, which is placed within and surrounded by the conductor. The height of the third embedded portion is greater than or equal to 0.02 mm. Additionally, the second end of the second weld portion, opposite to the first end, is recessed relative to the surface of the terminal to form a fourth recess, the depth of which is less than or equal to 0.02 mm. This further enhances the connection strength between the conductor and the terminal. Attached Figure Description

[0012] The accompanying drawings are provided to further illustrate the present invention and constitute a part of the present invention. The illustrative embodiments and descriptions of the present invention are used to explain the present invention and do not constitute an undue limitation of the present invention. In the drawings: Figure 1 This is a schematic partial perspective view of the electrical connector of this utility model; Figure 2 It is shown schematically. Figure 1 The diagram shows a partial perspective view of the electrical connector, in which a conductor has been removed to show the composite solder joint more clearly; Figure 3 This is a perspective view schematically showing the first weld portion in a composite weld portion according to one embodiment; Figure 4 This is a perspective view schematically showing a terminal of another embodiment; and Figure 5 This is a schematic perspective view of the second welding part in the composite welding part of this utility model.

[0013] List of reference numerals

[0014] 100 electrical connectors

[0015] 1. Cable

[0016] 11 Conductors

[0017] 11S surface

[0018] 2 terminals

[0019] 3 Composite Welding Section

[0020] 31 First Welding Section

[0021] 31S outer surface

[0022] 32 Second Welding Section

[0023] 32A First End

[0024] 32B Second End

[0025] 32S end face

[0026] H recess

[0027] H' another concave part Detailed Implementation

[0028] The technical solutions of the embodiments of this utility model will be described in detail below with reference to the accompanying drawings. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0029] In the following detailed description, reference is made to the accompanying drawings, which form a part of this specification, in which specific embodiments of the present invention are illustrated by way of example. Regarding the drawings, directional terms such as “top,” “bottom,” “inner,” “outer,” “upper,” “lower,” “front,” and “rear” are used with reference to the orientation of the drawings described. Since the components of the embodiments of the present invention can be positioned in many different orientations, the directional terms are for illustrative purposes only and are not intended to be limiting. It should be understood that other embodiments can be used, and structural or logical changes can be made without departing from the scope of the present invention. Therefore, the following detailed description should not be construed as limiting, and the present invention is defined by the appended claims.

[0030] Reference Figure 1 and Figure 2 As shown, this utility model proposes an electrical connector 100, which includes a cable 1 and terminals 2. The cable 1 includes at least one conductor 11, which is soldered to the terminals 2 to achieve an electrical connection. The figure exemplarily shows the cable 1 including two conductors 11, which are connected to two signal terminals 2 in a corresponding differential signal terminal pair. However, the form of the electrical connector 100 is not limited to this; the adapted cable may include a single conductor or more than two conductors. In this embodiment, the conductor 11 is the core wire of the cable 1. In this utility model, as... Figure 2 As best illustrated, the conductor 11 can be connected to the terminal 2 via a composite welding portion 3. The composite welding portion 3 may include a first welding portion 31 and a second welding portion 32, wherein the first welding portion 31 may be at least partially formed between the conductor 11 and the terminal 2, and the second welding portion 32 may be at least partially surrounded by the first welding portion 31, and the second welding portion 32 and the first welding portion 31 are connected by a metallurgical bond. It should be noted that the metallurgical bond mentioned in this invention refers to the formation of a whole at the interface of two welding portions (i.e., weld points) through the metallic bonding action between atoms or molecules. This can be achieved, but is not limited to, a fusion surface formed by melting and solidification or a diffusion bonding layer formed by solid-state diffusion. Specifically, in this invention, the fusion of the two welding portions is mainly achieved through a fusion surface formed by melting and solidification.

[0031] Specifically, the first welding part 31 is formed by resistance welding, laser welding, or ultrasonic welding, and the second welding part 32 is formed by resistance welding, laser welding, or ultrasonic welding. More specifically, the first welding part 31 is formed by resistance welding, and the second welding part 32 is formed by laser welding. In this invention, the first welding part 31 is first formed by resistance welding to form a positioning connection, ensuring the initial connection between the conductor 11 and the terminal 2. Then, the second welding part 32 is formed by laser welding, that is, a high-strength fusion connection point is created inside the first welding part 31. Specifically, when the interface between the second welding part 32 and the first welding part 31 melts, continuous grain growth can be formed, so that the load stress can be transmitted evenly and smoothly, avoiding stress concentration at the interface. The fusion connection point can bear vibration stress and can effectively avoid cracking when subjected to impact, thereby improving the vibration resistance of the connector and improving the electrical stability and reliability of long-term use.

[0032] Specifically, the first welded portion 31 is formed by connecting the conductor 11 and the terminal 2 together by resistance welding, and it can have a certain thickness. The second welded portion 32 is formed by laser welding through the conductor 11 and at least a portion of the first welded portion 31, and even through a portion of the terminal 2, to form the second welded portion 32 after fusion. Alternatively, the second welded portion 32 is formed by laser welding through the terminal 2 and at least a portion of the first welded portion 31, and even through a portion of the conductor 11, to form the second welded portion 32 after fusion and solidification. Accordingly, by combining resistance welding and laser welding, a composite welded portion 3, namely the first welded portion 31 and the second welded portion 32 fused together, can be formed to significantly enhance the connection strength between the conductor and the terminal, thereby improving conductivity stability and vibration resistance.

[0033] Furthermore, the composite welding portion 3 may include a plurality of second welding portions 32 that are separate from each other. In this invention, the number of second welding portions 32 is not limited; there may be one or more, and the number can be selected according to actual needs. Obviously, the more second welding portions 32 there are, the stronger the connection between the first welding portion 31 and the second welding portion 32 will be, thereby increasing the connection strength between the conductor 11 and the terminal 2.

[0034] Specifically, at least a portion of the plurality of second weld portions 32 may be arranged in a straight line along the extending direction of the conductor 11 or the terminal 2. Further or alternatively, at least three of the plurality of second weld portions 32 may be arranged in a triangular pattern, thereby further improving the connection strength between the conductor and the terminal. Of course, the present invention is not limited to this; for example, all of the plurality of second weld portions 32 may be arranged in a straight line, or a portion of them may be arranged in a straight line while every three of the remaining portions are arranged in a triangular pattern.

[0035] In one embodiment, the second weld portion 32 is perpendicular to the first weld portion 31. Specifically, as shown below... Figure 1 or Figure 2 As shown, laser welding can be performed on the top surface of the conductor 11 (i.e., the side of the conductor 11 opposite to the first welding portion 31), which is particularly convenient and easy to operate when the conductor 11 has a flat shape. Of course, the present invention is not limited to this. For example, laser welding can also be performed on the side of the conductor 11, in which case the second welding portion will be obliquely connected to the first welding portion.

[0036] Furthermore, the longitudinal section of the second welding portion 32 can be trapezoidal, inverted conical, rectangular, square, or irregular, etc. Specifically, the cross-sectional area of ​​the first end 32A of the second welding portion 32, which is used for fusion connection with the first welding portion 31, can be smaller than the cross-sectional area of ​​the second end 32B of the second welding portion 32, which is opposite to the first end 32A. This allows the second welding portion 32 to have a shape that tapers from the second end 32B to the first end 32A. Accordingly, fusion connection between the first welding portion and the second welding portion can be facilitated, and the connection strength between the conductor and the terminal can be improved.

[0037] In one embodiment, a fusion interface can be formed between the second weld portion 32 and the first weld portion 31. In other words, a portion of the second weld portion 32 and a portion of the first weld portion 31 fuse together during the fusion process to form a fusion interface. The thickness of the fusion interface is, for example, greater than or equal to 0.005 mm. During the fusion process, a portion of the second weld portion 32 and a portion of the first weld portion 31 can generate continuous grain growth and form a metallurgically integrated microstructure, which allows the load stress to be transmitted uniformly and smoothly, avoiding stress concentration at the fusion interface. Conversely, if the thickness of the fusion interface is less than 0.005 mm, cracks are easily generated under vibration or thermal stress. It is understood that the thicker the fusion interface, the stronger the connection strength between the first weld portion 31 and the second weld portion 32, thus preventing microcracks from directly propagating from the second weld portion 32 to the first weld portion 31. In addition, it allows the current to have a sufficiently large conduction cross section between the first weld portion 31 and the second weld portion 32, avoiding the risk of increased local resistance and overheating due to an excessively thin interface, and significantly improving the lifespan of the connector under long-term vibration.

[0038] In one embodiment, the second weld portion 32 passes through the conductor 11 or terminal 2 and is fused to the first weld portion 31. The second weld portion 32 may include a first insert portion, for example at the first end 32A, which is located within and surrounded by the first weld portion 31. Specifically, the height of the first insert portion is greater than or equal to 0.02 mm. In other words, for example... Figure 3 As shown, a recess H can be formed on the first weld portion 31, for example, recessed from the outer surface 31S of the first weld portion 31, and the first insert portion of the second weld portion 32 is placed in the recess H, so that a portion of the outer side surface of the second weld portion 32 fits into the first weld portion to improve the connection strength. The shape of the recess H is not limited to... Figure 3 The shape shown is circular, but it can also be square or other shapes.

[0039] In one embodiment, the first end 32A of the second welding portion 32 can be fused to the first welding portion 31, and the second end 32B of the second welding portion 32, opposite to the first end 32A, is recessed relative to the surface 11S of the conductor 11 to form a first recess, the depth of which can be less than or equal to 0.02 mm. Alternatively, the second end 32B of the second welding portion 32, opposite to the first end 32A, is recessed relative to the surface of the terminal 2 to form a second recess, the depth of which is less than or equal to 0.02 mm. Furthermore, the depth to which the first end 32A of the second welding portion 32 penetrates into the recess H can be greater than or equal to 0.02 mm. Accordingly, as fusion proceeds, the molten portion will enter more into the recess H of the first welding portion 31 due to the influence of gravity, thereby making the fusion of the second welding portion 32 and the first welding portion 31 more complete, and further enhancing the connection strength between the conductor and the terminal.

[0040] In one embodiment, the second welding portion 32 can sequentially pass through the conductor 11 and the first welding portion 31 and fuse with the terminal 2. In other words, unlike the previous embodiment, the recess H of the first welding portion 31 can be through-hole, and another recess H' is formed on the terminal 2. The second welding portion 32 passes through the through-hole recess H to fuse with the terminal 2 within the other recess H'. That is, the second welding portion 32 includes a second embedding portion at its first end 32A, which is placed inside and surrounded by the terminal 2, and the second end 32B of the second welding portion 32, opposite to the first end 32A, is recessed relative to the surface 11S of the conductor 11 to form a third recess. Accordingly, the connection strength between the conductor and the terminal can be further enhanced. In particular, the height of the second embedding portion is greater than or equal to 0.02 mm. It should be noted that the higher this height, the stronger the force and connection strength of the connected parts. Conversely, when it is less than 0.02 mm, the fusion volume is too small, and the bonding force cannot support the overall stress of the connector, which can easily lead to unstable electrical signals. In addition, the depth of the third recess is less than or equal to 0.02 mm. It should be noted that the smaller this depth, the stronger the conductor or terminal, the less likely it is to break, and the more it prevents damage to the conductor or terminal from over-soldering, thereby increasing the signal stability and service life of the connector. Conversely, when it is greater than 0.02 mm, the conductor or terminal will be too thin, and it will be easy to break under stress.

[0041] In an alternative embodiment, the second weld portion 32 can sequentially pass through the terminal 2 and the first weld portion 31 and be fused to the conductor 11. The second weld portion 32 includes a third embedding portion at its first end 32A, which is placed within and surrounded by the conductor 11. Specifically, the height of the third embedding portion is greater than or equal to 0.02 mm, and the second end 32B of the second weld portion 32, opposite to the first end 32A, is recessed relative to the surface of the terminal 2 to form a fourth recess. Specifically, the depth of the fourth recess is less than or equal to 0.02 mm. The effect of this embodiment is similar to that of the previous embodiment, both further enhancing the connection strength between the conductor and the terminal.

[0042] The above description is merely a preferred embodiment of this utility model and is not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. An electrical connector, characterized in that, The electrical connector (100) includes a cable (1) and a terminal (2). The cable (1) includes at least one conductor (11), which is connected to the terminal (2) via a composite solder joint (3). The composite solder joint (3) includes: A first weld portion (31) is at least partially formed between the conductor (11) and the terminal (2); and The second welded portion (32) is at least partially surrounded by the first welded portion (31), and the second welded portion (32) is connected to the first welded portion (31) by a metallurgical bond.

2. The electrical connector according to claim 1, characterized in that, The first welded part (31) is formed by resistance welding, laser welding or ultrasonic welding, and the second welded part (32) is formed by resistance welding, laser welding or ultrasonic welding.

3. The electrical connector according to claim 2, characterized in that, The first welded part (31) is formed by resistance welding, and the second welded part (32) is formed by laser welding.

4. The electrical connector according to any one of claims 1 to 3, characterized in that, The composite welded part (3) includes a plurality of second welded parts (32) that are separated from each other, wherein, At least a portion of the plurality of second weld portions (32) are arranged in a straight line along the extension direction of the conductor (11) or the terminal (2); and / or At least three of the second welded parts (32) are arranged in a triangular pattern.

5. The electrical connector according to any one of claims 1 to 3, characterized in that, The longitudinal section of the second welded part (32) is trapezoidal, inverted conical, rectangular, square, or irregular.

6. The electrical connector according to any one of claims 1 to 3, characterized in that, A fusion interface is formed between the second welded part (32) and the first welded part (31), and the thickness of the fusion interface is greater than or equal to 0.005 mm.

7. The electrical connector according to any one of claims 1 to 3, characterized in that, The second weld (32) passes through the conductor (11) or the terminal (2) and is fused to the first weld (31). The second weld (32) includes a first embedding part, which is placed inside the first weld (31) and surrounded by the first weld (31). The height of the first embedding part is greater than or equal to 0.02 mm.

8. The electrical connector according to any one of claims 1 to 3, characterized in that, The first end (32A) of the second welded part (32) is fused to the first welded part (31), and The second end (32B) of the second welded portion (32), opposite to the first end (32A), is recessed relative to the surface (11S) of the conductor (11) to form a first recess, the depth of which is less than or equal to 0.02 mm, or The second end (32B) of the second welded portion (32) opposite to the first end (32A) is recessed relative to the surface of the terminal (2) to form a second recess, the depth of the second recess being less than or equal to 0.02 mm.

9. The electrical connector according to any one of claims 1 to 3, characterized in that, The second welding part (32) passes sequentially through the conductor (11) and the first welding part (31) and is fused to the terminal (2), wherein, The second welding portion (32) includes a second embedding portion at the first end (32A), the second embedding portion being placed inside the terminal (2) and surrounded by the terminal (2), the height of the second embedding portion being greater than or equal to 0.02 mm, and the second end (32B) of the second welding portion (32) opposite to the first end (32A) being recessed relative to the surface (11S) of the conductor (11) to form a third recess, the depth of the third recess being less than or equal to 0.02 mm.

10. The electrical connector according to any one of claims 1 to 3, characterized in that, The second welding part (32) passes sequentially through the terminal (2) and the first welding part (31) and is fused to the conductor (11), wherein, The second welding portion (32) includes a third embedding portion at the first end (32A), the third embedding portion being placed inside and surrounded by the conductor (11), the height of the third embedding portion being greater than or equal to 0.02 mm, and the second end (32B) of the second welding portion (32) opposite to the first end (32A) being recessed relative to the surface of the terminal (2) to form a fourth recess, the depth of the fourth recess being less than or equal to 0.02 mm.

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