Connector compatible with ultrasonic welding

Abstract

To provide a connector compatible with ultrasonic welding, including a plug structure that is detachably connected, a socket structure, and an aluminum wire structure that is ultrasonically welded integrally with the plug structure.SOLUTION: A plug structure includes blades 14 that are ultrasonically welded to an aluminum wire connection portion and a hollow plug cover 11 that guides the blades during insertion. The socket structure includes an insert block 23 that houses the blades and an insert block cover 21 that is fitted to the outside of the insert block. A sealing structure is provided at the end of the insert block that is away from the blades. The outside of the insert block cover and the inside of the hollow plug cover are joined together by engagement. An elastic structure is provided between the insert block and the blades to reduce wear during insertion of the blades, and an engagement structure is further provided to prevent the blades from continuing to move forward after they are inserted and connected to a predetermined position.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention relates to the field of connectors, and more particularly to connectors that are compatible with ultrasonic welding. [Background technology]

[0002] Currently, connectors are devices that can achieve electrical connections and are generally divided into two parts. When the two parts are separated, electrical disconnection occurs, and when the two parts are connected, electrical continuity occurs. Conventional connectors use multiple methods to achieve electrical connections, i.e., to connect conductors, but most of them are complex, suffer from significant wear during use, and are difficult to manufacture and install. Mechanical crimping is typically used to connect the connector and conductor. While this method is not problematic when using copper conductors, it can be problematic when replacing aluminum conductors, as the contact surface is prone to oxidation.

[0003] Therefore, there is a strong demand for new solutions to the above problems. Summary of the Invention [Problem to be solved by the invention]

[0004] The present invention provides a connector adapted for ultrasonic welding, including a removably connectable plug structure, a socket structure, and an aluminum wire structure ultrasonically welded integrally with the plug structure. [Means for solving the problem]

[0005] The aluminum wire structure includes an aluminum wire body portion and an aluminum wire connection portion that are integrally connected, The plug structure includes blades that are ultrasonically welded together with aluminum wire connections, and a hollow plug cover that serves as a guide during insertion of the blades; The socket structure includes an insert block that accommodates the blades, and an insert block cover that is fitted onto the outside of the insert block, and a sealing structure is provided at an end of the insert block that is away from the blades, and the outside of the insert block cover and the inside of a hollow plug cover are integrally connected by engagement, a resilient structure is provided between the insert block and the blade to reduce wear during insertion of the blade; A locking structure is provided between the plug structure and the socket structure to prevent the blades from continuing to move forward after they are inserted and connected to a predetermined position.

[0006] Furthermore, the insert block is divided into two equal-sized sub-insert blocks, one above the other. Each sub-insert block includes a welded portion and an insertion connection portion. The elastic structure includes a plurality of elongated insert grooves on the inner surface of the insertion connection portion and springs placed in the insert grooves. The length of each insert groove is smaller than the width of the single sub-insert block, and the length of each insert groove is perpendicular to the insertion direction of the blade. Each insert groove includes a first insert groove portion and a second insert groove portion, where the cross-sectional shape of the first insert groove portion is semicircular and the cross-sectional shape of the second insert groove portion is a large divided circle.

[0007] Furthermore, the circumferential angle corresponding to the major dividing circle of the second insert groove portion is 240°.

[0008] Furthermore, in the single insert groove, the number of first insert groove portions is one, the number of second insert groove portions is one, and the length of the second insert groove portion is greater than the length of the first insert groove portion.

[0009] As another preferred solution, in the single insert groove, the number of the first insert groove portions is one, the number of the second insert groove portions is two, the single first insert groove portion is located between two of the second insert groove portions, and the length of the single second insert groove portion is the same as the length of the first insert groove portion.

[0010] In another preferred solution, the insert block is divided into two equal-sized sub-insert blocks, one above the other, and each sub-insert block includes a welded portion and an insertion connection portion. The elastic structure includes a plurality of elongated insert grooves on the inner surface of the insertion connection portion and springs placed in the insert grooves. The length of the insert grooves is perpendicular to the insertion direction of the blades, and the insert grooves penetrate the entire sub-insert block. The cross section of each insert groove is a large divided circle, and stoppers are fixedly installed on both ends of the insert groove to limit the position of the springs.

[0011] Furthermore, in the two upper and lower sub-insert blocks, the vertical distance between two adjacent springs is smaller than the thickness of the blade.

[0012] Furthermore, an upper locking block and a lower locking block that fit together vertically are provided on the inner wall of the hollow plug cover, and the gap formed between the upper locking block and the lower locking block is used for inserting and connecting the plug blade.

[0013] Furthermore, the fastening structure includes a third protrusion provided on the outer surface of the insert block cover and a second protrusion provided on the inner surface of the hollow plug cover, which snap-engages with the third protrusion.

[0014] Furthermore, a hollow end cap is attached to the end of the hollow plug cover closest to the aluminum wire structure, a hollow seal body is further fitted inside the hollow end cap, and a first contact prevention cap is attached to the side of the plug blade closest to the insert block. [Effects of the Invention]

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0016] 1. The present invention provides a detachably connectable plug structure, a socket structure, and an aluminum wire structure that is ultrasonically welded to the plug structure. This provides an elastic structure between the insert block and the plug blade, thereby reducing wear on the entire plug structure and aluminum wire structure during insertion into the socket structure.

[0017] 2. In the present invention, by providing ultrasonic welding positions at the ends of the plug blades, the connector can connect aluminum wires, ensuring connection reliability and service life, and the aluminum wires are significantly cheaper than copper wires.

[0018] 3. In the present invention, the blades are fixedly fastened to the plug structure, and the socket structure is provided with a plurality of sets of insert grooves for the insert springs. During the process of inserting the blades into the insert block, the springs rotate and roll together, thereby reducing friction and wear, and the elasticity of the springs ensures reliable contact.

[0019] 4. The present invention provides a first insert groove with a semicircular cross section and a second insert groove with a large circular cross section, which facilitates later spring replacement and reduces the cost of replacing the entire socket structure.

[0020] 5. The insert groove of the present invention penetrates the entire sub-insert block. After the spring is placed, stoppers are fixed and welded to both ends of the insert groove to limit the position of the spring. The insert groove penetrates the entire sub-insert block, making it easier to process and manufacture the insert groove. [Brief explanation of the drawings]

[0021] [Figure 1] 1 is a schematic diagram of the overall structure of a connector according to a first embodiment of the present invention. [Figure 2] 1 is a schematic diagram of the overall structure of a plug structure and an aluminum wire structure according to a first embodiment of the present invention. [Figure 3] 1 is an exploded schematic view of the overall structure of a plug structure and an aluminum wire structure according to a first embodiment of the present invention. [Figure 4] 1 is a schematic diagram of the overall structure of a socket structure according to a first embodiment of the present invention. [Figure 5] 1 is an exploded schematic view of the overall structure of a socket structure according to a first embodiment of the present invention. [Figure 6] 1 is a vertical central cross-sectional view of the overall structure of a connector according to a first embodiment of the present invention. [Figure 7] 1 is a vertical cross-sectional view of the overall structure of a plug structure according to a first embodiment of the present invention. [Figure 8] 1 is a vertical cross-sectional view of the overall structure of a socket structure according to a first embodiment of the present invention. [Figure 9] FIG. 9 is an enlarged schematic view of a portion A in FIG. 8. [Figure 10] 3 is a schematic diagram of the structure of an insert block cover in the first embodiment of the present invention. FIG. [Figure 11] FIG. 2 is a schematic diagram of the structure of a sub-insert block according to the first embodiment of the present invention. [Figure 12] FIG. 10 is a schematic diagram of the structure of a sub-insert block according to a second embodiment of the present invention. [Figure 13] FIG. 10 is a schematic diagram of the structure of a sub-insert block according to a third embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0022] In order to further understand the contents, features and effects of the present invention, the present invention will be described in detail below with reference to the following examples and accompanying drawings 1 to 13.

[0023] As shown in Figures 1 to 11, the present invention discloses a connector suitable for ultrasonic welding, which includes a plug structure 1 that is detachably connected, a socket structure 2, and an aluminum wire structure 3 that is ultrasonically welded integrally with the plug structure 1.

[0024] The aluminum wire structure 3 includes an aluminum wire main body 31 and an aluminum wire connection portion 32 that are integrally connected, The plug structure 1 includes a blade 14 that is ultrasonically welded integrally with an aluminum wire connection 32, and a hollow plug cover 11 that serves as a guide during insertion of the blade 14; The socket structure 2 includes an insert block 23 for receiving the blades 14, and an insert block cover 21 fitted onto the outside of the insert block 23. The insert block 23 is provided with a sealing structure at the end away from the blades 14. The insert block cover 21 is provided with holes for the blades 14 to pass through. The sealing structure includes a sealing gasket 25 and a sealing strip 24. A sealing adhesive is applied to the sealing gasket 25 to ensure a seal between the insert block cover 21 and the insert block 23. The outside of the insert block cover 21 and the inside of the hollow plug cover 11 are joined together by engagement. An elastic structure is provided between the insert block 23 and the blade 14 to reduce wear during insertion of the blade 14; Between the plug structure 1 and the socket structure 2, there is provided a locking structure for preventing further movement of the blades 14 after they have been inserted and connected to a predetermined position.

[0025] The present invention provides a detachably connectable plug structure, a socket structure, and an aluminum wire structure that is ultrasonically welded to the plug structure. By providing an elastic structure between the insert block and the blades, wear on the entire plug structure and aluminum wire structure during insertion into the socket structure is reduced. Furthermore, ultrasonic welding positions are provided at the ends of the blades, allowing the connector to connect aluminum wire, ensuring connection reliability and service life. Furthermore, aluminum wire is significantly cheaper than copper conductors.

[0026] 3, the plug structure 1 further includes a hollow end cap 12, a hollow sealing body 13, and a first touch-preventing cap 15 to prevent electric shock caused by touching the blades 14. The hollow end cap 12 is attached to the end of the hollow plug cover 11 close to the aluminum wire structure 3. The hollow end cap 12 further includes a hollow sealing body 13, and the first touch-preventing cap 15 is attached to the end of the blades 14 close to the insert block 23. Two blade stop holes 141 are provided in the middle of the blades 14, and two engagement posts 115 are provided on the upper surface of the hollow plug cover 11 in one-to-one correspondence with the blade stop holes 141.

[0027] In the first embodiment of the present invention, as shown in FIG. 7, an upper locking block 113 and a lower locking block 114 that fit together vertically are provided on the inner wall of the hollow plug cover 11, and the gap formed between the upper locking block 113 and the lower locking block 114 is used for inserting and connecting the plug blade 14.

[0028] In the first embodiment of the present invention, as shown in FIGS. 6 to 8, a first protrusion 111 and a second protrusion 112 are provided on the surface of both ends of the hollow plug cover 11, where the first protrusion 111 is used for engagement with the end of the hollow end cap 12, and a third protrusion 211 and a fourth protrusion 212 are provided on the outer surface of both ends of the insert block cover 21, where the second protrusion 112 and the third protrusion 211 are engaged with each other to prevent the plug blade 14 from continuing to move forward after it is inserted and connected to a predetermined position.

[0029] 5 and 8, in the first embodiment of the present invention, the socket structure 2 further includes a second contact-preventing lid 22 attached to the end of the insert block cover 21 to prevent people from touching the insert block 23 and getting an electric shock, and the fourth protrusion 212 is used to attach the second contact-preventing lid 22 to the insert block cover 21. Here, the insert block cover 21 has an inwardly bent portion 213 on the side closer to the sealing strip 24, which is fitted with an arc-shaped protrusion in the middle of the sub-insert block 231 to fix the insert block cover 21 and the insert block 23 relative to each other.

[0030] 5 to 11, in the first embodiment of the present invention, the insert block 23 is divided into two equal-sized sub-insert blocks 231, one above the other, and the other below. The single sub-insert block 231 includes a welded portion and an insertion connection portion. The welded portion is provided with a copper busbar connection hole 231d for connecting a copper busbar. The elastic structure includes four elongated insert grooves 231a provided on the inner surface of the insertion connection portion and springs 26 placed in the insert grooves 231a. The length of the insert grooves 231a is smaller than the width of the single sub-insert block 231, and the length direction of the insert grooves 231a is perpendicular to the insertion direction of the blades 14.

[0031] Preferably, as shown in FIG. 11 , the single insert groove 231a includes a first insert groove portion 231b and a second insert groove portion 231c. The cross-sectional shape of the first insert groove portion 231b is semicircular to facilitate placement of the compressed spring 26. After the spring 26 is inserted into the first insert groove portion 231b, it automatically expands under the action of repulsive force and abuts against the inner surfaces of both ends of the insert groove 231a in a free state. During the insertion of the blade 14 into the insert block 23, the spring 26 continues to rotate and roll together, reducing friction and wear, and ensuring contact reliability due to the spring's elasticity. The cross-sectional shape of the second insert groove portion 231c is a large divided circle. Preferably, the circumferential angle corresponding to the large divided circle of the second insert groove portion 231c is 240°, thus ensuring that the spring 26 remains in the insert groove 231a without falling off.

[0032] In this embodiment 1, as shown in Figure 11, in the single insert groove 231a, the number of first insert groove portions 231b is one, the number of second insert groove portions 231c is one, and the length of the second insert groove portion 231c is greater than the length of the first insert groove portion 231b.

[0033] In this embodiment 1, as shown in FIG. 8, the vertical distance between two adjacent springs 26 in the two upper and lower sub-insert blocks 231 is smaller than the thickness of the blade 14, thereby ensuring electrical contact between the two and forming a reliable electrical connection.

[0034] In this Example 1, as shown in Figures 1 to 9, when connecting a conductor, the aluminum wire body 31 first passes through the hollow end cap 12 and the hollow seal body 13 in that order, and the aluminum wire connection portion 32 is ultrasonically welded to the blade 14. The first contact-preventing cap 15 is attached to the end of the blade 14 and fixed with the locking portion thereon. The assembly of the blade 14 and the aluminum wire structure 3 is then inserted into the hollow plug cover 11, and the blade stop hole 141 in the middle of the blade 14 is fixed to the engagement post 115, completing the fixation. After fixation, the end cap 12 is placed over the end portion of the hollow plug cover 11, completing the assembly of the plug structure 1. After the spring 26 is placed into the insert groove 231a, the two sub-insert blocks 231 are welded together to form the insert block 23. The insert block 23 is then placed into the insert block cover 21, and the second contact prevention cover 22 is attached to fix the insert block 23. The sealing strip 24 is then fixed to the insert block cover 21, and the sealing gasket 25 is attached to the insert block cover 21 to complete the assembly of the socket structure 2. Here, the hollow plug cover 11 and the plug blades 14, and the insert block cover 21 and the insert block 23 are sealed with adhesive to protect the internal electrical connections.

[0035] 12, in the single insert groove 231a, the number of the first insert groove 231b is one, the number of the second insert grooves 231c is two, the single first insert groove 231b is provided between the two second insert grooves 231c, and the length of the single second insert groove 231c is the same as the length of the first insert groove 231b. By providing two second insert grooves 231c and one first insert groove 231b, the spring 26 can be fixed more stably.

[0036] In the second embodiment of the present invention, as shown in FIG. 12, the insert block 23 is divided into two equal-sized sub-insert blocks 231, one above the other. Each sub-insert block 231 includes a welded portion and an insertion joint. The elastic structure includes four elongated insert grooves 231a formed on the inner surface of the insertion joint, and springs 26 placed in the insert grooves 231a. The length of the insert grooves 231a is perpendicular to the insertion direction of the blade 14 and penetrates the entire sub-insert block 231, which facilitates the machining and manufacturing of the insert grooves. The cross section of each insert groove 231a is a large divided circle, and the corresponding circumferential angle is preferably 240°. Stoppers 231e are fixedly welded to both ends of the insert groove 231a to limit the position of the springs 26.

[0037] The above invention only shows the embodiments of the present invention, which cannot be understood as limiting the scope of the invention patent, and does not limit the structure of the embodiments of the present invention in any way. Those skilled in the art can make some modifications and improvements without departing from the concept of the embodiments of the present invention, and all of them belong to the protection scope of the embodiments of the present invention. [Explanation of symbols]

[0038] 1...plug structure, 11...hollow plug cover, 111...first protrusion, 112...second protrusion, 113...upper locking block, 114...lower locking block, 115...engagement post, 12...hollow end cap, 13...hollow seal body, 14...plug blade, 141...plug blade stop hole, 15...first contact prevention cap, 2...socket structure, 21...insert block cover, 211...third protrusion, 212...fourth protrusion, 213...bent portion, 22...second 2 contact prevention cover, 23...insert block, 231...sub-insert block, 231a...insert groove, 231b...first insert groove portion, 231c...second insert groove portion, 231d...copper bus bar connection hole, 231e...stopper, 24...sealing strip, 25...sealing gasket, 26...spring, 3...aluminum wire structure, 31...aluminum wire main body portion, 32...aluminum wire connection portion.

Claims

1. The device includes a plug structure (1) that can be detachably connected, a socket structure (2), and an aluminum wire structure (3) that is ultrasonically welded to the plug structure (1). The aluminum wire structure (3) includes an aluminum wire body (31) and an aluminum wire connection part (32) that are integrally connected, The plug structure (1) includes blades (14) that are ultrasonically welded together with aluminum wire connections (32), and a hollow plug cover (11) that serves as a guide during insertion of the blades (14). The socket structure (2) includes an insert block (23) that accommodates the blades (14) and an insert block cover (21) that is fitted onto the outside of the insert block (23), and a sealing structure is provided at the end of the insert block (23) that is away from the blades (14), and the outside of the insert block cover (21) and the inside of a hollow plug cover (11) are integrally connected by engagement. An elastic structure is provided between the insert block (23) and the blade (14) to reduce wear during insertion of the blade (14); Between the plug structure (1) and the socket structure (2), there is provided a locking structure for preventing the blades (14) from continuing to move forward after being inserted and connected to a predetermined position.

1. A connector adapted for ultrasonic welding.

2. The insert block (23) is divided into two equal-sized sub-insert blocks (231), one above the other. Each sub-insert block (231) includes a welded portion and an insertion connection portion. The elastic structure includes a plurality of elongated insert grooves (231a) formed on the inner surface of the insertion connection portion and springs (26) placed in the insert grooves (231a). The length of each insert groove (231a) is smaller than the width of the single sub-insert block (231). The length of each insert groove (231a) is perpendicular to the insertion direction of the blade (14). Each insert groove (231a) includes a first insert groove portion (231b) and a second insert groove portion (231c). The cross-sectional shape of the first insert groove portion (231b) is semicircular, and the cross-sectional shape of the second insert groove portion (231c) is a large divided circle.

2. A connector adapted for ultrasonic welding according to claim 1.

3. The circumferential angle corresponding to the major divided circle of the second insert groove portion (231c) is 240°.

3. A connector adapted for ultrasonic welding according to claim 2.

4. In the single insert groove (231a), the number of the first insert groove portion (231b) is one, the number of the second insert groove portion (231c) is one, and the length of the second insert groove portion (231c) is greater than the length of the first insert groove portion (231b); 3. A connector adapted for ultrasonic welding according to claim 2.

5. In the single insert groove (231a), the number of the first insert groove portion (231b) is one, the number of the second insert groove portion (231c) is two, the single first insert groove portion (231b) is provided between two of the second insert groove portions (231c), and the length of the single second insert groove portion (231c) is the same as the length of the first insert groove portion (231b).

3. A connector adapted for ultrasonic welding according to claim 2.

6. The insert block (23) is divided into two equal-sized sub-insert blocks (231), one above the other. Each sub-insert block (231) includes a welded portion and an insertion joint. The elastic structure includes a plurality of elongated insert grooves (231a) formed on the inner surface of the insertion joint, and springs (26) placed in the insert grooves (231a). The length of the insert grooves (231a) is perpendicular to the insertion direction of the blades (14). The insert grooves (231a) penetrate the entire sub-insert block (231). The cross section of the insert grooves (231a) is in the shape of a large divided circle. Stoppers (231e) are fixedly installed on both ends of the insert grooves (231a) to limit the position of the springs (26).

2. A connector adapted for ultrasonic welding according to claim 1.

7. In the two upper and lower sub-insert blocks (231), the vertical distance between two adjacent springs (26) is smaller than the thickness of the blade (14). A connector adapted for ultrasonic welding according to claim 2 or 6.

8. An upper locking block (113) and a lower locking block (114) that fit together vertically are provided on the inner wall of the hollow plug cover (11), and a gap formed between the upper locking block (113) and the lower locking block (114) is used for inserting and connecting the plug blades (14).

8. A connector adapted for ultrasonic welding according to claim 7.

9. The fastening structure includes a third protrusion (211) provided on the outer surface of the insert block cover (21) and a second protrusion (112) provided on the inner surface of the hollow plug cover (11) and snap-engaged with the third protrusion (211).

2. A connector adapted for ultrasonic welding according to claim 1.

10. A hollow end cap (12) is attached to the end of the hollow plug cover (11) close to the aluminum wire structure (3), a hollow seal body (13) is further fitted inside the hollow end cap (12), and a first contact prevention cap (15) is attached to the side of the plug blade (14) close to the insert block (23).

8. A connector adapted for ultrasonic welding according to claim 7.

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