A punch jack and high current injection molded connector

Abstract

The utility model discloses a kind of punch jack and large-current injection molding connector, comprising: jack, anti-touch finger and contact spring leaf;Jack is integrally punch forming structure, including the jack wall of inner set through-hole and wire pressing cylinder;Wire pressing cylinder is used for crimping wire, and its round direction is the direction of far from jack wall;Jack wall and wire pressing cylinder axial vertical arrangement, and are connected by connecting portion, and the intersection of the axis of wire pressing cylinder and jack wall is in jack, so that the tail injection molding structure of plastic package plug assembly and plug are staggered arrangement;Contact spring leaf is set in jack wall, anti-touch finger is covered on the upper end of jack wall and partially extends into its interior, and anti-touch finger is provided with downwardly extending anti-touch finger column;After installing jack, anti-touch finger and contact spring leaf, integrally injection molding forms plastic package plug assembly.The utility model realizes the compactness of entire connector volume and the significant reduction of material cost.

Description

Technical Field

[0001] This utility model relates to the field of electrical connector technology, specifically, to a punched socket and high-current injection molded connector. Background Technology

[0002] With the rapid development of the new energy and energy storage industries, the capacity requirements of battery PACK systems are constantly increasing, placing higher demands on the current transmission capabilities of electrical connectors. Traditional high-current connectors typically require larger conductor cross-sectional areas to meet increased current specifications, leading to larger connector tail structures and increased plug-socket mating lengths. Furthermore, the mating length of the socket and the size of the pins also need to be increased accordingly, further increasing the overall connector size and cost. In existing technologies, the socket structure is often a multi-segment combination or requires secondary machining, resulting in complex manufacturing processes, high costs, and hindering miniaturization design. Utility Model Content

[0003] The purpose of this utility model is to provide a punched socket and a high-current injection molded connector to solve the problems of large size, high cost and complex manufacturing process of existing high-current connectors.

[0004] The present invention solves the above problems through the following technical solution:

[0005] A stamped socket and high-current injection molded connector includes: a socket, a protective finger, and a contact spring; the socket is an integrally stamped structure, including a socket wall with an internal through hole and a crimping cylinder; the crimping cylinder is used to crimp the wire, and its rolling direction is away from the socket wall; the socket wall and the crimping cylinder are axially perpendicular and connected by a connecting part, and the intersection of the axes of the crimping cylinder and the socket wall is outside the socket, so that the tail injection molding structure of the plastic-encapsulated plug assembly is staggered from the plug mating structure; the contact spring is disposed inside the socket wall, the protective finger covers the upper end of the socket wall and partially extends into its interior, and the protective finger has a downwardly extending protective finger post; after the socket, the protective finger, and the contact spring are installed, the entire plastic-encapsulated plug assembly is integrally injection molded.

[0006] As a further improvement of this utility model, the connecting part includes a horizontally arranged connecting segment and an inclined connecting transition structure; the connecting segment is connected to the upper edge of the socket wall, and the connecting transition structure is connected between the connecting segment and the left edge of the pressure tube.

[0007] As a further improvement of this utility model, an inwardly contracting fixed platform is formed on the lower inner side of the socket wall for limiting the lower end of the contact spring.

[0008] As a further improvement of this utility model, the connector also includes a straight tube, a waterproof plug, and a tail nut; the straight tube is sleeved on the outer side of the tail of the plastic-encapsulated plug assembly, and its two ends abut against the shoulder of the plastic-encapsulated plug assembly and the waterproof plug, respectively; the outer side of the tail of the plastic-encapsulated plug assembly is provided with an external thread, and the tail nut is connected to the plastic-encapsulated plug assembly through the external thread, and the waterproof plug is pressed into the tail nut.

[0009] As a further improvement of this utility model, a waterproof O-ring is also provided between the plastic-sealed plug assembly and the tail nut.

[0010] As a further improvement of this utility model, the plastic-encapsulated plug assembly is connected to a socket plastic-encapsulated housing, and a plastic-encapsulated pin is provided inside the socket plastic-encapsulated housing, with a plastic-encapsulated pin insulation hole at the upper end of the plastic-encapsulated pin;

[0011] When the plug and socket are inserted, the anti-touch finger is inserted into the insulating hole of the plastic-encapsulated pin without contacting the plastic-encapsulated pin; the cooperation between the anti-touch finger and the insulating hole of the plastic-encapsulated pin constitutes an anti-misinsertion coding structure.

[0012] As a further improvement of this utility model, the lower end of the socket plastic shell extends into the socket plastic shell to form a socket plastic shell ventilation groove.

[0013] As a further improvement of this utility model, the plastic-encapsulated plug assembly and the plastic-encapsulated shell of the socket are connected by a snap-fit ​​connection through a hook on the plastic-encapsulated plug assembly.

[0014] As a further improvement of this utility model, the side of the anti-touch finger post is formed with several plate-like structures arranged in a ring, and the insulating hole of the plastic-sealed pin is formed with several end grooves that cooperate with the plate-like structures. By changing the number of plate-like structures and end grooves, and / or the width of the plate-like structures and the width of the end grooves, and / or the angle between two adjacent plate-like structures and end grooves, and / or the diameter of the anti-touch finger post and the insulating hole of the plastic-sealed pin, anti-misinsertion coding can be achieved.

[0015] As a further improvement of this utility model, the lower end of the plastic-encapsulated plug assembly is provided with a waterproof sleeve for mating. When the plug is inserted into the socket, the waterproof sleeve is located between the plastic-encapsulated plug assembly and the plastic-encapsulated shell of the socket to achieve a seal.

[0016] As a further improvement of this utility model, the socket's plastic-encapsulated outer shell is provided with a socket waterproof pad that mates with the mounting panel.

[0017] Compared with the prior art, this utility model has the following advantages and beneficial effects:

[0018] (1) By designing the socket as an integral stamping structure and setting the rolling direction of the wire pressing cylinder away from the socket wall, the tail wiring area and the front mating area of ​​the connector are spatially staggered, thereby significantly reducing the mating length of the plastic-encapsulated plug assembly and the size of the socket that it matches; thus achieving the compactness of the entire connector volume and a significant reduction in material costs.

[0019] (2) This utility model forms the entire insertion hole in one step by using stamping, stretching and upsetting processes, eliminating the need for secondary machining processes such as turning and milling. This directly simplifies the production process, greatly improves processing efficiency, and further reduces manufacturing costs.

[0020] (3) This utility model enhances the contact elasticity and holding force of the pins by setting a contact spring inside the socket, which together with the socket wall forms a double contact point, thus ensuring the stability of high current transmission. At the same time, by setting an anti-touch finger and its anti-touch finger post, it forms a coded fit with the plastic-sealed pin insulation hole at the socket end, effectively preventing mis-insertion, thereby improving the overall electrical reliability of the connection and the safety of equipment use. By setting a sealing system consisting of a straight tube, a waterproof plug, a tail nut and a waterproof O-ring at the end of the socket, and setting a waterproof sleeve at the interface, multiple waterproof barriers are formed, significantly optimizing the user's insertion and removal experience, and comprehensively improving the protection level of the connector in complex environments.

[0021] (4) By setting a hook, the plug and socket are mechanically locked after being inserted, which effectively prevents accidental loosening caused by vibration and other reasons, and ensures the long-term reliability and stability of the connection. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the socket structure of this utility model;

[0023] Figure 2 This is a schematic diagram showing the installation of the socket, anti-touch finger, and contact spring of this utility model;

[0024] Figure 3 This is a schematic diagram showing the fit between the straight pipe, waterproof plug, and tail nut of this utility model and the plastic-encapsulated plug assembly;

[0025] Figure 4 This is a schematic diagram of the structure of the socket of this utility model;

[0026] Figure 5 This is a schematic diagram of the connection between the socket and the plug of this utility model;

[0027] Figure 6 This is a cross-sectional view of the socket and plug of this utility model after they are connected;

[0028] Figure 7This is a schematic diagram of the anti-touch finger post of this utility model;

[0029] Figure 8 This is a schematic diagram of the anti-misinsertion coding structure of the anti-touch finger post and insulating hole of this utility model.

[0030] Figure label:

[0031] 1. Socket; 101. Connection dimension section; 102. Connection transition structure; 103. Fixed platform; 104. Socket wall; 105. Wire clamp; 2. Anti-finger; 201. Anti-finger post; 2011. Plate structure; 3. Contact spring; 4. Plastic-encapsulated plug assembly; 5. Waterproof sleeve for plug-in connection; 6. Waterproof O-ring; 7. Straight tube; 8. Waterproof plug; 9. Tail nut; 10. Plastic-encapsulated socket shell; 1001. Vent groove; 11. Waterproof socket gasket; 12. Plastic-encapsulated pin; 1201. Insulation hole; 1202. Hole end groove; 13. Hook; A. Rolling direction. Detailed Implementation

[0032] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0033] Example:

[0034] Combined with appendix Figure 1-8 As shown, a punched socket and high-current injection molded connector includes: a socket 1, a protective finger 2, and a contact spring 3.

[0035] The socket 1 is an integrally stamped structure, including a socket wall 104 and a wire crimping cylinder 105. The wire crimping cylinder 105 is used to crimp wires. The socket wall 104 and the wire crimping cylinder 105 are axially perpendicular and both have through holes. A connecting part is provided at the upper end edge of the socket wall 104. The connecting part extends out of the upper end of the socket wall 104 and connects to the left end edge of the wire crimping cylinder 105, so as to connect the socket wall 104 and the wire crimping cylinder 105 through the connecting part. The rolling direction A of the wire crimping cylinder is away from the socket wall 104. In four directions, the crimping cylinder 105 is positioned upward relative to the prior art, raising the tail structure of the plug. This eliminates the need to increase the size of the socket 1, allowing the tail injection molding structure of the encapsulated plug assembly 4, i.e., the crimping cylinder 105 end, to be staggered from the plug mating structure, i.e., the socket wall 104 end. This ensures that the intersection of the axes of the crimping cylinder 105 and the socket wall 104 is outside the socket 1, whereas in the prior art, the intersection of the axes of the crimping cylinder 105 and the socket wall 104 is inside the socket wall 104, thus reducing the mating length.

[0036] In a further technical solution, the connecting part includes an inclined connecting transition structure 102 for connecting the left end edge of the wire pressing cylinder 105, and a horizontally arranged connecting dimension section 101 for connecting the upper end of the socket wall 104. The rolling direction of the wire pressing cylinder 105 differs from that of a conventional socket structure, being away from the socket wall 104. This minimizes the horizontal distance between the connecting dimension section 101 and the connecting transition structure 102 and the end of the socket wall 104. The rolling direction of the wire pressing cylinder being away from the socket wall 104 allows the tail injection molding structure to be staggered from the plug-in structure, reducing the insertion length. The fixed platform is formed by mold upsetting, eliminating the need for secondary machining and reducing manufacturing costs.

[0037] Optionally, the socket wall 104 is formed by stretching; an inwardly recessed fixed platform 103 is formed at the lower end of the socket wall 104, and the fixed platform 103 is formed by die upsetting. The socket 1 has no other structures that require further machining on a lathe, resulting in low manufacturing cost for the entire socket 1. The fixed platform is formed by die upsetting, eliminating the need for secondary machining and reducing manufacturing costs.

[0038] The contact spring 3 is disposed in the through hole within the socket wall 104 and is limited at its lower end by the fixing platform 103; the anti-touch finger 2 covers the upper end of the socket wall 104 and extends into the socket wall 104, and the anti-touch finger post 201 in the middle of the anti-touch finger 2 extends into and passes through the contact spring 3 and the lower end of the socket wall 104, for insertion with the insulating hole 1201 of the plastic-encapsulated pin of the socket housing 10. During installation, after assembling the anti-touch finger 2 and the contact spring 3 into the socket 1, the entire assembly is injection molded to form the plastic-encapsulated plug assembly 4. The anti-touch finger 2 is provided with the anti-touch finger post 201. The contact spring 3 is used to enhance the contact elasticity and stability between the socket 1 and the mating pin, ensuring the reliability of high current transmission. Then, the assembled socket assembly is placed into the injection mold and injection molded as a whole to form the plastic-encapsulated plug assembly 4 of the plug. The engineering plastic encapsulates the structure of the socket 1, forming a robust insulating body.

[0039] In an optional embodiment, the connector further includes a straight tube 7, a waterproof plug 8, and a tail nut 9, which together constitute a complete waterproof structure and cable fixing structure. Specifically, the straight tube 7 is sleeved on the outer side of the tail of the plastic-encapsulated plug assembly 4, with its two ends abutting against the shoulder of the plastic-encapsulated plug assembly 4 and the end face of the waterproof plug 8, respectively. An external thread is provided on the outer side of this end of the plastic-encapsulated plug assembly 4, and the tail nut 9 is connected to the plastic-encapsulated plug assembly 4 through this external thread. When the tail nut 9 is tightened, its internal step presses the waterproof plug 8 inside and keeps it abutting against the straight tube 7, thereby achieving sealing and fixing of the cable clamping area. Preferably, a waterproof O-ring 6 is also provided between the joint of the plastic-encapsulated plug assembly 4 and the tail nut 9, further enhancing the radial sealing effect of the connection and forming multiple waterproof barriers.

[0040] In another optional embodiment, the plastic-encapsulated plug assembly 4 is connected to a socket, the socket mainly comprising a plastic-encapsulated housing 10, a waterproof gasket 11, and plastic-encapsulated pins 12. A vent groove 1001 is formed on the plastic-encapsulated housing 10. During the plug-socket insertion process, internal air can be discharged through this groove, effectively reducing insertion and removal resistance and making operation easier. After the plug and socket are fully inserted, they are locked together by a hook 13 to prevent loosening under vibration and ensure reliable connection.

[0041] Specifically, the lower end of the plastic-encapsulated plug assembly 4 has a groove for accommodating the waterproof sleeve 5, so as to realize the installation of the waterproof sleeve 5. The plastic-encapsulated socket housing 10 is inserted into the lower end of the plastic-encapsulated plug assembly 4, and after insertion, the waterproof sleeve 5 is located between the plastic-encapsulated socket housing 10 and the plastic-encapsulated plug assembly 4 to achieve a seal.

[0042] Preferably, the encapsulated plug assembly 4 has a hook 13 that snaps into the upper end of the socket encapsulated housing 10 to connect the encapsulated plug assembly 4 to the socket encapsulated housing 10. In this embodiment, an encapsulated pin 12 is coaxially disposed inside the socket encapsulated housing 10, and an insulating hole 1201 is formed at the upper end of the encapsulated pin 12. When the socket encapsulated housing 10 is plugged into the encapsulated plug assembly 4, the anti-touch finger 201 is inserted into the encapsulated pin 12 through the insulating hole 1201 and does not contact the encapsulated pin 12. The anti-touch finger 2 and the encapsulated pin 12 can achieve the function of preventing mis-coding by changing the number, width, distribution angle and diameter of the plate structure and the hole end groove.

[0043] In an optional embodiment, the anti-misinsertion coding structure comprises anti-touch finger posts 201 and encapsulated pin insulation holes 1201. The anti-touch finger posts 201 have several annularly distributed plate-like structures 2011 on their sides. The encapsulated pin insulation holes 1201 have several end-grooves 1202 that mate with the plate-like structures 2011, thereby achieving the anti-misinsertion coding function. A variety of anti-misinsertion coding functions can be achieved by changing the number of plate-like structures 2011 and end-grooves 1202, the width of the plate-like structures 2011 and the width of the end-grooves 1202, the angle between two adjacent plate-like structures 2011 and end-grooves 1202, and the diameters of the anti-touch finger posts 201 and encapsulated pin insulation holes 1201.

[0044] The lower end of the socket plastic shell 10 extends into the socket plastic shell 10 to form a socket plastic shell vent groove 1001. When the plug is inserted into or removed from the socket, the internal air can be expelled through the socket plastic shell vent groove 1001 to reduce insertion and removal resistance. When the plug is inserted into or removed from the socket, the plastic-encapsulated pin 12 is inserted into the contact spring 3, and the anti-touch finger post 201 is inserted into the plastic-encapsulated pin insulation hole 1201. The plastic-encapsulated plug assembly 4 is connected to the socket plastic shell 10 through the hook 13, and the lower end of the plastic-encapsulated plug assembly 4 abuts against the inside of the socket plastic shell 10 and the plastic-encapsulated pin 12 to limit the installation position of the socket plastic shell 10.

[0045] Optionally, a waterproof pad 11 is provided on the lower outer side of the socket plastic housing 10 to achieve a waterproof effect when the socket plastic housing 10 is fixedly installed on the mounting panel.

[0046] The entire part of socket 1 is formed in one step through cold working processes such as stamping, stretching, and upsetting, eliminating the need for subsequent machining processes such as turning and milling, which greatly improves production efficiency.

[0047] This invention achieves miniaturization, low cost, and high reliability of connectors under high current specifications by optimizing the integrated stamping structure of the socket, innovating the rolling direction of the wire compression cylinder, integrating anti-miscoding design, and setting a breathable and resistance-reducing structure. It is especially suitable for space- and cost-sensitive applications such as new energy and energy storage systems.

[0048] Although the present invention has been described herein with reference to illustrative embodiments, the above embodiments are merely preferred embodiments of the present invention, and the implementation of the present invention is not limited to the above embodiments. It should be understood that those skilled in the art can design many other modifications and implementations, which will fall within the scope and spirit of the principles disclosed in this application.

Claims

1. A punched socket and high-current injection molded connector, characterized in that, include: Socket (1), anti-touch finger (2) and contact spring (3); The socket (1) is an integral stamped structure, including a socket wall (104) with an internal through hole and a wire crimping cylinder (105); the wire crimping cylinder (105) is used to crimp the wire, and its rolling direction is away from the socket wall (104); the socket wall (104) and the wire crimping cylinder (105) are arranged axially perpendicularly and connected by a connecting part. The intersection of the axes of the wire crimping cylinder (105) and the socket wall (104) is outside the socket (1), so that the tail injection molding structure of the plastic-encapsulated plug assembly (4) is staggered from the plug mating structure; The contact spring (3) is disposed inside the socket wall (104), the anti-touch finger (2) covers the upper end of the socket wall (104) and partially extends into its interior, and the anti-touch finger (2) is provided with a downwardly extending anti-touch finger post (201); after the socket (1), anti-touch finger (2) and contact spring (3) are installed, the whole assembly is injection molded to form a plastic-encapsulated plug assembly (4); The connecting part includes a horizontally arranged connecting segment (101) and an inclined connecting transition structure (102); the connecting segment (101) is connected to the upper edge of the socket wall (104), and the connecting transition structure (102) is connected between the connecting segment (101) and the left edge of the wire pressing tube (105); The lower inner side of the socket wall (104) has an inwardly contracting fixed platform (103) for limiting the lower end of the contact spring (3); The connector also includes a straight tube (7), a waterproof plug (8), and a tail nut (9); The straight tube (7) is sleeved on the outer side of the tail of the plastic-sealed plug assembly (4), and its two ends abut against the shoulder and the waterproof plug (8) of the plastic-sealed plug assembly (4), respectively; The outer side of the tail of the plastic-encapsulated plug assembly (4) is provided with an external thread, and the tail nut (9) is connected to the plastic-encapsulated plug assembly (4) through the external thread, and the waterproof plug (8) is pressed into the tail nut (9); A waterproof O-ring (6) is also provided between the encapsulated plug assembly (4) and the tail nut (9). The encapsulated plug assembly (4) is connected to a socket encapsulated housing (10), and an encapsulated pin (12) is provided inside the socket encapsulated housing (10). The upper end of the encapsulated pin (12) is provided with an encapsulated pin insulation hole (1201). When the plug is inserted into the socket, the anti-touch finger (201) is inserted into the insulating hole (1201) of the plastic-encapsulated pin and does not contact the plastic-encapsulated pin (12); the cooperation between the anti-touch finger (201) and the insulating hole (1201) of the plastic-encapsulated pin constitutes an anti-misinsertion coding structure.

2. The punched socket and high-current injection molded connector according to claim 1, characterized in that, The lower end of the socket plastic shell (10) extends into the socket plastic shell (10) to form a socket plastic shell ventilation groove (1001). And / or the plastic-encapsulated plug assembly (4) and the plastic-encapsulated socket housing (10) are connected by a hook (13) on the plastic-encapsulated plug assembly (4).

3. The punched socket and high-current injection molded connector according to claim 1, characterized in that, The anti-touch finger post (201) has several plate-like structures (2011) arranged in a ring on its side. The insulating hole (1201) of the plastic-sealed pin has several end grooves (1202) that cooperate with the plate-like structures (2011). By changing the number of plate-like structures (2011) and end grooves (1202), and / or the width of the plate-like structures (2011) and the width of the end grooves (1202), and / or the angle between two adjacent plate-like structures (2011) and end grooves (1202), and / or the diameter of the anti-touch finger post (201) and the insulating hole (1201) of the plastic-sealed pin, the anti-misinsertion coding can be achieved.

4. The punched socket and high-current injection molded connector according to claim 1, characterized in that, The lower end of the plastic-sealed plug assembly (4) is provided with a waterproof sleeve (5). When the plug is inserted into the socket, the waterproof sleeve (5) is located between the plastic-sealed plug assembly (4) and the plastic-sealed outer shell (10) of the socket to achieve a seal.

5. A punched socket and high-current injection molded connector according to any one of claims 1-4, characterized in that, The socket plastic casing (10) is provided with a socket waterproof pad (11) that matches the mounting panel.

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