WO2021203527A1 - 导电金属条、插座及插座的装配方法 - Google Patents

导电金属条、插座及插座的装配方法 Download PDF

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Publication number
WO2021203527A1
WO2021203527A1 PCT/CN2020/091510 CN2020091510W WO2021203527A1 WO 2021203527 A1 WO2021203527 A1 WO 2021203527A1 CN 2020091510 W CN2020091510 W CN 2020091510W WO 2021203527 A1 WO2021203527 A1 WO 2021203527A1
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WO
WIPO (PCT)
Prior art keywords
socket
conductive metal
metal strip
boss
connecting portion
Prior art date
Application number
PCT/CN2020/091510
Other languages
English (en)
French (fr)
Inventor
唐金峰
刘金辉
罗斌彬
吴清发
周海红
Original Assignee
公牛集团股份有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from CN202020529519.XU external-priority patent/CN211480348U/zh
Priority claimed from CN202010280800.9A external-priority patent/CN111355073A/zh
Application filed by 公牛集团股份有限公司 filed Critical 公牛集团股份有限公司
Publication of WO2021203527A1 publication Critical patent/WO2021203527A1/zh

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/10—Sockets for co-operation with pins or blades
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/40—Securing contact members in or to a base or case; Insulating of contact members
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/502—Bases; Cases composed of different pieces
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R25/00—Coupling parts adapted for simultaneous co-operation with two or more identical counterparts, e.g. for distributing energy to two or more circuits
    • H01R25/16—Rails or bus-bars provided with a plurality of discrete connecting locations for counterparts
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/20—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for assembling or disassembling contact members with insulating base, case or sleeve

Definitions

  • This application relates to the technical field of sockets, and in particular to a method for assembling conductive metal strips, sockets and sockets.
  • Socket is a device commonly used in industrial production and daily life. It can be used as an intermediary to connect or disconnect power sources and electrical appliances.
  • the current socket structure includes a shell, a socket seat and a conductive metal strip located inside the shell, the shell has a socket hole, and the socket socket includes at least two sockets corresponding to the socket holes, a socket and a conductive metal strip Connect, so that the sockets can be respectively connected with the corresponding phase lines, so as to realize the conduction of current.
  • the soldering process is usually used during assembly. However, during the welding process, it is easy to leave some welding slag in the socket. Once the socket is energized, the welding slag may cause an internal short circuit in the socket, leading to safety problems in use.
  • the embodiments of the present application provide a conductive metal strip, a socket, and a method for assembling the socket, which can improve the safety of the socket.
  • the technical scheme is as follows:
  • a conductive metal strip in one aspect, includes a conductive metal strip body and at least one boss.
  • the boss has an accommodating space inside, and the accommodating space has an opening at the bottom of the boss.
  • the conductive metal strip provided by the embodiment of the present application provides a boss with accommodating space on the body of the conductive metal strip, and the boss can provide insertion space for other parts during assembly, thereby realizing the fixed connection between the parts .
  • the conductive metal strip based on this structure eliminates the need for soldering in the assembly process, avoids the generation of welding slag, does not leave a hidden danger of short circuit, and can greatly improve the safety of the product.
  • the cross section of the accommodating space is a long strip.
  • This cross-sectional design can facilitate the forming of the boss during the manufacturing process, and can increase the contact area between the parts to be connected and the inner wall of the accommodating space, and can improve the efficiency of conduction.
  • the width of the longitudinal section of the accommodating space gradually decreases from bottom to top.
  • This longitudinal section design can facilitate the forming of the boss during the manufacturing process, and because of the design with a wide bottom and a narrow top, the boss can be easily and quickly fitted on the parts to be connected during the assembly process.
  • the longitudinal section of the accommodating space includes a trapezoidal section and a first rectangular section, and the trapezoidal section is located below the first rectangular section.
  • This longitudinal section design can make the parts to be connected and the inner wall of the upper part of the boss have a larger contact area. During the assembly process of the product, the two parts can be fused more quickly, which improves the assembly of the product. efficient.
  • the height of the first rectangular cross-section is 0.05-3 mm.
  • This kind of boss design can make the parts to be connected and the inner wall of the upper part of the boss have a larger contact area. In the process of assembling the product, the two parts can be fused more quickly, and the product can be improved. The assembly efficiency.
  • the longitudinal section of the accommodating space further includes a second rectangular section, and the second rectangular section is located below the trapezoidal section.
  • the conductive metal strip body has at least one reinforcing rib, and the reinforcing rib is located between the two bosses.
  • the reinforcing rib is used to strengthen the strength of the conductive metal strip, avoid deformation of the conductive metal strip, and prolong the service life of the product.
  • the material of the conductive metal strip is copper.
  • the conductive metal strip made of copper has the advantages of high conductivity, easy processing and relatively low cost.
  • the accommodating space also has an opening at the end of the boss.
  • the boss in this design has openings at both the end and the bottom, that is, the accommodating space has a through-hole structure. This structure makes the boss and the parts to be connected when welding the boss and the parts to be connected, the boss And the connecting part is evenly heated, which is convenient for quick fusion between the two.
  • the conductive metal strip body is strip-shaped, and the strip-shaped conductive metal strip body can be installed at the bottom of the product, which does not require high side space of the product, and can reduce the width of the product.
  • the conductive metal strip body includes a strip-shaped trunk and a branch, the extending direction of the branch is perpendicular to the extending direction of the strip-shaped trunk, and the boss is located on the branch.
  • the conductive metal strip of this structure can be installed on the side of the product, and connect with the corresponding phase line of the power supply through the strip-shaped branch, and connect with the parts to be connected through the branch.
  • the requirement for the vertical space of the product is not high. Can reduce the thickness of the product.
  • a socket in one aspect, includes: a housing, at least one socket seat, and at least two conductive metal strips in any of the above-mentioned possible designs; the housing has at least two socket holes, and the socket The socket and the conductive metal strip are located in the housing; the socket socket includes a socket and at least two sockets, the socket has a slot corresponding to the socket hole, the socket is located in the slot; the socket The sleeve includes a clamping portion and a connecting portion.
  • the clamping portion is used to clamp the pin on the plug, and the connecting portion is used to connect the conductive metal strip; the conductive metal strips respectively correspond to the plug sleeves of different polarity, and the conductive metal strip has A conductive metal strip body and at least one boss, the boss has an accommodating space, the connecting part of the socket is located in the accommodating space in the boss, and the connecting part is fused with the end of the boss.
  • the fixed connection between the plug sleeve and the conductive metal strip is realized by fusing the connection part of the plug sleeve and the end of the boss of the conductive metal strip into one body.
  • the soldering process is different and will not produce welding slag. Therefore, the generation of welding slag is avoided, no short-circuit hazard will be left, and the safety of the socket can be greatly improved.
  • the connecting portion of the socket includes multiple conductive metal sheets.
  • Such a structure in which multiple layers of conductive metal sheets are stacked can increase the strength of the connection portion.
  • the melting speed of the structure of the multilayer conductive metal sheet is much faster than that of the single-layer conductive metal sheet of the same thickness. That is, this structure can reduce the welding time and improve the assembly of the socket. efficient.
  • the multilayer conductive metal sheet is formed by bending a conductive metal sheet.
  • the conductive metal sheet with the bent structure has higher strength, and can reduce the number of times of cutting the conductive metal sheet, and the processing cost is reduced.
  • the multilayer conductive metal sheet includes a plurality of independent conductive metal sheets.
  • the conductive metal sheet formed by stacking multiple conductive metal sheets has a simple manufacturing process and low processing cost.
  • At least one side wall of the connecting portion of the insert sleeve includes at least one protrusion.
  • This protruding structure can strengthen the strength of the connecting portion itself and ensure that the connecting portion can be in close contact with the inner wall of the boss.
  • the material of the insert sleeve is copper, so that the insert sleeve has the advantages of high conductivity, easy processing, and relatively low cost.
  • the conductive metal strip is located at the bottom of the socket seat.
  • the conductive metal strip body is strip-shaped. This strip-shaped conductive metal strip body can be installed at the bottom of the socket seat, facing the side of the socket. The space requirement is not high, and the width of the socket can be reduced.
  • the conductive metal strip is located on the side of the socket seat.
  • the conductive metal strip body includes a strip-shaped trunk and a branch.
  • the extension direction of the branch is perpendicular to the extension direction of the strip-shaped trunk.
  • the boss is located on the stem.
  • the conductive metal strip of this structure can be installed on the side of the socket socket, and connected with the corresponding phase line of the power supply through the strip-shaped branch, and connected with the connection part of the socket through the branch, which requires the vertical space of the socket Not high, can reduce the thickness of the socket.
  • a method for assembling a socket includes: fitting a boss of a conductive metal strip on a connecting part of a socket; using a welding process to melt the connecting part and the socket The material of the end of the boss is made to fuse the connecting part and the material of the end of the boss to connect the conductive metal strip and the socket; the connected conductive metal strip and the socket are fitted in the housing.
  • the welding current used in the fusion welding process is 40-80A.
  • the use of the current in this intensity range facilitates temperature control during the fusion welding process to improve assembly safety.
  • the welding time used in the fusion welding process is 0.1-0.3 s, and the welding time is controlled within this time range, which is convenient for the fusion welding process to control the temperature and the fusion welding progress.
  • the method further includes: during the fusion welding process, maintaining the distance between the welding head and the welding position at 1 to 5 mm, and by controlling the distance of the operation, it is convenient to control the temperature and temperature of the fusion welding process. Controlling the welding progress can also effectively improve the safety of assembly.
  • the sleeve of the boss of the conductive metal strip on the connection part of the socket includes: the connection part of the socket extends into the boss from the lower opening of the boss, so that the connection The end of the part protrudes 0.5-2mm from the upper opening of the boss, so that the amount of molten material can be controlled within a certain range, which can save material and ensure the fixing effect after welding.
  • FIG. 1 is a schematic structural diagram of a conductive metal strip 3 provided by an embodiment of the present application.
  • FIG. 2 is a schematic structural diagram of another conductive metal strip 3 provided by an embodiment of the present application.
  • FIG. 3 is a schematic structural diagram of a boss 32 of a conductive metal strip 3 provided by an embodiment of the present application;
  • FIG. 4 is a schematic structural diagram of a boss 32 of another conductive metal strip 3 provided by an embodiment of the present application.
  • FIG. 5 is a schematic structural diagram of a boss 32 of another conductive metal strip 3 according to an embodiment of the present application.
  • FIG. 6 is a schematic diagram of the internal structure of a rear view of a socket provided by an embodiment of the present application.
  • Figure 7 is a front view of a socket provided by an embodiment of the present application.
  • FIG. 8 is a schematic diagram of a front view internal structure of a socket provided by an embodiment of the present application.
  • FIG. 9 is a schematic structural diagram of a socket 22 provided by an embodiment of the present application.
  • FIG. 10 is a schematic structural diagram of the connecting portion 222 of another socket 22 provided by an embodiment of the present application.
  • FIG. 11 is a schematic structural diagram of the connecting portion 222 of another socket 22 provided by an embodiment of the present application.
  • FIG. 12 is a schematic structural diagram of the connecting portion 222 of another socket 22 provided by an embodiment of the present application.
  • FIG. 13 is a schematic structural diagram of the connecting portion 222 of another socket 22 provided by an embodiment of the present application.
  • FIG. 14 is a schematic structural diagram of the connecting portion 222 of another socket 22 provided by an embodiment of the present application.
  • FIG. 15 is a schematic structural diagram of the connecting portion 222 of another socket 22 provided by an embodiment of the present application.
  • FIG. 16 is a schematic structural diagram of the connecting portion 222 of another socket 22 provided by an embodiment of the present application.
  • FIG. 17 is a schematic diagram of the structure before welding of the connecting portion 222 and the boss 32 of another socket provided by an embodiment of the present application;
  • FIG. 18 is a schematic cross-sectional structure diagram of the connecting portion 222 and the boss 32 of another socket provided by an embodiment of the present application before fusion welding;
  • FIG. 19 is a schematic diagram of a structure before welding of the connecting portion 222 and the boss 32 of the socket provided by the embodiment of the present application;
  • 20 is a schematic cross-sectional structure diagram of the connecting portion 222 and the boss 32 of the socket provided by an embodiment of the present application before fusion welding;
  • FIG. 21 is a schematic diagram of a rear internal structure of another socket provided by an embodiment of the present application.
  • FIG. 22 is a schematic structural diagram of another conductive metal strip 3 provided by an embodiment of the present application.
  • FIG. 23 is a schematic diagram of an assembly process of a socket provided by an embodiment of the present application.
  • FIG. 24 is a schematic diagram of an assembly process of a socket provided by an embodiment of the present application.
  • FIG. 25 is a schematic diagram of an assembly process of a socket provided by an embodiment of the present application.
  • FIG. 26 is a schematic diagram of an assembly process of a socket provided by an embodiment of the present application.
  • FIG. 27 is a schematic diagram of a forming process of a conductive metal strip 3 provided by an embodiment of the present application.
  • FIG. 28 is a schematic diagram of a structure before welding of the connecting portion 222 and the boss 32 of the socket provided by an embodiment of the present application; FIG.
  • 29 is a structural schematic diagram of the welding process of the connecting portion 222 and the boss 32 of the socket provided by the embodiment of the present application;
  • FIG. 30 is a structural schematic diagram of the welding process of the connecting portion 222 and the boss 32 of the socket provided by the embodiment of the present application;
  • FIG. 31 is a schematic diagram of the structure after welding of the connecting portion 222 and the boss 32 of a socket provided by an embodiment of the present application.
  • azimuth pronouns such as “up” and “below” are used to describe the relationship between parts. It should be noted that the use of the above azimuth pronouns is only for convenience of description, and does not impose any limitation on the socket itself.
  • FIG. 1 is a schematic structural diagram of a conductive metal strip 3 provided by an embodiment of the present application.
  • the conductive metal strip 3 includes a conductive metal strip body 31 and at least one protrusion.
  • the platform 32 has an accommodating space 321 in the boss 32, and the accommodating space 321 has an opening at the bottom of the boss 32.
  • the end of the boss 32 connected to the conductive metal strip body 31 is described as the bottom of the boss 32, and the end of the boss 32 away from the conductive metal strip body 31 is described as the boss The end of 32.
  • a boss 32 with a accommodating space 321 is provided on the conductive metal strip body 31.
  • the shape of the accommodating space 321 in the boss 32 is the same as the shape of the parts to be connected.
  • the size of the accommodating space 321 is greater than or equal to the size of the parts to be connected, so that in the process of assembling the conductive metal strip 3 with other parts, the above-mentioned boss 32 can provide inserting space for the parts to be connected , So that the parts to be connected can extend from the opening at the bottom of the boss 32 into the accommodating space 321, and fuse with the end of the boss 32, so as to realize the connection between the conductive metal strip 3 and the part to be connected Fixed connection.
  • the conductive metal strip 3 based on this structure eliminates the need for a soldering process in the assembly process, thus avoiding the generation of welding slag, leaving no hidden danger of short circuit, and greatly improving the safety of the product.
  • the cross section of the accommodating space 321 is a long strip. This cross-sectional design can facilitate the molding of the boss 32 during the manufacturing process, and can increase the contact area between the parts to be connected and the inner wall of the accommodating space 321, and can improve the efficiency of conduction.
  • the width of the longitudinal section of the accommodating space 321 gradually decreases from bottom to top.
  • the accommodating space 321 in the boss 32 gradually decreases from bottom to top.
  • This longitudinal section design can facilitate the forming of the boss 32 during the manufacturing process, and due to this design with a wide bottom and a narrow top, the boss 32 can be easily and quickly fitted on the parts to be connected during the assembly process. .
  • the longitudinal section of the accommodating space 321 includes a trapezoidal section 3211 and a first rectangular section 3212, and the trapezoidal section 3211 is located below the first rectangular section 3212.
  • the inner wall of the boss 32 corresponding to the first rectangular section 3212 is in a vertical form, which can be ensured to be parallel to the outer wall of the part to be connected during installation, which is compared with the accommodating space 321
  • the width of the longitudinal section gradually becomes smaller from bottom to top.
  • the design of the first rectangular section 3212 enables a larger contact area between the parts to be connected and the inner wall of the upper part of the boss 32.
  • the width of the first rectangular cross section 3212 is equal to the upper side length of the trapezoidal cross section 3211, so that the inner wall at the junction of the first rectangular cross section 3212 and the trapezoidal cross section 3211 in the boss 32 smoothly transitions.
  • the width of the first rectangular cross section 3212 in the formed boss 32 can also be smaller or larger than the upper side length of the trapezoidal cross section 3211. This is the case in this application. Not limited.
  • the difference between the width of the first rectangular section 3212 in the boss 32 and the width of the part to be connected is 0.06 ⁇ 0.4mm, which can ensure that the part to be connected can be smoothly inserted into the container.
  • the height of the boss 32 can be 1 to 3 mm
  • the height of the first rectangular cross section 3212 of the boss 32 is 0.05 to 3 mm
  • the first rectangular cross section 3212 is used for In the area of contact with the product, the height of the first rectangular cross-section 3212 in the above design occupies a larger portion of the height of the entire boss.
  • This boss 32 design can make the parts to be connected and the inner wall of the upper part of the boss 32 between With a larger contact area, the two parts can be fused more quickly during the assembly process of the product, which improves the assembly efficiency of the product.
  • the accommodating space 321 The longitudinal cross-section of also includes a second rectangular cross-section 3213, which is located below the trapezoidal cross-section 3211.
  • the external structure may be a structure that matches the shape of the accommodating space 321.
  • the longitudinal section of the accommodating space 321 adopts a rectangular-trapezoidal shape from bottom to top. It has a rectangular structure. Therefore, from the outside, the boss 32 can be represented as a structure composed of at least three terraces.
  • the width of the second rectangular cross section 3213 is equal to the lower side length of the trapezoidal cross section 3211, so that the inner wall at the junction of the second rectangular cross section 3213 and the trapezoidal cross section 3211 in the boss 32 smoothly transitions.
  • the width of the second rectangular cross section 3213 in the formed boss 32 can also be smaller or larger than the lower side length of the trapezoidal cross section 3211. This is the case in the embodiment of the application. Not limited.
  • the height of the boss 32 can be 1 to 3 mm, and the height of the first rectangular section 3212 of the boss 32 It can also be 0.05 to 3 mm, so that the parts to be connected and the inner wall of the upper part of the boss 32 can have a larger contact area, and the assembly efficiency of the product can be improved.
  • the boss 32 in order to maintain uniform conductivity and uniform strength of the boss 32, the boss 32 can be designed to have a uniform wall thickness.
  • the shape of the boss 32 and the shape of the accommodating space 321 match.
  • the wall thickness of the boss 32 can also be designed to be inconsistent, which is not limited in the embodiment of the present application.
  • the conductive metal strip body 31 can also be designed as a reinforcing structure.
  • the conductive metal strip body 31 can have at least one reinforcing rib 33 located on two Between the bosses 32.
  • the reinforcing rib 33 is used to strengthen the strength of the conductive metal strip 3, avoid deformation of the conductive metal strip 3, and prolong the service life of the product.
  • the number of the reinforcing ribs 33 can be set according to actual needs.
  • the boss 32 and the conductive metal strip body 31 of the conductive metal strip 3 are smoothly transitioned to form an inwardly arced surface 34 at the connection. Please refer to Figure 2, lower the connection.
  • the accommodating space 321 of the boss 32 can form a through-hole structure (as shown in FIG. 1).
  • the parts to be connected can be opened from the bottom of the boss 32.
  • the technician can perform the welding operation through the end opening of the boss 32, so that the boss 32 and the parts to be connected are heated evenly during the welding process, which is convenient for the two. Fast fusion between.
  • the accommodating space 321 of the boss 32 can form a cavity structure design that is only open at the bottom and closed at the end, see FIG. 2. During the welding process, the material at the end of the boss 32 is heated and melted together with the parts inside the boss 32, and quickly fused.
  • the structural design and the position design of the boss 32 can be different.
  • the conductive metal strip body 31 can be designed in a strip shape (as shown in FIG. 1 and As shown in Fig. 2), the strip-shaped conductive metal strip body 31 can be installed at the bottom of the product, which does not require high side space of the product, and can reduce the width of the product.
  • the conductive metal strip body 31 includes a strip-shaped trunk 311 and a branch 312, the extending direction of the branch 312 is perpendicular to the extending direction of the strip-shaped trunk 311, and the boss 32 is located on the branch 312.
  • the conductive metal strip 3 of this structure can be installed on the side of the product, connected with the corresponding phase line of the power supply through the strip-shaped backbone 311, and connected with the parts to be connected through the branch 312, which does not require the vertical space of the product. High, can reduce the thickness of the product.
  • the material of the conductive metal strip 3 is copper.
  • the conductive metal strip 3 made of copper has the advantages of high conductivity, easy processing, and relatively low cost.
  • the structure of the conductive metal strip is introduced, and the socket to which the above-mentioned conductive metal strip 3 is applied is introduced below.
  • the socket provided by the embodiment of the present application includes: a housing 1, at least one socket socket 2 and at least two conductive metal strips 3.
  • the housing 1 has at least two socket holes 11, and the socket socket 2 and the conductive metal strip 3 are located in the housing 1.
  • the socket socket 2 includes a socket body 21 and at least two socket sockets 22, the socket body 21 has a slot corresponding to the socket hole 11, the socket 22 is located in the slot;
  • the socket 22 includes a clamping portion 221 and a connecting portion 222.
  • the clamping portion 221 is used to clamp the plug on the plug, and the connecting portion 222 is used to connect the conductive metal strip 3.
  • the conductive metal strips 3 respectively correspond to the sockets 22 of different polarities, and the conductive metal strips 3 have a conductive metal strip body 31 and at least one boss 32.
  • the boss 32 has a accommodating space 321.
  • the connection part of the socket 22 222 is located in the accommodating space 321 in the boss 32, and the connecting portion 222 is fused with the end of the boss 32.
  • the fixed connection between the socket 22 and the conductive metal strip 3 is achieved by fusing the connecting portion 222 of the socket 22 and the end of the boss 32 of the conductive metal strip 3 into one body.
  • the fusion welding process is different from the original soldering process, no welding slag will be generated. Therefore, the generation of welding slag will be avoided, no short-circuit hazard will be left, and the safety of the socket can be greatly improved.
  • the housing 1 is used for accommodating at least one plug socket 2 and at least two conductive metal strips 3.
  • the housing 1 includes an upper housing 12 and a lower housing 13, and the upper housing 12 and the lower housing 13 can be assembled together by a snap-fitting method.
  • the upper housing 12 has at least one insertion area 14, and each insertion area 14 has at least two socket holes 11.
  • a plug of an electrical appliance plug can be inserted into a socket hole 11 in an insertion area 14 to realize electrical connection between the electrical appliance and the socket.
  • one insertion area 14 can have different designs, and one insertion area 14 can include two socket holes 11, which can be used to insert a plug with two pins, and can also include three socket holes 11. Therefore, it can be used to insert a plug with three pins.
  • the insertion area 14 may also include five socket holes 11 (as shown in FIG. 7). That is, the insertion area 14 can be used to insert a plug with two pins, and can also be used to insert a plug with three pins.
  • the housing 1 can be made of insulating materials, which have strong insulating properties, which can protect internal components while also ensuring safety in use.
  • the insulating material may be plastic, which is both insulating and wear-resistant, and has good elasticity and strength.
  • At least one socket socket 2 is provided.
  • FIG. 8 is a front view internal structure diagram of a socket provided by an embodiment of the present application.
  • the socket 2 includes a socket 21 and at least two sockets 22.
  • the socket 21 has a slot corresponding to the socket hole 11.
  • the socket 22 is located in the slot, and the socket 22 is made of a conductive metal material. become.
  • the at least one socket socket 2 is used to insert a suitable plug to connect the electrical appliance and the socket.
  • the shape and size of the slot in the seat body 21 included in the socket sleeve 2 are adapted to the plug sleeve 22.
  • the shape and size of the slot on the socket body 21 can be set to different shapes and sizes, so as to be used for inserting different shapes of plug pins.
  • the numbers and positions of the above-mentioned slots and socket holes 11 are set correspondingly, so that the socket 22 installed in the slot and the socket holes 11 form a one-to-one correspondence relationship.
  • the inserted pin 11 can be inserted into the socket 22 in the socket socket 211 to realize the connection between the electrical appliance and the socket.
  • the number of sockets 22 of a socket socket 2 and the number of socket holes in the corresponding socket area 14 may be different according to the national standards supported by the socket. For example, if the socket is GB1002 standard, the number of sockets 22 on a socket 2 is 2 to 3; for another example, if the socket is GB1003 standard, the number of sockets 22 on a socket 2 is 4. It should be noted that for a socket, the number of sockets 22 of the socket socket 2 on the socket may not be exactly the same, that is, one socket may include sockets with two sockets 22 The socket 2 and the socket socket 2 with three sockets 22 are not limited in the embodiment of the present application.
  • the socket 22 includes a clamping portion 221 and a connecting portion 222.
  • the clamping portion 221 is used for clamping the plug on the plug, and the connecting portion 222 is used for connecting the conductive metal strip 3.
  • the clamping portion 221 can be implemented by any structure having a clamping function.
  • FIG. 9 provides a clamping portion 221, which can be composed of two elastic clamping pieces, and the latch is in When inserted into the two holding pieces, it can be fixed by the inward elastic force of the two holding pieces, thereby ensuring the reliability of the connection.
  • the clamping portion 221 may also be a metal ring, and when the plug is inserted into the metal ring, it can contact the inner side of the metal ring, thereby achieving electrical connection.
  • the material may be copper, so that the socket 22 has the advantages of high conductivity, easy processing, and relatively low cost.
  • the connecting portion 222 may be an extended structure of the clamping portion 221, and the specific shape and size of the connecting portion 222 may be adapted to the design of the boss 32 on the conductive metal strip 3.
  • the connecting portion 222 may be a strip-shaped conductive structure.
  • the connecting portion 222 may include a connected terrace structure and a strip-shaped structure (as shown in FIG. 9). The embodiment of the present application There is no limitation on the specific structure.
  • the material can also be copper, that is, in a possible design, the material of the socket 22 is copper, so that the socket 22 has high conductivity, is easy to process, and is relatively inexpensive. Etc. Both the plug sleeve 2 and the conductive metal strip 3 are made of copper, which can improve the fusion speed and fusion quality between the two.
  • the connecting portion 222 may include multiple conductive metal sheets 2221.
  • Such a structure in which multiple layers of conductive metal sheets 2221 are stacked can increase the strength of the connecting portion 222.
  • the melting speed of the structure of the multilayer conductive metal sheet 2221 is much faster than that of the single-layer conductive metal sheet of the same thickness. That is, this structure can reduce the welding time and improve the socket Assembly efficiency.
  • connection portion 222 adopts the structure of the multilayer conductive metal sheet 2221
  • any of the following structures may also be adopted to form the above-mentioned multilayer conductive metal sheet 2221.
  • the conductive metal sheet of this bent structure has higher strength, and can reduce the number of times of cutting the conductive metal sheet and reduce the processing cost.
  • the conductive performance of the connecting portion 222 is better, and the resistance will not increase due to the problem of the processing technology.
  • the multilayer conductive metal sheet 2221 includes a plurality of independent conductive metal sheets, that is, the edges of each layer of conductive metal sheets are not connected, and the conductive metal is formed by stacking multiple conductive metal sheets.
  • the manufacturing process is simple and the processing cost is low.
  • the strength of the connecting portion 222 itself can be improved by different shapes of the connecting portion 222, and it is ensured that the connecting portion 222 can be in close contact with the connected element after assembly, that is, Yes, at least one side wall of the connecting portion 222 includes at least one protrusion 2222 (as shown in FIG. 11).
  • the connecting portion 222 with protrusions 2222 on the side wall can be realized by any structure, for example, see FIG. 12, which provides a connecting portion 222 with two protrusions 2222 on the same side wall; and For example, referring to FIG. 13, this FIG.
  • the connecting portion 222 provides a connecting portion 222 having a protrusion 2222 on two side walls, but the protrusion positions of the two protrusions 2222 are different, as shown in FIG. 13, the two The two protrusions 2222 are located at different positions of the connecting portion 222, and the two protrusions 2222 form a wave shape; for another example, refer to FIG. 14, which provides a protrusion 2222 on two side walls.
  • the connecting portion 222 in this case, the connecting portion 222 is composed of two layers of conductive metal sheets, and each layer of conductive metal sheets has protrusions 2222 protruding in different directions at the same position.
  • the embodiment of the present application does not limit which of the above-mentioned protrusions 2222 is specifically used by the connecting portion 222.
  • the connecting portion 222 is raised on one side, the corresponding position on the other side is in the shape of a groove.
  • the protrusion 2222 is formed based on the bending of the connecting portion 222 itself, which can ensure the strength It saves materials while being tightly connected.
  • the corresponding position on the other side may be flat, that is, the protrusion 2222 is convex.
  • the connecting part 222 is a part of the material other than the body, this structure is convenient for molding.
  • the protrusion 2222 may be a symmetrical structure based on the symmetry plane 2223 of the connecting portion 222 to avoid uneven currents on the left and right sides of the protrusion 2222 due to the irregular shape of the protrusion 2222, thereby avoiding The loss of the connecting part 222 during long-term use prolongs the service life.
  • connection between the above-mentioned protrusion 2222 and other parts of the connecting portion 222 may adopt a smooth transition design, so as to avoid affecting the conduction of current.
  • protrusion 2222 may also adopt any design that is beneficial to the strength and the tight connection between the parts, which is not limited in the embodiment of the present application.
  • the boss 32 on the conductive metal strip 3 adopts the design of the accommodating space 321 as a through hole (as shown in FIG. 1)
  • the connecting part 222 can be removed from the boss
  • the bottom opening of 32 extends into the accommodating space 321 of the boss 32 and extends from the top opening of the boss to form a structure as shown in FIG. 17. Its cross-sectional view can be seen as shown in FIG. 18. Later, the operator can perform a welding operation by heating the protruding part of the connecting portion 222, and the boss 32 and the connecting portion 222 are fused after being heated to form the shape shown in FIG. 6.
  • the connection The portion 222 extends from the bottom opening of the boss 32 into the accommodating space 321 of the boss 32 to form a structure as shown in FIG.
  • the welding operation is performed by heating the end of the boss 32, and the boss 32 and the connecting portion 222 are fused after being heated to form a shape as shown in FIG. 6.
  • the cross section of the accommodating space 321 is elongated.
  • Such a cross-sectional design can facilitate the molding of the boss 32 during the manufacturing process, and can increase the contact area between the connecting portion 222 of the socket 22 and the inner wall of the accommodating space 321 in the socket, and can improve the efficiency of conduction.
  • the width of the longitudinal section of the accommodating space 321 gradually decreases from bottom to top.
  • the accommodating space 321 in the boss 32 gradually becomes smaller from bottom to top.
  • This longitudinal section design can facilitate the forming of the boss 32 during the manufacturing process, and due to this design with a wide bottom and a narrow top, the boss 32 can be easily and quickly fitted to the connection of the socket 22 during the assembly process. ⁇ 222 ⁇ .
  • the longitudinal section of the accommodating space 321 includes a trapezoidal section 3211 and a first rectangular section 3212, and the trapezoidal section 3211 is located below the first rectangular section 3212.
  • the inner wall of the boss 32 corresponding to the first rectangular section 3212 is in a vertical form, which can be ensured to be parallel to the outer wall of the part to be connected during installation, which is compared with the accommodating space 321
  • the width of the longitudinal section gradually becomes smaller from bottom to top.
  • the design of the first rectangular section 3212 enables a larger contact area between the parts to be connected and the inner wall of the upper part of the boss 32. During the assembly process of the product, The two parts can be fused more quickly, and the assembly efficiency of the product can be improved.
  • the width of the first rectangular cross section 3212 is equal to the upper side length of the trapezoidal cross section 3211, so that the inner wall at the junction of the first rectangular cross section 3212 and the trapezoidal cross section 3211 in the boss 32 smoothly transitions.
  • the width of the first rectangular cross section 3212 in the formed boss 32 can also be smaller or larger than the upper side length of the trapezoidal cross section 3211. This is the case in this application. Not limited.
  • the difference between the width of the first rectangular section 3212 in the boss 32 and the width of the part to be connected is 0.06 ⁇ 0.4mm, which can ensure that the part to be connected can be smoothly inserted into the container.
  • the height of the boss 32 can be 1 to 3 mm
  • the height of the first rectangular cross section 3212 of the boss 32 is 0.05 to 3 mm
  • the first rectangular cross section 3212 is used for In the area of contact with the product, the height of the first rectangular cross-section 3212 in the above design occupies a larger portion of the height of the entire boss.
  • This boss 32 design can make the parts to be connected and the inner wall of the upper part of the boss 32 between With a larger contact area, the two parts can be fused more quickly during the assembly process of the product, which improves the assembly efficiency of the product.
  • FIG. 4 is a front cross-sectional view and a left cross-sectional view of the boss 32 of another conductive metal strip 3 provided by an embodiment of the present application. Please refer to FIG. 4.
  • the accommodating space 321 The longitudinal cross-section of also includes a second rectangular cross-section 3213, which is located below the trapezoidal cross-section 3211.
  • FIG. 5 shows a schematic diagram of the appearance structure of the boss 32. It can be seen from FIG. 5 that the boss 32 may be composed of at least three terraces, for example, see the first terrace 322, the second terrace 323 and the third terrace 324 in FIG. 5.
  • the width of the second rectangular cross section 3213 is equal to the lower side length of the trapezoidal cross section 3211, so that the inner wall at the junction of the second rectangular cross section 3213 and the trapezoidal cross section 3211 in the boss 32 smoothly transitions.
  • the width of the second rectangular cross section 3213 in the formed boss 32 can also be smaller or larger than the lower side length of the trapezoidal cross section 3211. This is the case in this application. Not limited.
  • the boss 32 in order to maintain uniform conductivity and uniform strength of the boss 32, the boss 32 can be designed to have a uniform wall thickness.
  • the shape of the boss 32 and the shape of the accommodating space 321 match.
  • the wall thickness of the boss 32 can also be designed to be inconsistent, which is not limited in the embodiment of the present application.
  • the installation position of the conductive metal strip 3 may be different, and accordingly, the structure of the conductive metal strip 3 may have some changes.
  • the conductive metal strip 3 may be located at the bottom of the socket seat 2 (as shown in FIG. 6 ), that is, the conductive metal strip 3 is installed near the lower housing 13.
  • the conductive metal strip body 31 can be designed in a strip shape, and this strip-shaped conductive metal strip body 31 can be installed at the bottom of the socket socket 2, which does not require high side space of the socket, and can reduce the size of the socket. The width.
  • the conductive metal strip 3 can be located on the side of the socket seat 2 (as shown in Figures 21-22), that is, the conductive metal strip 3 is installed near the upper housing 12. s position.
  • the conductive metal strip 3 is located on the side of the socket seat 2, and the conductive metal strip body 31 includes a strip-shaped trunk 311 and a branch 312.
  • the extension direction of the branch 312 is the same as that of the strip-shaped trunk 311.
  • the extending direction of ⁇ is vertical, and the boss 32 is located on the branch 312.
  • the conductive metal strip 3 of this structure can be installed on the side of the socket socket 2 and connected to the corresponding phase line of the power supply through the strip-shaped backbone 311, and connected to the connecting portion 222 of the socket 22 through the branch 312 to connect the socket.
  • the vertical space requirements are not high, and the thickness of the socket can be reduced.
  • the conductive metal strip body 31 can also be designed as a reinforcing structure.
  • the conductive metal strip body 31 can have at least one reinforcing rib 33 located on two Between the bosses 32.
  • the reinforcing rib 33 is used to strengthen the strength of the conductive metal strip 3, avoid deformation of the conductive metal strip 3, and prolong the service life of the socket.
  • the number of the reinforcing ribs 33 can be set according to actual needs.
  • the socket can be provided with three sockets 2 side by side.
  • a conductive metal strip 3 can be provided with three bosses 32, and two reinforcing ribs 33 can be arranged between the three bosses 32. .
  • the boss 32 and the conductive metal strip body 31 of the conductive metal strip 3 smoothly transition to form an inwardly arced surface at the connection, reducing the resistance at the connection and facilitating current flow. Of conduction.
  • the material of the conductive metal strip 3 is copper.
  • the conductive metal strip 3 made of copper has the advantages of high conductivity, easy processing, and relatively low cost.
  • Figures 23 to 26 are schematic diagrams of the assembly process of a socket provided by an embodiment of the present application. The method is used to assemble the socket provided in the above embodiment. Please refer to Figures 23 to 26. The method includes:
  • Step 1 Prepare the housing 1, at least one socket socket 2 and at least two conductive metal strips 3 (see Fig. 23).
  • the shell 1 may be processed by an insulating material through an injection molding process, that is, after the insulating material is heated and melted, it is injected into the cavity of a closed mold to form the shell 1.
  • an injection molding process that is, after the insulating material is heated and melted, it is injected into the cavity of a closed mold to form the shell 1.
  • the mold is first manufactured based on the required shell design, and then the mold is used for mass production. The production process is fast and reliable.
  • the socket socket 2 includes a socket body 21 and at least two socket sockets 22, and the socket sockets 22 are arranged in the slots of the socket body 21.
  • the above-mentioned seat body 21 may also be processed from an insulating material through an injection molding process, and the molding process principle is the same as that of the housing 1, which will not be repeated here.
  • the socket 22 includes a clamping portion 221 and a connecting portion 222.
  • the clamping portion 221 may include two elastic clamping pieces for clamping the plug on the plug.
  • the insert sleeve 22 may be processed by a bending process from a conductive metal sheet, and by bending the clamping pieces inwardly, the two clamping pieces have an inward elastic force.
  • the material of the insert sleeve 22 is copper, so that the insert sleeve 22 has the advantages of high conductivity, easy processing, and relatively low cost.
  • the connecting portion 222 adopts a structure design of a multilayer conductive metal sheet 2221
  • a conductive metal sheet with a width multiple of that of the connecting portion 222 can be prepared, folded and pressed at least once to form a bent structure, and The gap between adjacent conductive metal sheets is reduced, thereby reducing the risk of false welding in the subsequent welding process with the boss 32.
  • the structural design of the multilayer conductive metal sheet 2221 can also be obtained by stacking the multilayer independent conductive metal sheets, which is not limited in the embodiment of the present application.
  • the bosses 32 of the at least two conductive metal strips 3 can be formed by stamping the raw material of the conductive metal strip 3 (see FIG. 27).
  • it can be formed by at least two stamping, that is, a small boss 32 is formed on the raw material of the conductive metal strip 3 through a stamping operation, and then On the basis of the small boss 32, a stamping operation is further performed to form a boss 32 with a higher height, so as to overcome the height limitation of the stamping operation itself.
  • a mold can be used to stamp the conductive metal strip body 31 of the conductive metal strip 3 to sink the material of the stamped part to form the reinforcement rib 33.
  • Step 2 Sleeve the boss 32 of the conductive metal strip 3 on the connecting portion 222 of the socket 22 in the socket socket 2 to form a shape as shown in FIG. 24.
  • the connecting portion 222 of the socket 22 can be extended into the boss 32 from the bottom opening of the boss 32 so that the connecting part 222 protrudes from the end opening of the boss 32.
  • the length of the protruding part can be between 0.5-2 mm, which facilitates the subsequent welding operation, and can also ensure that the boss 32 and the connecting portion 222 are more fully fused, thereby ensuring the strength of the connection between the parts .
  • the protruding part is the base material for the fusion welding operation, and the above height can ensure that the amount of this part of the base material is not too much or less, which neither weakens the connection effect nor causes waste of materials.
  • the end of the connecting part 222 can be kept flush with the end opening of the boss 32. Or lower than the end opening, thereby making the use scene of the part more flexible, which is not limited in the embodiment of the present application.
  • the connecting part 222 can be kept in a centered state in the accommodating space 321 of the boss 32 (see the top view and Front view), that is, the gap between each side surface of the connecting portion 222 and the corresponding inner wall of the boss 32 is equal, and the distance can be between 0.03 and 0.2mm. Keeping the small distance can make the melting The material melted during the welding process can quickly fuse the connecting portion 222 and the end of the boss 32 together, so as not to flow away through the gap and cause material waste, which can reduce the time consumption of welding and improve the assembly efficiency.
  • Step 3 Use a fusion welding process to melt the material of the connecting portion 222 and the end of the boss 32, so that the connecting portion 222 and the material of the end of the boss 32 are fused, thereby connecting the conductive metal strip 3 and the socket 22 to form the shape shown in FIG. 25.
  • the fusion welding process may use a tungsten electrode as a welding head to perform micro-arc welding to realize the fusion of materials.
  • the micro-arc welding process can adopt argon gas protection.
  • the flow rate of argon gas is maintained at 5-20L/min (min), so as to ensure that the welding part is isolated from air, avoid oxidation, and improve Welding quality.
  • the welding current used is 40-80A, and the current in this intensity range is used to facilitate temperature control during the fusion welding process to improve the safety of assembly.
  • the welding time used in the fusion welding process is 0.1-0.3 s, and the welding time is controlled within this time range, which is convenient for the fusion welding process to control the temperature and the fusion welding progress.
  • Step 4 Assemble the connected conductive metal strip 3 and the socket 22 in the housing 1 to form a socket as shown in Figures 7 and 26 ( Figure 7 shows the three-dimensional form of the socket as viewed from the front side , Figure 26 shows the three-dimensional form of the socket viewed from the rear side).
  • the socket socket 2 is inserted into the fixing groove of the upper housing 12, thereby fixing the socket socket 2 on the upper housing 12 ⁇ 12 ⁇ In the housing 12. Connect the end of each conductive metal strip 3 away from the connecting portion 222 of the socket 22 to each phase line of the power supply. After the socket can realize its conductive function, the lower shell 13 is buckled on the upper shell 12 , Cover the internal components of the upper housing 12 to complete the assembly.
  • the above steps are only an example of the assembly process of the socket. According to different production conditions, the socket may also have other assembly processes.
  • the embodiment of the present application does not limit the specific sequence between the assembly steps. For example, first fix the socket holder 2 with the socket 22 inside the upper housing 12, and then fit the boss 32 of the conductive metal strip 3 on the connecting portion 222 of the socket 22 in the socket holder 2 and fuse it. Welding, finally buckle the lower shell 13 on the upper shell 12 to complete the assembly.
  • soldering process due to the uncontrollable problem of manual operation, it is very likely that excessive tin delivery or poor soldering may occur, leaving tin metal inside the socket, which may cause the socket in the subsequent use of the socket Short-circuit and other consequences, therefore, the use of fusion welding process instead of soldering process can ensure the safety of the socket. At the same time, the use of fusion welding technology can also avoid possible pollution caused by solder wire and achieve the purpose of protecting the environment.
  • the use of fusion welding has higher economic value than soldering.
  • the cost of traditional soldering is 0.07249
  • the cost of fusion welding is 0.03034 yuan, and the cost of traditional soldering is about 2.4 times that of fusion welding, that is, the cost of fusion welding is about 41.8% of that of traditional soldering.
  • the boss 32 of the conductive metal strip 3 is sleeved on the connecting part 222 of the socket 22 in the socket seat 2, and the welding process is used to make the connecting part 222 of the socket 22 and the conductive metal
  • the ends of the boss 32 of the strip 3 are fused into one body to realize the fixed connection between the socket 22 and the conductive metal strip 3. Since the fusion welding process is different from the original soldering process, no welding slag will be generated, so Therefore, the generation of welding slag is avoided, no short-circuit hazard will be left, and the safety of the socket can be greatly improved. At the same time, avoid possible pollution caused by solder wire and protect the environment.
  • the above-mentioned fusion welding process has high connection strength, which can reduce assembly costs.

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Abstract

一种导电金属条（3）、插座及插座的装配方法，属于电连接技术领域。该插座中，插套（22）以及导电金属条（3）之间的固定连接，是通过插套（22）的连接部（222）与导电金属条（3）的凸台（32）的端部熔合为一体来实现的，而由于熔焊工艺与原有的锡焊工艺不同，不会产生焊渣，因此，也就避免了焊渣的产生，不会遗留短路隐患，能够大大提高插座的安全性。

Description

导电金属条、插座及插座的装配方法
本申请要求于2020年04月10日提交的申请号为202010280800.9、发明名称为“导电金属条、插座及插座的装配方法”的中国专利申请，以及于2020年04月10日提交的申请号为202020529519.X、发明名称为“导电金属条及插座”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本申请涉及插座技术领域，特别涉及一种导电金属条、插座及插座的装配方法。
背景技术
插座是工业生产和日常生活中普遍使用的装置，可以作为中间媒介，来实现电源与电器之间的连接或断开。
目前的插座结构包括：壳体以及位于壳体内部的插套座和导电金属条，壳体具有插座孔，插套座包括至少两个与插座孔相对应的插套，插套和导电金属条连接，使得插套可以分别与对应的相线连通，从而实现电流的传导。
为了将插套和导电金属条连接起来，在装配时，通常会采用锡焊工艺实现。然而，在焊接过程中，很容易在插座中遗留一些焊渣，一旦插座通电，这些焊渣就可能造成插座内部短路，导致出现使用安全问题。
发明内容
本申请实施例提供了一种导电金属条、插座及插座的装配方法，能够提高插座的安全性。该技术方案如下：
一方面，提供了一种导电金属条，该导电金属条包括导电金属条本体和至少一个凸台，该凸台内具有容置空间，该容置空间具有位于该凸台的底部的开口。本申请实施例所提供的导电金属条，在导电金属条本体上提供了具有容置空间的凸台，其凸台可以在装配时为其他零件提供插入的空间，从而实现零件之间的固定连接。基于这种结构的导电金属条，使得装配过程无需采用锡焊工 艺，也就避免了焊渣的产生，不会遗留短路隐患，能够大大提高产品的安全性。
在一种可能设计中，该容置空间的横截面为长条形。这种横截面设计在制造过程中能够便于凸台的成型，且能够增大待连接的零件与容置空间内壁之间的接触面积，可以提高导电的效率。
在一种可能设计中，该容置空间的纵截面的宽度从下至上逐渐变小。这种纵截面设计，在制造过程中能够便于凸台的成型，且由于这种下面宽上面窄的设计，使得在装配过程中可以简易、快捷的将凸台套装在待连接的零件上。
在一种可能设计中，该容置空间的纵截面包括梯形截面以及第一矩形截面，该梯形截面位于该第一矩形截面的下方。这种纵截面设计，可以使待连接的零件与凸台上部的内壁之间具有较大的接触面积，在对产品进行装配过程中，能够使得这两部分更快速的熔合，提高了产品的装配效率。
在一种可能设计中，该第一矩形截面的高度为0.05～3mm。这种凸台设计，可以使待连接的零件与凸台上部的内壁之间具有较更大的接触面积，在对产品进行装配的过程中，能够使得这两部分更快速的熔合，提高了产品的装配效率。
在一种可能设计中，该容置空间的纵截面还包括第二矩形截面，该第二矩形截面位于该梯形截面的下方。这种纵截面的设计，在凸台壁厚均匀的情况下，使得凸台上可以形成棱部，该棱部可以起到加强凸台的强度的作用。
在一种可能设计中，该导电金属条本体具有至少一条加强筋，该加强筋位于两个凸台之间。该加强筋用于加强该导电金属条的强度，避免导电金属条变形，延长了产品的使用寿命。
在一种可能设计中，该导电金属条的材质为铜。采用铜材质的导电金属条，具有导电性高、易于加工以及比较廉价等优点。
在一种可能设计中，该容置空间还具有位于该凸台的端部的开口。在该设计中的凸台在端部和底部均具有开口，也即是，该容置空间呈一个通孔结构，这种结构使得在对凸台和待连接的零件进行熔焊时，凸台和连接部受热均匀，便于两者之间的快速熔合。
在一种可能设计中，该导电金属条本体为条形，这种条形的导电金属条本体可以安装在产品的底部，对产品侧面空间的要求不高，可以降低产品的宽度。
在一种可能设计中，该导电金属条本体包括条形主干和支干，该支干的延伸方向与该条形主干的延伸方向垂直，该凸台位于该支干上。这种结构的导电 金属条可以安装在产品的侧面，通过条形支干来与电源对应的相线连接，通过支干来与待连接的零件进行连接，对产品的垂直空间的要求不高，可以降低产品的厚度。
一方面，提供了一种插座，该插座包括：壳体、至少一个插套座以及如上述任一种可能设计中的至少两根导电金属条；该壳体具有至少两个插座孔，该插套座和该导电金属条位于该壳体内；该插套座包括座体和至少两个插套，该座体具有与该插座孔对应的槽位，该插套位于该槽位中；该插套包括夹持部和连接部，该夹持部用于夹持插头上的插销，该连接部用于连接该导电金属条；导电金属条分别对应不同极性的插套，且导电金属条具有导电金属条本体和至少一个凸台，该凸台内具有容置空间，该插套的连接部位于该凸台内的容置空间内，且该连接部与该凸台的端部熔合。
本申请的插座中，插套以及导电金属条之间的固定连接，是通过插套的连接部与导电金属条的凸台的端部熔合为一体来实现的，而由于熔焊工艺与原有的锡焊工艺不同，不会产生焊渣，因此，也就避免了焊渣的产生，不会遗留短路隐患，能够大大提高插座的安全性。
在一种可能设计中，该插套的连接部包括多层导电金属片。这种多层导电金属片叠置的结构可以提高该连接部的强度。在熔焊过程中，多层导电金属片的结构的熔化速度较之于相同厚度的单层导电金属片要快很多，也即是，这种结构可以降低熔焊耗时，从而提高插座的装配效率。
在一种可能设计中，该多层导电金属片由一片导电金属片弯折而成。这种弯折结构的导电金属片，强度较高，而且可以降低对导电金属片的切割次数，加工成本降低。
在一种可能设计中，该多层导电金属片包括多片独立导电金属片。这种多片导电金属片叠置而成的导电金属片，其制造过程简易，加工成本较低。
在一种可能设计中，该插套的连接部的至少一个侧壁上包括至少一个凸起。这种凸起的结构，可以加强连接部本身的强度，并保证连接部能够与凸台内壁紧密接触。
在一种可能设计中，该插套的材质为铜，从而使得插套具有导电性高、易于加工以及比较廉价等优点。
在一种可能设计中，导电金属条位于插套座的底部，相应的，该导电金属条本体为条形，这种条形的导电金属条本体可以安装在插套座的底部，对插座侧面空间的要求不高，可以降低插座的宽度。
在一种可能设计中，导电金属条位于插套座的侧面，相应的，该导电金属条本体包括条形主干和支干，该支干的延伸方向与该条形主干的延伸方向垂直，该凸台位于该支干上。这种结构的导电金属条可以安装在插套座的侧面，通过条形支干来与电源对应的相线连接，通过支干来与插套的连接部进行连接，对插座的垂直空间的要求不高，可以降低插座的厚度。
在本申请实施例的又一方面，提供了一种插座的装配方法，该方法包括：将导电金属条的凸台套装在插套的连接部上；采用熔焊工艺，熔化该连接部与该凸台端部的材料，使该连接部与该凸台端部的材料熔合，从而连接该导电金属条和该插套；将连接好的该导电金属条和该插套装配在壳体中。
在一种可能实现方式中，该熔焊工艺采用的焊接电流为40～80A。采用这种强度范围的电流，便于熔焊过程中对温度进行控制，以提高装配的安全性。
在一种可能实现方式中，该熔焊工艺采用的焊接时间为0.1～0.3s，而将焊接时间控制在这个时间范围内，便于熔焊过程对温度和熔焊进度进行控制。
在一种可能实现方式中，该方法还包括：在熔焊过程中，保持焊接头与焊接位置之间的距离为1～5mm，通过对操作的距离进行控制，便于对熔焊过程的温度和熔焊进度进行控制，也能够有效的提高装配的安全性。
在一种可能实现方式中，该将导电金属条的凸台套装在插套的连接部上包括：将该插套的连接部从该凸台的下开口中伸入该凸台，使得该连接部的端部从该凸台的上开口伸出0.5～2mm，从而可以将熔化材料的量控制在一定范围内，既能够节约材料还可以保证熔焊后的固定效果。
附图说明
为了更清楚地说明本申请实施例中的技术方案，下面将对实施例描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本申请的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1是本申请实施例提供的一种导电金属条3的结构示意图；
图2是本申请实施例提供的另一种导电金属条3的结构示意图；
图3是本申请实施例提供的一种导电金属条3的凸台32的结构示意图；
图4是本申请实施例提供的一种另一种导电金属条3的凸台32的结构示意图；
图5是本申请实施例提供的一种另一种导电金属条3的凸台32的结构示意图；
图6是本申请实施例提供的一种插座的后视内部结构示意图；
图7是本申请实施例提供的一种插座的前视图；
图8是本申请实施例提供的一种插座的前视内部结构示意图；
图9是本申请实施例提供的一种插套22的结构示意图；
图10是本申请实施例提供的另一种插套22的连接部222的结构示意图；
图11是本申请实施例提供的另一种插套22的连接部222的结构示意图；
图12是本申请实施例提供的另一种插套22的连接部222的结构示意图；
图13是本申请实施例提供的另一种插套22的连接部222的结构示意图；
图14是本申请实施例提供的另一种插套22的连接部222的结构示意图；
图15是本申请实施例提供的另一种插套22的连接部222的结构示意图；
图16是本申请实施例提供的另一种插套22的连接部222的结构示意图；
图17是本申请实施例提供的另一种插座的连接部222和凸台32的熔焊前的结构示意图；
图18是本申请实施例提供的另一种插座的连接部222和凸台32的熔焊前的剖面结构示意图；
图19是本申请实施例提供的一种插座的连接部222和凸台32的熔焊前的结构示意图；
图20是本申请实施例提供的一种插座的连接部222和凸台32的熔焊前的剖面结构示意图；
图21是本申请实施例提供的另一种插座的后视内部结构示意图；
图22是本申请实施例提供的另一种导电金属条3的结构示意图；
图23是本申请实施例提供的一种插座的装配过程示意图；
图24是本申请实施例提供的一种插座的装配过程示意图；
图25是本申请实施例提供的一种插座的装配过程示意图；
图26是本申请实施例提供的一种插座的装配过程示意图；
图27是本申请实施例提供的一种导电金属条3的成型过程示意图；
图28是本申请实施例提供的一种插座的连接部222和凸台32的熔焊前的结构示意图；
图29是本申请实施例提供的一种插座的连接部222和凸台32的熔焊过程结构示意图；
图30是本申请实施例提供的一种插座的连接部222和凸台32的熔焊过程结构示意图；
图31是本申请实施例提供的一种插座的连接部222和凸台32的熔焊后的结构示意图。
附图中的各个标号说明如下：
1-壳体；
11-插座孔，12-上壳体，13-下壳体，14-插位区域；
2-插套座；
21-座体；
22-插套；
221-夹持部；
222-连接部；
2221-多层导电金属片，2222-凸起，2223-对称面；
3-导电金属条；
31-导电金属条本体；
311-条形主干，312-支干；
32-凸台；
321-容置空间；
3211-梯形截面，3212-第一矩形截面，3213-第二矩形截面；
322-第一梯台；
323-第二梯台；
324-第三梯台；
325-棱部；
33-加强筋；
34-圆弧面。
具体实施方式
为使本申请的目的、技术方案和优点更加清楚，下面将结合附图对本申请实施方式作进一步地详细描述。
在附图的描述中，使用“上”“下”等方位代词来描述零件之间的关系，需要说明的是，上述方位代词的使用仅为方便描述，对插座本身不造成任何限定。
本申请实施例提供了一种导电金属条，该导电金属条可以作为产品中的导体来对电流进行传导。下面对导电金属条的结构进行具体说明，参见图1，图1是本申请实施例提供的一种导电金属条3的结构示意图，该导电金属条3包括导电金属条本体31和至少一个凸台32，该凸台32内具有容置空间321，该容置空间321具有位于该凸台32的底部的开口。需要说明的是，在本申请实施例中，将凸台32与导电金属条本体31连接的一端描述为凸台32的底部，将凸台32的远离导电金属条本体31的一端描述为凸台32的端部。
本申请实施例所提供的导电金属条3，在导电金属条本体31上提供了具有容置空间321的凸台32，该凸台32内的容置空间321的形状与待连接的零件的形状适配，容置空间321的尺寸大于或等于待连接的零件的尺寸，这样在将导电金属条3与其他零件装配在一起的过程中，上述凸台32可以为待连接的零件提供插入的空间，使得待连接的零件可以从凸台32的底部的开口伸入至该容置空间321中，并与该凸台32的端部熔合，从而实现导电金属条3与该待连接的零件之间的固定连接。基于这种结构的导电金属条3，使得装配过程无需采用锡焊工艺，也就避免了焊渣的产生，不会遗留短路隐患，能够大大提高产品的安全性。
下面对上述凸台32的结构设计进行介绍：
对于凸台32来说，该容置空间321的横截面为长条形。这种横截面设计在制造过程中能够便于凸台32的成型，且能够增大待连接的零件与容置空间321内壁之间的接触面积，可以提高导电的效率。
在一种可能设计中，该容置空间321的纵截面的宽度从下至上逐渐变小。参见图3中提供的凸台32设计，可以看出该凸台32中容置空间321从下到上 逐渐变小。这种纵截面设计，在制造过程中能够便于凸台32的成型，且由于这种下面宽上面窄的设计，使得在装配过程中可以简易、快捷的将凸台32套装在待连接的零件上。
请继续参见图3，在一种可能设计中，该容置空间321的纵截面包括梯形截面3211以及第一矩形截面3212，该梯形截面3211位于该第一矩形截面3212的下方。在这种纵截面设计中，该第一矩形截面3212对应的凸台32的内壁呈竖直形态，在安装时，可以保证与待连接的零件的外壁平行，相比于该容置空间321的纵截面的宽度从下至上逐渐变小的结构，第一矩形截面3212的设计可以使待连接的零件与凸台32上部的内壁之间具有较大的接触面积，在对产品进行装配过程中，能够使得这两部分更快速的熔合，提高了产品的装配效率。在一种可能设计中，该第一矩形截面3212的宽度等于该梯形截面3211的上边长，以使凸台32中第一矩形截面3212与梯形截面3211连接处的内壁平滑过渡。考虑到可以通过多种不同的工艺加工该凸台32，成型后的凸台32中，该第一矩形截面3212的宽度也可以小于或大于该梯形截面3211的上边长，本申请实施例对此不作限定。为了便于装配，在零件的尺寸上，凸台32内的第一矩形截面3212的宽度与待连接的零件的宽度之差均为0.06～0.4mm，可以保证待连接的零件能够顺畅地插入到容置空间321中。
请继续参见图3，在一种可能设计中，凸台32的高度可以是1～3mm，该凸台32中第一矩形截面3212的高度为0.05～3mm，而第一矩形截面3212是用于与产品之间接触的区域，上述设计中第一矩形截面3212的高度在整个凸台高度中占比较大，这种凸台32设计，可以使待连接的零件与凸台32上部的内壁之间具有更大的接触面积，在对产品进行装配过程中，能够使得这两部分更快速的熔合，提高了产品的装配效率。
图4是本申请实施例提供的一种另一种导电金属条3的凸台32的前视截面图和左视截面图，请参见图4，在一种可能设计中，该容置空间321的纵截面还包括第二矩形截面3213，该第二矩形截面3213位于该梯形截面3211的下方。对于图4中的凸台32结构，其外部结构可以是与该容置空间321的形状匹配的结构，由图5可见，由于容置空间321的纵截面从下到上采用了矩形-梯形-矩形的结构，因此，从外部来说，该凸台32可以表现为由至少三个梯台构成的结构，例如，参见图5中的第一梯台322、第二梯台323和第三梯台324。这种纵截面 的设计，在凸台32壁厚均匀的情况下，使得凸台32上各个梯台之间的连接处可以形成棱部325，该棱部325可以起到加强凸台32的强度的作用。在一种可能设计中，该第二矩形截面3213的宽度等于该梯形截面3211的下边长，以使凸台32中第二矩形截面3213与梯形截面3211连接处的内壁平滑过渡。考虑到可以通过多种不同的工艺加工该凸台32，成型后的凸台32中，该第二矩形截面3213的宽度也可以小于或大于该梯形截面3211的下边长，本申请实施例对此不作限定。
需要说明的是，对于图4和图5中描述的凸台32的结构，在一种可能设计中，凸台32的高度可以是1～3mm，该凸台32中第一矩形截面3212的高度也可以为0.05～3mm，从而也可以使待连接的零件与凸台32上部的内壁之间具有更大的接触面积，提高产品的装配效率。
在上述可能设计中，为了保持该凸台32的导电性能均匀以及强度均匀，可以将该凸台32设计为均匀的壁厚，这种情况下，凸台32的外形和容置空间321的形状匹配。当然，出于对某个位置的强度要求等设计因素，还可以将凸台32的壁厚设计为不一致，本申请实施例对此不作限定。
在一种可能设计中，还可以将导电金属条本体31设计为一种加强结构，参见图1和图2，该导电金属条本体31可以具有至少一条加强筋33，该加强筋33位于两个凸台32之间。该加强筋33用于加强该导电金属条3的强度，避免导电金属条3变形，延长了产品的使用寿命。该加强筋33的数量可以根据实际需要设定。
在上述任一可能设计中，该凸台32与导电金属条3的导电金属条本体31之间圆滑过渡，以在连接处形成一个向内的圆弧面34，请参见图2，降低连接处的电阻，从而便于电流的传导。
在一种可能结构设计中，该凸台32的容置空间321可以形成一个通孔结构(如图1所示)，在装配过程中，可以将待连接的零件从该凸台32的底部开口伸入凸台32的容置空间321，则技术人员可以通过该凸台32的端部开口来进行熔焊操作，使熔焊过程中凸台32和待连接的零件受热均匀，便于两者之间的快速熔合。
在另一种可能结构设计中，该凸台32的容置空间321可以形成一个仅在底部开口而端部封闭的腔体结构设计，参见图2。在熔焊过程中，该凸台32端部 的材料在受热熔化与凸台32内的零件同时受热熔化，并快速熔合。
对于导电金属条本体31来说，为了适应于不同的安装位置，其结构设计以及凸台32的位置设计可以有所不同，例如，该导电金属条本体31可以设计为条形(如图1和图2所示)，这种条形的导电金属条本体31可以安装在产品的底部，对产品侧面空间的要求不高，可以降低产品的宽度。又例如，该导电金属条本体31包括条形主干311和支干312，该支干312的延伸方向与该条形主干311的延伸方向垂直，该凸台32位于该支干312上。这种结构的导电金属条3可以安装在产品的侧面，通过条形主干311来与电源对应的相线连接，通过支干312来与待连接的零件进行连接，对产品的垂直空间的要求不高，可以降低产品的厚度。
在上述任一可能设计中，该导电金属条3的材质为铜。采用铜材质的导电金属条3，具有导电性高、易于加工以及比较廉价等优点。
上述实施例中，对导电金属条的结构进行了介绍，下面对应用了上述导电金属条3的插座进行介绍。
参见图6，本申请实施例所提供的插座包括：壳体1、至少一个插套座2以及至少两根导电金属条3。该壳体1具有至少两个插座孔11，该插套座2和该导电金属条3位于该壳体1内。该插套座2包括座体21和至少两个插套22，该座体21具有与该插座孔11对应的槽位，该插套22位于该槽位中；该插套22包括夹持部221和连接部222，该夹持部221用于夹持插头上的插销，该连接部222用于连接该导电金属条3。导电金属条3分别对应不同极性的插套22，且导电金属条3具有导电金属条本体31和至少一个凸台32，该凸台32内具有容置空间321，该插套22的连接部222位于该凸台32内的容置空间321内，且该连接部222与该凸台32的端部熔合。
本申请实施例提供的插座中，插套22以及导电金属条3之间的固定连接，是通过插套22的连接部222与导电金属条3的凸台32的端部熔合为一体来实现的，而由于熔焊工艺与原有的锡焊工艺不同，不会产生焊渣，因此，也就避免了焊渣的产生，不会遗留短路隐患，能够大大提高插座的安全性。
下面基于上述结构，对所涉及的各个零件进行分别介绍：
壳体1
请参见图6，该壳体1用于容纳至少一个插套座2以及至少两根导电金属条3。壳体1包括上壳体12和下壳体13，上壳体12和下壳体13可以通过扣装方式装配在一起。
通过图7所示出的前视图，可以看出，该上壳体12上具有至少一个插位区域14，每个插位区域14上具有至少两个插座孔11，在使用插座的过程中，可以将一个电器插头的插销插入一个插位区域14内的插座孔11中，以实现电器与插座之间的电连接。需要说明的是，一个插位区域14可以有不同的设计，在一个插位区域14可以包括两个插座孔11，从而可以用于插入具有两个插销的插头，还可以包括三个插座孔11，从而可以用于插入具有三个插销的插头，而为了缩小插座的体积，提高插座的可复用性，插位区域14还可以包括五个插座孔11(如图7中所示)，也即是，该插位区域14可以用于插入具有两个插销的插头，还可以用于插入具有三个插销的插头。
该壳体1可以采用绝缘材料，绝缘材料的绝缘性强，可以在保护内部元件的同时，还可以保障使用安全。例如，该绝缘材料可以为塑料，这种材料既绝缘又耐磨损，且弹性和强度都较好。
至少一个插套座2
对应于图7中的每个插位区域14，在壳体内部安装有一个插套座2，图8是本申请实施例提供的一种插座的前视内部结构图，参见图8，该插套座2包括座体21和至少两个插套22，该座体21具有与该插座孔11对应的槽位，该插套22位于该槽位中，插套22由能够导电的金属材料制成。
继续参见图8，该至少一个插套座2用于插入适配的插头，以连接电器和插座。对于一个插座套2来说，其所包括的座体21中槽位的形状和尺寸与插套22适配。而需要说明的是，对于一个插套座2来说，其座体21上的槽位形状和尺寸可设置为不同的形状和尺寸，从而用于插入不同形态的插销。在本申请实施例所提供的插座中，上述槽位与插座孔11的数量和位置均对应设置，使得安装于槽位内的插套22与插座孔11形成一一对应的关系，从插座孔11插入的插销能够插入插套座211中插套22，以实现电器和插座之间的连接。
在上述实施例中，一个插套座2所具有的插套22的数量，以及相应的插位 区域14中插座孔的数量，可以根据该插座所支持的国家标准不同而不同。例如，若插座为GB1002标准，则一个插套座2上的插套22的数量为2～3个；又例如，若插座为GB1003标准，则一个插套座2上的插套22的数量为4个。需要说明的是，对于一个插座来说，该插座上的插套座2所具有的插套22的数量可以不完全一致，也即是，一个插座上可以包括具有2个插套22的插套座2以及具有3个插套22的插套座2，本申请实施例对此不作限定。
下面对插套座2中的插套22进行介绍：
请参见图9，上述插套22包括夹持部221和连接部222，该夹持部221用于夹持插头上的插销，该连接部222用于连接该导电金属条3。
该夹持部221可以采用任一种具有夹持功能的结构实现，例如，图9提供了一种夹持部221，该夹持部221可以由两个具有弹性的夹持片构成，插销在插入到该两个加持片中时，可以被该两个加持片向内的弹力所固定，从而保证连接的可靠性。又例如，该夹持部221还可以是一个金属环，插销在插入到该金属环内时，可以与金属环的内侧接触，从而实现电连接。对于夹持部221来说，其材质可以为铜，从而使得插套22具有导电性高、易于加工以及比较廉价等优点。
该连接部222可以是夹持部221的延伸结构，该连接部222具体形状和尺寸可以与导电金属条3上凸台32的设计适配。例如，该连接部222可以为一长条形的导电结构，又例如，该连接部222可以包括有相连接的梯台结构和长条形结构(如图9中所示)，本申请实施例对其具体采用何种结构不作限定。
而对于连接部222来说，其材质也可以为铜，也即是，在一种可能设计中，该插套22的材质为铜，从而使得插套22具有导电性高、易于加工以及比较廉价等优点。插套2和导电金属条3均为铜制，能够提高两者之间的熔合速度和熔合质量。
请参见图10，该连接部222可以包括多层导电金属片2221。这种多层导电金属片2221叠置的结构可以提高该连接部222的强度。在熔焊过程中，多层导电金属片2221的结构的熔化速度较之于相同厚度的单层导电金属片要快很多，也即是，这种结构可以降低熔焊耗时，从而提高插座的装配效率。
在连接部222采用多层导电金属片2221的结构的情况下，还可以采用下述 任一种结构来构成上述多层导电金属片2221。第一种结构：该多层导电金属片2221由一片导电金属片弯折而成。参见图10，每两层导电金属片的一侧边缘是连接的，这种弯折结构的导电金属片，强度较高，而且可以降低对导电金属片的切割次数，加工成本降低。而且，由于每层导电金属片之间相连接，使得连接部222的导电性能更好，不会由于加工工艺的问题而增加电阻。第二种结构：该多层导电金属片2221包括多片独立导电金属片，也即是，每层导电金属片的边缘之间不相连，这种多片导电金属片叠置而成的导电金属片，其制造过程简易，加工成本较低。
在本申请实施例提供的另一可能设计中，还可以通过对连接部222的不同形状来提高连接部222本身的强度，并保证连接部222能够在装配后与所连接元件紧密接触，也即是，该连接部222的至少一个侧壁上包括至少一个凸起2222(如图11所示)。侧壁上具有凸起2222的连接部222可以采用任一种结构实现，例如，参见图12，该图12提供了一种在同一个侧壁上具有两个凸起2222的连接部222；又例如，参见图13，该图13提供了一种在两个侧壁上各具有一个凸起2222的连接部222，但是该两个凸起2222的凸起位置不同，如图13所示，两个凸起2222分别位于连接部222的不同位置，且两个凸起2222形成波浪状；再例如，参见图14，该图14提供了一种在两个侧壁上各具有一个凸起2222的连接部222，这种情况下，该连接部222由两层导电金属片构成，每层导电金属片在相同的位置具有向不同方向凸出的凸起2222。本申请实施例对连接部222具体采用上述哪种凸起2222不作限定。
在图11至图13中，在连接部222一侧凸起的同时，另一侧的相应位置呈凹槽状，通过基于连接部222本身上的弯折来形成凸起2222，可以在保证强度和紧密连接的同时，节省材料。而在另一种可能设计中，如图15所示，在连接部222一侧凸起的同时，另一侧的相应位置可以呈平面状，也即是，该凸起2222为凸出于平整的连接部222的本体之外的一部分材料，这种结构便于成型。
进一步地，请参见图16，该凸起2222可以是基于该连接部222的对称面2223的对称结构，避免由于凸起2222的不规则形状导致凸起2222左右两侧的电流不均匀，进而避免长期使用过程中连接部222的损耗，延长使用寿命。
需要说明的是，上述凸起2222和连接部222的其他部分之间的连接处可以采用圆滑过渡的设计，从而可以避免影响电流的传导。
当然，上述凸起2222还可以采用任一种有利于强度和零件之间紧密连接的设计，本申请实施例对此不作限定。
插座中的至少两根导电金属条3
需要说明的是，在上述导电金属条3的实施例中，主要介绍了装配之前的导电金属条3的结构设计，而对于导电金属条3来说，凸台32的端部在其装配前和装配后的结构可能发生一定变化。
若导电金属条3上凸台32采用容置空间321为通孔的设计(如图1所示)，在将凸台32套装在上述连接部222上时，可以将连接部222从该凸台32的底部开口伸入凸台32的容置空间321，并从该凸台的顶部开口伸出，以形成如图17中所示的结构，其截面视图可以参见图18中所示，套装完毕后，操作人员可以通过加热该连接部222伸出的部分来进行熔焊操作，凸台32和连接部222在受热后熔合，以形成如图6所示的形状。
若导电金属条3上凸台32采用容置空间321为底部开口端部封闭的腔体结构设计(如图2所示)，在将凸台32套装在上述连接部222上时，可以将连接部222从该凸台32的底部开口伸入凸台32的容置空间321，以形成如图19中所示的结构，其截面视图可以参见图20中所示，套装完毕后，操作人员可以通过加热该凸台32的端部来进行熔焊操作，凸台32和连接部222在受热后熔合，以形成如图6所示的形状。
在一种可能结构设计中，对于凸台32来说，该容置空间321的横截面为长条形。这种横截面设计在制造过程中能够便于凸台32的成型，且能够增大插座中插套22的连接部222与容置空间321内壁之间的接触面积，可以提高导电的效率。
在一种可能设计中，该容置空间321的纵截面的宽度从下至上逐渐变小。参见图3中提供的凸台32设计，可以看出该凸台32中容置空间321从下到上逐渐变小。这种纵截面设计，在制造过程中能够便于凸台32的成型，且由于这种下面宽上面窄的设计，使得在装配过程中可以简易、快捷的将凸台32套装在插套22的连接部222上。
在一种可能设计中，该容置空间321的纵截面包括梯形截面3211以及第一矩形截面3212，该梯形截面3211位于该第一矩形截面3212的下方。在这种纵 截面设计中，该第一矩形截面3212对应的凸台32的内壁呈竖直形态，在安装时，可以保证与待连接的零件的外壁平行，相比于该容置空间321的纵截面的宽度从下至上逐渐变小的结构，第一矩形截面3212的设计可以使待连接的零件与凸台32上部的内壁之间具有较大的接触面积，在对产品进行装配过程中，能够使得这两部分更快速的熔合，提高了产品的装配效率。在一种可能设计中，该第一矩形截面3212的宽度等于该梯形截面3211的上边长，以使凸台32中第一矩形截面3212与梯形截面3211连接处的内壁平滑过渡。考虑到可以通过多种不同的工艺加工该凸台32，成型后的凸台32中，该第一矩形截面3212的宽度也可以小于或大于该梯形截面3211的上边长，本申请实施例对此不作限定。为了便于装配，在零件的尺寸上，凸台32内的第一矩形截面3212的宽度与待连接的零件的宽度之差均为0.06～0.4mm，可以保证待连接的零件能够顺畅地插入到容置空间321中。
请继续参见图3，在一种可能设计中，凸台32的高度可以是1～3mm，该凸台32中第一矩形截面3212的高度为0.05～3mm，而第一矩形截面3212是用于与产品之间接触的区域，上述设计中第一矩形截面3212的高度在整个凸台高度中占比较大，这种凸台32设计，可以使待连接的零件与凸台32上部的内壁之间具有更大的接触面积，在对产品进行装配过程中，能够使得这两部分更快速的熔合，提高了产品的装配效率。
图4是本申请实施例提供的一种另一种导电金属条3的凸台32的前视截面图和左视截面图，请参见图4，在一种可能设计中，该容置空间321的纵截面还包括第二矩形截面3213，该第二矩形截面3213位于该梯形截面3211的下方。对于图4中的凸台32结构，图5示出了该凸台32的外观结构示意图。由图5可见，该凸台32可以由至少三个梯台构成，例如，参见图5中的第一梯台322、第二梯台323和第三梯台324。这种纵截面的设计，在凸台32壁厚均匀的情况下，使得凸台32上各个梯台之间的连接处可以形成棱部325，该棱部325可以起到加强凸台32的强度的作用。使得凸台32与连接部222之间的连接更加稳固，不易随着使用时间的延长而变形，延长了插座的使用寿命。在一种可能设计中，该第二矩形截面3213的宽度等于该梯形截面3211的下边长，以使凸台32中第二矩形截面3213与梯形截面3211连接处的内壁平滑过渡。考虑到可以通过多种不同的工艺加工该凸台32，成型后的凸台32中，该第二矩形截面3213 的宽度也可以小于或大于该梯形截面3211的下边长，本申请实施例对此不作限定。
在上述可能设计中，为了保持该凸台32的导电性能均匀以及强度均匀，可以将该凸台32设计为均匀的壁厚，这种情况下，凸台32的外形和容置空间321的形状匹配。当然，出于对某个位置的强度要求等设计因素，还可以将凸台32的壁厚设计为不一致，本申请实施例对此不作限定。
针对于不同的插座型号，导电金属条3的安装位置可能不同，相应的，该导电金属条3的结构可能有一些变化。例如，对于一些插座来说，其导电金属条3可以位于该插套座2的底部(如图6所示)，也即是，导电金属条3被安装于靠近下壳体13的位置。在这种情况下，该导电金属条本体31可以设计为条形，这种条形的导电金属条本体31可以安装在插套座2的底部，对插座侧面空间的要求不高，可以降低插座的宽度。
又例如，对于一些插座来说，其导电金属条3可以位于该插套座2的侧面(如图21～图22所示)，也即是，导电金属条3被安装于靠近上壳体12的位置。在这种情况下，该导电金属条3位于该插套座2的侧面，且该导电金属条本体31包括条形主干311和支干312，该支干312的延伸方向与该条形主干311的延伸方向垂直，该凸台32位于该支干312上。这种结构的导电金属条3可以安装在插套座2的侧面，通过条形主干311来与电源对应的相线连接，通过支干312来与插套22的连接部222进行连接，对插座的垂直空间的要求不高，可以降低插座的厚度。
在一种可能设计中，还可以将导电金属条本体31设计为一种加强结构，参见图1和图2，该导电金属条本体31可以具有至少一条加强筋33，该加强筋33位于两个凸台32之间。该加强筋33用于加强该导电金属条3的强度，避免导电金属条3变形，延长了插座的使用寿命。该加强筋33的数量可以根据实际需要设定。例如，该插座上可以设有并排的三个插套座2，相应地，一根导电金属条3上可以设三个凸台32，这三个凸台32之间可以设置两个加强筋33。
在上述任一可能设计中，该凸台32与导电金属条3的导电金属条本体31之间圆滑过渡，以在连接处形成一个向内的圆弧面，降低连接处的电阻，从而便于电流的传导。
在上述任一可能设计中，该导电金属条3的材质为铜。采用铜材质的导电 金属条3，具有导电性高、易于加工以及比较廉价等优点。
图23～图26是本申请实施例提供的一种插座的装配过程示意图，该方法用于装配如上述实施例所提供的插座，请参见图23～图26，该方法包括：
步骤1、准备壳体1、至少一个插套座2以及至少两根导电金属条3(参见图23)。
其中，壳体1可以是由绝缘材料经过注射成型工艺加工而成，也即是，在将绝缘材料加热熔化后，注射到闭合模具的模腔中，以形成壳体1。在采用注射成型工艺进行生产的过程中，先基于所需的壳体设计制造出模具，再使用模具批量生产，生产过程快速可靠。
插套座2包括座体21和至少两个插套22，插套22设置在座体21的槽位中。上述座体21也可以是由绝缘材料经过注射成型工艺加工而成的，其成型工艺原理与壳体1的相同，在此不再赘述。
该插套22包括夹持部221和连接部222，该夹持部221可以包括两个具有弹性的夹持片，用于夹持插头上的插销。该插套22可以是由导电金属板料通过弯折工艺加工而成，通过将夹持片向内弯折，使上述两个夹持片具有向内的弹力。在一种可能设计中，该插套22的材质为铜，从而使得插套22具有导电性高、易于加工以及比较廉价等优点。
其中，若连接部222采用多层导电金属片2221的结构设计，则可以准备宽度为连接部222的多倍的导电金属片，对其进行至少一次折叠和压紧，从而形成弯折结构，并且减小相邻导电金属片之间的缝隙，从而降低后续与凸台32之间的焊接过程的虚焊风险。该多层导电金属片2221的结构设计，还可以通过将该多层独立导电金属片进行叠置加工得到，本申请实施例对此不作限定。
该至少两个导电金属条3的凸台32可以通过在导电金属条3原料进行冲压操作来成型(请参见图27)。对于上述实施例中所涉及的不同形状的容置空间321设计，可以通过至少两次冲压来成型，也即是，先在导电金属条3原料上通过冲压操作形成一个小凸台32，再在该小凸台32的基础上进一步进行冲压操作，以形成具有更高高度的凸台32，以克服冲压操作本身的高度限制。
进一步地，若该导电金属条3上需要增加加强筋33的设计，则可以使用模具对该导电金属条3的导电金属条本体31进行冲压，使被冲压部分的材料下陷， 形成加强筋33。
步骤2、将导电金属条3的凸台32套装在插套座2中插套22的连接部222上，以形成如图24所示的形态。
在该步骤中，可以将该插套22的连接部222从该凸台32的底部开口伸入该凸台32，使得该连接部222从该凸台32的端部开口伸出。可选地，该伸出部分的长度可以在0.5～2mm之间，从而便于后续熔焊操作的进行，还能够保证凸台32和连接部222的熔合更加充分，从而保证零件之间的连接强度。同时，在上述设计中，该伸出部分是熔焊操作的母材，上述高度可以保证这部分母材的量不多不少，既不会削弱连接效果，也不会造成材料的浪费。
在另一种可能实现方式中，在将该连接部222从凸台32的底部开口伸入该凸台32后，还可以保持该连接部222的端部与凸台32端部开口平齐，或低于该端部开口，从而使得零件的使用场景更加灵活，本申请实施例对此不作限定。
在将导电金属条3的凸台32套装在插套22的连接部222上时，可以保持该连接部222在凸台32的容置空间321中处于居中状态(请参见图28中的俯视图和正视图)，也即是，该连接部222的各个侧面与凸台32的相应内壁之间的缝隙相等，该距离可以为0.03～0.2mm之间，保持该较小的距离，可以使得在熔焊过程中熔化掉的材料能够迅速将连接部222和凸台32的端部熔合在一起，而不至于通过缝隙流走而造成材料的浪费，能够降低熔焊耗时，提高装配效率。
步骤3、采用熔焊工艺，熔化该连接部222与该凸台32端部的材料，使该连接部222与该凸台32端部的材料熔合，从而连接该导电金属条3和该插套22，以形成如图25所示的形态。
在一种可能实现方式中，该熔焊工艺可以采用钨极作为焊接头，进行微电弧焊，以实现对材料的熔合。可选地，该微电弧焊过程可以采用氩气保护，在熔焊过程中，保持氩气的流速在5～20L/min(分)，从而可以保证焊接部位隔绝空气，避免发生氧化现象，提高焊接质量。
可选地，在熔焊过程中，采用的焊接电流为40～80A，采用这种强度范围的电流，便于熔焊过程中对温度进行控制，以提高装配的安全性。可选地，该熔焊工艺采用的焊接时间为0.1～0.3s，而将焊接时间控制在这个时间范围内，便于熔焊过程对温度和熔焊进度进行控制。
可以参考如图29所示的焊接过程所示的焊接方式，将焊接头置于已套装完 成的凸台32和连接部222上方，将该焊接头与焊接位置之间距离保持在1～5mm来进行熔焊操作，以使得连接部222的一部分材料和凸台32的一部分材料能够熔化而形成如图30所示的熔池，待熔池固化后，则可以使得连接部222与凸台32熔合为一体(如图31所示)。通过上述实施例中对操作的距离进行控制，便于对温度和熔焊进度进行控制，能对凸台32和连接部222充分焊接的基础上避免加热插套座2，保证插套座2的质量，也能够有效的提高装配的安全性。
步骤4、将连接好的该导电金属条3和该插套22装配在壳体1中，以形成如图7和图26所示的插座(图7示出了插座的从前侧观察的立体形态，图26示出了插座的从后侧观察的立体形态)。
在该步骤中，在导电金属条3和位于插套座2中的插套22连接完成后，将插套座2装嵌在上壳体12的固定槽内，从而将插座套2固定在上壳体12中。将各个导电金属条3的远离插套22的连接部222的一端与电源的各个相线之间连接起来，该插座可以实现其导电功能后，将下壳体13扣装在上壳体12上，覆盖上壳体12内部的各元件，完成装配。
需要说明的是，上述步骤仅为插座的装配过程的一个示例，根据生产情况的不同，插座还可以有其他的装配过程，本申请实施例对装配步骤之间的具体顺序不作限定。例如，先将内设有插套22的插套座2固定在上壳体12中，再将导电金属条3的凸台32套装在插套座2中插套22的连接部222上并熔焊，最后将下壳体13扣装在上壳体12上，完成装配。
上述熔焊工艺中，两种母材均熔化后形成一体，能够避免虚焊，零件之间的连接强度高，且连接处耐受的电流强度高，降低了使用过程中连接处在通电过程中熔化的可能。
若采用锡焊过程，由于手工操作具有不可控的问题，很可能会出现送锡过多或焊接不良等情况，使得锡金属遗留在插座内部，在后续插座的使用过程中，就可能造成的插座短路等后果，因此，用熔焊工艺来替代锡焊工艺，可以保证插座的安全性。同时，采用熔焊工艺，还可以避免焊锡丝可能造成的污染，达到保护环境的目的。
在成本方面，采用熔焊方式，相对于锡焊，具有较高的经济价值，例如，对于九个凸台32和九个连接部222之间的分别焊接的过程，传统锡焊的成本是0.07249元，熔焊的成本为0.03034元，传统锡焊的成本约为熔焊的2.4倍，也 即是，熔焊的成本约为传统锡焊的41.8％。
本申请的插座在装配过程中，将导电金属条3的凸台32套装在插套座2中插套22的连接部222上，采用熔焊工艺，使插套22的连接部222与导电金属条3的凸台32的端部熔合为一体，来实现插套22以及导电金属条3之间的固定连接，而由于熔焊工艺与原有的锡焊工艺不同，不会产生焊渣，因此，也就避免了焊渣的产生，不会遗留短路隐患，能够大大提高插座的安全性。同时，避免焊锡丝可能造成的污染，保护环境。并且上述熔焊工艺连接强度高，能够降低装配成本。
上述所有可选技术方案，可以采用任意结合形成本申请的可选实施例，在此不再一一赘述。
上述仅为本申请的可选实施例，并不用以限制本申请，凡在本申请的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本申请的保护范围之内。

Claims (19)

  1. 一种导电金属条(3)，其特征在于，所述导电金属条(3)包括导电金属条本体(31)和至少一个凸台(32)，所述凸台(32)内具有容置空间(321)，所述容置空间(321)具有位于所述凸台(32)的底部的开口。
  2. 根据权利要求1所述的导电金属条(3)，其特征在于，所述容置空间(321)的横截面为长条形。
  3. 根据权利要求1所述的导电金属条(3)，其特征在于，所述容置空间(321)的纵截面的宽度从下至上逐渐变小。
  4. 根据权利要求1所述的导电金属条(3)，其特征在于，所述容置空间(321)的纵截面包括梯形截面(3211)以及第一矩形截面(3212)，所述梯形截面(3211)位于所述第一矩形截面(3212)的下方。
  5. 根据权利要求4所述的导电金属条(3)，其特征在于，所述第一矩形截面(3212)的高度为0.05～3mm。
  6. 根据权利要求4所述的导电金属条(3)，其特征在于，所述容置空间(321)的纵截面还包括第二矩形截面(3213)，所述第二矩形截面(3213)位于所述梯形截面(3211)的下方。
  7. 根据权利要求1所述的导电金属条(3)，其特征在于，所述导电金属条本体(31)具有至少一条加强筋(33)，所述加强筋(33)位于两个凸台(32)之间。
  8. 根据权利要求1所述的导电金属条(3)，其特征在于，所述容置空间(321)还具有位于所述凸台(32)的端部的开口。
  9. 根据权利要求1所述的导电金属条(3)，其特征在于，所述导电金属条 本体(31)为条形。
  10. 根据权利要求1所述的导电金属条(3)，其特征在于，所述导电金属条本体(31)包括条形主干(311)和支干(312)，所述支干(312)的延伸方向与所述条形主干(311)的延伸方向垂直，所述凸台(32)位于所述支干(312)上。
  11. 一种插座，其特征在于，所述插座包括：壳体(1)、至少一个插套座(2)以及至少两根如权利要求1至7任一项所述的导电金属条(3)；
    所述壳体(1)具有至少两个插座孔(11)，所述插套座(2)和所述导电金属条(3)位于所述壳体(1)内；
    所述插套座(2)包括座体(21)和至少两个插套(22)，所述座体(21)具有与所述插座孔(11)对应的槽位，所述插套(22)位于所述槽位中；
    所述插套(22)包括夹持部(221)和连接部(222)，所述夹持部(221)用于夹持插头上的插销，所述连接部(222)用于连接所述导电金属条(3)；
    所述导电金属条(3)分别对应不同极性的插套(22)，且所述插套(22)的连接部(222)位于所述导电金属条(3)的凸台(32)内的容置空间(321)内，且所述连接部(222)与所述凸台(32)的端部熔合。
  12. 根据权利要求11所述的插座，其特征在于，所述插套(22)的连接部(222)包括多层导电金属片(2221)。
  13. 根据权利要求12所述的插座，其特征在于，所述多层导电金属片(2221)由一片导电金属片弯折而成。
  14. 根据权利要求12所述的插座，其特征在于，所述多层导电金属片(2221)包括多片独立导电金属片。
  15. 根据权利要求11所述的插座，其特征在于，所述插套(22)的连接部(222)的至少一个侧壁上包括至少一个凸起(2222)。
  16. 根据权利要求11所述的插座，其特征在于，所述导电金属条(3)位于所述插套座(2)的底部，且所述导电金属条本体(31)为条形。
  17. 根据权利要求11所述的插座，其特征在于，所述导电金属条(3)位于所述插套座(2)的侧面，且所述导电金属条本体(31)包括条形主干(311)和支干(312)，所述支干(312)的延伸方向与所述条形主干(311)的延伸方向垂直，所述凸台(32)位于所述支干(312)上。
  18. 一种插座的装配方法，其特征在于，所述方法包括：
    将导电金属条(3)的凸台(32)套装在插套(22)的连接部(222)上；
    采用熔焊工艺，熔化所述连接部(222)与所述凸台(32)端部的材料，使所述连接部(222)与所述凸台(32)端部的材料熔合，从而连接所述导电金属条(3)和所述插套(22)；
    将连接好的所述导电金属条(3)和所述插套(22)装配在壳体(1)中。
  19. 根据权利要求18所述的方法，其特征在于，所述将导电金属条(3)的凸台(32)套装在插套(22)的连接部(222)上包括：
    将所述插套(22)的连接部(222)从所述凸台(32)的底部开口中伸入所述凸台(32)，使得所述连接部(222)从所述凸台(32)的端部开口伸出0.5～2mm。
PCT/CN2020/091510 2020-04-10 2020-05-21 导电金属条、插座及插座的装配方法 WO2021203527A1 (zh)

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CN207052768U (zh) * 2017-04-27 2018-02-27 公牛集团有限公司 一种激光焊接插座
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US20150155692A1 (en) * 2013-12-03 2015-06-04 Lsis Co., Ltd. Busbar coupling device assembly
CN104253334A (zh) * 2014-09-04 2014-12-31 公牛集团有限公司 插座电气连接结构
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