Connectors suitable for 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 specifically to connectors suitable for ultrasonic welding.

Background Art

[0002] Currently, a connector, as a device that can achieve electrical connection, is generally divided into two parts. When the two parts are separated, electrical disconnection can be achieved, and when the two parts are connected, electrical conduction can be achieved. There are multiple methods for a general connector to achieve electrical connection, that is, to connect conductor to conductor, but most of them are complex, have large wear during use, and are difficult to manufacture and install. Usually, a mechanically crimping method is used for the connection part between the connector and the wire. Such a method has no problem when using copper wires, but when replacing with aluminum wires, there are problems such as the contact surface being easily oxidized.

[0003] Therefore, there is a strong demand for new solutions to solve the above problems.

Summary of the Invention

Problems to be Solved by the Invention

[0004] The present invention provides a connector suitable for ultrasonic welding, including a plug structure that is detachably connected, a socket structure, and an aluminum wire structure that is integrally welded to the plug structure by ultrasonic waves.

Means for Solving the Problems

[0005] The aluminum wire structure includes an integrally connected aluminum wire body part and an aluminum wire connection part. The plug structure includes a plug blade that is integrally welded to the aluminum wire connection part by ultrasonic waves, and a hollow plug cover that plays a guiding role during the insertion of the plug blade. The socket structure includes an insert block for housing the plug blade and an insert block cover fitted to the outside of the insert block, a sealing structure is provided at the end of the insert block away from the plug blade, and the outside of the insert block cover and the inside of the hollow plug cover are integrally joined by locking. An elastic structure is provided between the insert block and the plug blade to reduce wear during insertion of the plug blade. A locking mechanism is provided between the plug structure and the socket structure to prevent the plug blade from continuing to move forward after it has been inserted and connected in a predetermined position.

[0006] Furthermore, the insert block is divided into two sub-insert blocks of the same size, one above the other, and each sub-insert block includes a welded portion and an insertion connection portion, and the elastic structure includes a plurality of elongated insert grooves provided on the inner surface of the insertion connection portion and a spring placed in the insert groove, the length of the insert groove is smaller than the width of the single sub-insert block, the longitudinal direction of the insert groove is perpendicular to the insertion direction of the plug blade, and 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 inscribed angle corresponding to the large division circle of the second insert groove is 240°.

[0008] Furthermore, in a 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 a single insert groove, the number of first insert grooves is one, the number of second insert grooves is two, the single first insert groove is located between the two second insert grooves, and the length of the single second insert groove is the same as the length of the first insert groove.

[0010] As another preferred solution, the insert block is divided into two sub-insert blocks of the same size, one above the other, and each sub-insert block includes a welded portion and an insertion connection portion, and the elastic structure includes a plurality of elongated insert grooves provided on the inner surface of the insertion connection portion and springs placed in the insert grooves, the longitudinal direction of the insert grooves is perpendicular to the insertion direction of the plug blade, the insert grooves penetrate the entire sub-insert block, the cross-sectional shape of the insert grooves is that of a large divided circle, and stoppers are fixedly installed at both ends of the insert grooves to restrict 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 plug blade.

[0012] Furthermore, the inner wall of the hollow plug cover is provided with an upper locking block and a lower locking block that fit together vertically, 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 engagement structure includes a third projection provided on the outer surface of the insert block cover and a second projection provided on the inner surface of the hollow plug cover that snaps into place with the third projection.

[0014] Furthermore, a hollow end cap is attached to the end of the hollow plug cover closest to the aluminum wire structure, a hollow sealing 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 to the conventional technology, the beneficial effects of the present invention are as follows:

[0016] 1. The present invention provides a plug structure that is detachably connected, a socket structure, and an aluminum wire structure that is integrally welded to the plug structure by ultrasonic waves, thereby providing an elastic structure between the insert block and the plug blade, and thereby reducing wear of the entire plug structure and aluminum wire structure during the process of insertion into the socket structure.

[0017] 2. In this invention, by providing an ultrasonic welding position at the end of the plug blade, the connector can connect to an aluminum wire, ensuring connection reliability and service life, and the aluminum wire can be used at a significantly lower cost compared to copper wire.

[0018] 3. In this invention, by fixing the plug blade to the plug structure and providing multiple sets of insert grooves for placing insert springs in the socket structure, the springs rotate and roll together with the plug blades as they are inserted into the insert block, thereby reducing friction and wear, and ensuring reliable contact due to the elasticity of the springs.

[0019] 4. The present invention provides a first insert groove portion with a semicircular cross-sectional shape and a second insert groove portion with a large divided circle shape, thereby facilitating the replacement of the spring in the later stages and reducing the cost of replacing the entire socket structure.

[0020] 5. The insert groove of the present invention penetrates the entire sub-insert block, and after the spring is placed, stoppers are fixedly welded to both ends of the insert groove to limit the position of the spring. By adopting a form in which the insert groove penetrates the entire sub-insert block, the processing and manufacturing of the insert groove becomes easier. [Brief explanation of the drawing]

[0021] [Figure 1] It is a schematic diagram of the overall structure of the connector in the first embodiment of the present invention. [Figure 2] It is a schematic diagram of the overall structure of the plug structure and the aluminum wire structure in the first embodiment of the present invention. [Figure 3] It is an exploded schematic diagram of the overall structure of the plug structure and the aluminum wire structure in the first embodiment of the present invention. [Figure 4] It is a schematic diagram of the overall structure of the socket structure in the first embodiment of the present invention. [Figure 5] It is an exploded schematic diagram of the overall structure of the socket structure in the first embodiment of the present invention. [Figure 6] It is a longitudinal sectional view of the overall structure of the connector in the first embodiment of the present invention. [Figure 7] It is a longitudinal sectional view of the overall structure of the plug structure in the first embodiment of the present invention. [Figure 8] It is a longitudinal sectional view of the overall structure of the socket structure in the first embodiment of the present invention. [Figure 9] It is an enlarged schematic diagram of part A in FIG. 8. [Figure 10] It is a schematic diagram of the structure of the insert block cover in the first embodiment of the present invention. [Figure 11] It is a schematic diagram of the structure of the sub-insert block in the first embodiment of the present invention. [Figure 12] It is a schematic diagram of the structure of the sub-insert block in the second embodiment of the present invention. [Figure 13] It is a schematic diagram of the structure of the sub-insert block in the third embodiment of the present invention.

Mode for Carrying Out the Invention

[0022] In order to further understand the content, features and effects of the present invention, the following examples are given and will be described in detail as follows while referring to the attached drawings 1 to 13.

[0023] 〈0000114〉As shown in Figures 1 to 11, the present invention discloses a connector suitable for ultrasonic welding, comprising a plug structure 1 that is detachably connected, a socket structure 2, and an aluminum wire structure 3 that is integrally welded to the plug structure 1 by ultrasonic waves.

[0024] The above aluminum wire structure 3 includes an integrally connected aluminum wire body portion 31 and an aluminum wire connecting portion 32. The plug structure 1 described above includes a plug blade 14 which is integrally welded with the aluminum wire connection part 32 by ultrasonic waves, and a hollow plug cover 11 which serves as a guide during insertion of the plug blade 14. The socket structure 2 includes an insert block 23 that houses the plug blade 14 and an insert block cover 21 fitted to the outside of the insert block 23. A sealing structure is provided at the end of the insert block 23 away from the plug blade 14, and the insert block cover 21 is provided with an opening for the plug blade 14 to pass through. The sealing structure includes a sealing gasket 25 and a sealing strip 24. A sealing adhesive is applied to this area 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 integrally joined by fastening. Between the insert block 23 and the plug blade 14, an elastic structure is provided to reduce wear of the plug blade 14 during insertion. A locking mechanism is provided between the plug structure 1 and the socket structure 2 to prevent the plug blade 14 from moving further after it has been inserted and connected in a predetermined position.

[0025] The present invention provides a plug structure that can be detachably connected, a socket structure, and an aluminum wire structure that is integrally welded to the plug structure by ultrasonic waves. By providing an elastic structure between the insert block and the plug blade, wear of the entire plug structure and aluminum wire structure during the process of insertion into the socket structure is reduced. Furthermore, by providing an ultrasonic welding position at the end of the plug blade, the connector can connect the aluminum wire, ensuring connection reliability and service life, and the aluminum wire can be used at a significantly lower cost compared to copper wire.

[0026] In Embodiment 1 of the present invention, as shown in Figure 3, the plug structure 1 further includes a hollow end cap 12, a hollow seal body 13, and a first contact prevention cover 15, which can prevent a person from being electrocuted by touching the plug blade 14. Here, the hollow end cap 12 is attached to the end of the hollow plug cover 11 on the side closer to the aluminum wire structure 3, the hollow seal body 13 is further fitted inside the hollow end cap 12, and the first contact prevention cover 15 is attached to the side of the plug blade 14 closer to the insert block 23. Two plug blade blind holes 141 are provided in the middle of the plug blade 14, and two engagement posts 115 corresponding one-to-one with the plug blade blind holes 141 are provided on the upper surface inside the hollow plug cover 11.

[0027] In Embodiment 1 of the present invention, as shown in Figure 7, the inner wall of the hollow plug cover 11 is provided with an upper locking block 113 and a lower locking block 114 that fit together vertically, 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 Embodiment 1 of the present invention, as shown in Figures 6-8, a first projection 111 and a second projection 112 are provided on the surfaces of both ends of the hollow plug cover 11, respectively. Here, the first projection 111 is used for engagement with the end of the hollow end cover 12, and a third projection 211 and a fourth projection 212 are provided on the outer surfaces of both ends of the insert block cover 21, respectively. The second projection 112 and the third projection 211 engage with each other to prevent the plug blade 14 from continuing to move forward after it has been inserted and connected in a predetermined position.

[0029] In Embodiment 1 of the present invention, as shown in Figures 5 and 8, the socket structure 2 further includes a second contact prevention cover 22 that engages with the end of the insert block cover 21, preventing a person from touching the insert block 23 and being electrocuted, and the fourth projection 212 is used to engage the second contact prevention cover 22 with the insert block cover 21. Here, on the side of the insert block cover 21 closest to the sealing strip 24, there is an inwardly bent portion 213 that engages with an arc-shaped projection in the middle of the sub-insert block 231 to relatively fix the insert block cover 21 and the insert block 23.

[0030] In Embodiment 1 of the present invention, as shown in Figures 5 to 11, the insert block 23 is divided into two sub-insert blocks 231 of the same size, one above and one below. Each 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 a spring 26 placed in the insert grooves 231a. The length of the insert grooves 231a is less 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 plug blade 14.

[0031] Preferably, as shown in Figure 11, a single insert groove 231a includes a first insert groove portion 231b and a second insert groove portion 231c, where the cross-sectional shape of the first insert groove portion 231b is semicircular to facilitate the placement of the compressed spring 26. After the spring 26 is placed in the first insert groove portion 231b, it automatically extends under the action of repulsive force and contacts the inner surfaces of both ends of the insert groove 231a in a free state. During the process of inserting the plug blade 14 into the insert block 23, the spring 26 rotates and continues to roll, reducing friction and thereby reducing wear, and the elasticity of the spring ensures reliable contact. The cross-sectional shape of the second insert groove portion 231c is a large division circle. Preferably, the inscribed angle corresponding to the large division circle of the second insert groove portion 231c is 240°, thus ensuring that the spring 26 remains in the insert groove 231a without falling out.

[0032] In this embodiment 1, as shown in Figure 11, in a single insert groove 231a, there is one first insert groove portion 231b, one second insert groove portion 231c, 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 Figure 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 plug blade 14. By ensuring that the two are in contact and electrically conductive in this way, a reliable electrical connection can be formed.

[0034] In this embodiment 1, as shown in Figures 1 to 9, when connecting the conductor, the aluminum wire body 31 is first passed through the hollow end cap 12 and the hollow seal body 13 in sequence, the aluminum wire connection part 32 is welded to the plug blade 14 by ultrasonic waves, the first contact prevention cap 15 is attached to the end of the plug blade 14 and fixed with the locking part above it, then the assembly of the plug blade 14 and the aluminum wire structure 3 is placed in the hollow plug cover 11, and the plug blade stop hole 141 in the middle of the plug blade 14 is fixed to the engagement post 115 to complete the fixing, and after fixing, the end cap 12 is placed over the end of the hollow plug cover 11 to complete the assembly of the plug structure 1. After inserting the spring 26 into the insert groove 231a, the two sub-insert blocks 231 are welded together to form the insert block 23. After placing the insert block 23 into the insert block cover 21, the second contact prevention cover 22 is attached to secure 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. At this point, the hollow plug cover 11 and plug blade 14, and the insert block cover 21 and insert block 23 are sealed with adhesive to protect the internal electrical connections.

[0035] As an embodiment 2 of the present invention, as shown in Figure 12, in a single insert groove 231a, there is one first insert groove portion 231b and two second insert groove portions 231c, and the single first insert groove portion 231b is provided between the two 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. By providing two second insert groove portions 231c and one first insert groove portion 231b, the spring 26 can be fixed more stably.

[0036] As an embodiment 2 of the present invention, as shown in Figure 12, the insert block 23 is divided into two sub-insert blocks 231 of the same size, one above and one below. Each sub-insert block 231 includes a welded portion and an insertion connection portion. The elastic structure includes four elongated insert grooves 231a provided on the inner surface of the insertion connection portion and a spring 26 placed in the insert grooves 231a. The length direction of the insert grooves 231a is perpendicular to the insertion direction of the plug blade 14. The insert grooves 231a penetrate the entire sub-insert block 231, thereby facilitating the processing and manufacturing of the insert grooves. The cross-sectional shape of the insert grooves 231a is that of a large divided circle, preferably with an angle corresponding to its inscribed angle of 240°. Stoppers 231e for positioning the spring 26 are fixedly welded to both ends of the insert grooves 231a.

[0037] The above invention merely illustrates embodiments of the present invention and should not be understood as limiting the scope of the invention patent, nor does it limit the structure of the embodiments of the present invention in any way. Those skilled in the art can make several modifications and improvements without departing from the conceptual framework of the embodiments of the present invention, all of which fall within the scope of protection of the embodiments of the present invention. [Explanation of symbols]

[0038] 1…Plug structure, 11…Hollow plug cover, 111…First projection, 112…Second projection, 113…Upper locking block, 114…Lower locking block, 115…Engaging post, 12…Hollow end cover, 13…Hollow seal body, 14…Plug blade, 141…Plug blade blind hole, 15…First contact prevention cover, 2…Socket structure, 21…Insert block cover, 211…Third projection, 212…Fourth projection, 213…Bent part, 22…First 2... Contact prevention cover, 23... Insert block, 231... Sub-insert block, 231a... Insert groove, 231b... First insert groove section, 231c... Second insert groove section, 231d... Copper busbar connection hole, 231e... Stopper, 24... Seal strip, 25... Seal gasket, 26... Spring, 3... Aluminum wire structure, 31... Aluminum wire body section, 32... Aluminum wire connection section.

Claims

1. It includes a plug structure (1) that is detachably connected, a socket structure (2), and an aluminum wire structure (3) that is integrally welded to the plug structure (1) by ultrasonic waves. The aluminum wire structure (3) includes an integrally connected aluminum wire body portion (31) and an aluminum wire connecting portion (32), The plug structure (1) includes a plug blade (14) which is integrally welded with the aluminum wire connection portion (32) by ultrasonic waves, and a hollow plug cover (11) which serves as a guide during insertion of the plug blade (14). The socket structure (2) includes an insert block (23) that houses the plug blade (14) and an insert block cover (21) fitted to the outside of the insert block (23), wherein a seal structure is provided on the outside of the insert block (23) on the side farther from the plug blade (14), and the seal structure is in contact with the insert block cover (21), and the outside of the insert block cover (21) and the inside of the hollow plug cover (11) are integrally joined by locking. An elastic structure is provided between the insert block (23) and the plug blade (14) to reduce wear of the plug blade (14) during insertion. A locking structure is provided between the plug structure (1) and the socket structure (2) to prevent the plug blade (14) from continuing to move forward after it has been inserted and connected to a predetermined position. A connector suitable for ultrasonic welding, characterized by the following features.

2. The insert block (23) is divided into two sub-insert blocks (231) of the same size, 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) provided on the inner surface of the insertion connection portion and a spring (26) placed in the insert grooves (231a). The length of the insert grooves (231a) is less than the width of the single sub-insert block (231). The length direction of the insert grooves (231a) is perpendicular to the insertion direction of the plug blade (14). Each insert groove (231a) includes a first insert groove portion (231b) and a second insert groove portion (231c). Here, 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 split circle (a large arc-circular fragment shape). A connector suitable for ultrasonic welding as described in claim 1, characterized in that...

3. The central angle corresponding to the large circular section of the second insert groove (231c) is 240°. A connector suitable for ultrasonic welding as described in claim 2, characterized in that

4. In a single insert groove (231a), there is one first insert groove portion (231b), there is one second insert groove portion (231c), and the length of the second insert groove portion (231c) is greater than the length of the first insert groove portion (231b). A connector suitable for ultrasonic welding as described in claim 2, characterized in that

5. In a single insert groove (231a), there is one first insert groove portion (231b) and two second insert groove portions (231c), the single first insert groove portion (231b) is located between the two 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). A connector suitable for ultrasonic welding as described in claim 2, characterized in that

6. The insert block (23) is divided into two sub-insert blocks (231) of the same size, 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) provided on the inner surface of the insertion connection portion, and springs (26) placed in the insert grooves (231a). The length direction of the insert grooves (231a) is perpendicular to the insertion direction of the plug blade (14). The insert grooves (231a) penetrate the entire sub-insert block (231). The cross-sectional shape of the insert grooves (231a) is a large oval. Stoppers (231e) are fixedly installed at both ends of the insert grooves (231a) to restrict the position of the springs (26). The central angle corresponding to the large circular section of the insert groove (231a) is 240°. A connector suitable for ultrasonic welding as described in claim 1, characterized in that...

7. In the two upper and lower sub-insert blocks (231), the vertical distance between two adjacent springs (26) is less than the thickness of the plug blade (14). A connector suitable for ultrasonic welding according to claim 2 or 6, characterized in that it is a connector suitable for ultrasonic welding as described in claim 2 or 6.

8. The inner wall of the hollow plug cover (11) is provided with an upper locking block (113) and a lower locking block (114) that fit together vertically, and the gap formed between the upper locking block (113) and the lower locking block (114) is provided for the insertion and connection of the plug blade (14). A connector suitable for ultrasonic welding as described in claim 7, characterized in that it is a connector suitable for ultrasonic welding as described in claim 7.

9. The engagement structure includes a third projection (211) provided on the outer surface of the insert block cover (21) and a second projection (112) provided on the inner surface of the hollow plug cover (11) that snap-engages with the third projection (211). A connector suitable for ultrasonic welding as described in claim 1, characterized in that...

10. A hollow end cap (12) is attached to the end of the hollow plug cover (11) closest 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 cover (15) is attached to the side of the plug blade (14) closest to the insert block (23). A connector suitable for ultrasonic welding as described in claim 7, characterized in that it is a connector suitable for ultrasonic welding as described in claim 7.

Images