WO2023284861A1 - 一种筒式端子、对插连接结构及其加工方法 - Google Patents

一种筒式端子、对插连接结构及其加工方法 Download PDF

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Publication number
WO2023284861A1
WO2023284861A1 PCT/CN2022/106005 CN2022106005W WO2023284861A1 WO 2023284861 A1 WO2023284861 A1 WO 2023284861A1 CN 2022106005 W CN2022106005 W CN 2022106005W WO 2023284861 A1 WO2023284861 A1 WO 2023284861A1
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WO
WIPO (PCT)
Prior art keywords
barrel terminal
section
terminal according
contact
barrel
Prior art date
Application number
PCT/CN2022/106005
Other languages
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 CN202110803204.9A external-priority patent/CN113471733A/zh
Priority claimed from CN202121613435.5U external-priority patent/CN216251220U/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 JP2024501824A priority Critical patent/JP2024525743A/ja
Priority to MX2024000809A priority patent/MX2024000809A/es
Priority to US18/579,387 priority patent/US20240339775A1/en
Priority to EP22841494.2A priority patent/EP4372922A1/en
Publication of WO2023284861A1 publication Critical patent/WO2023284861A1/zh
Priority to ZA2024/00523A priority patent/ZA202400523B/en

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Classifications

    • 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
    • H01R13/04—Pins or blades for co-operation with sockets
    • 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
    • H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
    • 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
    • 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
    • H01R13/405—Securing in non-demountable manner, e.g. moulding, riveting
    • 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
    • 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
    • H01R13/15—Pins, blades or sockets having separate spring member for producing or increasing contact pressure
    • H01R13/18—Pins, blades or sockets having separate spring member for producing or increasing contact pressure with the spring member surrounding the socket
    • 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
    • H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
    • H01R13/521—Sealing between contact members and housing, e.g. sealing insert
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/70—Energy storage systems for electromobility, e.g. batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/7072—Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/10—Technologies relating to charging of electric vehicles
    • Y02T90/14—Plug-in electric vehicles

Definitions

  • the present application relates to the field of electrical connection, and in particular to a barrel terminal, a mating connection structure and a processing method thereof.
  • plug-in terminals In the field of electrical connection, there are many electrical circuits that require plug-in terminals for connection. At present, most of them use male terminals and female terminals for connection, especially on wire harnesses with large currents and large wire diameters. For example, the current development For fast new energy vehicles, the charging gun head and charging stand for charging the battery, the internal terminals are all male terminals and female terminals. Due to the large carrying current, the cross-sectional area of the plug-in terminal is also large. Now the commonly used plug-in terminals are all processed by turning copper rods. The material utilization rate is low, the processing technology is complicated, and the processing time is long. Especially It is the processing of the female terminal, which wastes more copper, and the cost of the charging system cannot be reduced.
  • the application provides a barrel type terminal, a mating connection structure and a processing method thereof, which improves the utilization rate of terminal processing materials, has simple processing technology and short time, and greatly reduces the production cost of the terminal.
  • the embodiment of the first aspect of the present application provides a barrel terminal, including: a contact section, a fixing section and a connecting section,
  • the fixed section includes an extension section and an assembly part arranged on the extension section;
  • the contact section, the extension section and the connection section are integrally formed as a cylindrical tube
  • At least two axial slots are provided on the contact section, so that the side wall of the contact section is divided into at least two pieces of contact elastic pieces;
  • the contact section is sunken radially inward, so that the contact elastic piece forms an arc structure
  • the connecting section is electrically connected with the wire.
  • the embodiment of the second aspect of the present application provides a plug-in connection structure.
  • the plug-in connection structure includes a plug-in terminal and the barrel terminal described in the embodiment of the first aspect.
  • the plug-in terminal is inserted into the contact Inside the segment, the outer sidewall of the pair of plug terminals is in close contact with the inner sidewall of the contact spring.
  • the embodiment of the third aspect of the present application provides a processing method for manufacturing the barrel terminal of the embodiment of the first aspect, including:
  • the mold is divided into an inner mold and an outer mold.
  • the inner mold is provided with an arc-shaped depression and the first groove, and the outer mold is provided with an arc-shaped protrusion and a shear table;
  • the extruder drives the shear table of the outer mold to continue to move, and cooperates with the first groove of the inner mold to extrude the contact section of the cylindrical tube into an axial slot;
  • the extruder drives the outer mold back to the original position, takes out the extruded tubular tube and the inner mold from the outer mold, and takes out the inner mold.
  • the cylindrical terminal of the present application is processed by a cylindrical tube without using rod-shaped materials, which can greatly improve the utilization rate of materials.
  • the cylindrical terminal of this application adopts an extrusion machine or a rolling machine, which can process the depression and groove on the contact section, and the opening of the extension section at one time, without complicated mechanical processing, and reduces the processing time .
  • the assembly part is directly injected on the cylindrical tube without processing on the cylindrical tube material, which can reduce material waste and can process complex assembly shapes.
  • the first groove can be provided in the assembly part, and the sealing ring can be assembled, or the sealing ring can be directly injected into the assembly part, so as to reduce the complexity of the processing technology and reduce the processing man-hours.
  • the contact section can adapt to the processing error of the spigot terminal, so that the combination force between the barrel terminal and the spigot terminal of the application is greater, ensuring more contact area, and realizing Better electrical and mechanical properties;
  • the cross-sectional shape of the inner hole of the contact section is designed into various shapes, which is convenient for designers to select different shapes of cylindrical terminals according to the actual environment of the cylindrical terminal arrangement, and reduces the volume of the plug-in structure. Optimize the contact area and enhance the electrical performance of the barrel terminal;
  • the barrel terminal of this application can be equipped with an elastic kit.
  • the elastic kit can be used to supplement the grip of the barrel terminal and the mating terminal;
  • the barrel terminal of this application adopts tellurium-copper alloy, which makes the terminal have good conductivity and easy processing performance, ensures electrical performance and improves processability, and at the same time, the elasticity of tellurium-copper alloy is also very good;
  • the barrel terminal of this application adopts a coating, which can better increase the anti-corrosion performance.
  • the composite coating is preferably used, which can better improve the firmness of the coating. After multiple plugs and pulls, the coating can still be guaranteed. No shedding and corrosion resistance.
  • Figure 1 is a cross-sectional view of the barrel terminal described in this application.
  • Fig. 2 is a sectional view of the processing opening of the extension section described in the present application.
  • FIG. 3 is a cross-sectional view of another example of the barrel terminal described in the present application.
  • FIG. 4 is a cross-sectional view of another example of the barrel terminal described in the present application.
  • Fig. 5 is a structural schematic diagram of a plug-in connection structure of the present application.
  • Fig. 6 is a structural schematic diagram of another plug-in connection structure of the present application.
  • Fig. 7 is a schematic flow chart of the first embodiment of the processing method of the barrel terminal described in the present application.
  • FIG. 8 is a schematic flow diagram of a second embodiment of the method for processing a barrel terminal described in the present application.
  • FIG. 9 is a schematic flow diagram of a third embodiment of the method for processing a barrel terminal described in the present application.
  • FIG. 10 is a schematic flow diagram of a fourth embodiment of the method for processing a barrel terminal described in the present application.
  • Fig. 11 is a schematic flow chart of the fifth embodiment of the processing method of the barrel terminal described in the present application.
  • Fig. 12 is a schematic flow diagram of the sixth embodiment of the processing method of the barrel terminal described in the present application.
  • Fig. 13 is a schematic flow diagram of the seventh embodiment of the processing method of the barrel terminal described in the present application.
  • Fig. 14 is a schematic flow chart of the eighth embodiment of the processing method of the barrel terminal described in the present application.
  • Fig. 15 is a schematic flowchart of the ninth embodiment of the processing method of the barrel terminal described in the present application.
  • Fig. 16 is a schematic flowchart of the tenth embodiment of the processing method of the barrel terminal described in the present application.
  • Fig. 17 is a schematic flow diagram of a fifteenth embodiment of the processing method of a barrel terminal described in the present application.
  • Fig. 18 is a schematic flowchart of a sixteenth embodiment of the method for processing a barrel terminal described in the present application.
  • connection should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, a direct connection, or an indirect connection through an intermediary.
  • the present application provides a barrel terminal, as shown in FIG. 1 , including: a contact section 10 , a fixing section 20 and a connecting section 30 , wherein the fixing section 20 includes an extension section 201 and an assembly provided on the extension section 201 Section 202.
  • the contact section 10 , the extension section 201 and the connection section 30 are integrally formed of a cylindrical tube. At least two axial slots 102 are provided on the contact section 10 , so that the side wall of the contact section 10 is divided into at least two contact elastic pieces 103 .
  • the contact segment 10 is radially provided with a recess 101 inwardly, so that the contact elastic piece 103 forms an arc structure.
  • the connection section 30 is electrically connected to the wire.
  • the barrel-type terminal of the present application is provided with a contact section 10 , and the inside of the contact section 10 is a cavity with at least one side opening, and is connected with the mating terminal 40 to realize electrical conduction.
  • At least two axial slots 102 are provided on the contact section 10, so that the side wall of the contact section 10 is divided into at least two pieces of contact springs 103, so that the contact section 10 can adapt to the processing error of the socket terminal 40 , the contact springs 103 can be contact-connected to the pair of plug terminals 40 respectively, which can increase the contact area between the contact section 10 and the pair of plug terminals 40, reduce the contact resistance, and avoid the problem caused by the uneven or uneven surface of the pair of plug terminals 40.
  • the contact section 10 is radially provided with a recess 101 inward, so that the contact elastic piece 103 forms an arc structure, so that the contact elastic piece 103 has an elastic force toward the inside, so that the contact section 10 and the mating terminal 40 have a greater bonding force and contact
  • the arc-shaped structure of the shrapnel 103 is deformed with the surface of the mating terminal 40, ensuring more contact area, achieving better electrical and mechanical properties, and solving the problem that the existing barrel terminals cannot meet the requirements of mechanical properties and temperature rise. question.
  • the cylindrical terminal of the present application is provided with a fixed section 20, the fixed section 20 includes an extension section 201 and an assembly part 202 provided on the extension section 201, one end of the extension section 201 is connected to the contact section 10, and the other end is connected to the connection section 30 , and can be electrically connected with the contact segment 10 and the connecting segment 30 .
  • the assembly part 202 can be extruded or rolled by the extension section 201, or the plastic material can be directly injected on the extension section 201 by an injection molding machine, and the assembly part 202 is fixedly connected with the extension section 201.
  • the installation position is assembled and fixed, so that the barrel terminal can be fixed at the corresponding position of the electrical device, and it is convenient to connect with the mating terminal 40 .
  • the barrel-type terminal of the present application is provided with a connecting section 30, which is electrically connected to the wire to realize the transmission of electric energy and signals.
  • the cross-sectional shape of the connecting section 30 is circular, oval, open ring, U-shaped, plate-shaped, polygonal, and different cross-sectional shapes can be selected according to the cross-sectional shape of the paired wire or the corresponding connection method.
  • the connection between the connection section 30 and the wire can be connected by crimping or welding.
  • the crimping is a mechanical deformation method, and pressure is applied to deform the connection section 30 and part of the wires inside it.
  • the inside of the wire and the connection section 30 are fully contact and are held together by friction.
  • Welding methods include ultrasonic welding, resistance welding, arc welding, pressure welding, electromagnetic welding, laser welding and other welding methods.
  • the connection section 30 and some wires are welded together to achieve stable electrical and mechanical properties.
  • the ultrasonic welding method is to use high-frequency vibration waves to transmit to the surfaces of two objects to be welded. Under pressure, the surfaces of the two objects are rubbed against each other to form fusion between molecular layers.
  • the resistance welding method refers to a method that uses a strong current to pass through the contact point between the electrode and the workpiece, and generates heat from the contact resistance to achieve welding.
  • the arc welding method refers to using the arc as a heat source and using the physical phenomenon of air discharge to convert electrical energy into thermal energy and mechanical energy required for welding, so as to achieve the purpose of connecting metals.
  • the main methods are electrode arc welding, submerged arc welding, and gas protection. welding etc.
  • the pressure welding method is a method of applying pressure to the weldment so that the joint surfaces are in close contact to produce a certain plastic deformation to complete the welding.
  • the electromagnetic welding method uses an electromagnetic induction coil to generate a short and very strong current from a pulse generator.
  • the electromagnetic field generated by the induction coil can instantly collide and squeeze the materials to be welded together.
  • Laser welding is an efficient and precise welding method that uses a high-energy-density laser beam as a heat source.
  • the barrel terminal of the present application has a slot 102 on the contact section 10 running through the side of the contact section 10 away from the fixed section 20 , and the end of the contact elastic piece 103 is a free end.
  • Such contact elastic pieces 103 can adapt to the processing error of the spigot terminal 40, and a plurality of contact elastic pieces 103 can be respectively contact-connected with the pair of spigot terminals 40, thereby increasing the contact area between the contact section 10 and the pair of spigot terminals 40, The contact resistance is reduced, and the contact section 10 is not in good contact with the mating terminal 40 due to the uneven or unrounded surface of the mating terminal 40, resulting in excessive temperature rise of the mating structure of the terminals, resulting in a burning accident.
  • the contact elastic piece 103 is a free end at one end, the contact force with the mating terminal 40 is guaranteed by the material elasticity of the contact elastic piece 103 itself.
  • the elastic force is small and it is not easy to recover by itself after deformation.
  • the tolerance of the plug-in terminal 40 is relatively large, and the relative movement after mating is relatively small.
  • the width of the slot 102 on the contact section 10 on the side close to the fixing section 20 is greater than or equal to the width on the side away from the fixing section 20 .
  • the slot 102 on the contact section 10 is on the side away from the fixed section 20, and is generally the position where the contact spring 103 contacts the mating terminal 40. In order to obtain a larger contact area, the slot 102 on the contact section 10 is on the The smaller the width of the side away from the fixing section 20, the better.
  • the positions for discharging sediment and water should be designed on the barrel terminal, so The larger the width of the slot 102 on the contact section 10 near the fixed section 20 is, the better the sediment and drainage performance will be.
  • the assembly part 202 can be directly extruded or rolled out on the extension section 201 without adding other processing methods or
  • the rest of the components are provided with simple processing and can be processed together with the groove and depression 101, saving processing man-hours and improving production efficiency.
  • the assembly part 202 of the cylindrical terminal of the present application when the shape of the fixed section is complicated, or additional parts need to be added for assembly, the processing and molding of the assembly part 202 can be performed by injection molding.
  • the assembly part 202 is made of plastic material.
  • the injection molding process is mature and the processing hours are less.
  • the plastic material has high strength, which can realize stable fixing of the barrel terminal in the electrical device.
  • an opening 206 is provided on the extension section 201 , so that the assembly part 202 formed by injection molding can be integrally formed inside and outside the cylindrical tube.
  • the assembly part 202 is assembled and fixed with the installation position of the electric device, so that the barrel terminal can be fixed at the corresponding position of the electric device, and it is convenient to connect with the mating terminal 40 . If the assembly part 202 and the extension section 201 are not firmly fixed, the barrel terminal will move in the electrical device, resulting in unstable contact between the barrel terminal and the mating terminal 40, and the mating structure cannot achieve better mechanical properties and electrical properties. performance.
  • An opening is provided on the extension section 201, so that when the assembly section 202 is injected, the molten assembly section 202 material enters from the outside of the cylindrical tube along the opening into the interior of the cylindrical tube, so that the assembly section 202 and the extension section 201 can be firmly connected. At the same time, it is ensured that the assembly part 202 will not be separated from the extension section 201 during the use of the mating structure, and the stability of the mating structure is ensured.
  • the cylindrical pipe is a seamless pipe, or a seamed pipe made of plate rolls.
  • the clamping force is mainly provided by the elasticity of the contact spring 103, the requirement for whether the cylindrical tube is closed is not high, so the cylindrical tube can be a seamless tube or a slit tube.
  • the width of the seam of the cylindrical pipe cannot be greater than the width of the groove 102 on the contact section 10, and, in the process of processing, there cannot be a seam on the contact elastic piece 103, and the contact section 10
  • the slot 102 is arranged on the seam of the cylindrical tube, which can ensure the elasticity of the contact spring 103 and make the cylindrical terminal and the mating terminal 40 more stable after being inserted.
  • the inscribed cross-sectional shape of the inner surface of the arc-shaped structure of the contact section 10 is circular or oval or polygonal or flat or E-shaped or F-shaped or H-shaped or K-shaped or L-shaped or T-shaped or U-shape or V-shape or W-shape or X-shape or Y-shape or Z-shape or half arc or arc or wave.
  • the inscribed cross-sectional shape of the inner surface of the arc-shaped structure of the contact section 10 is designed into various shapes, which is convenient for designers to choose different shapes of barrel terminals according to the actual arrangement environment of barrel terminals, reduces the volume of the plug-in structure, and optimizes the contact area , Enhance the electrical performance of the barrel terminal.
  • the inscribed section of the barrel terminal has a variety of shapes, which can match more shapes of mating terminal 40, and can provide designers with more choices.
  • the distance between the inner surface of the arc-shaped structure of the contact section 10 and the axis of the cylindrical terminal is the same.
  • the cross-sectional area of the mating position of the mating terminal 40 is circular, the distance between the contact elastic piece 103 and the mating terminal 40 is consistent, which can ensure that the clamping force of the contacting shrapnel 103 and the mating terminal 40 is basically the same.
  • Make the socket structure obtain stable electrical and mechanical properties and achieve longer service life.
  • the end of the contact section away from the fixing section is provided with an outwardly expanding chamfer, and the angle range of the chamfer is 17°-178°.
  • the opening of the front section is expanded, which is beneficial to guide the insertion of the plug terminal 40.
  • the inventor repeatedly used different angles to test. When the angle of the chamfer is less than 17°, it is difficult to directly insert the plug terminal 40 into the contact section 10, which requires multiple times. Insert to complete the mating. Similarly, when the angle of the chamfer is greater than 178°, the plug terminal 40 is easily pushed inside the chamfer when inserted, and multiple insertions are required to complete the insertion.
  • the inventor selected 10 plug-in terminals with the same diameter and the same expansion-shrinkage joint width for testing, set different chamfer angles respectively, and matched the same pair of plug-in terminals 40, and tested 10,000 times of plug-in and pull-out experiments. Insert the number of times in place, and record the value.
  • Table 1 The test results are shown in Table 1.
  • the barrel terminal of the present application can be made of copper or copper alloy with good electrical conductivity and excellent elastic properties.
  • the material cost of using copper as the barrel terminal will become higher and higher.
  • the content of metal aluminum in the earth's crust is about 7.73%.
  • the price is relatively low.
  • aluminum is lighter in weight and its conductivity is second only to copper.
  • Aluminum can replace part of copper in the field of electrical connections. Therefore, it is also possible to choose aluminum or aluminum alloy with better electrical conductivity and general elastic properties of the material, but at a lower price.
  • the copper material contains tellurium material, so that the terminal has good electrical conductivity and easy cutting performance, ensures electrical performance and improves processability, and at the same time, the elasticity of the tellurium copper alloy is also improved. very good.
  • the tellurium content in the tellurium-copper alloy is 0.1%-5%, and more preferably, the tellurium content in the tellurium-copper alloy is 0.2%-1.2%.
  • the inventor selected 10 plug-in terminals with the same shape and the same expansion and contraction joint width for testing.
  • Each terminal is a tellurium-copper alloy, and the content of tellurium is 0.05%, 0.1%, 0.2%, 1%. 1.2%, 1.8%, 3%, 5%, 6%, 7%.
  • the test results are shown in Table 2.
  • the electrical device where the cylindrical terminal of this application is located works outdoors in many cases, and it is inevitable that water will enter the electrical device.
  • the cylindrical terminal A sealing structure needs to be provided. Since the barrel terminal is assembled with the electric device through the assembly part 202, a first groove 203 needs to be provided on the outer periphery of the assembly part 202, and a sealing ring is installed in the first groove 203, and the sealing ring is connected with the electric device. The internal coordination of the device can effectively seal the electrical device, ensuring that external water will not enter the electrical device.
  • the sealing ring is made of rubber, which has good elasticity. It can be squeezed and deformed after the assembly of the barrel terminal and the electrical device to form a sealing structure to prevent water from entering the electrical device.
  • the rubber material has good water resistance and Oil resistance, which can prolong the service life of the sealing structure.
  • the outer side of the contact section 10 has a second groove 104 arranged in the circumferential direction, the second groove 104 is an annular groove, and at least one elastic sleeve 105 is sleeved on the The second groove 104 is used to fasten the contact section 10 so that the contact spring 103 fits better with the mating terminal 40 .
  • the elastic sleeve 105 can be used to supplement the gripping force of the barrel terminal and the mating terminal 40 .
  • the elastic sleeve 105 can be an elastic rubber body or an open elastic rigid body, which can limit the outward expansion of the contact elastic piece 103 of the barrel terminal and increase the gripping force between the contact elastic piece 103 and the plug terminal 40 .
  • At least part of the plating layer is provided on the contact section 10 and/or the connection end 30, in order to improve corrosion resistance, improve electrical conductivity, increase the number of times of insertion, and better extend the contact section 10 and connection. End 30 service life.
  • the plating layer can adopt methods such as electroplating, chemical plating, magnetron sputtering or vacuum plating.
  • the electroplating method is the process of plating a thin layer of other metals or alloys on some metal surfaces by using the principle of electrolysis.
  • the electroless plating method is a process of metal deposition through a controllable oxidation-reduction reaction under the catalysis of metals.
  • the magnetron sputtering method uses the interaction between the magnetic field and the electric field to make electrons run in a spiral shape near the target surface, thereby increasing the probability of electrons colliding with argon to generate ions.
  • the generated ions hit the target surface under the action of the electric field to sputter out the target material.
  • the vacuum plating method is to deposit various metal and non-metal films on the surface of parts by distillation or sputtering under vacuum conditions.
  • the coating material is one or more combinations of gold, silver, nickel, tin, tin-lead alloy, zinc, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver and silver-gold-zirconium alloy.
  • an active metal copper or aluminum will oxidize with oxygen and water during use, so one or more inert metals are required as the coating to prolong the service life of the barrel terminal.
  • a better wear-resistant metal is also required as a coating, which can greatly increase the service life of the contacts.
  • the contacts need good electrical conductivity.
  • the electrical conductivity and stability of the above metals are better than copper or copper alloy, aluminum or aluminum alloy, which can make the barrel terminal obtain better electrical performance and longer service life. life.
  • the number of plugging and unplugging in Table 3 below is to fix the barrel terminal and the mating terminal 40 on the test bench respectively, and use a mechanical device to simulate plugging and unplugging of the barrel terminal and the mating terminal 40, and every 100 times of plugging If the surface coating of the barrel terminal is scratched and the material of the barrel terminal itself is exposed, the experiment stops and the number of plugging and pulling at that time is recorded. In this embodiment, it is unqualified if the number of times of plugging and unplugging is less than 8000 times.
  • the corrosion resistance time test in Table 3 below is to put the barrel terminal into the salt spray test box, spray salt spray on each position of the barrel terminal, take it out and clean it every 20 hours to observe the surface corrosion, That is, one cycle, until the corrosion area on the surface of the barrel terminal is greater than 10% of the total area, stop the test and record the number of cycles at that time. In this embodiment, the number of cycles less than 80 is considered unqualified.
  • the coating material is gold, silver, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, and silver-gold-zirconium alloy
  • the experimental results exceed the standard value more often, and the performance comparison Stablize.
  • the coating material is gold, silver, nickel, tin, tin-lead alloy, zinc
  • the coating material is gold, silver, nickel, tin, tin-lead alloy, zinc, silver-antimony alloy, One or more combinations of palladium, palladium-nickel alloy, graphite silver, graphene silver and silver-gold-zirconium alloy.
  • Plating includes bottom layer and surface layer.
  • the plating layer adopts the method of multi-layer plating. After the contact segment 10 and the connection end 30 are processed, there are still many gaps and holes under the surface microscopic interface. These gaps and holes are the contact segment 10 and the connection end 30. The biggest cause of wear and corrosion during use, so it is necessary to plate a bottom layer on the surface of the contact section 10 and the connection end 30 to fill the gaps and holes on the surface, so that the surface of the contact section 10 and the connection end 30 is flat and free of holes , and then plate the surface coating, the combination will be stronger and smoother, and the surface of the coating will have no gaps and holes, so that the wear resistance, corrosion resistance and electrical performance of the barrel terminal are better, and the barrel terminal is greatly extended. service life.
  • the underlying material of the coating is one or more combinations of gold, silver, nickel, tin, tin-lead alloy and zinc; the surface material of the coating is gold, silver, nickel, tin, tin-lead alloy, zinc, silver-antimony alloy, One or more combinations of palladium, palladium-nickel alloy, graphite silver, graphene silver and silver-gold-zirconium alloy.
  • the thickness of the bottom layer is 0.01 ⁇ m-15 ⁇ m.
  • the bottom layer has a thickness of 0.1 ⁇ m-9 ⁇ m.
  • the thickness of the surface layer is 0.5 ⁇ m-55 ⁇ m.
  • the thickness of the surface layer is 1 ⁇ m-35 ⁇ m.
  • the temperature rise test in Table 4 below is to apply the same current to the plug-in barrel terminal and to the plug-in terminal 40, and detect the temperature at the same position of the barrel terminal before power-on and after the temperature is stabilized in a closed environment, and Take the difference and take the absolute value. In this embodiment, a temperature rise greater than 50K is considered unqualified.
  • the corrosion resistance time test in Table 4 below is to put the barrel terminal into the salt spray test box, spray salt spray on each position of the barrel terminal, take it out and clean it every 20 hours to observe the surface corrosion, That is, one cycle, until the corrosion area on the surface of the barrel terminal is greater than 10% of the total area, stop the test and record the number of cycles at that time. In this embodiment, the number of cycles less than 80 is considered unqualified.
  • the thickness of the underlying nickel plating layer is greater than 15 ⁇ m, due to the thicker underlying coating, the heat generated by the barrel terminal cannot be dissipated, which makes the temperature rise of the barrel terminal unqualified, and the thicker plating layer is easy to fall off from the surface of the terminal, resulting in corrosion resistance Decreased number of sexual cycles. Therefore, the inventors choose the thickness of the bottom plating layer to be 0.01 ⁇ m-15 ⁇ m. Preferably, the inventors found that when the thickness of the bottom layer coating is 0.1 ⁇ m-9 ⁇ m, the comprehensive effect of the temperature rise and corrosion resistance of the barrel terminal is better. Therefore, in order to further improve the safety, reliability and practicability of the product itself, the bottom layer is preferred.
  • the coating thickness is 0.1 ⁇ m-9 ⁇ m.
  • the experimental method is the same as the above-mentioned experimental method.
  • the thickness of the surface silver plating layer is greater than 55 ⁇ m, due to the thicker bottom layer, the heat generated by the barrel terminal cannot be dissipated, so that the temperature rise of the barrel terminal is unqualified, and the thicker coating is easy to fall off from the surface of the terminal, resulting in corrosion resistance Decreased number of sexual cycles.
  • the surface coating metal is more expensive, the use of a thicker coating does not improve performance, and there is no use value. Therefore, the inventor chooses the thickness of the surface silver plating layer to be 0.1 ⁇ m-55 ⁇ m.
  • the inventors found that when the thickness of the surface coating is 1 ⁇ m-35 ⁇ m, the comprehensive effect of the temperature rise and corrosion resistance of the barrel terminal is better. Therefore, in order to further improve the safety, reliability and practicability of the product itself, the surface coating is preferred.
  • the thickness is 1 ⁇ m-35 ⁇ m.
  • the application provides a cylindrical terminal, which improves the utilization rate of the terminal processing material by using a cylindrical tube as the terminal material and producing the assembly part by injection molding.
  • the processing technology is simple, the time is short, and the production of the terminal is greatly reduced. cost.
  • the barrel terminal can not only achieve effective contact connection, but also effectively reduce the hidden danger of electric shock casualties and equipment damage caused by poor connector structure.
  • the barrel terminal in this embodiment is basically the same as the barrel terminal in Embodiment 1, and the differences are as follows:
  • both ends of the slot 102 on the contact section 10 are closed, and both ends of the contact elastic piece 103 are fixed.
  • Such a contact elastic piece 103 is fixed at both ends, and the clamping force obtained by the deformation of the middle contact elastic piece 103 with the spigot terminal 40 can obtain greater clamping force than the contact elastic piece 103 with one end being a free end.
  • the contact area ensures that the terminal mating structure has better mechanical properties and electrical properties, but because the two ends of the contact shrapnel 103 are fixed, there is no large amount of deformation, and it is suitable for the mating terminal 40. large applications.
  • the side wall of the extension section 201 is configured as a corrugated shape 205 , and the assembly part 202 is formed on the outer periphery of the extension section 201 .
  • the conduction current of the barrel terminal is too large and the cross-sectional area of the terminal is designed without excess, it is not suitable to open the extension section 201 of the barrel terminal, which will reduce the cross-sectional area of the barrel terminal and increase the resistance, resulting in The heat generation of the barrel terminal increases.
  • the side wall of the extension section 201 is provided with a corrugated shape 205, the assembly part 202 is directly injected on the outer periphery of the extension section 201, and the interior of the assembly part 202 matches the corrugated shape 205 of the extension section 201, resulting in The larger contact area prevents axial displacement between the assembly part 202 and the extension section 201, ensuring the stability of the mating structure.
  • the outer periphery of the assembly part 202 is provided with a first groove 203, and then the cylindrical terminal is put into the mold of the injection molding machine, and the sealing ring is continuously injected to make the sealing ring and the assembly part 202 into one, saves the installation process of the sealing ring, improves the possibility of automation of the assembly line, and also prevents the sealing ring from being missed or dropped, and avoids the unqualified sealing of the electrical device due to missing or falling. Since the sealing ring and the assembly part 202 are integrated, the sealing ring will not rub against the assembly position and break away from the first groove 203 when the barrel terminal is installed, ensuring the stability of the seal and prolonging the service life of the electrical device.
  • the barrel terminal in this embodiment is basically the same as the barrel terminal in Embodiment 2, and the differences are as follows:
  • the slot 102 on the contact section 10 is arranged obliquely relative to the axis of the barrel terminal.
  • the contact between the inside of the contact spring 103 and the surface of the mating terminal 40 is a spiral contact, which can obtain a larger contact area and make the contact
  • the contact resistance of the plug structure is reduced to ensure reliable electrical performance.
  • the slot 102 is set obliquely, so that the contact section 10 of the barrel terminal can be shortened under the premise of ensuring the same length of the contact elastic piece 103 and the same elastic force of the contact elastic piece 103, which can save the material used by the terminal, and can also be compressed more
  • the design space of the electric device makes it smaller and lighter, and optimizes the space structure of the electric device.
  • the diameter of the connection section 30 is smaller than or equal to the diameter of the contact section 10 or the extension section 201 .
  • the inner diameter of the cylindrical tube is much larger than the diameter of the conductor connection part.
  • the inner diameter of the connecting section 30 can be reduced to match the size of the connecting section 30 and the conductor connecting part. The cooperation makes the crimping or welding process between the connection section 30 and the conductor connection part easier, and a more stable electrical connection can also be obtained.
  • the present application also provides a plug-in connection structure, which includes a plug-in terminal 40 and the barrel terminal in Embodiment 1.
  • the contact part of the plug-in terminal 40 is inserted into the cavity of the contact section 10 of the barrel terminal. Inside the body, and the outer wall of the socket terminal 40 is in close contact with the inner wall of the cavity of the barrel terminal contact section 10 .
  • the structure, working principle and beneficial effects of the barrel terminal in this embodiment are the same as those in Embodiment 1, and will not be repeated here.
  • an insulating protective cap 401 is provided at the front end of the mating terminal 40 to prevent the surface of the terminal from melting due to discharge at the contact position and the arc temperature being too high when the mating terminal 40 is mated with the barrel terminal, or This results in melting of the consumer or assembly 202 .
  • the front end of the mating terminal 40 is provided with a positioning hole 402 , and a positioning pin 207 is provided in the assembly part 202 of the barrel terminal, and the positioning pin 207 is aligned with the mating terminal 40 .
  • the positioning holes 402 of the locating holes 402 are inserted and connected to each other, so that the longer mating terminal 40 can be positioned in the barrel terminal, so that the front end of the mating terminal 40 will not shake in the contact section 10 of the barrel terminal due to vibration, that is, to prevent shaking
  • the resulting change in contact resistance maintains the current stability of the plug-in connection structure; it can also avoid excessive shaking of the plug-in terminal 40, causing the cables connected to the rear end of the terminal to contact each other to cause a short circuit, reducing short-circuit accidents and electric shock casualties.
  • the present application also provides a processing method for a barrel terminal, including:
  • S10 preparing a cylindrical tube. According to the requirements of material conductivity and elasticity, select the material of the cylindrical tube; according to the outer diameter of the plug terminal 40, select the inner diameter of the cylindrical tube; Selection of wall thickness; according to the installation space position of the barrel terminal, select the length and dimension of the barrel tube.
  • the extrusion die is divided into an inner die and an outer die.
  • the inner die is provided with arc-shaped depressions 101 and grooves
  • the outer die is provided with arc-shaped protrusions and extrusion shearing tables.
  • the size of the inner mold and the outer mold matches the cylindrical tube; the arc-shaped depression 101 on the inner mold cooperates with the arc-shaped protrusion on the outer mold to process the depression 101 on the contact section 10 of the cylindrical terminal; the concave on the inner mold
  • the slot cooperates with the extruding and shearing table on the outer mold to process the slot 102 on the contact section 10 of the barrel terminal.
  • the arc-shaped protrusion of the outer mold moves toward the arc-shaped depression of the inner mold, and extrudes the contact section 10 of the cylindrical tube into an inner depression.
  • the arc-shaped protrusions of the outer mold are arranged in the circumferential direction and are respectively driven by the driving device to move in the axial direction of the barrel terminal until the depression 101 of the contact section 10 is extruded.
  • the extruder drives the extruding and shearing table of the outer mold to continue to move, cooperates with the groove of the inner mold, and extrudes the contact section 10 of the cylindrical copper tube into an axial slot 102 .
  • the extruding and shearing tables of the outer mold are arranged in the circumferential direction and are respectively driven by the driving device to move in the axial direction of the barrel terminal until the slot 102 of the contact section 10 is sheared into shape.
  • the extruder drives the outer mold back to the original position, takes out the extruded tubular tube and the inner mold from the outer mold, and takes out the inner mold.
  • S50 is to use a shearing device to shear or cut an axial slot into the contact section of the cylindrical tube.
  • the present application also provides another method for processing barrel terminals, including:
  • S10 preparing a cylindrical tube. According to the requirements of material conductivity and elasticity, select the material of the cylindrical tube; according to the outer diameter of the plug terminal 40, select the inner diameter of the cylindrical tube; Selection of wall thickness; according to the installation space position of the barrel terminal, select the length and dimension of the barrel tube.
  • the rolling mold is divided into an inner mold and an outer mold, the inner mold is provided with arc-shaped depressions 101 and grooves, and the outer mold is provided with arc-shaped protrusions and shearing platforms.
  • the dimensions of the inner mold and the outer mold match the cylindrical tube; the arc-shaped depressions on the inner mold cooperate with the arc-shaped protrusions on the outer mold to process the depression 101 on the contact section 10 of the cylindrical terminal; the grooves on the inner mold Cooperate with the extruding and shearing table on the outer mold to process the slot 102 on the contact section 10 of the barrel terminal.
  • the arc-shaped protrusions of the outer mold move toward the arc-shaped depressions of the inner mold, and roll the contact section 10 of the cylindrical tube to be depressed inward.
  • the outer mold is divided into an upper mold and a lower mold.
  • the lower mold remains stationary, and the upper mold drives the lower mold as a whole to move closer.
  • the cylindrical tube between the upper and lower molds is rolled to cooperate with the inner mold.
  • the depression 101 on the contact segment 10 is roll formed.
  • the rolling machine drives the shearing table of the outer mold to continue to move, cooperates with the groove of the inner mold, and rolls the contact section 10 of the cylindrical tube into an axial slot 102 .
  • the rolling machine drives the outer mold to return to the original position, takes out the rolled cylindrical tube and the inner mold from the outer mold, and takes out the inner mold.
  • S50 is to use a shearing device to shear or cut an axial slot into the contact section of the cylindrical tube.
  • Embodiment 1 differs from Embodiment 1 in that the processing equipment used is different, and the manufactured barrel terminals are all consistent.
  • the present application also provides another method for processing barrel terminals, including:
  • the processing method of this embodiment is basically the same as that of Embodiment 5 and Embodiment 6, except that after step S40, step S45 is also included, the outer mold moves to the inner mold, and the extension section of the cylindrical tube is extruded into an assembly part.
  • the present application also provides another method for processing barrel terminals, including:
  • the processing method of this embodiment is basically the same as that of the fifth embodiment and the sixth embodiment, except that after the step S50, a step S56 is also included to cut out an opening on the extension section 201, which can be connected with the groove 102 on the contact section 10 Extruded or rolled together to form.
  • the present application also provides another method for processing barrel terminals, including:
  • the processing method of this embodiment is basically the same as that of Embodiment 5 and Embodiment 6, except that after step S50, step S57 is also included, extruding or rolling corrugated 205 on the extension section 201, which can be connected with the contact section 10
  • step S50 step S57 is also included, extruding or rolling corrugated 205 on the extension section 201, which can be connected with the contact section 10
  • the depressions 101 above are extruded or rolled together.
  • the present application also provides another method for processing barrel terminals, including:
  • the processing method of this embodiment is basically the same as that of Embodiment 5 and Embodiment 6, except that after step S50, step S70 is also included, putting the extruded or rolled cylindrical tube into the injection molding machine, and injection molding into assembly department.
  • the present application also provides another method for processing barrel terminals, including:
  • step S58 is also included to extrude or roll out a second groove 104 on the contact section 10, which can be in contact with The depressions 101 on the segments 10 are co-extruded or rolled.
  • the present application also provides another method for processing barrel terminals, including:
  • step S50 step S59 is also included to extrude or roll the connecting section 30 until the diameter is reduced so that it can be connected to the contact section 10
  • step S59 is also included to extrude or roll the connecting section 30 until the diameter is reduced so that it can be connected to the contact section 10
  • the depressions 101 are extruded or rolled together.
  • the present application also provides another method for processing barrel terminals, including:
  • the processing method of this embodiment is basically the same as that of Embodiment 5 and Embodiment 6, except that after step S60, a step S66 is further included to provide a plating layer on at least the contact segment 10 and/or the connection segment 30 .
  • the present application also provides another method for processing barrel terminals, including:
  • the processing method of this embodiment is basically the same as that of Embodiment 5 and Embodiment 6, except that after Step S60, a step S80 is included: putting the injection-molded barrel terminal into an injection molding machine, and injection-molding a sealing ring.
  • the present application also provides another method for processing barrel terminals, including:
  • the processing method of this embodiment is basically the same as that of Embodiment 5 and Embodiment 6, except that step S90 is further included after step S60: assembling a sealing ring in the first groove 203 .
  • the present application also provides another method for processing barrel terminals, including:
  • the processing method of this embodiment is basically the same as that of the fifth and sixth embodiments, except that after the step S70, a step S100 is further included: assembling the elastic sleeve 105 in the second groove 104 .

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  • Manufacturing & Machinery (AREA)
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  • Manufacturing Of Electrical Connectors (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Abstract

一种筒式端子，筒式端子包括接触段（10）、固定段（20）和连接段（30），其中固定段（20）包括延伸段（201）和注塑在延伸段（201）上的装配部（202）。接触段（10）、延伸段（201）和连接段（30）为筒状管一体成型。在接触段（10）上设置至少两个轴向的开槽（102），使接触段（10）侧壁分割为至少两片的接触弹片（103）。接触段（10）径向向内部设置凹陷（101），使接触弹片（103）形成弧形结构。对插连接结构包括对插端端子（40）和筒式端子。还公开了一种筒式端子的加工方法。

Description

一种筒式端子、对插连接结构及其加工方法
相关申请
本申请要求于2021年7月15日递交的申请号为202110803204.9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202121613435.5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
本申请涉及电气连接领域，尤其涉及一种筒式端子、对插连接结构及其加工方法。
背景技术
在电气连接领域，有很多电气回路都需要接插端子进行连接，目前大多数使用的都是公端子与母端子对插实现连接，尤其是在大电流、大线径的线束上，例如目前发展迅速的新能源汽车，为电池进行充电的充电枪头和充电座，内部的端子都是公端子与母端子对插的结构。由于承载电流较大，因此需要接插端子的截面积也很大，现在常用的接插端子，都是使用铜棒进行车削加工出来的，材料利用率低，加工工艺复杂，加工时间长，尤其是母端子的加工，浪费的铜材更多，充电系统的成本无法下降。
另外，为了实现端子在用电装置上进行装配及密封，在端子电气功能区域之外，还需要设置装配区和密封区，同样需要进行复杂的加工流程，并且会损失一部分原材料，使材料利用率更低。
因此，现有技术中亟需一种新的方案来解决上述问题。
发明内容
本申请提供了一种筒式端子、对插连接结构及其加工方法，提高端子加工材料的利用率，加工工艺简单，时间短，极大的降低了端子的生产成本。
本申请提供的技术方案为：
本申请第一方面的实施例提供一种筒式端子，包括：接触段、固定段和连接段，
其中所述固定段包括延伸段和设置在所述延伸段上的装配部；
所述接触段、所述延伸段和所述连接段为筒状管一体成型；
在所述接触段上设置至少两个轴向的开槽，使所述接触段侧壁分割为至少两片的接触弹片；
所述接触段径向向内部凹陷，使所述接触弹片形成弧形结构；
所述连接段与导线电性连接。
本申请第二方面的实施例提供一种对插连接结构，所述对插连接结构包括对插端端子和第一方面实施例所述的筒式端子，所述对插端端子插入所述接触段内部，所述对插端端子的外侧壁与所述接触弹片的内侧壁紧密贴合。
本申请第三方面的实施例提供一种用于制造第一方面实施例的筒式端子的加工方法，包括：
S10、制备筒状管；
S20、准备挤压机和模具，模具分为内模和外模，内模上设置弧形凹陷和第一凹槽，外模上设置弧形凸起和剪切台；
S30、将内模放置在筒状管中，然后一起放入外模中；
S40、启动挤压机，外模的弧形凸起向内模的弧形凹陷移动，将筒状管的接触段挤压为向内部凹陷；
S50、挤压机驱动外模的剪切台继续移动，与内模的第一凹槽配合，将筒状管的接触段挤压成轴向的开槽；
S60、挤压机驱动外模退回原位，将挤压后的筒状管和内模从外模中取出，并取出内模。
本申请可以带来如下有益效果：
1、本申请的筒式端子，采用筒状管加工，不使用棒状材料，能够极大的提高材料利用率。
2、本申请的筒式端子，采用挤压机或滚压机，能够将接触段上凹陷和开槽，以及延伸段的开孔一次性加工出来，不需要复杂的机械加工过程，降低加工工时。
3、本申请的筒式端子，在筒状管上直接注塑装配部，不需要在筒状管材料上加工，能够降低材料的废料，并且能够加工复杂的装配形状。
4、本申请的筒式端子，可以在装配部设置第一凹槽，装配密封环，或者直接在装配部注塑密封环，降低加工工艺的复杂程度，减少加工工时。
5、本申请通过设置具有弹性的接触弹片，使接触段能够适应对插端端子的加工误差，使本申请的筒式端子与对插端端子结合力更大，保证更多的接触面积，实现更好的电学性能和力学性能；
6、本申请的筒式端子，接触段的内孔截面形状设计成各种形状，方便设计人员根据实际筒式端子布置的环境，选择不同形状的筒式端子，减小插接结构的体积，优化接触面积，增强筒式端子的电学性能；
7、本申请的筒式端子，可以设置弹性套件，当筒式端子本身因设计原因弹性不足时，可以使用弹性套件补充筒式端子与对插端端子的抓紧力；
8、本申请的筒式端子，采用了碲铜合金，使端子具有良好的导电性和易加工性能，保证电学性能也能提高加工性，同时，碲铜合金的弹性也很优良；
9、本申请的筒式端子，采用了镀层，能够更好的增加防腐性能，优选的采用复合镀层，能够更好的提高镀层的牢固度，在多次的插拔后，依然能够保证镀层的不脱落和耐腐蚀性。
附图说明
图1为本申请所述的筒式端子剖面图；
图2为本申请所述的延伸段加工开口的剖面图；
图3为本申请所述的筒式端子的另一种示例的剖面图；
图4为本申请所述的筒式端子的再一种示例的剖面图；
图5为本申请一种对插连接结构的结构示意图；
图6为本申请另一种对插连接结构的结构示意图；
图7为本申请所述的筒式端子的加工方法的第一种实施例的流程示意图；
图8为本申请所述的筒式端子的加工方法的第二种实施例的流程示意图；
图9为本申请所述的筒式端子的加工方法的第三种实施例的流程示意图；
图10为本申请所述的筒式端子的加工方法的第四种实施例的流程示意图；
图11是本申请所述的筒式端子的加工方法的第五种实施例的流程示意图；
图12是本申请所述的筒式端子的加工方法的第六种实施例的流程示意图；
图13是本申请所述的筒式端子的加工方法的第七种实施例的流程示意图；
图14是本申请所述的筒式端子的加工方法的第八种实施例的流程示意图；
图15是本申请所述的筒式端子的加工方法的第九种实施例的流程示意图；
图16是本申请所述的筒式端子的加工方法的第十种实施例的流程示意图；
图17是本申请所述的筒式端子的加工方法的第十五种实施例的流程示意图；
图18是本申请所述的筒式端子的加工方法的第十六种实施例的流程示意图。
具体实施方式
下面对本申请做进一步的详细说明，以令本领域技术人员参照说明书文字能够据以实施。为了对本申请的技术特征、目的和效果有更加清楚的理解，现对照附图说明本申请的具体实施方式。其中，术语“第一”、“第二”等仅用于描述目的，而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量，由此，限定有“第一”、“第二”等的特征可以明示或者隐含地包括一个或者更多个该特征。在本申请的描述中，除非另有说明，“多个”的含义是两个或两个以上。在本申请的描述中，除非另有说明，术语“连接”应做广义理解，例如，可以是固定连接，可以是可拆卸连接，可以是直接连接，可以是通过中间媒介间接连接，对于本领域的普通技术人员而言，可以根据具体情况理解上述术语在本专利中的具体含义。
实施方式一
本申请提供一种筒式端子，如图1所示，包括：接触段10、固定段20和连接段30，其中所述固定段20包括延伸段201和设置在所述延伸段201上的装配部202。所述接触段10、延伸段201和连接段30为筒状管一体成型。在所述接触段10上设置至少两个轴向的开槽102，使所述接触段10侧壁分割为至少两片的接触弹片103。所述接触段10径向向内部设置凹陷101，使所述接触弹片103形成弧形结构。所述连接段30与导线电性连接。
本申请的筒式端子，设置接触段10，接触段10内部是至少单侧开口的空腔，是与对插端端子40进行对插连接，实现电气导通。在所述接触段10上设置至少两个轴向的开槽102，使所述接触段10侧壁分割为至少两片的接触弹片103，使接触段10能够适应对插端端子40的加工误差，接触弹片103能够分别与对插端端子40进行接触式连接，能够增大接触段10与对插端端子40的接触面积，减小接触电阻，避免由于对插端端子40表面不平整或者不圆整，导致接触段10与对插端端子40接触不良，造成端子对插结构升温过大导致燃烧事故。所述接触段10径向向内部设置凹陷101，使所述接触弹片103形成弧形结构，使接触弹片103有向着内部的弹力，使接触段10与对插端端子40结合力更大，接触弹片103的弧形结构随着对插端端子40表面变形，保证更多的接触面积，实现更好的电学性能和力学性能，解决了现有筒式端子无法满足力学性能需求和温升要求的问题。
本申请的筒式端子，设置固定段20，固定段20包括延伸段201和设置在所述延伸段201上的装配部202，延伸段201一端与接触段10连接，另一端与连接段30连接，并且与接触段10和连接段30都能电性连接。装配部202可以由延伸段201挤压或滚压成型，也可以通过注塑机直接将塑料材质注塑在延伸段201上，装配部202与延伸段201固定连接，装配部202是与用电装置的安装位置进行装配固定，使筒式端子能够固定在用电装置的相应位置，方便与对插端端子40进行连接。
本申请的筒式端子，设置连接段30，连接段30与导线进行电性连接，实现电能和信号的传递。连接段30截面形状为圆形、椭圆形、开口环形、U型、平板形、多边形，可以根据对配导线的截面形状或者对应的连接方式，选择不同的截面形状。连接段30与导线的连接，可以采用压接或焊接的方式 进行连接，压接是采用机械变形的方式，施加压力使连接段30和其内部的部分导线一起变形，导线和连接段30内部充分接触并依靠摩擦力连接在一起。焊接的方式包括超声波焊接、电阻焊接、弧焊、压力焊接、电磁焊接、激光焊接等焊接方式，将连接段30和部分导线焊接在一起，实现稳定的电学性能和力学性能。
超声波焊接方式，是利用高频振动波传递到两个需焊接的物体表面，在加压的情况下，使两个物体表面相互摩擦而形成分子层之间的熔合。
电阻焊接方式，是指一种利用强大电流通过电极和工件间的接触点，由接触电阻产生热量而实现焊接的一种方法。
弧焊方式，是指以电弧作为热源，利用空气放电的物理现象，将电能转换为焊接所需的热能和机械能，从而达到连接金属的目的，主要方法有焊条电弧焊、埋弧焊、气体保护焊等。
压力焊接方式，是对焊件施加压力，使接合面紧密地接触产生一定的塑性变形而完成焊接的方法。
电磁焊接方式，是运用电磁感应圈，从一个脉冲发生器中产生出短暂而非常强的电流，感应圈产生出的电磁场，可以瞬间将待焊接材料碰撞并挤压在一起。
激光焊接方式，是利用高能量密度的激光束作为热源的一种高效精密焊接方法。
本申请的筒式端子，如图1所示，接触段10上的开槽102贯穿接触段10远离固定段20的一侧，接触弹片103一端为自由端。这样的接触弹片103能够适应对插端端子40的加工误差，多个接触弹片103能够分别与对插端端子40进行接触式连接，能够增大接触段10与对插端端子40的接触面积，减小接触电阻，避免由于对插端端子40表面不平整或者不圆整，导致接触段10与对插端端子40接触不良，造成端子对插结构升温过大导致燃烧事故。由于接触弹片103为一端自由端，与对插端端子40的接触力是靠接触弹片103本身的材料弹性保证，弹力较小并且变形后不容易靠自身恢复，适用于导通电流较小，对插端端子40公差较大，对插后相对活动量较小的应用场合。
本申请的筒式端子，接触段10上的开槽102在靠近所述固定段20一侧的宽度，大于或等于在远离所述固定段20一侧的宽度。接触段10上的开槽102在远离所述固定段20一侧，一般是接触弹片103和对插端端子40接触的位置，为了获得更大的接触面积，接触段10上的开槽102在远离所述固定段20一侧的宽度越小越好。另外，由于接触段10的腔体在使用过程中会进入水和泥沙，为了使插接结构的性能更好，使用寿命更长，筒式端子上要设计排泥沙和排水的位置，因此接触段10上的开槽102在靠近所述固定段20一侧的宽度越大越具有良好的排泥沙和排水性能。
本申请的筒式端子，在固定段的形状要求不太复杂的实施例中，可以在延伸段201上，直接挤压或滚压出装配部202，不需要增加其他的加工方法，也不需要提供其余的部件，加工简单，可以与开槽和凹陷101一同加工出来，节省加工工时，提高生产效率。
本申请的筒式端子的装配部202，当固定段的形状要求复杂，或者需要添加额外部件才能进行装配的情况，可以通过注塑的方式进行装配部202的加工和成型，一般情况下，此时装配部202的材质为塑料材质。注塑加工工艺成熟、加工工时较少。并且塑料材质强度较高，能够实现稳固的将筒式端子固定在用电装置中。
本申请的筒式端子，如图2所示，在延伸段201上设置开孔206，能够使通过注塑成型的所述装配部202在筒状管内部和筒状管外部形成一体。装配部202是与用电装置的安装位置进行装配固定，使筒式端子能够固定在用电装置的相应位置，方便与对插端端子40进行连接。如果装配部202与延伸段201固定不稳固，会使筒式端子在用电装置内活动，导致筒式端子与对插端端子40接触不稳定，对插结构无法实现较好的力学性能和电学性能。在延伸段201上设置开口，可以在注塑装配部202的时 候，熔融的装配部202材料从筒状管外部，沿开口进入筒状管内部，使装配部202与延伸段201能够稳固的连接在一起，保证对插结构在使用过程中，不会发生装配部202与延伸段201脱离的情况，保证对插结构的稳定性。
本申请的筒式端子，所述筒状管为无缝管，或者由板材卷制成的有缝管。加工本申请的筒式端子，由于夹紧力主要是靠接触弹片103的弹性提供，对筒状管是否封闭要求不高，因此筒状管可以是无缝管，也可以是有缝管。
当筒状管为有缝管时，筒状管的接缝的宽度不能大于接触段10上开槽102的宽度，并且，在加工过程中，接触弹片103上不能存在接缝，接触段10上的开槽102设置在筒状管的接缝上，能够保证接触弹片103的弹性，使筒式端子与对插端端子40插接后更加稳固。
本申请的筒式端子，接触段10弧形结构内表面的内接截面形状为圆形或椭圆形或多边形或扁平形或E形或F形或H形或K形或L形或T形或U形或V形或W形或X形或Y形或Z形或半弧形或弧形或波浪形。接触段10弧形结构内表面的内接截面形状设计成各种形状，方便设计人员根据实际筒式端子布置的环境，选择不同形状的筒式端子，减小插接结构的体积，优化接触面积，增强筒式端子的电学性能。并且，筒式端子的内接截面形状多样，可以匹配更多形状的对插端端子40，能够为设计人员提供更多的选择。
本申请的筒式端子，接触段10弧形结构内表面相对于筒式端子的轴线距离相同。当对插端端子40的对插位置的截面积为圆形时，接触弹片103与对插端端子40接触的距离一致，能够保证接触弹片103与对插端端子40的夹紧力基本一致，使接插结构获得稳定的电学性能和力学性能，实现更长的使用寿命。
在一些实施例中，接触段远离固定段的一端，设置向外扩张的倒角，倒角的角度范围为17°-178°。前段扩张开口，有利于对插端端子40导向插入，发明人通过反复采用不同角度进行测试，当倒角的角度小于17°时，对插端端子40很难直接插入接触段10，需要多次插入才能完成插接。同样，当倒角的角度大于178°后，对插端端子40插入时极易顶在倒角内侧，也需要多次插入才能完成插接。
发明人选用了10个相同直径、相同胀缩缝宽度的插接端子进行测试，分别设置不同的倒角角度，并匹配相同的对插端端子40，测试1万次插拔实验，观察没有对插到位的次数，并记录数值，测试结果如表1所示。
在本实施例中，对插不到位的次数，小于5次为理想值。
表1：不同倒角角度对对插连接结构对插不到位次数的影响
Figure PCTCN2022106005-appb-000001
从表1可知，当接触段上的倒角角度小于17°，和大于178°时，对插端端子40插入到插接端子内的对插不到位次数，都超过理想值，并不能保证对插连接结构的工作稳定性，并且对插不到位的情况，也会对端子造成损害，极大的降低了对插连接结构的使用寿命，严重时会造成端子损坏，对插连接结构温升过高导致用电装置烧毁，造成人员电击伤亡的事故。因此，发明人将接触段的倒角的角度范围设定为17°～178°。
本申请的筒式端子，材质可以选择导电性能好，材料的弹性性能优良的铜或铜合金，但是，随着铜价日益上涨，使用铜材作为筒式端子的材料成本会越来越高。金属铝在地壳中的含量约为7.73％， 提炼技术优化后，价格相对较低，并且相对于铜，铝的重量较轻，导电率仅次于铜，铝在电气连接领域可以替代部分铜。因此也可以选择导电性能较好，材料的弹性性能一般，但价格更低的铝或铝合金。
当筒式端子的材料选择铜合金时，优选的，铜材质中含有碲材质，使端子具有良好的导电性和易切削性能，保证电学性能也能提高加工性，同时，碲铜合金的弹性也很优良。
优选的，碲铜合金中，碲的含量为0.1％-5％，进一步优选的，碲铜合金中，碲的含量为0.2％-1.2％。
发明人选用了10个相同形状、相同胀缩缝宽度的插接端子进行测试，每个端子均为碲铜合金，其中碲的含量占比分别为0.05％、0.1％、0.2％、1％、1.2％、1.8％、3％、5％、6％、7％。测试结果如表2所示。
表2：不同碲含量的碲铜合金对导电率的影响
碲含量 0.05％ 0.1％ 0.2％ 1％ 1.2％ 1.8％ 3％ 5％ 6％ 7％
导电率 93.8％ 95.2％ 97.5％ 97.1％ 98.3％ 96.8％ 96.6％ 94.8％ 93.9％ 92％
由表2可知，当碲的含量占比小于0.1％时或者大于5％时，导电率明显下降，不能满足实际需求。当碲的含量占比大于等于0.2％且小于等于1.2％时，导电性能最好，因此发明人选用碲的含量为0.1％-5％的碲铜合金。在最理想的情况下选用含量为0.2％-1.2％的碲铜合金。
本申请的筒式端子所在的用电装置，很多情况都在室外工作，难免会有水进入到用电装置中，为了保证电气连接的安全性，以及用电装置的使用寿命，筒式端子上需要设置密封结构。由于筒式端子是通过装配部202与用电装置装配在一起的，因此需要在装配部202外周设置有第一凹槽203，并在第一凹槽203内装配密封环，密封环与用电装置的内部配合，能够有效对用电装置进行密封，保证外界的水不会进入到用电装置内部。密封环材质为橡胶材质，具有良好的弹性，可以在筒式端子与用电装置装配后挤压变形，形成密封结构，阻止水进入到用电装置中，并且橡胶材质有很好的耐水性和耐油性，能够延长密封结构的使用寿命。
本申请的筒式端子，如图1和图3所示，接触段10的外侧具有沿周向设置的第二凹槽104，第二凹槽104为环形槽，至少一个弹性套件105套设在第二凹槽104上，用于紧固接触段10，使接触弹片103与对插端端子40的贴合性更好。需要说明的是，当筒式端子由于使用环境的原因，壁厚设计过薄，或者开口数量较多，或者与对插端端子40直径差距较大时，接触弹片103与对插端端子40的抓紧力会不足，会导致筒式端子与对插端端子40的接触面积减小，电学性能变差。当筒式端子本身因设计原因弹性不足时，可以使用弹性套件105补充筒式端子与对插端端子40的抓紧力。弹性套件105可以是弹性橡胶体，也可以是开口的弹性刚体，可以限制筒式端子的接触弹片103继续向外扩展，增大接触弹片103与对插端端子40的抓紧力。
本申请的筒式端子，在接触段10和/或连接端30上至少部分设置镀层，是为了提高的耐腐蚀性，提高导电性能，增加接插次数，能够更好的延长接触段10和连接端30的使用寿命。
镀层可采用电镀、化学镀、磁控溅射或者真空镀等方法。
电镀方法，就是利用电解原理在某些金属表面上镀上一薄层其它金属或合金的过程。
化学镀方法，是在金属的催化作用下，通过可控制的氧化还原反应产生金属的沉积过程。
磁控溅射方法，是利用磁场与电场交互作用，使电子在靶表面附近成螺旋状运行，从而增大电子撞击氩气产生离子的概率。所产生的离子在电场作用下撞向靶面从而溅射出靶材。
真空镀方法，是采用在真空条件下，通过蒸馏或溅射等方式在零件表面沉积各种金属和非金属薄膜。
镀层材质为金、银、镍、锡、锡铅合金、锌、银锑合金、钯、钯镍合金、石墨银、石墨烯银和银 金锆合金中的一种或多种组合。铜或铝作为一种活泼金属，在使用过程中会与氧气和水发生氧化反应，因此需要一种或几种不活泼金属作为镀层，延长筒式端子的使用寿命。另外，对于需要经常插拔的金属触点，也是需要较好的耐磨金属作为镀层，能够极大的增加触点的使用寿命。还有触点需要很好的导电性能，上述金属的导电性和稳定性，都要优于铜或铜合金、铝或铝合金，能够使筒式端子获得更好的电学性能和更长的使用寿命。
为了论证不同镀层材质对筒式端子整体性能的影响，发明人使用相同规格、材质，采用不同镀层材料的筒式端子样件，利用同种规格的对插端端子40做一系列插拔次数和耐腐蚀性时间测试。实验结果如下表3所示。
下表3中的插拔次数是将筒式端子和对插端端子40分别固定在实验台上，采用机械装置使筒式端子和对插端端子40模拟插拔，并且每经过100次的插拔，就要停下来观察筒式端子表面镀层破坏的情况，筒式端子表面镀层出现划伤，并露出筒式端子本身材质，则实验停止，记录当时的插拔次数。在本实施例中，插拔次数小于8000次为不合格。
下表3中的耐腐蚀性时间测试，是将筒式端子放入到盐雾喷淋试验箱内，对筒式端子的各个位置喷淋盐雾，每隔20小时取出清洗观察表面腐蚀情况，即为一个周期，直到筒式端子表面腐蚀面积大于总面积的10％的时候，停止测试，并记录当时的周期数。在本实施例中，周期数小于80次认为不合格。
表3：不同镀层材质对筒式端子插拔次数和耐腐蚀性的影响
Figure PCTCN2022106005-appb-000002
从上表3可以看出，当选用镀层材质为金、银、银锑合金、钯、钯镍合金、石墨银、石墨烯银和银金锆合金时，实验结果超过标准值较多，性能比较稳定。当选用镀层材质为镍、锡、锡铅合金、锌时，实验结果也是能够符合要求的，因此，发明人选择镀层材质为金、银、镍、锡、锡铅合金、锌、银锑合金、钯、钯镍合金、石墨银、石墨烯银和银金锆合金中的一种或多种组合。
镀层包括底层和表层。
在一些实施例中，镀层采用多层镀的方法，接触段10和连接端30在加工后，其实表面微观界面下，还是存在很多缝隙和孔洞，这些缝隙和孔洞是接触段10和连接端30在使用过程中磨损和腐蚀的最大原因，因此需要在接触段10和连接端30的表面，先镀一层底层，填补表面的缝隙和孔洞，使接触段10和连接端30的表面平整无孔洞，然后再镀表层镀层，就会结合更加牢固，也会更加平整，镀层表面无缝隙和孔洞，使筒式端子的耐磨性能、抗腐蚀性能、电学性能更优，极大的延长筒式端子的使用寿命。
镀层的底层材质为金、银、镍、锡、锡铅合金和锌中的一种或多种组合；镀层的表层材质为金、银、镍、锡、锡铅合金、锌、银锑合金、钯、钯镍合金、石墨银、石墨烯银和银金锆合金中的一种或多种组合。
在另一实施例中，所述底层厚度为0.01μm-15μm。优选的，所述底层厚度为0.1μm-9μm。
在另一实施例中，表层厚度为0.5μm-55μm。优选的是，表层厚度为1μm-35μm。
为了论证底层镀层厚度变化对筒式端子整体性能的影响，发明人使用相同规格、材质，采用不同镀镍底层厚度，相同的镀银表层厚度的筒式端子样件，利用同种规格的对插端端子40做一系列温升和耐腐蚀性时间测试，实验结果如下表4所示。
下表4中的温升测试是将对插后的筒式端子和对插端端子40通相同的电流，在封闭的环境下检测通电前和温度稳定后的筒式端子相同位置的温度，并做差取绝对值。在本实施例中，温升大于50K认为不合格。
下表4中的耐腐蚀性时间测试，是将筒式端子放入到盐雾喷淋试验箱内，对筒式端子的各个位置喷淋盐雾，每隔20小时取出清洗观察表面腐蚀情况，即为一个周期，直到筒式端子表面腐蚀面积大于总面积的10％的时候，停止测试，并记录当时的周期数。在本实施例中，周期数小于80次认为不合格。
表4：不同底层镀层厚度对筒式端子温升和耐腐蚀性的影响
Figure PCTCN2022106005-appb-000003
从上表4可以看出，当底层镀镍层厚度小于0.01μm时，筒式端子的温升虽然合格，但是由于镀层太薄，筒式端子的耐腐蚀性周期数小于80，不符合筒式端子的性能要求。对接插件的整体性能和寿命都有很大的影响，严重时造成产品寿命骤减甚至失效发生燃烧事故。当底层镀镍层厚度大于15μm时，由于底层镀层较厚，筒式端子产生的热量散发不出来，使筒式端子的温升不合格，而且镀层较厚反而容易从端子表面脱落，造成耐腐蚀性周期数下降。因此，发明人选择底层镀层厚度为0.01μm-15μm。优选的，发明人发现底层镀层厚度为0.1μm-9μm时，筒式端子的温升及耐腐蚀性的综合效果更好，因此，为了进一步提高产品本身的安全性可靠性及实用性，优选底层镀层厚度为0.1μm-9μm。
为了论证表层镀层厚度变化对筒式端子整体性能的影响，发明人使用相同规格、材质，采用相同镀镍底层厚度，不同的镀银表层厚度的筒式端子样件，利用同种规格的对配接插件做一系列温升和耐腐蚀性时间测试，实验结果如下表5所示。
实验方法与上述实验方法相同。
表5：不同表层镀层厚度对温升和耐腐蚀性的影响
Figure PCTCN2022106005-appb-000004
从上表5可以看出，当表层镀银层厚度小于0.5μm时，筒式端子的温升虽然合格，但是由于镀层太薄，筒式端子的耐腐蚀性周期数小于80，不符合筒式端子的性能要求。对插结构的整体性能和寿命 都有很大的影响，严重时造成产品寿命骤减甚至失效发生燃烧事故。当表层镀银层厚度大于55μm时，由于底层镀层较厚，筒式端子产生的热量散发不出来，使筒式端子的温升不合格，而且镀层较厚反而容易从端子表面脱落，造成耐腐蚀性周期数下降。并且，由于表层镀层金属较贵，因此使用较厚的镀层，性能没有上升，不存在使用价值。因此，发明人选择表层镀银层厚度为0.1μm-55μm。优选的，发明人发现表层镀层厚度为1μm-35μm时，筒式端子的温升及耐腐蚀性的综合效果更好，因此，为了进一步提高产品本身的安全性可靠性及实用性，优选表层镀层厚度为1μm-35μm。
本申请提供一种筒式端子，通过采用筒状管作为端子材料，并且用注塑的方法生产装配部，提高端子加工材料的利用率，加工工艺简单，时间短，极大的降低了端子的生产成本。通过设置接触弹片、以及弹性套件，使筒式端子在使用时，不仅可以达到有效接触连接，还可以有效地降低接插件结构不良而造成人员电击伤亡及设备损坏的隐患。
实施方式二
本实施例中的筒式端子，基本与实施方式一的筒式端子相同，不同的内容如下：
本申请的筒式端子，如图3所示，接触段10上的开槽102两端封闭，接触弹片103两端固定。这样的接触弹片103由于两端固定，靠中间的接触弹片103变形获得与对插端端子40的夹紧力，相对于一端为自由端的接触弹片103，能够获得更大的夹紧力，更大的接触面积，保证端子对插结构有较好的力学性能和电学性能，但是由于接触弹片103两端固定，没有很大的变形量，适用于对插端端子40公差较小，导通电流较大的应用场合。
本申请的筒式端子，延伸段201侧壁设置为波纹状205，所述装配部202在所述延伸段201外周成型。当筒式端子的导通电流过大，端子截面积设计无过多余量的情况下，不适合在筒式端子的延伸段201上开口，会减小筒式端子的截面积，增加电阻，导致筒式端子的发热量增大。为了保证装配部202和延伸段201能够稳固连接，延伸段201侧壁设置为波纹状205，装配部202直接注塑在延伸段201外周，装配部202内部与延伸段201的波纹状205匹配，产生更大的接触面积，并且使装配部202和延伸段201不会产生轴向的位移，保证对插结构的稳定性。
本申请的筒式端子，如图3所示，装配部202外周设置有第一凹槽203，然后将筒式端子放入到注塑机的模具中，继续注塑密封环，使密封环与装配部202成为一体，节省了密封环安装的工序，提高组装线自动化的可能性，也使密封环不会漏装，不会掉落，避免因为漏装和掉落导致用电装置密封性不合格。由于密封环和装配部202成为一体，在安装筒式端子的时候，密封环不会和装配位置摩擦而脱离第一凹槽203，保证密封的稳定性，延长用电装置的使用寿命。
实施方式三
本实施例中的筒式端子，基本与实施方式二的筒式端子相同，不同的内容如下：
本申请的筒式端子，如图4所示，接触段10上的开槽102相对于所述筒式端子的轴线倾斜设置。筒式端子与对插端端子40对插后，由于开槽102为倾斜设置，因此接触弹片103的内部与对插端端子40表面接触是螺旋式接触，能够获得更大的接触面积，使接插结构的接触电阻减小，保证可靠的电学性能。另外，开槽102为倾斜设置，从而在保证接触弹片103长度相同，接触弹片103相同弹力的前提下，使筒式端子的接触段10更短，能够节省端子使用材料，也可以更大的压缩用电装置的设计空间，使其更小、更轻，优化了用电装置的空间结构。
本申请的筒式端子，如图4所示，连接段30直径小于或等于接触段10或延伸段201的直径。在某些使用环境中，筒状管的内径要远大于导体连接部分的直径，此时使用压接或焊接的方式进行连接段30和导体的连接，会使连接段30产生较大的变形量，从而使连接段30和导体的连接不稳固，因 此，根据筒式端子需要连接的导体连接部分的外径，可以将连接段30的内径减小，从而匹配连接段30和导体连接部分的尺寸配合，使连接段30和导体连接部分的压接或焊接过程更加容易，也能获得更加稳定的电性连接。
实施方式四
如图5所示，本申请还提供一种对插连接结构，其包括对插端端子40和实施方式一的筒式端子，对插端端子40的接触部分插入筒式端子接触段10的腔体内，且对插端端子40的外壁与筒式端子接触段10的腔体的内侧壁紧密贴合。本实施方式中的筒式端子与实施方式一的结构、工作原理和有益效果相同，在此不再赘述。
进一步的，对插端端子40前端还设有绝缘防护帽401，用来避免在对插端端子40与筒式端子对插时，由于接触位置放电，电弧温度过高，导致端子表面熔化，或导致用电装置或装配部202熔化。
如图6所示，所述对插端端子40的前端设有定位孔402，所述筒式端子的装配部202内设有定位销207，所述定位销207与所述对插端端子40的定位孔402互插连接，可以使较长的对插端端子40在筒式端子内定位，不至于由于振动导致对插端端子40前端在筒式端子的接触段10内晃动，即防止晃动导致的接触电阻变化，维持对插连接结构的电流稳定；也可以避免对插端端子40晃动幅度过大，导致端子后端连接的线缆相互接触引发短路，降低短路事故及人员电击伤亡。
实施方式五
如图7所示，本申请还提供一种筒式端子的加工方法，包括：
S10、制备筒状管。根据对材料导电率、弹性的要求，进行筒状管的材质选择；根据对插端端子40的外径，进行筒状管内径尺寸的选择；根据筒式端子的导通电流，进行筒状管壁厚尺寸的选择；根据筒式端子的安装空间位置，进行筒状管长度尺寸的选择。
S20、准备挤压机和挤压模具，挤压模具分为内模和外模，内模上设置弧形凹陷101和凹槽，外模上设置弧形凸起和挤压剪切台。内模和外模的尺寸与筒状管相匹配；内模上的弧形凹陷101和外模上的弧形凸起配合，加工筒式端子接触段10上的凹陷101；内模上的凹槽和外模上的挤压剪切台配合，加工筒式端子接触段10上的开槽102。
S30、将内模放置在筒状管中，然后一起放入外模中。
S40、启动挤压机，外模的弧形凸起向内模的弧形凹陷移动，将筒状管的接触段10挤压为向内部凹陷。外模的弧形凸起为周向布置，分别由驱动装置驱动，向筒式端子的轴线方向移动，直到将接触段10的凹陷101挤压成型。
S50、挤压机驱动外模的挤压剪切台继续移动，与内模的凹槽配合，将筒状铜管的接触段10挤压成轴向的开槽102。外模的挤压剪切台为周向布置，分别由驱动装置驱动，向筒式端子的轴线方向移动，直到将接触段10的开槽102剪切成型。
S60、挤压机驱动外模退回原位，将挤压后的筒状管和内模从外模中取出，并取出内模。
在一些实施例中，S50为使用剪切设备将筒状管的接触段剪切或切割出轴向开槽。
实施方式六
如图8所示，本申请还提供另一种筒式端子的加工方法，包括：
S10、制备筒状管。根据对材料导电率、弹性的要求，进行筒状管的材质选择；根据对插端端子40的外径，进行筒状管内径尺寸的选择；根据筒式端子的导通电流，进行筒状管壁厚尺寸的选择；根据筒式端子的安装空间位置，进行筒状管长度尺寸的选择。
S20，准备滚压机和滚压模具，滚压模具分为内模和外模，内模上设置弧形凹陷101和凹槽，外 模上设置弧形凸起和剪切台。内模和外模的尺寸与筒状管相匹配；内模上的弧形凹陷和外模上的弧形凸起配合，加工筒式端子接触段10上的凹陷101；内模上的凹槽和外模上的挤压剪切台配合，加工筒式端子接触段10上的开槽102。
S30、将内模放置在筒状管中，然后一起放入外模中。
S40，启动滚压机，外模的弧形凸起向内模的弧形凹陷移动，将筒状管的接触段10滚压为向内部凹陷。外模分为上模和下模，下模保持不动，上模为整体驱动向下模靠拢，依靠上下模相对的滚动，将上下模之间的筒状管进行滚压，与内模配合滚压成型接触段10上的凹陷101。
S50，滚压机驱动外模的剪切台继续移动，与内模的凹槽配合，将筒状管的接触段10滚压成轴向的开槽102。
S60，滚压机驱动外模退回原位，将滚压后的筒状管和内模从外模中取出，并取出内模。
在一些实施例中，S50为使用剪切设备将筒状管的接触段剪切或切割出轴向开槽。
本实施例与实施方式一只是采用的加工设备不同，制作的筒式端子都是一致的。
实施方式七
如图9所示，本申请还提供另一种筒式端子的加工方法，包括：
本实施例的加工方法与实施方式五和实施方式六基本相同，只是在S40步骤之后，还包括步骤S45，外模向内模移动，将筒状管的延伸段挤压成型为装配部。
实施方式八
如图10所示，本申请还提供另一种筒式端子的加工方法，包括：
本实施例的加工方法与实施方式五和实施方式六基本相同，只是在S50步骤之后，还包括步骤S56，在所述延伸段201上剪切出开口，可以和接触段10上的开槽102一起挤压或滚压加工成型。
实施方式九
如图11所示，本申请还提供另一种筒式端子的加工方法，包括：
本实施例的加工方法与实施方式五和实施方式六基本相同，只是在S50步骤之后，还包括步骤S57，在所述延伸段201上挤压或滚压出波纹状205，可以和接触段10上的凹陷101一起挤压或滚压加工成型。
实施方式十
如图12所示，本申请还提供另一种筒式端子的加工方法，包括：
本实施例的加工方法与实施方式五和实施方式六基本相同，只是在S50步骤之后，还包括步骤S70，将挤压或滚压后的筒状管放入到注塑机中，注塑成型为装配部。
实施方式十一
如图13所示，本申请还提供另一种筒式端子的加工方法，包括：
本实施例的加工方法与实施方式五和实施方式六基本相同，只是在S50步骤之后，还包括步骤S58，在所述接触段10上挤压或滚压出第二凹槽104，可以和接触段10上的凹陷101一起挤压或滚压加工成型。
实施方式十二
如图14所示，本申请还提供另一种筒式端子的加工方法，包括：
本实施例的加工方法与实施方式五和实施方式六基本相同，只是在S50步骤之后，还包括步骤S59，将所述连接段30挤压或滚压至直径减小，可以和接触段10上的凹陷101一起挤压或滚压加工成型。
实施方式十三
如图15所示，本申请还提供另一种筒式端子的加工方法，包括：
本实施例的加工方法与实施方式五和实施方式六基本相同，只是在S60步骤之后，还包括步骤S66，至少在所述接触段10和/或所述连接段30上设置镀层。
实施方式十四
如图16所示，本申请还提供另一种筒式端子的加工方法，包括：
本实施例的加工方法与实施方式五和实施方式六基本相同，只是在S60步骤之后还包括步骤S80：将完成注塑的筒式端子放入到注塑机中，注塑成型密封环。
实施方式十五
如图17所示，本申请还提供另一种筒式端子的加工方法，包括：
本实施例的加工方法与实施方式五和实施方式六基本相同，只是在S60步骤之后还包括步骤S90：在所述第一凹槽203内装配密封环。
实施方式十六
如图18所示，本申请还提供另一种筒式端子的加工方法，包括：
本实施例的加工方法与实施方式五和实施方式六基本相同，只是在S70步骤之后还包括步骤S100：在所述第二凹槽104内装配弹性套件105。
尽管本申请的实施方案已公开如上，但其并不仅仅限于说明书和实施方式中所列运用，它完全可以被适用于各种适合本申请的领域，对于熟悉本领域的人员而言，可容易地实现另外的修改，因此在不背离权利要求及等同范围所限定的一般概念下，本申请并不限于特定的细节和这里示出与描述的图例。

Claims (43)

  1. 一种筒式端子，其中，
    包括：接触段、固定段和连接段，
    其中所述固定段包括延伸段和设置在所述延伸段上的装配部；
    所述接触段、所述延伸段和所述连接段为筒状管一体成型；
    在所述接触段上设置至少两个轴向的开槽，使所述接触段侧壁分割为至少两片的接触弹片；
    所述接触段径向向内部设置凹陷，使所述接触弹片形成弧形结构；
    所述连接段与导线电性连接。
  2. 根据权利要求1所述的筒式端子，其中，
    所述开槽贯穿所述接触段远离所述固定段的一侧，所述接触弹片一端为自由端。
  3. 根据权利要求1所述的筒式端子，其中，
    所述开槽两端封闭，所述接触弹片两端固定。
  4. 根据权利要求1所述的筒式端子，其中，
    所述开槽在靠近所述固定段一侧的宽度，大于或等于在远离所述固定段一侧的宽度。
  5. 根据权利要求1所述的筒式端子，其中，
    所述开槽相对于所述筒式端子的轴线倾斜设置。
  6. 根据权利要求1所述的筒式端子，其中，
    所述装配部为所述延伸段挤压成型。
  7. 根据权利要求1所述的筒式端子，其中，
    所述装配部材质为塑料材质，所述装配部通过注塑设置在所述延伸段上。
  8. 根据权利要求7所述的筒式端子，其中，
    所述延伸段设置开孔，能够使所述装配部在所述筒状管内部和所述筒状管外部形成一体。
  9. 根据权利要求7所述的筒式端子，其中，
    所述延伸段侧壁设置为波纹状，所述装配部在所述延伸段外周成型。
  10. 根据权利要求1所述的筒式端子，其中，
    所述筒状管为无缝管，或者由板材卷制成的有缝管。
  11. 根据权利要求10所述的筒式端子，其中，
    当所述筒状管为有缝管时，所述接触弹片上不能存在接缝。
  12. 根据权利要求1所述的筒式端子，其中，
    所述弧形结构内表面的内接截面形状为圆形或椭圆形或多边形或扁平形或E形或F形或H形或K形或L形或T形或U形或V形或W形或X形或Y形或Z形或半弧形或弧形或波浪形。
  13. 根据权利要求1所述的筒式端子，其中，
    所述弧形结构内表面相对于所述筒式端子的轴线距离相同。
  14. 根据权利要求1所述的筒式端子，其中，
    所述连接段直径小于或等于所述接触段或所述延伸段的直径。
  15. 根据权利要求1所述的筒式端子，其中，
    所述接触段远离所述固定段的一端，设置向外扩张的倒角，所述倒角的角度范围为17°-178°。
  16. 根据权利要求1所述的筒式端子，其中，
    所述筒状管材质为铜或铜合金、铝或铝合金。
  17. 根据权利要求16所述的筒式端子，其中，
    所述筒状管材质为铜合金时，铜材质中含有碲材质。
  18. 根据权利要求17所述的筒式端子，其中，
    所述筒状管材质中碲的含量为0.1％-5％。
  19. 根据权利要求1所述的筒式端子，其中，
    所述装配部外周设置有第一凹槽，所述筒式端子还包括套设在所述第一凹槽上的密封环，所述密封环材质为橡胶材质。
  20. 根据权利要求1所述的筒式端子，其中，
    所述接触段的外侧具有沿周向设置的第二凹槽，所述筒式端子还包括套设在所述第二凹槽上的弹性套件，所述弹性套件为橡胶材质。
  21. 根据权利要求1所述的筒式端子，其中，
    在所述接触段和/或所述连接段上至少部分设置镀层。
  22. 根据权利要求21所述的筒式端子，其中，
    所述镀层材质为金、银、镍、锡、锡铅合金、锌、银锑合金、钯、钯镍合金、石墨银、石墨烯银和银金锆合金中的一种或多种组合。
  23. 根据权利要求22所述的筒式端子，其中，
    所述镀层包括底层和表层。
  24. 根据权利要求23所述的筒式端子，其中，
    所述底层材质为金、银、镍、锡、锡铅合金和锌中的一种或多种组合；所述表层材质为金、银、镍、锡、锡铅合金、锌、银锑合金、钯、钯镍合金、石墨银、石墨烯银和银金锆合金中的一种或多种组合。
  25. 根据权利要求23所述的筒式端子，其中，
    所述底层厚度为0.01μm-15μm。
  26. 根据权利要求23所述的筒式端子，其中，
    所述底层厚度为0.1μm-9μm。
  27. 根据权利要求23所述的筒式端子，其中，
    所述表层厚度为0.5μm-55μm。
  28. 据权利要求23所述的筒式端子，其中，
    所述表层厚度为1μm-35μm。
  29. 一种对插连接结构，其中，
    所述对插连接结构包括对插端端子和如权利要求1至28任一项所述的筒式端子，所述对插端端子插入所述接触段内部，所述对插端端子的外侧壁与所述接触弹片的内侧壁紧密贴合。
  30. 根据权利要求29所述的一种对插连接结构，其中：
    所述筒式端子的装配部内设有定位销，所述对插端端子的前端设有定位孔，所述定位销与所述定位孔插接。
  31. 一种用于制造如权利要求1-28任一项所述的筒式端子的加工方法，其中，
    包括：
    S10、制备筒状管；
    S20、准备挤压机和模具，模具分为内模和外模，内模上设置弧形凹陷和第一凹槽，外模上设置 弧形凸起和剪切台；
    S30、将内模放置在筒状管中，然后一起放入外模中；
    S40、启动挤压机，外模的弧形凸起向内模的弧形凹陷移动，将筒状管的接触段挤压为向内部凹陷；
    S50、挤压机驱动外模的剪切台继续移动，与内模的第一凹槽配合，将筒状管的接触段挤压成轴向的开槽；
    S60、挤压机驱动外模退回原位，将挤压后的筒状管和内模从外模中取出，并取出内模。
  32. 根据权利要求31所述的筒式端子的加工方法，其中，
    所述步骤S20、S40、S50和S60中的挤压机为滚压机。
  33. 根据权利要求31或32所述的筒式端子的加工方法，其中，
    所述步骤S50为：将筒状管的接触段剪切或切割出轴向开槽。
  34. 根据权利要求31或32所述的筒式端子的加工方法，其中，
    在S40步骤之后，还包括步骤S45，外模向内模移动，将筒状管的延伸段挤压成型为装配部。
  35. 根据权利要求31或32所述的筒式端子的加工方法，其中，
    在S50步骤之后，还包括步骤S56，在所述延伸段上剪切出开口。
  36. 根据权利要求31或32所述的筒式端子的加工方法，其中，
    在S50步骤之后，还包括步骤S57，在所述延伸段上挤压或滚压出波纹状。
  37. 根据权利要求31或32所述的筒式端子的加工方法，其中，
    在S60步骤之后，还包括步骤S70，将挤压或滚压后的筒状管放入到注塑机中，注塑成型为装配部。
  38. 根据权利要求31或32所述的筒式端子的加工方法，其中，
    在S50步骤之后，还包括步骤S58，在所述接触段上挤压或滚压出第二凹槽。
  39. 根据权利要求31或32所述的筒式端子的加工方法，其中，
    在S50步骤之后，还包括步骤S59，将所述连接段挤压或滚压至直径减小。
  40. 根据权利要求31或32所述的筒式端子的加工方法，其中，
    在S60步骤之后，还包括步骤S66，至少在所述接触段和/或所述连接段上设置镀层。
  41. 根据权利要求31或32所述的筒式端子的加工方法，其中，
    在S60步骤之后还包括步骤S80：将挤压或滚压后的筒状管放入到注塑机中，注塑成型密封环。
  42. 根据权利要求31或32所述的筒式端子的加工方法，其中，
    在S60步骤之后还包括步骤S90：在所述第一凹槽内装配密封环。
  43. 根据权利要求38所述的筒式端子的加工方法，其中，
    在S60步骤之后还包括步骤S100：在所述第二凹槽内装配弹性套件。
PCT/CN2022/106005 2021-07-15 2022-07-15 一种筒式端子、对插连接结构及其加工方法 WO2023284861A1 (zh)

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