CN1228629A - Electrical connector - Google Patents

Abstract

The invention relates to an electrical connector, especially relates to a plug pin connector of home plug type. As everyone knows, a sudden electric shock danger when the plug is removed from a receptacle portion can be reduced by providing a forwards extending portion of a plug pin having an insulative layer. The plug is manufactured by performing various process for machining a solid plug, thereby the cost is increased and material is wasted. The invention provides a plug pin formed by folding a flat blank, havng a first portion with a size requested by the plug pin and a second portion with a smaller size, the second portio is used for mounting the insulative layer. The invention need not machining.

Description

Electric connector

The present invention relates to a kind of electric connector, especially, be not limited in and relate to a kind of plug base pin connector, for example family expenses plug.The invention still further relates to a kind of method of making electric connector.

Well-known plug base pin connector, generally comprise an extension forward, in use stretch out and comprise that one is roughly that planar chip shape plug connector elements or cannon plug pin engage with suitable jack (for example socket aperture) mechanical type or electricity engages from the panel of plug body.They also comprise the part that extends back, and in use are installed in the plug and are used to link to each other with electric conductor.This part that extends back generally includes a position of curling with respect to an exposed lead and comprises the another one part or the position of curling round wire insulation.In most household plug outlet, adopt a plurality of such connectors (being generally three).In manufacture process, many plug base pins are installed in the compartment of a panel that forms plug by slit or hole, and remain on preposition in compartment mutually.Lead is injected the part that extends back, and lead is curled, and then this lead and the part that extends back are put in the insulating material.The plug of Zhi Zaoing is very safe in this way, because anyone can not enter plug or give the plug rewiring.

The problem of the electric connector of such a household plug outlet formula is, in some cases, plug may slightly be shifted out or tilt to cause plug base pin partly to expose from socket, and still be electrically connected with socket the end of extension this moment forward, this danger close, if less child slides into their finger between charged plug panel and the socket panel and contacts energized conductor, metal between plug panel and the socket panel or other conductive component also will be connected and self is charged, cause the possibility of getting an electric shock and dying unexpectedly.

Advise that at some national plug base pin manufacturing industry of this problem should there be insulated position the extension forward.Preferably extend along the sufficient length of the extension forward of plug base pin at this insulation position, promptly, if plug that plug base pin has been installed from socket part shift out, so its forward effective conducting position of extension before it stops to electrically contact with socket, can not be exposed.And when keeping in touch, have only insulated part to expose with power supply.This has just dwindled the chance of accidental shock.

The problem of present employed blind plug pin is the manufacturing cost height.The blind plug pin type that two kinds of well-known types are arranged.One generally is used for Britain's (Anglicism), and such extension forward comprises that is roughly a solid rectilinear sheet metal, and it passes through special cutting so that the insulating barrier of a moldings formed therefrom is installed in position of extension forward.Cutting is necessary, because the size of plug base pin is strict with, they can be cooperated with corresponding socket.Strict size is established in various standards.Therefore the extension forward of plug base pin must so that provide the space for increasing insulating barrier, and make because the size that insulating barrier increases can not cause pin to exceed the size of standard-required through special cutting with minification.

The another kind of blind plug pin that generally is used at present European countries, for example German and France's (European plan), the plug base pin here extension forward comprises a solid cylinder rolled-up and that be cut substantially.Equally, cutting is that so the final size of plug base pin will meet corresponding standard for the size of dwindling the part plug base pin needs so that insulating barrier is installed.This plug base pin cost height, and waste material simultaneously.

The Australian small-sized patent NO.659988 that is awarded in the time of has earlier disclosed a kind of electric connector, and as the plug base pin connector, it comprises the plate part of extending forward of a basic hollow.The special construction of this hollow plug base pin has been saved manufacturing cost.Small-sized patent NO.659988 institute disclosure is here comprehensively adopted as a reference.

The plate that extends forward in the small-sized patent of first to file is to constitute to form the relative plate that is separated by a division board by folding plate of conductive material blank.Therefore can keep the required overall dimension of respective standard, save lot of materials simultaneously, because plate is a hollow, so do not need to use a lot of materials.The rigidity and the intensity that provide division board can keep this plate.This technology is specially adapted to make the connector with flat-panel component, and it is widely used in Australia and part Asian countries.But be not limited in this.

The invention provides a kind of electric connector making method, this electric connector comprises a conducting element that extends forward, it is suitable for engaging with suitable groove mechanical or electricity engages, this method comprises the following steps: that the electric conducting material flat blank of preparing a corresponding size is used to form the element that extends forward, folding this plate has the first and first overall dimension with formation and has second portion and less than the element that extends forward of second overall dimension of first's overall dimension, and provide an insulating barrier or an insulating element that is wrapping second portion at least in part, here the overall dimension of second portion and insulating barrier or insulating element combine should less than or be substantially equal to the overall dimension of first, and this step of preparing flat blank comprises from every side of flat board cuts electric conducting material to form recess, its length is substantially equal to the length of second portion, thereby can be by being folded to form the second portion of size reduced.

Preferably first adopts hollow structure.

Best, insulating barrier or insulating element are positioned at when the extension is connected with electrically conductive socket with convenient first hollow space forward, and insulated part can reduce the chance of the accidental shock that personnel are caused.Electric connector preferably adopts the plug base pin connector and insulating barrier is installed or insulating element when being installed on the plug body with convenient connector, and insulating barrier extends to the extension forward of connector from the panel position of plug body.

Extend conducting element forward and comprise a plate of conductive material blank that is folded.Best, for forming first, the both sides of this blank are folded into relative sheet shape plate, and this relative plate is preferably separated by dividing plate so that play booster action, adopts the method at the described formation connector of the small-sized patent NO.659988 of first to file.Similarly, second portion preferably adopts folded part electric conducting material blank to form.The size of conductive plate preferably like this, promptly conductive plate is folded to form second portion, two sheet shape plates that second portion is relative contact with each other to form and have dwindled the second portion of size thus.Therefore second portion does not preferably adopt hollow structure.

In another embodiment, the division board that has reduced height in first's division board also extends along second portion, so second portion is a hollow in this embodiment.

Insulated part can adopt moldings formed therefrom or be formed also by insulating tape and can adopt other method, so the overall dimension of insulating barrier is no more than the overall dimension of pin.

Electric connector preferably also comprises an element that extends back, and this element that extends back has the part that a relative lead curls.Disclosed a kind of connector of curling drum at the small-sized patent NO.678541 of first to file, it comprises the cylindrical portions may of a hollow, make the overlapped formation overlap joint in the two ends of flat blank by a flat blank that is curled into cylindrical shape or is roughly cylindrical in cross-section.This structure is particularly suitable for the assembling and the manufacturing of plug.Combine the structure that small-sized patent NO.678541 disclosed here as a reference in first to file.

The electric connector made from method of the present invention has an element that extends back, and it is roughly the same with the shape described in the patent NO.678541 of first to file.

The first of extending conducting element forward of electric connector preferably makes with above-described identical, relative sheet shape plate is separated by dividing plate, what a sheet shape plate by along the broken line that separates relative to one another two parts of folding plate of conductive material form, and division board is to constitute by folding relative two-part edge, and two of this plate parts extend transverse to another relative plate so that make relative plate keep separating in contact of seam place and two-part edge from a plate thus.Division board is preferably along the length method extension of the first of extending element forward.

In another embodiment of Tao Luning, division board also extends along second portion in the above, isolates two relative sheet shape plates of second portion.The sheet shape plate of second portion uses the mode identical with the sheet shape plate of first to make.

The advantage of the electric connector that the method according to this invention forms is that it is made by folding plate of conductive material blank.Can by die-cut operation former conductive plate blank be cut into required size before folding finishes.Do not need expensive cutting operation.It has one than the cheap a lot of blind plug pin of existing blind plug pin this electric connector of making thus.

In most preferred embodiment, the other part of the extending element forward of connector is made into measure-alike with first.In this case, insulated part is preferably between first and second portion.This other part preferably has a suitable size, and this size is suitable for injecting in the slit of grafting panel or bridge plug, being convenient to assembling and making, and helps the stability of plug panel.Most of slit is all made the size that is fit to the standard plug connector elements in advance.

This electric connector does not need to comprise that substantially is the extending element forward of flat-panel component, as described in the small-sized patent of first to file.This element can be rectangle substantially, and is similar to the plug base pin of Anglicism.Be roughly rectangular plug base pin and can make the structure of shape by folding flat blank as " box ".

Embody the features and advantages of the present invention with the method for giving an example in conjunction with the accompanying drawings by description below to embodiment.

Figure 1A is the perspective view of the electric connector of the present invention from top and unilateral observation when not insulating.

Figure 1B is the perspective view that when insulation arranged from electric connector shown in Figure 1A of top and unilateral observation.

Fig. 2 A and 2B are that connector shown in the Figure 1A that observes from top and rear side is not insulating and perspective view under the situation of insulation is arranged respectively.

Fig. 3 is the plane graph of connector shown in Figure 1A.

Fig. 4 is the end view of connector shown in Figure 1A.

Fig. 5 is the B-B sectional view of Fig. 4.

Fig. 6 is the A-B sectional view of Fig. 4.

Fig. 7 A be from the one embodiment of the invention that top and rear side are observed another connector at the perspective view that has under the insulation situation.

Fig. 7 B is from the view of connector under not insulation situation shown in Fig. 7 A of top and rear side observation.

Fig. 8 A is the plane graph that forms the flat blank of connector shown in Fig. 7 A and Fig. 7 B.

Fig. 8 B is the plane graph of flat blank shown in a plurality of Fig. 8 A that are connected on the type bar.

Fig. 9 A is the plane graph of flat blank that is used to form another embodiment of electric connector of the present invention.

Fig. 9 B is the plane graph of flat blank shown in a plurality of Fig. 9 A that are connected on the type bar.

Figure 10 is from the grafting panel that is inserted with electric connector shown in Fig. 9 A and Fig. 9 B of top and unilateral observation or bridge plug (plug bridge).

Figure 11 is the front view of bridge plug shown in Figure 10.

Figure 12 is the end view of bridge plug shown in Figure 10.

Figure 13 is the rearview of bridge plug shown in Figure 10.

With reference to accompanying drawing, with label 1 expression, connector comprises a conducting element 2 that extends forward to electric connector of the present invention generally, and in the present embodiment, this conducting element is roughly the plane film-shaped device.This film-shaped device 2 comprises the first 3 (Figure 1A) that one first overall dimension is wide W and thick B.

This film-shaped device also comprises the second portion 4 (Figure 1A) that one second overall dimension is wide W2 and thick B2.Second overall dimension is less than first overall dimension.

In the operation, second portion 4 has at least a part to be insulated layer or insulating element 5 covers (Figure 1B and Fig. 2 B).This insulating barrier or insulating element 5 can be plastic insulation material layer or the plastic sheath or the bands of injection mo(u)lding.

The electric connector of this embodiment also comprises an element that extends back 6.This element that extends back 6 comprises a curling body 7, and this curling body is to a conducting connecting part crimp, as a lead.

In the operation, the element 6 that extends back is installed in the plug body and (do not show among the figure, but this technical field technical staff is expressly understood and knows very much).This element that extends back 6 is loaded in the plug body after the body that curls is curled by the electric conductor in plug.The element 2 of Yan Shening stretches out plug body and one and for example joins for equipment provides the respective socket of power supply forward.The plug surface that part 3 is stretched out nestles up insulator 5 in operation or extends through insulator 5 slightly.This is similar to the plug in Britain discussed above or Europe.

In the operating process of plug, part 3 electrically contacts with supply socket.If plug is slightly released socket, insulator 5 will guarantee that nobody can get an electric shock.The length of part 3 and part 4 is preferably when plug is extracted to current-carrying part 3 exposures, and current-carrying part 3 does not electrically contact with supply socket.

The size of insulator 5 should be when insulator 5 is installed on the second portion, and the overall dimension of the insulator 5 that is mounted is less than or equal to the size of the W and the B of first 3.The size of W and B depends on the needed standard of size of the pin plug of mating with respective socket.When plug base pin is finished, add additional insulator 5, forward extension 4 or prepare to extend to the size that part in the receptacle sockets will meet all needs at least.When the overall dimension of insulator 5 does not have oversize W and B, insulator 5 will can not cooperate with jack in overslaugh.

Embodiment shown in the figure is made by original electric conducting material plate blank.This plate blank is by electric conducting material (for example: copper or brass) plate is made through striking out corresponding shape and size.Folding then this flat board is to form final plug base pin.

Electric conducting material is the material that a kind of thickness is similar to required size B 1/3rd.For the size of guaranteeing first 3 just in time is B, it is made into one as the hollow space of clearly being described among Fig. 53.The part 8,9 of conducting plate blank is folded to form top board spare 8,9 relatively, and other part 10 and 11 is folded to form division board 10,11 and is used for the base plate 12 of top board spare and the part 3 relative with it is kept apart.This structure is identical with the structure of the patent in first to file discussed above (small-sized patent NO.659988).But in this a connector, only there is the first 3 of plug base pin to adopt this method formation rather than whole this method of 2 usefulness of extension forward to constitute.

Part 4 is to constitute with a kind of diverse ways.This is to be made by the material of same thickness (identical blank), but this part material is according to following size punching press, it can directly fold up part 14 and 15 ones and is connected together to form top sheet shape plate 14 at seam 16 places, 15, this plate 14,15 directly leans the bottom sheet shape plate 17 of part 2.The gross thickness of part 2 is that B2 and width are W2 thus, (see figure 6).Thereby can increase insulating barrier or insulator 5.

The element that extends back can not be the shape shown in the described embodiment but it can be other arbitrary shape.With regard to most preferred embodiment, its shape discloses in the small-sized patent NO.678541 in first to file, and as shown in Figure 7A and 7B, this is easy to assemble in the manufacture process of plug and being connected of conductor.

In Fig. 7 A and 7B with before identical label symbol in the accompanying drawing be used on the same parts of connector.In this case, the plate blank of shape was made the structure identical with small-sized patent NO.678541 shown in the element 20 that extends back was rolled into from one, thereby so that provided a conical entrance 21 to be easy to assembling.

Fig. 8 A has shown that a plate blank that is cut into suitable shape is so that by folding and curl into the pin shown in Fig. 7 A and the 7B.The technology people of this area will know how this plug forms.The each several part that forms the flat blank of element has adopted the label symbol identical with 7B with Fig. 7 A.Fig. 8 B has shown a plurality of plate blanks that are connected on the type bar 23.

" the every side in flat blank forms recess 51,52 by the cutting electric conducting material, and recess 51,52 cardinal principle development lengths are the length that forms the flat blank of connector second portion (reduced size).Circular arc is located to be cut into as marking shown in 53 and 54 near the formation first (large-size) of flat blank in the end of recess 51,52.Cut a flat blank with recess 51 and 52 and be easy to the formation of the second portion of minification.Recess 51 and 52 circular arc end 53,54 reduce stress when flat board is folded to form connector, keep the intensity of formed connector.Recess 51A similarly, 52A and circular arc 53A, 54A, 55,56 occur in the embodiment of Fig. 9 A and 9B.

Among the former embodiment, the element 2 of Yan Shening has and the identical size in position that is used to install insulating part or insulating barrier 5 near the part place that extends back forward.Preferably this position near the element that extends back has size W and the B identical with first 3.There is such one to be easy to fit into bridge plug or grafting panel with first same wide other position.Bridge plug or grafting panel have a slit each plate that extends forward that is used to peg graft.This slit is determined size usually so that the grafting AN connector.If be placed in usually in this slit and it is identical with B then more superior with the size W of AN connector (and first) near the position of the part that extends back.Yet preferably this other position (in Fig. 7 A with alphabetical A indication) is used to form first's 3 identical methods and makes, and has size W identical with first and B.Preferably it also has a division board to isolate relative plate, and is the same with first 3.

Fig. 9 A and 9B have shown a flat blank that is used to form the plug pin connector, and this electric plug connector has an other position 25 with same size W of first and B.Other characteristic is identical with blank shown in Fig. 8 A and the 8B.Difference is that the size of position A has been increased.

Figure 10 to 13 has shown a bridge plug or grafting panel, and it is made into standard shape and is used to receive by the dull and stereotyped connector of making shown in Fig. 9 A and the 9B.Connector is respectively with 31,32 and 33 expressions.Along with connector inserts plugboard 30, the element 20 that connector extends back reeve and they will be curled there.Plug body will be loaded onto and be done then.Here used technology is conventionally known to one of skill in the art.

Electric connector of the present invention does not need the surface plate of the extension forward of a sheet shape.The pin connector of other type, for example, the manufacturing that can use the same method of the connector of thicker Britain's shape.That is, the extension can provide a wide portions to form and second portion can form suitable thickness and constitute by doubling is dull and stereotyped by folding forward.

If desired can be in the hollow space 3 of connector packing material to provide support.Usually preferably keep hollow, use division board as needed strutting piece.

In the embodiment of above-mentioned accompanying drawing demonstration and description, owing to formed the second portion that has dwindled size, plate 14,15 is directly adjacent with base plate 17.So the gross thickness of this part 2 is two times of electric conducting material thickness.

(not shown) in another embodiment, the part 2 of having dwindled size has a division board that extends along the length of part 2.The method that forms this division board is identical with the method for the division board 10,11 that forms the first 2 among the embodiment above-mentioned.But in this another embodiment, the division board of second portion is different with the height of the division board of first, so this second portion has dwindled size, therefore insulating barrier can be installed.The electric conducting material flat board can be thinner than the electric conducting material blank among the embodiment discussed above, so that provide the space for the another one division board that extends along second portion.Can dwindle the cost of material according to the made electric connector of this another embodiment,, therefore not need the material of as much to make the connector of an intended size because electric conducting material is thinner.

Those skilled in the art will know more than not breaking away from the basis of the thinking of the present invention roughly described and scope, and multiple variation and/or multiple modification are made in the invention of several specific embodiments that can be as shown above.Therefore embodiments of the invention are exemplary from every side, rather than circumscribed.

Claims (6)

1. method that forms electric connector, this electric connector comprises a conducting element that extends forward, it is fit to engage with a groove mechanical that is complementary and electricity, this method may further comprise the steps: prepare one and be used to form the electric conducting material flat blank of the appropriate size of extending element forward, folding this flat board so as to form first with first overall dimension and second overall dimension less than the extension forward with second portion of first overall dimension, an insulating barrier or an insulating element that is covered with second portion at least in part is provided, here the overall dimension of second portion and insulating barrier or insulating element combination should less than or be substantially equal to first overall dimension, and the step of preparing flat blank comprises from every side cutting electric conducting material of flat board so that form the recess that roughly extends by the length of second portion, and the second portion of reduced here size can and roughly form by folding recess.

2. the formation method of electric connector according to claim 1, its step that forms recess comprise to the end circle of contact of recess so that the intensity when keeping folded metal.

3. method according to claim 1 and 2, folded flat has the step of the first of first overall dimension with formation, comprises folding each several part to form the step of a relative plate and a division board, and wherein division board is used for the relative plate of bridge joint.

4. method according to claim 3, folded flat has the step of the second portion of second overall dimension with formation, comprise folding each several part so that other relative plate and other division board and the step of extending along second portion to be provided, wherein other division board is used for the other relative plate of bridge joint.

5. according to the formed electric connector of any one method in the claim 1 to 4.

6. according to any formed plug that electric connector is installed of claim 1 to 4.

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