WO2023284857A1 - 一种含有冲压弹片结构的端子 - Google Patents

一种含有冲压弹片结构的端子 Download PDF

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Publication number
WO2023284857A1
WO2023284857A1 PCT/CN2022/105970 CN2022105970W WO2023284857A1 WO 2023284857 A1 WO2023284857 A1 WO 2023284857A1 CN 2022105970 W CN2022105970 W CN 2022105970W WO 2023284857 A1 WO2023284857 A1 WO 2023284857A1
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WO
WIPO (PCT)
Prior art keywords
elastic sheet
sheet structure
elastic
stamped
terminal
Prior art date
Application number
PCT/CN2022/105970
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English (en)
French (fr)
Inventor
王超
Original Assignee
长春捷翼汽车零部件有限公司
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 CN202121611169.2U external-priority patent/CN215119305U/zh
Priority claimed from CN202110803160.XA external-priority patent/CN113410685A/zh
Application filed by 长春捷翼汽车零部件有限公司 filed Critical 长春捷翼汽车零部件有限公司
Priority to EP22841490.0A priority Critical patent/EP4372921A1/en
Publication of WO2023284857A1 publication Critical patent/WO2023284857A1/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
    • H01R13/11—Resilient sockets
    • H01R13/111—Resilient sockets co-operating with pins having a circular transverse section
    • 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
    • H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending

Definitions

  • the present application relates to a terminal with a stamped elastic sheet structure.
  • the current charging gun and charging stand terminals are all formed by integral machining of copper.
  • the disadvantage is that the cost is high, the processing time is long, and if there is a problem, it can only be replaced as a whole, which is not good for the cost control of the charging system.
  • this application provides a terminal with a stamped spring structure.
  • the terminal with a stamped spring structure is changed from the overall processing to the stamped spring and the mounting base, which are processed separately and then assembled into one body. It greatly saves the cost of the terminal, reduces the processing time, and can also ensure that the shrapnel is in full contact with the conductive part of the mating terminal to meet the mechanical requirements and temperature rise requirements of the charging system.
  • a terminal with a stamped elastic sheet structure includes a mounting base and an outer elastic sheet structure, one end of the outer elastic sheet structure is connected to one end of the installation base, the mounting base and the outer elastic sheet structure are separately formed, and the outer elastic sheet structure is a stamped structure.
  • the stamped shrapnel (which may include the outer shrapnel structure and the inner shrapnel structure) and the installation base are processed and manufactured separately and then assembled into one body, so that the charging terminal does not need to be machined as a whole, which not only saves processing time, but also saves materials.
  • stamping shrapnel processed by stamping method has simple processing method, low working hours, and can retain the conductive and elastic properties of the material.
  • FIG. 1 is a schematic perspective view of a terminal including a stamped elastic sheet structure in Embodiment 1 of the present application.
  • FIG. 2 is a schematic front view of the terminal including the stamped elastic sheet structure described in Embodiment 1 of the present application.
  • FIG. 3 is a schematic diagram of the first connection mode between the outer elastic structure and the installation base in Embodiment 1.
  • FIG. 3 is a schematic diagram of the first connection mode between the outer elastic structure and the installation base in Embodiment 1.
  • FIG. 4 is a schematic diagram of the second connection mode between the outer elastic structure and the installation base in Embodiment 1.
  • FIG. 4 is a schematic diagram of the second connection mode between the outer elastic structure and the installation base in Embodiment 1.
  • FIG. 5 is a schematic diagram of the third connection method between the outer elastic structure and the installation base in Embodiment 1.
  • FIG. 5 is a schematic diagram of the third connection method between the outer elastic structure and the installation base in Embodiment 1.
  • FIG. 6 is a schematic plan view of the first outer elastic sheet structure in Embodiment 1.
  • FIG. 6 is a schematic plan view of the first outer elastic sheet structure in Embodiment 1.
  • FIG. 7 is a schematic front view of the outer elastic strips of the second outer elastic structure in Embodiment 1.
  • FIG. 7 is a schematic front view of the outer elastic strips of the second outer elastic structure in Embodiment 1.
  • FIG. 8 is a schematic perspective view of the outer elastic strips of the second outer elastic structure in Embodiment 1.
  • FIG. 8 is a schematic perspective view of the outer elastic strips of the second outer elastic structure in Embodiment 1.
  • FIG. 9 is a schematic plan view of the second outer elastic sheet structure in Embodiment 1.
  • FIG. 9 is a schematic plan view of the second outer elastic sheet structure in Embodiment 1.
  • FIG. 10 is a schematic perspective view of a terminal including a stamped elastic sheet structure in Embodiment 2 of the present application.
  • FIG. 11 is a schematic cross-sectional view of a terminal including a stamped elastic sheet structure in Embodiment 2 of the present application.
  • Fig. 12 is a schematic cross-sectional view of the structure of the inner elastic sheet in Embodiment 2.
  • FIG. 13 is a schematic plan view of the first inner elastic sheet structure in Embodiment 2.
  • FIG. 13 is a schematic plan view of the first inner elastic sheet structure in Embodiment 2.
  • Fig. 14 is a schematic plan view of the second inner elastic sheet structure in embodiment 2.
  • the embodiment of the present application provides a terminal with a punched elastic structure, including a mounting base 1 and an outer elastic structure 2, one end of the outer elastic structure 2 is connected to one end of the installation base 1, and the installation base 1 and the outer elastic structure are divided into two parts.
  • the body is formed, and the outer elastic structure 2 is a stamping structure, as shown in Figures 1 to 3.
  • the installation base 1 and the outer shrapnel structure 2 are processed and formed separately, and then assembled into one body, and finally the terminal with the stamped shrapnel structure is formed, which greatly saves the cost of the terminal, reduces the processing time, and can also ensure that the shrapnel is compatible with the mating
  • the conductive parts of the terminals are in full contact.
  • the outer elastic structure 2 is cylindrical. Along the circumferential direction of the outer elastic structure 2, the outer elastic structure 2 contains a plurality of (such as two) outer elastic segments 21, and the planar expansion structure of the outer elastic segments 21 is approximately It is fan-shaped, and the section of the outer elastic segment 21 is arc-shaped.
  • the thickness of the outer elastic sheet structure 2 is 0.035mm-4.712mm. When the thickness is less than 0.035mm, the elasticity of the outer elastic sheet structure 2 is insufficient. When the thickness is greater than 4.712mm, the difficulty of deformation increases and the processing is more difficult, which does not have the meaning of actual production.
  • each group contains 7 terminals with stamped shrapnel structure, and tested the elasticity of the outer shrapnel strip 212 respectively.
  • the method of testing the elastic force is to use a precision dynamometer to detect the elastic force of a single outer elastic strip 212 or the opening position of the outer elastic strip 22 moving 1mm.
  • the elastic force of the outer elastic strips 212 or the outer elastic strips 22 is less than 3N and greater than 10N is unqualified. Because the elastic force is small, the contact stress between the outer elastic sheet structure 2 and its mating terminal will be small, resulting in a reduced contact area and an increased contact resistance. The elastic force is large, and the insertion force of the outer elastic sheet structure 2 against the mating terminal increases, making it relatively difficult to insert and pull the mating terminal.
  • Table 1 Effect of the thickness and quantity of the outer shrapnel structure 2 on the elasticity of the outer shrapnel strip 212
  • each outer elastic segment 21 includes an outer connecting portion 211 and a plurality of outer elastic strips 212, and an outer gap is formed between two adjacent outer elastic strips 212. 213, as shown in Figure 6.
  • the outer elastic strip 212 can adapt to the processing error of the mating terminal, so that the outer elastic strip 212 and the mating terminal have a greater bonding force, ensure more contact area, and achieve better electrical and mechanical properties.
  • the terminal cannot meet the mechanical requirements and temperature rise requirements.
  • the outer elastic structure 2 is cylindrical, and along the circumferential direction of the outer elastic structure 2 , the outer elastic structure 2 contains a plurality of independent outer elastic strips 22 .
  • Such independent outer elastic strips can be directly processed on a punching machine or a rolling machine, saving materials, and can use raw materials with a smaller width for processing.
  • the outer shrapnel structure 2 is damaged during use, the entire terminal can be replaced differently, and only the damaged outer shrapnel structure 2 needs to be replaced, which reduces waste of terminals, improves maintenance efficiency, and greatly saves costs.
  • the plurality of outer elastic strips 22 are connected by the outer annular base belt 23, the outer annular base belt 23 is located at one end of the outer elastic sheet structure 2, the outer elastic strips 22 and the outer annular base belt 23 are stacked, and the outer annular base belt 23 is ring-shaped after winding , that is, the outer elastic sheet structure 2 in FIG. 9 is cylindrical after being wound.
  • the independent outer elastic strips 22 have the advantages of material saving and partial replacement when damaged, when the number of independent outer elastic strips 22 is large, the independent outer elastic strips 22 are respectively fixed on the base 1. It is complicated and takes a long time, which limits the use of independent outer elastic strips 22 instead.
  • the outer elastic strip 22 and the outer annular base belt 23 can be stacked and fixed first, and then fixed to the base 1 in a cylindrical shape after winding, which can greatly reduce the number of independent outer elastic strips 22 hours of installation time, improve the work efficiency of assembly.
  • the outer shrapnel structure 2 since the outer shrapnel structure 2 is cylindrical, the outer shrapnel structure 2 contains an internal cavity, and the inner cavity of the outer shrapnel structure 2 is tapered, that is, the inner diameter of one end of the outer shrapnel structure 2 is larger than that of the outer shrapnel structure 2 The inner diameter of the other end, as shown in Figure 4. If the inner diameter of the inner cavity of the outer shrapnel structure 2 is exactly the same as the outer diameter of the mating end terminal, due to the tolerance fit, the mating end terminal cannot be inserted into the inner cavity, or the mating end terminal and the outer Most of the shrapnel structure 2 has areas that cannot be touched, resulting in failure to achieve electrical conduction, or a small contact area.
  • the inventor sets the inner cavity of the outer shrapnel structure 2 to be tapered, so that the mating end terminal can be inserted into the inner cavity, and at the same time, the outer shrapnel structure 2 has a larger deformation space, so that the outer shrapnel structure 2 and the paired Mating terminal mating for greater gripping force.
  • the inner surface of the outer elastic sheet structure 2 may be provided with an outer curved neck section 24 .
  • the inner diameter of the outer arc-shaped necking section 24 is smaller than the inner diameter of the outer shrapnel structure 2, so that the inner surface of the outer arc-shaped necking section 24 can always contact the outer surface of the mating end terminal, and at the same time, the outer arc-shaped necking section after mating
  • the angle between the inner surface of 24 and the axis of the terminal is the same as the angle between the outer surface of the mating end terminal and the axis of the terminal, so that the inner surface of the outer arc-shaped necking section 24 can form surface contact with the outer surface of the mating end terminal, increasing the size of the outer elastic piece
  • the contact area between the structure 2 and the mating terminal reduces the contact resistance, improves the conductivity of the terminal with the stamped shrapnel structure, and increases the safety and stability of the electrical
  • the inner surface of the outer elastic sheet structure 2 can also be provided with an outer arc-shaped neck expansion section 25, that is, along the direction from one end of the outer elastic sheet structure 2 to the other end of the outer elastic sheet structure 2, the outer elastic sheet structure 2
  • the inner surface of the outer arc-shaped necking section 24 and the outer arc-shaped neck expansion section 25 are sequentially provided, as shown in Figure 3 and Figure 5 .
  • the internal cavity of the outer shrapnel structure 2 is generally a tapered hole, the opening diameter of the internal cavity is smaller than the diameter of the mating end terminal, so an outer arc-shaped neck expansion section 25 should be provided inside the opening side of the internal cavity to match the mating end.
  • the insertion of the mating terminal is guided to guide the smooth insertion of the mating terminal, and the outer elastic structure 2 can be expanded to be inserted into the inner cavity of the outer elastic structure 2 .
  • the outer arc necking section 24 and the outer arc neck expansion section 25 are approximately tapered, and the taper of the outer arc necking section 24 and the outer arc neck expansion section 25 can be the same, as shown in FIG. 4 .
  • the taper of the outer arc necking section 24 is smaller than the taper of the outer arc neck expansion section 25, the outer arc neck expansion section 25 is located at the other end of the outer shrapnel structure 2, and the outer arc neck expansion section 25 is in a flanging structure ,As shown in Figure 3.
  • one end of the installation base is provided with an installation groove
  • the installation groove is located on the outside, inside or middle of one end of the installation base, and the outer shrapnel structure is matched with the installation groove
  • a detachable or non-detachable connection can be used between the outer elastic structure 2 and the installation base 1.
  • the outer elastic structure 2 and the installation base 1 are connected by crimping, screw connection, screw connection, or bolt connection. , snap connection, bonding, welding and riveting in one or more.
  • one end of the installation base 1 is provided with an installation groove 11, and the installation groove 11 is located on the outer side (as shown in Figure 5 ) and the inner side of one end of the installation base 1. Or the middle part (as shown in FIG. 3 ), the outer elastic structure 2 is mated with the installation groove 11 .
  • the outer elastic structure 2 is bonded or welded to the installation base 1
  • one end of the installation base 1 may not be provided with an installation groove 11 , as shown in FIG. 4 .
  • connection between the outer shrapnel structure 2 and the installation base 1 can be connected by crimping or welding.
  • the parts where the base 1 is nested with each other, or the parts where multiple independent outer elastic strips 22 contained in the outer elastic structure 2 are connected with the installation grooves on the installation base 1 can be realized by tinning crimping or welding Non-detachable connection.
  • a threaded connection can be used between the outer shrapnel structure 2 and the installation base 1.
  • the inner wall of the outer connection part 21 is provided with an internal thread sleeve, and the installation base An external thread is provided on the outer wall of one side of the seat 1.
  • the mounting base 1 is a tubular hollow structure or a solid cylinder structure.
  • the radial structure of the outer connecting portion 211 of the outer shrapnel structure 2 is a ring structure
  • the outer wall of the outer connecting portion 21 is provided with external threads
  • the inner wall of one side of the mounting base 1 is provided with internal threads.
  • the mounting base 1 is tubular hollow structure, the detachable connection is realized by matching the internal thread/external thread on one side of the outer spring structure 2 with the external thread/internal thread on the side of the mounting base 1 respectively.
  • screw connection can be used between the outer shrapnel structure 2 and the installation base 1, the screw has a screw head and a screw shank, one end of the screw shank is a free end, and the radial structure of the outer connection part 211 of the outer shrapnel structure 2 is a ring
  • the outer connection part 21 and the mounting base 1 are provided with a threaded hole for the screw to pass through. After the screw passes through the threaded hole, the nut is connected to the screw from the free end side of the screw.
  • the parts where the structure 2 and the installation base 1 are nested are fixed between the screw heads and the nuts to realize a detachable connection.
  • the outer elastic structure 2 and the installation base 1 can be connected by screws, or multiple independent outer elastic strips contained in the outer elastic structure 2 can be respectively pierced by a plurality of screws from the free end side of the screw rod. 22 and the installation groove insertion part on the installation base 1, at this time, through the interference connection between the screw and the elastic strip 22 and the installation base 1, a non-detachable connection is realized
  • the outer elastic structure 2 and the installation base 1 can be connected by a bolt, and the bolt runs through the multiple independent outer elastic strips 22 contained in the outer elastic structure 2 and the installation groove on the installation base 1. , one end of the bolt located inside the installation base 1 is interference-connected, and one end of the bolt located outside the installation base 1 is riveted to achieve a non-detachable connection.
  • the outer elastic structure 2 and the installation base 1 can be connected by a bolt, and the bolt runs through the joint of the outer elastic structure 2 and the installation base 1, and the two ends of the outer elastic structure 2 and the installation base 1 are exposed.
  • the pin end of the socketed part can be riveted to realize non-detachable connection.
  • conductive glue can be used between the outer shrapnel structure 2 and the installation base 1 to realize the adhesive connection between the outer shrapnel structure 2 and the installation base 1, or the conductive glue can be used to realize multiple independent parts contained in the outer shrapnel structure 2.
  • the outer elastic strip 22 of the outer elastic strip 22 is adhesively connected to the insertion part of the installation groove on the installation base 1. At this time, the non-detachable connection between the outer elastic sheet structure 2 and the installation base 1 can be realized and the normal power supply of the terminal can be ensured.
  • the outer shrapnel structure 2 and the installation base 1 can be connected by riveting, the rivet runs through the joint between the outer shrapnel structure 2 and the installation base 1, and the two ends of the outer shrapnel structure 2 and the installation base 1 are exposed.
  • the pin end of the socketed part can be riveted to realize non-detachable connection.
  • the outer shrapnel structure 2 and the installation base 1 can be connected by riveting, and the rivets run through the multiple independent outer elastic strips 22 contained in the outer shrapnel structure 2 and the installation groove insertion parts on the installation base 1
  • the installation base 1 is a tubular hollow structure
  • the rivet can penetrate the multiple independent outer elastic strips 22 contained in the outer shrapnel structure 2 and the insertion part of the installation groove on the installation base 1, and the rivets exposed at both ends
  • the ends can be connected non-detachably by riveting.
  • connection methods can be used alone or in combination.
  • threaded connection it can also be connected through conductive glue at the same time.
  • the connection between the outer shrapnel structure 2 and the installation base 1 can be realized. a more stable connection.
  • the installation base 1 includes a power transmission part 12 and an outer connection part 13 of the elastic piece connected in sequence.
  • the function of the power transmission part 12 is to install and connect with the wire.
  • the power transmission part 12 needs to be electrically connected to the wire, generally by crimping or welding. Therefore, the power transmission part 12 is designed in a variety of structures, which can be based on the requirements of electrical connection and the requirements of the electrical device. According to the assembly environment, different structures of the power transmission part 12 can be selected, and a stable electrical connection can be established with the wire. In general, U-shaped structure or arc-shaped structure or cylindrical structure or polygonal structure is suitable for crimping and welding, and flat structure or bowl-shaped structure is suitable for welding.
  • the elastic piece outer connecting part 13 is to install and connect with the outer elastic piece structure 2, and to match and install with the electric device in addition.
  • the outer connecting portion 13 of the elastic piece is provided with a plurality of annular grooves.
  • the mounting base 1 is turned and formed, and the outer shrapnel structure 2 is stamped and formed.
  • This embodiment is an improvement to Embodiment 1.
  • the main difference between this embodiment and Embodiment 1 is that this embodiment adds an inner shrapnel structure 3 on the basis of Embodiment 1, that is, the inner shrapnel structure 3 containing the punched shrapnel structure.
  • the terminal also includes an inner shrapnel structure 3, which is stacked with the outer shrapnel structure 2, one end of the inner shrapnel structure 3 is connected to the installation base 1, or one end of the inner shrapnel structure 3 is connected to the outer shrapnel structure 2, or the inner shrapnel One end of the structure 3 is connected with the installation base 1 and the outer elastic structure 2, as shown in Fig. 10 and Fig. 11 .
  • the inner shrapnel structure 3 is provided to enhance the mechanical properties of the terminal mating structure.
  • the inner shrapnel structure 3 and the outer shrapnel structure 2 are electrically connected to the mating end terminal together, which increases the contact area between the terminal containing the stamped shrapnel structure and the mating end terminal, reduces the contact resistance of the terminal mating structure, and can Better conduction current and temperature rise control greatly improve the electrical performance of the terminal-to-plug structure.
  • the inner elastic sheet structure 3 is sheathed in the outer elastic sheet structure 2, which not only increases the contact area between the terminal with the stamped elastic sheet structure and the terminal at the mating end, but also does not increase the terminal with the stamped elastic sheet structure volume of.
  • the installation base 1, the outer elastic structure 2 and the inner elastic structure 3 are uniformly formed, and the inner elastic structure 3 is a stamping structure.
  • the inner elastic sheet structure 3 can also be stamped and formed by sheet material, which can greatly save the material used for the terminal.
  • due to the complex structure of the terminal containing the stamped elastic sheet structure the cost of the integrated processing method is high, and the processing time is long.
  • the terminal containing the stamped elastic sheet structure can be divided into several parts for processing, and then the inner elastic sheet structure 3 and the outer shrapnel structure 2 are assembled with the installation base 1 respectively, which can improve work efficiency and reduce material waste.
  • both the inner elastic structure 3 and the outer elastic structure 2 are cylindrical, and the length of the outer elastic structure 2 is greater than that of the inner elastic structure 3 . Since both the inner elastic structure 3 and the outer elastic structure 2 need to be electrically connected to the mating terminal, and the inner elastic structure 3 and the outer elastic structure 2 are stacked, so the length of the outer elastic structure 2 needs to be greater than that of the inner elastic structure 3 Length, so that the mating end terminal can contact the inner elastic structure 3 and the outer elastic structure 2 at the same time.
  • the axis of the outer elastic sheet structure 2 coincides with the axis of the inner elastic sheet structure 3. Since the outer elastic sheet structure 2 and the inner elastic sheet structure 3 are connected to the same mating end terminal, the mating end terminal The male end will be inserted into the inner cavity of the outer shrapnel structure 2 and the inner shrapnel structure 3 at the same time, so the axis of the outer shrapnel structure 2 needs to coincide with the axis of the inner shrapnel structure 3, which is also the axis of the mating end terminal after insertion. coincide. Both the inner cavity of the outer shrapnel structure 2 and the inner cavity of the inner shrapnel structure 3 are conical.
  • the inventors set the inner cavity of the outer shrapnel structure 2 and the inner shrapnel structure 3 to be tapered, so that the mating end terminal can be inserted into the inner cavity, and at the same time, the outer shrapnel structure 2 and the inner shrapnel structure 3 can have a larger gap.
  • the deformation space enables the outer elastic sheet structure 2 and the inner elastic sheet structure 3 to obtain greater gripping force after they are mated with the mating terminal.
  • the taper of the inner cavity of the outer shrapnel structure 2 is smaller than the taper of the inner cavity of the inner shrapnel structure 3. Since the outer shrapnel structure 2 is at the periphery of the inner shrapnel structure 3, the inner cavity of the outer shrapnel structure 2 The taper of the inner shrapnel structure 3 is smaller than the taper of the inner cavity of the inner shrapnel structure 3, so that the front ends of the outer shrapnel structure 2 and the inner shrapnel structure 3 can touch the mating terminal to realize electrical conduction.
  • the structure of the outer elastic sheet structure 2 is completely the same, partly the same or completely different from that of the inner elastic sheet structure 3.
  • the outer elastic sheet structure 2 can choose various structural forms in Embodiment 1, and the inner elastic sheet structure 3 can also be Referring to Embodiment 1, there are various structural forms, and the combination of the outer elastic sheet structure 2 and the inner elastic sheet structure 3 can be selected according to needs.
  • the inner shrapnel structure 3 is cylindrical, and along the circumferential direction of the inner shrapnel structure 3, the inner shrapnel structure 3 contains a plurality of inner shrapnel segments 31, the sections of the inner shrapnel segments 31 are arc-shaped, and the inner shrapnel structure 3
  • the thickness is 0.2mm-5mm.
  • the inventor selected 11 groups, each with 7 terminals containing stamped shrapnel structures, and tested the elasticity of the inner shrapnel strips 312 respectively.
  • the testing method of the elastic force is to use a precision force gauge to detect the elastic force of a single inner elastic strip 312 or the opening position of the inner elastic strip 32 moving 1 mm.
  • the elastic force of the inner elastic strips 312 or inner elastic strips 32 is less than 3N and greater than 10N, it is unqualified. Because the elastic force is small, the contact stress between the inner elastic sheet structure 3 and its mating terminal will be small, resulting in a reduced contact area and an increased contact resistance.
  • the elastic force is large, and the insertion force of the inner elastic sheet structure 3 to its mating terminal increases, making it relatively difficult to insert and pull the mating terminal.
  • the inner elastic segment 31 includes an inner connecting portion 311 and a plurality of inner elastic strips 312 , and inner gaps 313 are formed between two adjacent inner elastic strips 312 , as shown in FIG. 13 .
  • the inner elastic strip 312 can adapt to the processing error of the mating terminal, so that the inner elastic strip 312 has a greater bonding force to the mating terminal, ensures more contact area, achieves better electrical and mechanical properties, and solves the problem of existing terminals. Problems that cannot meet the mechanical requirements and temperature rise requirements.
  • the inner elastic sheet structure 3 is cylindrical, and along the circumferential direction of the inner elastic sheet structure 3 , the inner elastic sheet structure 3 contains a plurality of independent inner elastic strips 32 .
  • independent inner elastic strips can be directly processed on a punching machine or a rolling machine, saving materials and using raw materials with a smaller width for processing.
  • the entire terminal can be replaced differently, and only the damaged inner shrapnel structure 3 needs to be replaced, which reduces waste of terminals, improves maintenance efficiency, and greatly saves costs.
  • the plurality of inner elastic strips 32 are connected by an inner annular base belt 33, the inner elastic strips 32 and the inner annular base belt 33 are stacked, and the inner annular base belt 33 is located at one end of the inner elastic sheet structure 3, as shown in FIG. 14 .
  • the independent inner elastic strips 32 have the advantages of material saving and partial replacement when damaged, when the number of independent inner elastic strips 32 is large, the independent inner elastic strips 32 are respectively fixed on the base 1. It is complicated and takes a long time, which limits the use of independent inner elastic strips 32 instead.
  • the inner elastic strip 32 and the inner annular base belt 33 can be stacked and fixed first, and then fixed to the base 1 in a cylindrical shape after winding, which can greatly reduce the number of independent inner elastic strips 32 hours of installation time, improving the work efficiency of assembly.
  • the inner shrapnel structure 3 is cylindrical, the inner cavity of the inner shrapnel structure 3 is conical, and the inner diameter of one end of the inner shrapnel structure 3 is larger than the inner diameter of the other end of the inner shrapnel structure 3 . If the inner diameter of the inner cavity of the inner shrapnel structure 3 is exactly the same as the outer diameter of the mating end terminal, due to the tolerance fit, the mating end terminal cannot be inserted into the inner cavity, or the mating end terminal cannot be inserted into the inner cavity. Most of the shrapnel structure 3 has areas that cannot be touched, resulting in failure to achieve electrical conduction, or a small contact area.
  • the inventor sets the inner cavity of the inner elastic sheet structure 3 to be tapered, so that the mating end terminal can be inserted into the inner cavity, and at the same time, the inner elastic sheet structure 3 can have a larger deformation space, so that the inner elastic sheet structure 3 is compatible with the opposite Mating terminal mating for greater gripping force.
  • the inner surface of the inner elastic structure 3 is provided with an inner arc-shaped necking section 34 .
  • the inner diameter of the inner arc-shaped necking section 34 is smaller than the inner diameter of the inner shrapnel structure 3, so that the inner surface of the inner arc-shaped necking section 34 can always contact the outer surface of the mating end terminal, and at the same time, the inner arc-shaped necking section after mating
  • the angle between the inner surface of 34 and the axis of the terminal is the same as the angle between the outer surface of the mating end terminal and the axis of the terminal, so that the inner surface of the inner arc-shaped necking section 34 can form surface contact with the outer surface of the mating end terminal, increasing the size of the inner elastic piece
  • the contact area between the structure 3 and the mating terminal reduces the contact resistance, improves the conductivity of the terminal with the stamped shrapnel structure, and increases the safety and stability of the electrical device
  • the inner surface of the inner elastic sheet structure 3 is sequentially provided with an inner arc-shaped necking section 34 and an inner arc-shaped neck expansion section 35, As shown in Figure 12. Since the inner cavity of the inner shrapnel structure 3 is generally a tapered hole, the opening diameter of the inner cavity is smaller than the diameter of the mating end terminal, so an inner arc-shaped neck expansion section 35 should be provided inside the opening side of the inner cavity to match the mating end. The insertion of the mating terminal is guided to guide the smooth insertion of the mating terminal, and the inner elastic structure 3 can be expanded and inserted into the inner cavity of the inner elastic structure 3 .
  • one end of the installation base 1 is provided with an installation groove 11
  • the installation groove 11 is located on the outside, inside or middle of one end of the installation base 1
  • the outer elastic structure 2 is plugged into the installation groove 11 .
  • the inner elastic structure 3 and the outer elastic structure 2 can be inserted into the same or different installation grooves 11 .
  • one end of the inner shrapnel structure 3 is connected to one end of the installation base 1 or one end of the outer shrapnel structure 2, and the connection method can be crimping, threaded connection, screw connection, plug-in connection, bolt connection, buckle One or more of joining, bonding, welding and riveting.

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Abstract

一种含有冲压弹片结构的端子，包括安装基座(1)和外弹片结构(2)，外弹片结构(2)的一端与安装基座(1)的一端连接，安装基座(1)和外弹片结构(2)分体成型，外弹片结构(2)为冲压成型结构。该含有冲压弹片结构的端子，由整体加工变更为使用冲压弹片和安装基座分别加工制造后再组装成一体，极大的节省端子成本，降低加工工时，也能够保证弹片与对插端子导电部分充分接触，满足充电系统的力学需求和温升要求。

Description

一种含有冲压弹片结构的端子
相关申请
本申请要求于2021年7月15日递交的申请号为202110803160.X的中国发明专利申请，以及于2021年7月15日递交的申请号为202121611169.2的中国实用新型专利申请的优先权，并引用上述专利申请公开的内容作为本申请的一部分。
技术领域
本申请涉及一种含有冲压弹片结构的端子。
背景技术
电动汽车的线缆由于电压高、电流大，因此都需要使用大线径的导线进行电流的传导，目前的充电枪和充电座端子都是采用铜材进行整体机加工形成。其缺点是，成本高，加工工时长，出现问题只能整体更换，对充电系统的成本控制不利。
发明内容
为了降低充电端子的制造成本，本申请提供了一种含有冲压弹片结构的端子，该含有冲压弹片结构的端子，由整体加工变更为使用冲压弹片和安装基座分别加工制造后再组装成一体，极大的节省端子成本，降低加工工时，也能够保证弹片与对插端子导电部分充分接触，满足充电系统的力学需求和温升要求。
本申请解决其技术问题所采用的技术方案是：
一种含有冲压弹片结构的端子，包括安装基座和外弹片结构，外弹片结构的一端与安装基座的一端连接，安装基座和外弹片结构分体成型，外弹片结构为冲压成型结构。
本申请的有益效果是：
1、冲压弹片(可以包括外弹片结构和内弹片结构)和安装基座分别加工制造后再组装成一体，使充电端子不需要进行整体机加工，既节省了加工工时，也节省了材料。
2、冲压方式加工的冲压弹片，加工方式简单，工时低，能够保留材料的导电特性和弹性特性。
3、对于冲压弹片损坏的端子，只需要更换冲压弹片，不需要更换整个端子，节省端子和维修成本。
附图说明
此处所说明的附图用来提供对本申请的进一步理解，构成本申请的一部分，并不构成对本申请的限定。在附图中：
图1是在实施例1中本申请所述含有冲压弹片结构的端子的立体示意图。
图2是在实施例1中本申请所述含有冲压弹片结构的端子的主视示意图。
图3是在实施例1中外弹片结构与安装基座采用第一种连接方式的示意图。
图4是在实施例1中外弹片结构与安装基座采用第二种连接方式的示意图。
图5是在实施例1中外弹片结构与安装基座采用第三种连接方式的示意图。
图6是在实施例1中第一种外弹片结构的平面展开示意图。
图7是在实施例1中第二种外弹片结构的外弹片条的主视示意图。
图8是在实施例1中第二种外弹片结构的外弹片条的立体示意图。
图9是在实施例1中第二种外弹片结构的平面展开示意图。
图10是在实施例2中本申请所述含有冲压弹片结构的端子的立体示意图。
图11是在实施例2中本申请所述含有冲压弹片结构的端子的剖视示意图。
图12是在实施例2中内弹片结构的断面示意图。
图13是在实施例2中第一种内弹片结构的平面展开示意图。
图14是在实施例2中第二种内弹片结构的平面展开示意图。
具体实施方式
为使本申请实施例的目的、技术方案和优点更加清楚明白，下面结合附图对本申请实施例做进一步详细说明。在此，本申请的示意性实施例及其说明用于解释本申请，但并不作为对本申请的限定。
实施例1
本申请实施例提供一种含有冲压弹片结构的端子，包括安装基座1和外弹片结构2，外弹片结构2的一端与安装基座1的一端连接，安装基座1和外弹片结构2分体成型，外弹片结构2为冲压成型结构，如图1至图3所示。
其中，安装基座1和外弹片结构2先分别加工成型，再组装成一体，最终形成所述含有冲压弹片结构的端子，极大的节省端子成本，降低加工工时，也能够保证弹片与对插端子导电部分充分接触。
在本实施例中，外弹片结构2呈筒形，沿外弹片结构2的周向，外弹片结构2含有的多个(如两个)外弹片段21，外弹片段21的平面展开结构大致呈扇形，外弹片段21的断面呈 弧形。外弹片结构2的厚度为0.035mm-4.712mm，当厚度小于0.035mm时，外弹片结构2的弹性不足，当厚度大于4.712mm时形变难度增加，加工也更困难，不具有实际生产的意义。
发明人选用11组，每组7个含有冲压弹片结构的端子，分别进行外弹片条212的弹力测试。
弹力的测试方法是使用精密测力计，检测单个外弹片条212或外弹性条片22开口位置移动1mm的弹力。根据外弹片条212或外弹性条片22的个数及其厚度，在本实施例中，外弹片条212或外弹性条片22弹力小于3N、大于10N为不合格。因为弹力小，外弹片结构2对与其对插端子的接触应力就会小，导致接触面积减小，接触电阻增大。弹力大，外弹片结构2对与其对插端子插入力增大，对插端子的插拔变得相对困难。
表1：外弹片结构2厚度和数量对外弹片条212弹力的影响
Figure PCTCN2022105970-appb-000001
从上表1中可以看出，通过设定外弹片结构2的厚度和数量，可以获得符合要求的弹力要求的含有冲压弹片结构的端子，但是，当外弹片结构2的厚度小于0.035mm时，无论外弹片结构2的数量为多少，外弹片条212弹力全部不合格，同样，当外弹片结构2的厚度大于4.712mm，无论外弹片结构2的数量为多少，外弹片条212弹力全部不合格。因此发明人选择外弹片结构2的厚度为0.035mm-4.712mm。
在本实施例中，沿外弹片结构2的轴向，每个外弹片段21均含有外连接部211和多个外弹片条212，相邻的两个外弹片条212之间形成外间隔缝213，如图6所示。外弹片条212能够适应对配端端子的加工误差，使外弹片条212与对配端端子结合力更大，保证更多的接触面积，实现更好的电学性能和力学性能，解决了现有端子无法满足力学需求和温升要求的问题。
在本实施例中，如图7，图8所示，外弹片结构2呈筒形，沿外弹片结构2的周向，外弹 片结构2含有的多个独立的外弹性条片22。这样独立的外弹性条片，可以在冲压机或者滚压机上直接加工出来，用料节省，可以使用较小宽度的原材料进行加工。当外弹片结构2在使用过程中受到损坏时，可以不同更换整个端子，只需要更换损坏的外弹片结构2即可，减少端子的浪费，提高维修的效率，能够极大的节省成本。
在其他实施例中，如图9所示。所述多个外弹性条片22通过外环形基带23连接，外环形基带23位于外弹片结构2的一端，外弹性条片22与外环形基带23层叠设置，外环形基带23卷绕后呈环形，即图9中的外弹片结构2卷绕后呈筒形。独立的外弹性条片22虽然有用料节省、损坏时可部分更换的优点，但是当独立的外弹性条片22数量较多时，分别将独立的外弹性条片22固定在基座1上工序复杂，用时较长，反而限制了独立的外弹性条片22的使用。通过设置外环形基带23，可以先将外弹性条片22与外环形基带23进行层叠固定，然后再卷绕后呈筒形与基座1进行固定，能够极大的减少独立的外弹性条片22的安装时间，提高装配的工作效率。
在本实施例中，由于外弹片结构2呈筒形，外弹片结构2含有内部空腔，外弹片结构2的内部空腔呈锥形，即外弹片结构2的一端的内径大于外弹片结构2的另一端的内径，如图4所示。外弹片结构2的内部空腔的内径与对配端端子外径完全一样的话，由于公差配合的原因，两者会出现对配端端子插不进内部空腔内，或者对配端端子与外弹片结构2有大部分接触不到的区域，导致无法实现电气导通，或者接触面积小等情况。因此发明人设置外弹片结构2的内部空腔呈锥形，使对配端端子能够插入到内部空腔内，同时可以使外弹片结构2有更大的变形空间，使外弹片结构2与对配端端子对插后获得更大的抓紧力。
在本实施例中，沿外弹片结构2的一端向外弹片结构2的另一端的方向，外弹片结构2的内表面可以设有外弧形缩颈段24。外弧形缩颈段24的内径小于外弹片结构2的内径，能够使外弧形缩颈段24内表面始终接触对配端端子的外表面，同时，对插后的外弧形缩颈段24内表面与端子轴线的角度，与对配端端子外表面与端子轴线的角度相同，可以使外弧形缩颈段24内表面与对配端端子的外表面形成面接触，增大外弹片结构2与对插端子的接触面积，减小了接触电阻，提高了含有冲压弹片结构的端子的导电性能，增加了用电装置的安全性和稳定性。
为了便于对插端子的进入，外弹片结构2的内表面还可以设有外弧形扩颈段25，即沿外弹片结构2的一端向外弹片结构2的另一端的方向，外弹片结构2的内表面依次设有外弧形缩颈段24和外弧形扩颈段25，如图3和图5所示。由于外弹片结构2的内部空腔一般为锥孔，内部空腔的开口直径要小于对配端端子的直径，因此要在内部空腔开口侧内部设置外弧形扩颈段25，以对对配端端子的插入进行导向，引导对配端端子顺利插入，并且能够胀开外 弹片结构2，插入到外弹片结构2的内部空腔中。
外弧形缩颈段24和外弧形扩颈段25大致呈锥形结构，外弧形缩颈段24的锥度和外弧形扩颈段25的锥度可以相同，如图4所示。或者，外弧形缩颈段24的锥度小于外弧形扩颈段25的锥度，外弧形扩颈段25位于外弹片结构2的另一端，外弧形扩颈段25呈外翻边结构，如图3所示。
在本实施例中，安装基座的一端设有安装凹槽，安装凹槽位于安装基座的一端的外侧、内侧或中部，外弹片结构与安装凹槽匹配对接
在本实施例中，外弹片结构2与安装基座1之间可以采用可拆卸或不可拆卸连接，具体的，外弹片结构2与安装基座1采用压接、螺纹连接、螺钉连接、插销连接、卡扣连接、粘接、焊接和铆接中的一种或多种。
当外弹片结构2与安装基座1采用压接时，安装基座1的一端设有安装凹槽11，安装凹槽11位于安装基座1的一端的外侧(如图5所示)、内侧或中部(如图3所示)，外弹片结构2与安装凹槽11匹配对接。当外弹片结构2与安装基座1采用粘接或焊接时，安装基座1的一端可以不设置安装凹槽11，如图4所示。
具体实施时，外弹片结构2与安装基座1之间可采用压接方式连接或焊接方式连接，外弹片结构2的外连接部211径向结构为圆环结构时，外连接部21与安装基座1相互套接的部位，或外弹片结构2含有的多个独立的外弹性条片22与安装基座1上的安装凹槽插接部位，可采用镀锡压接方式或焊接方式实现不可拆卸连接。
具体实施时，外弹片结构2与安装基座1之间可采用螺纹连接，外弹片结构2的外连接部211径向结构为圆环结构时，外连接部21内壁设置内螺纹套，安装基座1一侧外壁上设置外螺纹，此时，安装基座1为管状空心结构或实心柱体结构。或者，外弹片结构2的外连接部211径向结构为圆环结构时，外连接部21外壁设置外螺纹，安装基座1一侧内壁设置内螺纹，此时，安装基座1为管状空心结构，通过外弹片结构2一侧的内螺纹/外螺纹分别与安装基座1一侧外螺纹/内螺纹相配合实现可拆卸连接。
具体实施时，外弹片结构2与安装基座1之间可采用螺钉连接，螺钉具有螺钉头和螺钉杆，螺钉杆一端为自由端，外弹片结构2的外连接部211径向结构为圆环结构时，外连接部21与安装基座1相互套接的部位设置供螺杆穿设的螺纹孔，螺杆穿设过螺纹孔后，螺母从螺钉杆自由端一侧与螺杆连接，可将外弹片结构2与安装基座1相互套接的部位固定在螺钉头和螺母之间，实现可拆卸连接。具体实施时，外弹片结构2与安装基座1之间可采用螺钉连接，也可为多个螺钉自螺钉杆自由端一侧分别穿设外弹片结构2含有的多个独立的外弹性条片22与安装基座1上的安装凹槽插接部位，此时，通过螺钉与弹性条片22及安装基座1之 间的过盈连接，实现不可拆卸连接
具体实施时，外弹片结构2与安装基座1之间可采用插销连接，插销贯穿外弹片结构2含有的多个独立的外弹性条片22与安装基座1上的安装凹槽插接部位，插销位于安装基座1内侧的一端过盈连接，插销位于安装基座1外侧的一端铆接连接，实现不可拆卸连接。
具体实施时，外弹片结构2与安装基座1之间可采用插销连接，插销贯穿外弹片结构2与安装基座1相互套接的部位，两端露出外弹片结构2与安装基座1相互套接的部位的插销端部可通过铆接实现不可拆卸连接。
具体实施时，外弹片结构2与安装基座1之间可采用导电胶实现外弹片结构2与安装基座1之间的粘接连接，或采用导电胶实现外弹片结构2含有的多个独立的外弹性条片22与安装基座1上的安装凹槽插接部位的粘接连接，此时，可实现外弹片结构2与安装基座1之间的不可拆卸连接且保证端子正常通电。
具体实施时，外弹片结构2与安装基座1之间可采用铆接连接，铆钉贯穿外弹片结构2与安装基座1相互套接的部位，两端露出外弹片结构2与安装基座1相互套接的部位的插销端部可通过铆接实现不可拆卸连接。
具体实施时，外弹片结构2与安装基座1之间可采用铆接连接，铆钉贯穿外弹片结构2含有的多个独立的外弹性条片22与安装基座1上的安装凹槽插接部位，此时安装基座1为管状空心结构时，铆钉可贯穿外弹片结构2含有的多个独立的外弹性条片22与安装基座1上的安装凹槽插接部位，两端露出的铆钉端部可通过铆接实现不可拆卸连接。
以上各种连接方式，可以一种单独使用，也可以几种组合使用，例如，例如采用螺纹连接时，也可同时通过导电胶连接，此时可实现外弹片结构2与安装基座1之间的更稳定的连接。
在本实施例中，安装基座1含有依次连接的电能传输部12和弹片外连接部13，电能传输部12的作用是与导线安装连接，电能传输部12呈平板状结构(或U形结构或优弧状结构或圆筒状结构或圆柱状结构或碗状结构或多边形结构。
在一些实施例中，电能传输部12需要与导线电性连接，一般采用压接或焊接的工艺，因此电能传输部12设计为多种结构，可以根据电性连接的要求，以及用电装置的装配环境，选择不同的电能传输部12结构，并能够与导线建立稳定的电连接。一般情况下，U形结构或优弧状结构或圆筒状结构或多边形结构适用于压接和焊接，平板状结构或碗状结构适用于焊接。
弹片外连接部13的作用一是与外弹片结构2安装连接，另外是与用电装置匹配安装。根据装配需要，弹片外连接部13外设有多个环形凹槽。
下面介绍所述含有冲压弹片结构的端子的制造过程。
1、将安装基座1车削加工成型，将外弹片结构2冲压成型。
2、将安装基座1和外弹片结构2压接组装成一体，如图5所示。
实施例2
本实施例是对实施例1的一种改进，本实施例与实施例1的主要区别，本实施例是在实施例1的基础上增加了内弹片结构3，即所述含有冲压弹片结构的端子还包括内弹片结构3，内弹片结构3与外弹片结构2层叠设置，内弹片结构3的一端与安装基座1连接，或内弹片结构3的一端与外弹片结构2连接，或内弹片结构3的一端与安装基座1和外弹片结构2连接，如图10和图11所示。
由于外弹片结构2一般为冲压成型，受板材厚度的限制，外弹片结构2的厚度不一定能够满足含有冲压弹片结构的端子与对配端端子的抓紧力要求，因此需要在外弹片结构2的内部设置内弹片结构3，用来增强端子对插结构的力学性能。同时，内弹片结构3与外弹片结构2一起与对配端端子电性连接，增大了含有冲压弹片结构的端子与对配端端子的接触面积，降低了端子对插结构的接触电阻，能够更好的导通电流和控制温升，极大的提高了端子对插结构的电学性能。
在本实施例中，内弹片结构3套设于外弹片结构2内，这样既增大了含有冲压弹片结构的端子与对配端端子的接触面积，也不会增大含有冲压弹片结构的端子的体积。安装基座1、外弹片结构2和内弹片结构3均分体成型，内弹片结构3为冲压成型结构。同样的，内弹片结构3也可以使用板材进行冲压成型，能够极大的节省端子的使用材料。另外，在一些实施例中，由于含有冲压弹片结构的端子的结构复杂，一体加工方法成本高，加工工时长，可以将含有冲压弹片结构的端子分成几个部分进行加工，然后将内弹片结构3和外弹片结构2分别与安装基座1进行装配，能够提高工作效率，减少材料的浪费。
在本实施例中，内弹片结构3和外弹片结构2均呈筒形，外弹片结构2的长度大于内弹片结构3的长度。由于内弹片结构3和外弹片结构2都需要与对配端端子电性连接，而内弹片结构3与外弹片结构2是层叠设置，因此就需要外弹片结构2的长度大于内弹片结构3的长度，这样才能使对配端端子同时接触到内弹片结构3与外弹片结构2。
在本实施例中，外弹片结构2的轴线与内弹片结构3的轴线重合，由于外弹片结构2和内弹片结构3是与同一个对配端端子进行插接连接，因此对配端端子的公端会同时插入到外弹片结构2和内弹片结构3的内部空腔中，因此需要外弹片结构2的轴线与内弹片结构3的轴线重合，也是与插接后的对配端端子的轴线重合。外弹片结构2的内部空腔和内弹片结构3的内部空腔均呈锥形，内弹片结构3的内部空腔的内径与对配端端子外径完全一样的话， 由于公差配合的原因，两者会出现对配端端子插不进内弹片结构3的内部空腔内，或者对配端端子与弹片结构3有大部分接触不到的区域，导致无法实现电气导通，或者接触面积小等情况。因此发明人设置外弹片结构2和内弹片结构3的内部空腔呈锥形，使对配端端子能够插入到内部空腔内，同时可以使外弹片结构2和内弹片结构3有更大的变形空间，使外弹片结构2和内弹片结构3与对配端端子对插后获得更大的抓紧力。
在本实施例中，外弹片结构2的内部空腔的锥度小于内弹片结构3的内部空腔的锥度，由于外弹片结构2处于内弹片结构3的外围，因此外弹片结构2的内部空腔的锥度小于内弹片结构3的内部空腔的锥度，这样才能使外弹片结构2和内弹片结构3的前端都能接触到对配端端子，实现电气导通。
在本实施例中，外弹片结构2的构造与内弹片结构3的构造完全相同、部分相同或完全不同，外弹片结构2可以选择实施例1中的多种构造形式，内弹片结构3也可以参照实施例1含有多种构造形式，外弹片结构2和内弹片结构3之间可以根据需要选择组合。
在本实施例中，内弹片结构3呈筒形，沿内弹片结构3的周向，内弹片结构3含有的多个内弹片段31，内弹片段31的断面呈弧形，内弹片结构3的厚度为0.2mm-5mm。
发明人选用11组，每组7个含有冲压弹片结构的端子，分别进行内弹片条312的弹力测试。
弹力的测试方法是使用精密测力计，检测单个内弹片条312或内弹性条片32开口位置移动1mm的弹力。根据内弹片条312或内弹性条片32的个数及其厚度，在本实施例中，内弹片条312或内弹性条片32弹力小于3N、大于10N为不合格。因为弹力小，内弹片结构3对与其对插端子的接触应力就会小，导致接触面积减小，接触电阻增大。弹力大，内弹片结构3对与其对插端子插入力增大，对插端子的插拔变得相对困难。
表2：内弹片结构3的厚度对内弹片条312弹性的影响
Figure PCTCN2022105970-appb-000002
从上表2中可以看出，通过设定内弹片结构3的厚度和数量，可以获得符合要求的弹力要求的含有冲压弹片结构的端子，但是，当内弹片结构3的厚度小于0.2mm时，无论内弹片结构3的数量为多少，内弹片条312弹力全部不合格，同样，当内弹片结构3的厚度大于5mm，无论内弹片结构3的数量为多少，内弹片条312弹力全部不合格。因此发明人选择内弹片结构3的厚度为0.2mm-5mm。
沿内弹片结构3的轴向，内弹片段31含有内连接部311和多个内弹片条312，相邻的两个内弹片条312之间形成内间隔缝313，如图13所示。内弹片条312能够适应对配端端子的加工误差，使内弹片条312对配端端子结合力更大，保证更多的接触面积，实现更好的电学性能和力学性能，解决了现有端子无法满足力学需求和温升要求的问题。
或者，内弹片结构3成筒形，沿内弹片结构3的周向，内弹片结构3含有的多个独立的内弹性条片32。这样独立的内弹性条片，可以在冲压机或者滚压机上直接加工出来，用料节省，可以使用较小宽度的原材料进行加工。当内弹片结构3在使用过程中受到损坏时，可以不同更换整个端子，只需要更换损坏的内弹片结构3即可，减少端子的浪费，提高维修的效率，能够极大的节省成本。
所述多个内弹性条片32通过内环形基带33连接，内弹性条片32与内环形基带33层叠设置，内环形基带33位于内弹片结构3的一端，如图14所示。独立的内弹性条片32虽然有用料节省、损坏时可部分更换的优点，但是当独立的内弹性条片32数量较多时，分别将独立的内弹性条片32固定在基座1上工序复杂，用时较长，反而限制了独立的内弹性条片32的使用。通过设置内环形基带33，可以先将内弹性条片32与内环形基带33进行层叠固定，然后再卷绕后呈筒形与基座1进行固定，能够极大的减少独立的内弹性条片32的安装时间，提高装配的工作效率。
内弹片结构3呈筒形，内弹片结构3的内部空腔呈锥形，内弹片结构3的一端的内径大于内弹片结构3的另一端的内径。内弹片结构3的内部空腔的内径与对配端端子外径完全一样的话，由于公差配合的原因，两者会出现对配端端子插不进内部空腔内，或者对配端端子与内弹片结构3有大部分接触不到的区域，导致无法实现电气导通，或者接触面积小等情况。因此发明人设置内弹片结构3的内部空腔呈锥形，使对配端端子能够插入到内部空腔内，同时可以使内弹片结构3有更大的变形空间，使内弹片结构3与对配端端子对插后获得更大的抓紧力。
在本实施例中，沿内弹片结构3的一端向内弹片结构3的另一端的方向，内弹片结构3的内表面设有内弧形缩颈段34。内弧形缩颈段34的内径小于内弹片结构3的内径，能够使内弧形缩颈段34内表面始终接触对配端端子的外表面，同时，对插后的内弧形缩颈段34内 表面与端子轴线的角度，与对配端端子外表面与端子轴线的角度相同，可以使内弧形缩颈段34内表面与对配端端子的外表面形成面接触，增大内弹片结构3与对插端子的接触面积，减小了接触电阻，提高了含有冲压弹片结构的端子的导电性能，增加了用电装置的安全性和稳定性。
在本实施例中，沿内弹片结构3的一端向内弹片结构3的另一端的方向，内弹片结构3的内表面依次设有内弧形缩颈段34和内弧形扩颈段35，如图12所示。由于内弹片结构3的内部空腔一般为锥孔，内部空腔的开口直径要小于对配端端子的直径，因此要在内部空腔开口侧内部设置内弧形扩颈段35，以对对配端端子的插入进行导向，引导对配端端子顺利插入，并且能够胀开沿内弹片结构3，插入到沿内弹片结构3的内部空腔中。
在本实施例中，安装基座1的一端设有安装凹槽11，安装凹槽11位于安装基座1的一端的外侧、内侧或中部，外弹片结构2与安装凹槽11插接。内弹片结构3和外弹片结构2可以插接于相同或不同的安装凹槽11内。
在本实施例中，内弹片结构3的一端与安装基座1的一端或外弹片结构2的一端连接，连接方式可以采用压接、螺纹连接、螺钉连接、插接连接，插销连接、卡扣连接、粘接、焊接和铆接中的一种或多种。
本实施例中的其余技术特征可以与实施例1中的相同，为了节约篇幅，本实施例不再详细介绍。
以上所述仅为本申请的实施例而已，并不用于限制本申请。对于本领域技术人员来说，本申请可以有各种更改和变化。凡在本申请的精神和原理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权利要求范围之内。

Claims (24)

  1. 一种含有冲压弹片结构的端子，其中，所述含有冲压弹片结构的端子包括安装基座(1)和外弹片结构(2)，外弹片结构(2)的一端与安装基座(1)的一端连接，安装基座(1)和外弹片结构(2)分体成型，外弹片结构(2)为冲压成型结构。
  2. 根据权利要求1所述的含有冲压弹片结构的端子，其中，外弹片结构(2)呈筒形，沿外弹片结构(2)的周向，外弹片结构(2)含有的多个外弹片段(21)，外弹片段(21)的断面呈弧形，外弹片结构(2)的厚度为0.035mm-4.712mm。
  3. 根据权利要求2所述的含有冲压弹片结构的端子，其中，沿外弹片结构(2)的轴向，外弹片段(21)含有外连接部(211)和多个外弹片条(212)，相邻的两个外弹片条(212)之间形成外间隔缝(213)。
  4. 根据权利要求1所述的含有冲压弹片结构的端子，其中，外弹片结构(2)呈筒形，沿外弹片结构(2)的周向，外弹片结构(2)含有的多个独立的外弹性条片(22)。
  5. 根据权利要求4所述的含有冲压弹片结构的端子，其中，多个外弹性条片(22)通过外环形基带(23)连接，外弹性条片(22)与外环形基带(23)层叠设置，外环形基带(23)位于外弹片结构(2)的一端。
  6. 根据权利要求1所述的含有冲压弹片结构的端子，其中，外弹片结构(2)的内部空腔呈锥形，外弹片结构(2)的一端的内径大于外弹片结构(2)的另一端的内径。
  7. 根据权利要求1所述的含有冲压弹片结构的端子，其中，沿外弹片结构(2)的一端向外弹片结构(2)的另一端的方向，外弹片结构(2)的内表面设有外弧形缩颈段(24)。
  8. 根据权利要求1所述的含有冲压弹片结构的端子，其中，沿外弹片结构(2)的一端向外弹片结构(2)的另一端的方向，外弹片结构(2)的内表面依次设有外弧形缩颈段(24)和外弧形扩颈段(25)。
  9. 根据权利要求1所述的含有冲压弹片结构的端子，其中，安装基座(1)的一端设有安装凹槽(11)，安装凹槽(11)位于安装基座(1)的一端的外侧、内侧或中部，外弹片结构(2)与安装凹槽(11)匹配对接。
  10. 根据权利要求1所述的含有冲压弹片结构的端子，其中，外弹片结构(2)与安装基座(1)采用压接、螺纹连接、螺钉连接、插接连接、插销连接、卡扣连接、粘接、焊接和铆接中的一种或多种。
  11. 根据权利要求1所述的含有冲压弹片结构的端子，其中，所述含有冲压弹片结构的端子还包括内弹片结构(3)，内弹片结构(3)与外弹片结构(2)层叠设置，内弹片结构(3)的一端与安装基座(1)和/或外弹片结构(2)连接。
  12. 根据权利要求11所述的含有冲压弹片结构的端子，其中，安装基座(1)、外弹片结构(2)和内弹片结构(3)均分体成型，内弹片结构(3)为冲压成型结构。
  13. 根据权利要求11所述的含有冲压弹片结构的端子，其中，外弹片结构(2)和内弹片结构(3)均呈筒形，内弹片结构(3)套设于外弹片结构(2)内，外弹片结构(2)的长度大于内弹片结构(3)的长度。
  14. 根据权利要求13所述的含有冲压弹片结构的端子，其中，外弹片结构(2)的轴线与内弹片结构(3)的轴线重合，外弹片结构(2)的内部空腔和内弹片结构(3)的内部空腔均呈锥形。
  15. 根据权利要求14所述的含有冲压弹片结构的端子，其中，外弹片结构(2)的内部空腔的锥度小于内弹片结构(3)的内部空腔的锥度。
  16. 根据权利要求11所述的含有冲压弹片结构的端子，其中，内弹片结构(3)呈筒形，沿内弹片结构(3)的周向，内弹片结构(3)含有的多个内弹片段(31)，内弹片段(31)的断面呈弧形，内弹片结构(3)的厚度为0.2mm-5mm。
  17. 根据权利要求16所述的含有冲压弹片结构的端子，其中，沿内弹片结构(3)的轴向，内弹片段(31)含有内连接部(311)和多个内弹片条(312)，相邻的两个内弹片条(312)之间形成内间隔缝(313)。
  18. 根据权利要求11所述的含有冲压弹片结构的端子，其中，内弹片结构(3)呈筒形，沿内弹片结构(3)的周向，内弹片结构(3)含有的多个独立的内弹性条片(32)。
  19. 根据权利要求18所述的含有冲压弹片结构的端子，其中，多个内弹性条片(32)通过内环形基带(33)连接，内弹性条片(32)与内环形基带(33)层叠设置，内环形基带(33)位于内弹片结构(3)的一端。
  20. 根据权利要求11所述的含有冲压弹片结构的端子，其中，内弹片结构(3)呈筒形，内弹片结构(3)的内部空腔呈锥形，内弹片结构(3)的一端的内径大于内弹片结构(3)的另一端的内径。
  21. 根据权利要求11所述的含有冲压弹片结构的端子，其中，沿内弹片结构(3)的一端向内弹片结构(3)的另一端的方向，内弹片结构(3)的内表面设有内弧形缩颈段(34)。
  22. 根据权利要求11所述的含有冲压弹片结构的端子，其中，沿内弹片结构(3)的一端向内弹片结构(3)的另一端的方向，内弹片结构(3)的内表面依次设有内弧形缩颈段(34)和内弧形扩颈段(35)。
  23. 根据权利要求11所述的含有冲压弹片结构的端子，其中，安装基座(1)的一端设有安装凹槽(11)，安装凹槽(11)位于安装基座(1)的一端的外侧、内侧或中部，外弹片 结构(2)与安装凹槽(11)插接。
  24. 根据权利要求11所述的含有冲压弹片结构的端子，其中，内弹片结构(3)的一端与安装基座(1)的一端采用压接、螺纹连接、螺钉连接、插接连接、插销连接、卡扣连接、粘接、焊接和铆接中的一种或多种。
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JP2013161640A (ja) * 2012-02-03 2013-08-19 Hirose Electric Co Ltd 電気コネクタ
CN107112673A (zh) * 2014-10-10 2017-08-29 株式会社藤仓 端子及其制造方法
CN111478079A (zh) * 2020-03-10 2020-07-31 挚行电子(苏州)有限公司 组合式电连接器
CN113410685A (zh) * 2021-07-15 2021-09-17 长春捷翼汽车零部件有限公司 一种含有冲压弹片结构的端子

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2013161640A (ja) * 2012-02-03 2013-08-19 Hirose Electric Co Ltd 電気コネクタ
CN107112673A (zh) * 2014-10-10 2017-08-29 株式会社藤仓 端子及其制造方法
CN111478079A (zh) * 2020-03-10 2020-07-31 挚行电子(苏州)有限公司 组合式电连接器
CN113410685A (zh) * 2021-07-15 2021-09-17 长春捷翼汽车零部件有限公司 一种含有冲压弹片结构的端子

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