Female terminal and connector
Patent Information
- Application Number
- CN202521878641.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-01
- Publication Date
- 2026-10-27
- Estimated Expiration
- 2035-09-01
AI Technical Summary
[0003]目前市面上主流的高压连接器为泰科电子(TE Connectivity)的CSJ系列连接器，但其结构复杂，通常需要多个导电片进行铆接组装
[0007]本申请通过将第一复合层和第二复合层复合形成导电片，使得汇流排在第二方向的一侧仅需一个导电片，替代了传统母端子中多层导电片的复杂设计，由此可以简化母端子的导电片的结构，使得汇流排的母端对配部处更加紧凑，外形尺寸更小，有助于开发出外形尺寸更小的连接器，从而在整车的安装布置上提供更大的灵活性和优势。由于导电片的复合设计，可以简化导电片的安装工艺，提高了母端子的组装精度和可靠性，降低了生产成本和时间，提高了生产效率。导电片利用第一复合层作为载流层，并利用第二复合层为第一复合层提供正向力，确保了母端子所需的正向力和稳定的接触电阻，这种设计不仅提高了母端子的载流能力，还保证了电气连接的稳定性和可靠性，减少了电气故障的风险。
Smart Images
Figure CN224908501U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of connector technology, and more particularly to a female terminal and connector. Background Technology
[0002] With increasing global demands for sustainable development and environmental protection, electric vehicle (EV) technology has developed rapidly. One of the core components of an EV is the electric drive system, whose performance directly affects the vehicle's power output and range. As EV technology advances, the power requirements of the electric drive system are constantly increasing, and the current in the high-voltage electrical circuits supplying power to the system is also rising. This places higher demands on the current-carrying capacity of the high-voltage connectors that provide reliable electrical connections to the electric drive system to ensure efficient current transmission.
[0003] Currently, the mainstream high-voltage connectors on the market are TE Connectivity's CSJ series connectors, but their complex structure typically requires multiple conductive pieces to be riveted together. This complex structure increases the difficulty of manufacturing and assembly, and also results in larger terminal dimensions in the thickness direction, which is not conducive to the lightweight and compact design requirements of electric vehicles. Utility Model Content
[0004] The purpose of this application is to provide a female terminal and connector to at least partially solve the above-mentioned technical problems.
[0005] To achieve the above objectives, this application provides a female terminal having intersecting first and second directions. The female terminal includes: a busbar having a female terminal mating portion and a female terminal connecting portion at its two ends in the first direction; and two conductive sheets connected to the female terminal mating portion on both sides in the second direction; wherein at least one of the two conductive sheets includes a composite first composite layer and a composite second layer, with the second composite layer located on the side of the first composite layer away from the female terminal mating portion.
[0006] To achieve the above objectives, this application also provides a connector, including a male connector and a female connector that are mated together, wherein the male connector is provided with the female terminal of this application.
[0007] This application combines a first composite layer and a second composite layer to form a conductive sheet, requiring only one conductive sheet on one side of the busbar in the second direction. This replaces the complex design of multiple conductive sheets in traditional female terminals, simplifying the structure of the conductive sheet in the female terminal. This results in a more compact mating section at the busbar's female end, smaller overall dimensions, and facilitates the development of smaller connectors, thus providing greater flexibility and advantages in vehicle installation. The composite design of the conductive sheet simplifies the installation process, improves the assembly accuracy and reliability of the female terminal, reduces production costs and time, and increases production efficiency. The conductive sheet utilizes the first composite layer as a current-carrying layer and the second composite layer to provide positive force to the first composite layer, ensuring the required positive force and stable contact resistance of the female terminal. This design not only improves the current-carrying capacity of the female terminal but also guarantees the stability and reliability of the electrical connection, reducing the risk of electrical failures.
[0008] Other features and advantages of this application will be described in detail in the following detailed description section. Attached Figure Description
[0009] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0010] To gain a more complete understanding of this application and its beneficial effects, the following description will be provided in conjunction with the accompanying drawings, wherein the same reference numerals in the following description denote the same parts.
[0011] Figure 1 This is a schematic diagram of the structure of the female terminal provided in Exemplary Embodiment 1 of this disclosure;
[0012] Figure 2 This is an exploded view of the female terminal provided in Exemplary Embodiment 1 of this disclosure;
[0013] Figure 3 This is a partial schematic diagram of the composite conductive sheet provided in Exemplary Embodiment 1 of this disclosure;
[0014] Figure 4 This is a schematic diagram of the riveting of the conductive sheet and the busbar provided in Exemplary Embodiment 1 of this disclosure;
[0015] Figure 5 This is a schematic diagram of the structure of the female terminal provided in Exemplary Embodiment 2 of this disclosure;
[0016] Figure 6This is a partial schematic diagram of the composite bus provided in Exemplary Embodiment 2 of this disclosure;
[0017] Figure 7 This is a schematic diagram of the insertion of the female and male terminals of the connector provided in Exemplary Embodiment 3 of this disclosure;
[0018] Figure 8 This is a schematic diagram of the insertion of the female and male terminals of the connector provided in Exemplary Embodiment 4 of this disclosure.
[0019] Explanation of reference numerals in the attached figures:
[0020] 100, Female terminal; 200, Male terminal; M, First direction; N, Second direction; P, Third direction;
[0021] 1. Busbar; 2. Conductive sheet; 3. Fixture;
[0022] 11. Female end mating part; 12. Female end connecting part; 21. Main body; 22. Elastic arm; 111. First connecting hole; 211. Second connecting hole; 110. Aluminum layer; 120. Copper layer; 210. First composite layer; 220. Second composite layer. Detailed Implementation
[0023] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the protection scope of this application.
[0024] Example 1
[0025] Please see Figure 1 and Figure 2 This application provides a female terminal 100. The female terminal 100 has a first direction M, a second direction N, and a third direction P that intersect each other. In this embodiment, the first direction M, the second direction N, and the third direction P are perpendicular to each other. The perpendicularity of the first direction M, the second direction N, and the third direction P can be understood as the included angle between each pair of the first direction M, the second direction N, and the third direction P being 80° to 90°, which is not limited here.
[0026] Please see Figure 1 and Figure 2 The female terminal 100 includes: busbar 1 and two conductive plates 2.
[0027] Bus 1 is the core component of the female terminal 100, responsible for conducting current in the circuit. It is typically made of a highly conductive material to ensure efficient current transmission. Bus 1 has a female terminal mating part 11 and a female terminal connecting part 12 at its two ends in the first direction M. The female terminal mating part 11 is used for electrical connection with the male terminal 200, and the female terminal connecting part 12 is used for connecting power supplies, loads, or other electrical components. The female terminal connecting part 12 can be flexibly adjusted according to changes in the internal installation structure of different equipment; it may not be a straight structure but may have a bent structure. The material of bus 1 includes at least one of copper, copper-aluminum composite material, and aluminum alloy. In this embodiment, the material of bus 1 is copper.
[0028] Two conductive pieces 2 are respectively connected to the female terminal mating part 11 on both sides in the second direction N. The conductive pieces 2 have a certain degree of elasticity, which allows them to apply appropriate contact pressure to ensure a tight contact between the female terminal 100 and the male terminal 200, helping to maintain a stable electrical connection and preventing poor contact. In vehicles or other mobile devices, the connector may be subjected to vibration and shock; the elasticity of the conductive pieces 2 can absorb these mechanical stresses, reducing the impact on the connector and thus improving the reliability and durability of the connection. The conductive pieces 2 can accommodate a certain range of tolerances and alignment errors; even with minor dimensional deviations during manufacturing or installation, the conductive pieces 2 can still ensure good electrical contact.
[0029] Please see Figure 3At least one of the two conductive sheets 2 includes a composite first composite layer 210 and a second composite layer 220, with the second composite layer 220 located on the side of the first composite layer 210 away from the female mating portion 11. In this embodiment, both conductive sheets 2 include a composite first composite layer 210 and a second composite layer 220. By combining the first composite layer 210 and the second composite layer 220 to form the conductive sheet 2, the busbar 1 only requires one conductive sheet 2 on one side in the second direction N, replacing the complex design of the traditional female terminal 100 where the busbar 1 requires multiple conductive sheets on one side. Without changing the current carrying capacity, this simplifies the structure of the conductive sheet 2 of the female terminal 100, making the female mating portion 11 of the busbar 1 more compact and smaller in size. This helps in developing connectors with smaller dimensions, thus providing greater flexibility and advantages in the overall vehicle installation layout. Due to the composite design of the conductive sheet 2, the installation process of the conductive sheet 2 can be simplified, improving the assembly accuracy and reliability of the female terminal 100, reducing production costs and time, and increasing production efficiency. The conductive sheet 2 uses the first composite layer 210 as a current-carrying layer and the second composite layer 220 to provide positive force to the first composite layer 210, ensuring the positive force and stable contact resistance required by the female terminal 100. This design not only improves the current-carrying capacity of the female terminal 100, but also ensures the stability and reliability of the electrical connection and reduces the risk of electrical failure.
[0030] In some embodiments, the first composite layer 210 may be made of copper. In this embodiment, the first composite layer 210 is made of pure copper. Copper has extremely high conductivity and is a commonly used material in electrical connectors. Using copper to form the first composite layer 210 as the current-carrying layer of the conductive sheet 2 ensures efficient current transmission, reduces power loss, ensures the stable contact resistance required by the female terminal 100, and improves the current-carrying capacity of the female terminal 100. In other embodiments, the first composite layer 210 may also be made of other materials with high current-carrying capacity.
[0031] In some embodiments, the material of the second composite layer 220 can be steel. For example, SUS430, SUS304, or SUS301. Steel has excellent mechanical strength and durability. Using steel to form the second composite layer 220 provides positive force to the first composite layer 210, ensuring the positive force required by the female terminal 100, and also ensuring the stability and reliability of the electrical connection, reducing the risk of electrical failure.
[0032] In some implementations, the ratio of the thickness of the first composite layer 210 to the thickness of the second composite layer 220 is 1-2. The ratio can be any one or a range between any two values from 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, and 2. In this embodiment, the thickness of the first composite layer 210 can be 1.2 mm, the thickness of the second composite layer 220 can be 0.6 mm, and the ratio of the thickness of the first composite layer 210 to the thickness of the second composite layer 220 is 2, which satisfies the maximum thickness requirement of 70 mm. 2 The conductor requires a current carrying capacity of 250A. In other embodiments, based on different current carrying requirements and spring structure, the thicknesses of the first composite layer 210 and the second composite layer 220 can be adjusted. For example, the thickness of the first composite layer 210 can be 1mm, and the thickness of the second composite layer 220 can be 0.5mm, with a ratio of 2 to 1, thus meeting the requirement of low current carrying capacity; or the thickness of the first composite layer 210 can be 1.4mm, and the thickness of the second composite layer 220 can be 0.8mm, with a ratio of 1.75 to 1,000, thus meeting the requirement of higher current carrying capacity.
[0033] The first composite layer 210 and the second composite layer 220 are combined using one of the following processes: solid-liquid composite process, solid-solid composite process, or friction welding process. Solid-liquid composite process is a manufacturing technology that combines solid and liquid materials to form a composite material. Solid-solid composite process involves combining two or more solid materials to form a composite material. Friction welding is a solid-state welding process that joins two workpieces together using heat generated by friction.
[0034] Please see Figure 2 Each conductive sheet 2 includes a body 21 and at least one elastic arm 22. The body 21 is connected to the mating portion 11 on one side in the second direction N, and the elastic arm 22 is connected to the side of the body 21 away from the busbar 1 in the first direction M. In this embodiment, each conductive sheet 2 includes multiple elastic arms 22, which are spaced apart in the third direction P. The multiple elastic arms 22 are manufactured using a stamping process, such as a stamping tearing process or a stamping blanking process.
[0035] In this embodiment, multiple elastic arms 22 are manufactured using a stamping tearing process, which ensures that the contacts of the elastic arms 22 are closely arranged, with a sufficient number of contacts and high current-carrying capacity. Stamping tearing is a process that tears the material along a predetermined path by applying localized stress. It is commonly used to manufacture parts with elasticity or complex shapes. The stamping tearing process can quickly produce elastic arms 22 with complex shapes, greatly improving production efficiency; it can maximize material utilization and reduce waste, thereby lowering material costs; multiple elastic arms 22 can be formed in a single stamping, reducing subsequent processing steps and time; the stamping process enables high-precision dimensional control, ensuring that the shape and size of each elastic arm 22 are consistent, improving product reliability and consistency.
[0036] In other embodiments, based on different current-carrying requirements, multiple elastic arms 22 can also be produced using a stamping blanking process, thereby expanding the gap between the contacts of the conductive sheets and adjusting the number of conductive sheets while keeping the overall width of the female terminal 100 unchanged. The stamping blanking process can produce a large number of elastic arms 22 in a short time, improving production efficiency. This process is easily automated, further improving production speed and efficiency; by optimizing the layout design, the sheet metal can be utilized to the maximum extent, reducing material waste and lowering costs; automated stamping equipment can reduce reliance on manual operation, lowering labor costs; the stamping blanking process can achieve high-precision dimensional control, ensuring that the shape and size of each elastic arm 22 are consistent, improving product reliability.
[0037] Please see Figure 2 and Figure 4 The female end mating portion 11 is provided with a first connecting hole 111, which penetrates the female end mating portion 11 along the second direction N. The main body 21 is provided with a second connecting hole 211, which penetrates the main body 21 along the second direction N. The female end terminal 100 also includes a fixing member 3, which passes through the first connecting hole 111 and the second connecting hole 211 to fix the main body 21 and the female end mating portion 11. In this embodiment, the fixing member 3 can be a rivet, but is not limited to this.
[0038] Example 2
[0039] Please see Figure 5 and Figure 6 The female terminal 100 provided in this embodiment includes most of the technical features of Embodiment 1. The difference between this embodiment and Embodiment 1 is that the busbar 1 in this embodiment is made of copper-aluminum composite material. The main body 21 is welded to the female terminal mating part 11, and the fixing member 3 is eliminated. Specifically, the copper-aluminum composite material of the busbar 1 includes: an aluminum layer 110 and two second copper layers 120. The two second copper layers 120 are respectively disposed on both sides of the aluminum layer 110 in the second direction N.
[0040] Since the busbar 1 is made of copper-aluminum composite material, its strength is insufficient. When the main body 21 is connected to the mating part 11 by riveting, the riveting process may damage the aluminum material. Therefore, in this embodiment, the main body 21 is welded to the mating part 11, eliminating the fastener 3 and avoiding damage to the busbar 1.
[0041] It is worth noting that when the busbar 1 is made of aluminum alloy, there may be insufficient strength of the busbar 1. When the main body 21 is connected to the mating part 11 by riveting, there is a risk that the riveting process may damage the aluminum material. Therefore, when the busbar 1 is made of aluminum alloy, the main body 21 is welded to the mating part 11.
[0042] Example 3
[0043] This embodiment provides a connector (not shown). The connector includes a male connector and a female connector that interlock. The connector in this embodiment is a 180° connector.
[0044] Conventional designs place the female terminal 100 inside the female connector and connect it to the wire using ultrasonic welding technology. However, during ultrasonic welding, the female terminal 100 may resonate due to high-frequency vibration, leading to stress concentration and terminal breakage. This phenomenon not only affects the reliability of the connector but may also cause electrical system malfunctions, thereby impacting vehicle safety and performance.
[0045] In this embodiment, the male connector contains the female terminal 100 described in the above embodiment, and the female connector contains the male terminal 200 that is mated with the female terminal 100. Placing the female terminal 100 in the male connector can avoid the resonance problem caused by ultrasonic welding.
[0046] Please see Figure 7 The male terminal 200 has a male mating part and a male connecting part at both ends in the first direction M, and the male mating part is inserted into the female mating part 11. That is, the extension direction of the male terminal 200 is parallel to the extension direction of the female terminal 100.
[0047] Example 4
[0048] This embodiment provides a connector (not shown). The connector includes a male connector and a female connector that interlock. The connector in this embodiment is a 90° connector.
[0049] Conventional designs place the female terminal 100 inside the female connector and connect it to the wire using ultrasonic welding technology. However, during ultrasonic welding, the female terminal 100 may resonate due to high-frequency vibration, leading to stress concentration and terminal breakage. This phenomenon not only affects the reliability of the connector but may also cause electrical system malfunctions, thereby impacting vehicle safety and performance.
[0050] In this embodiment, the male connector contains the female terminal 100 described in the above embodiment, and the female connector contains the male terminal 200 that is mated with the female terminal 100. Placing the female terminal 100 in the male connector can avoid the resonance problem caused by ultrasonic welding.
[0051] Please see Figure 8 The male terminal 200 has a male mating part and a male connecting part at both ends of the third direction P, and the male mating part is inserted into the female mating part 11. That is, the extension direction of the male terminal 200 intersects the extension direction of the female terminal 100.
[0052] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.
[0053] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.
[0054] The embodiments, implementation methods, and related technical features of this application can be combined and substituted for each other without conflict.
[0055] The above are merely preferred embodiments of this application and are not intended to limit this application in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of this application without departing from the scope of the technical solution of this application shall still fall within the scope of the technical solution of this application.
Claims
1. A female terminal, characterized in that, Having intersecting first and second directions, the female terminal includes: A busbar, having a female end mating portion and a female end connecting portion at its two ends in the first direction, respectively; and Two conductive sheets are respectively connected to the two sides of the mating part at the female end in the second direction; Wherein, at least one of the two conductive sheets includes a first composite layer and a second composite layer, wherein the second composite layer is located on the side of the first composite layer away from the mating portion of the female end.
2. The female terminal according to claim 1, characterized in that, The ratio of the thickness of the first composite layer to the thickness of the second composite layer is 1-2.
3. The female terminal according to claim 1, characterized in that, The first composite layer and the second composite layer are combined using one of the following processes: solid-liquid composite process, solid-solid composite process, and friction welding process.
4. The female terminal according to claim 1, characterized in that, The first composite layer is made of copper, and the second composite layer is made of steel.
5. The female terminal according to claim 1, characterized in that, Each of the conductive sheets includes a body and at least one elastic arm, the body being connected to the female end mating portion on one side in the second direction, and the elastic arm being connected to the body on the side in the first direction away from the busbar.
6. The female terminal according to claim 5, characterized in that, The female end mating part is provided with a first connecting hole, and the first connecting hole penetrates the female end mating part along the second direction; The main body is provided with a second connecting hole, which penetrates the main body along the second direction; The female terminal also includes a fixing member that passes through the first connecting hole and the second connecting hole to fix the body and the female terminal mating part.
7. The female terminal according to claim 5, characterized in that, The main body is welded to the mating part at the female end.
8. The female terminal according to claim 5, characterized in that, The female terminal also has a third direction that intersects both the first direction and the second direction; Each of the conductive sheets includes a plurality of elastic arms, which are arranged at intervals in the third direction and are manufactured by a stamping process.
9. A connector, characterized in that, It includes a male connector and a female connector that are mated together, wherein the male connector is provided with a female terminal as described in any one of claims 1-8.
10. The connector according to claim 9, characterized in that, The female connector has a male terminal that is plugged into and mates with the female terminal.
11. The connector according to claim 10, characterized in that, The male terminal has a male mating part and a male connecting part at both ends in the first direction, and the male mating part is inserted into the female mating part.
12. The connector according to claim 10, characterized in that, The female terminal also has a third direction that intersects both the first direction and the second direction; The male terminal is provided with a male mating part and a male connecting part at both ends of the third direction, and the male mating part is inserted into the female mating part.