WO2023284865A1 - 一种插接端子 - Google Patents

一种插接端子 Download PDF

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Publication number
WO2023284865A1
WO2023284865A1 PCT/CN2022/106038 CN2022106038W WO2023284865A1 WO 2023284865 A1 WO2023284865 A1 WO 2023284865A1 CN 2022106038 W CN2022106038 W CN 2022106038W WO 2023284865 A1 WO2023284865 A1 WO 2023284865A1
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WO
WIPO (PCT)
Prior art keywords
plug
terminal
elastic
resistant layer
conductive wear
Prior art date
Application number
PCT/CN2022/106038
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 CN202121611139.1U external-priority patent/CN218242293U/zh
Priority claimed from CN202110803170.3A external-priority patent/CN113410686A/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 EP22841498.3A priority Critical patent/EP4372923A1/en
Publication of WO2023284865A1 publication Critical patent/WO2023284865A1/zh
Priority to US18/413,060 priority patent/US20240154336A1/en

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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
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/03—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the relationship between the connecting locations
    • H01R11/05—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the relationship between the connecting locations the connecting locations having different types of direct connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • 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
    • 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

Definitions

  • the present application relates to the field of electrical connection, in particular to a plug terminal.
  • the plug-in terminal needs to be plugged with the mating terminal.
  • the plug-in terminal will be worn, which will not only reduce the service life of the plug-in terminal, but also cause poor contact of the plug-in terminal. , affect the normal use, serious will cause safety accidents.
  • the purpose of this application is to provide an elastic plug-in terminal to solve the problem that the existing plug-in terminals are easy to wear.
  • the present application proposes a plug terminal, which includes a connecting unit and an elastic unit arranged and connected along the axial direction of the plug terminal; A plurality of elastic sheets are provided, and the ends of the plurality of elastic sheets away from the connecting unit constitute the free end of the elastic unit, and the plurality of elastic sheets enclose a cavity, and the cavity is for receiving from the connection unit.
  • the mating terminal inserted into the free end; the plug terminal also includes a conductive wear-resistant layer located in the cavity and fixed on the inner wall of each elastic piece, and the conductive wear-resistant layer protrudes from the The inner wall surface of the elastic sheet can be in contact with the outer wall of the mating terminal.
  • the elastic unit has elasticity, can be in close contact with the mating terminal, ensures more contact area, and achieves better electrical and mechanical properties.
  • the conductive wear-resistant layer on the one hand it can To achieve the wear-resistant effect, prevent the inner wall of the elastic sheet from being worn, prolong the service life of the plug-in terminal, and on the other hand, electrically connect the elastic sheet to the mating terminal to play a conductive role;
  • This application arranges multiple conductive wear-resistant layers on each elastic sheet, and each elastic sheet contacts the outer wall of the mating terminal through multiple conductive wear-resistant layers, which not only increases the contact between the plug-in terminal and the mating terminal area, and improve wear resistance;
  • This application sets scraping protrusions on the inner wall of each elastic sheet.
  • the scraping protrusion first contacts with the mating terminal, removes the sundries on the mating terminal, and prevents the mating terminal from being scratched.
  • the debris is sandwiched between the conductive wear-resistant layer and the mating terminal, so that the conductive wear-resistant layer and the mating terminal maintain good electrical contact;
  • Fig. 1 is a schematic diagram of the external structure of the plug terminal according to the first embodiment of the present application
  • Fig. 2 is a cross-sectional view of the plug terminal in Fig. 1;
  • FIG. 3 is a cross-sectional view of a plug terminal according to a second embodiment of the present application.
  • FIG. 4 is a cross-sectional view of a plug terminal according to a third embodiment of the present application.
  • Fig. 5 is a cross-sectional view of a plug terminal according to a fourth embodiment of the present application.
  • connection means two or more.
  • 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 plug terminal, which includes a connecting unit 1 and an elastic unit 2 arranged and connected along the axial direction of the plug terminal.
  • the plug terminal also includes a conductive wear-resistant layer 3 located in the cavity and fixed on the inner wall of each elastic sheet 21, the conductive wear-resistant layer 3 protrudes from the inner wall surface 211 of the elastic sheet 21, and can be connected with The outer wall of the mating terminal contacts.
  • the elastic unit 2 has elasticity, can be in close contact with the mating terminal, ensures more contact area, and achieves better electrical and mechanical properties.
  • the conductive wear-resistant layer 3 on the one hand It has a wear-resistant effect, prevents the inner wall of the elastic sheet 21 from being worn out, and prolongs the service life of the plug-in terminal.
  • it electrically connects the elastic sheet 21 to the mating terminal to conduct electricity.
  • the conductive wear-resistant layers 3 on the plurality of elastic sheets 21 correspond in turn in the circumferential direction of the plug terminal, that is, the conductive wear-resistant layers 3 on the plurality of elastic sheets 21 constitute A wear-resistant ring extending discontinuously along the circumferential direction of the plug-in terminal.
  • the conductive wear-resistant layer 3 is arranged adjacent to the free end 22 to prevent the mating terminal from rubbing against the free end of the elastic piece 21 when inserted into the cavity.
  • both axial ends of the conductive wear-resistant layer 3 are chamfered or rounded to facilitate the insertion of mating terminals.
  • the conductive wear-resistant layer 3 protrudes from the inner wall surface 211 of the elastic sheet 21 as a whole, that is, the inner wall surface of the elastic sheet 21 is smooth, and the conductive wear-resistant layer 3 is fixed on the elastic sheet 21.
  • the overall protrusion height is 0.5 ⁇ m-70 ⁇ m.
  • the present application is not limited thereto, and the conductive wear-resistant layer 3 may also be fixed on the inner wall surface of the elastic sheet 21 by other means.
  • the inventor selected ten groups of terminal groups with different protrusion heights for testing, and tested the wear of the conductive wear-resistant layer 3 respectively. The number of times of plugging and unplugging and conductivity, the test results are shown in Table 1.
  • the number of plugging and unplugging in Table 1 below is to fix the plug-in terminals on the test bench respectively, and use a mechanical device to make the plug-in terminals simulate the plug-in and pull-out of the opposite plug-in terminals, and stop and observe after every 100 plug-in and pull-outs
  • the experiment is stopped, and the number of plugging and unplugging 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.
  • Table 1 The influence of different conductive wear-resistant layer 3 protrusion heights on the number of plug-in and pull-out times and conductivity of the plug-in terminal
  • the inventor chooses the value range of the protruding height to be between 0.5 ⁇ m and 70 ⁇ m, which can not only meet the requirement of plug-in and pull-out times of the plug-in terminal, but also satisfy the conductivity of the plug-in terminal. It greatly guarantees the electrical performance of the plug-in connection mechanism and prolongs the service life of the electrical device.
  • the inner surface 31 of the conductive wear-resistant layer 3 is a circular arc surface that can be attached to the outer wall of the mating terminal, so as to increase the contact area between the conductive wear-resistant layer and the mating terminal.
  • the cross-section of the plug-in terminal and the mating terminal is generally circular.
  • the inner wall surface 211 of the elastic sheet 21 is provided with a spiral protrusion for contacting the mating terminal, and the spiral protrusion can increase the positive pressure after mating with the mating terminal, thereby effectively reducing the contact resistance. Reduces fire risk due to temperature rise.
  • the inner wall surface 211 of the elastic piece 21 is provided with a plurality of bumps for contacting with the mating terminal, and the bumps can increase the positive pressure after mating with the mating terminal, thereby effectively reducing the contact. resistance, reducing the risk of fire due to temperature rise.
  • the inner wall surface 211 of the elastic sheet 21 is provided with a spiral protrusion and a plurality of protrusions for contacting the mating terminal, and the spiral protrusion and the plurality of protrusions are provided at the same time, which can further increase the size of the elastic sheet.
  • the contact area between 21 and the mating terminal further increases the positive pressure after mating with the mating terminal, thereby effectively reducing the contact resistance and reducing the risk of fire caused by temperature rise.
  • the number of plugging and unplugging in the following table 2 is to fix the mating terminals on the test bench respectively, and use a mechanical device to simulate plugging and unplugging of the mating terminals, and after every 100 times of plugging and unplugging, stop to observe the conductivity and wear resistance of the terminal surface If the layer 3 is damaged, the conductive wear-resistant layer 3 on the surface of the terminal is scratched, and the material of the terminal itself is exposed, then the experiment is stopped, and the number of plugging and unplugging 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 conductivity in the following table 2 is after the plug terminal and the mating terminal are plugged together, the structure of the mating terminal is passed a current, and the conductivity of the corresponding terminal mating is detected. In this embodiment, the conductivity is greater than 99 % is qualified.
  • Table 2 The influence of different materials of conductive wear-resistant layer 3 on the number of plug-in and pull-out times and conductivity of plug-in terminals
  • the experimental results exceed the standard value. Many, the performance is relatively stable.
  • the material of the conductive wear-resistant layer 3 is nickel, tin, tin-lead alloy, and zinc, the experimental results also meet the requirements.
  • the inventor selects the material of the conductive wear-resistant layer 3 to be gold, silver, nickel, tin, tin-lead One or more combinations of alloy, zinc, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver and silver-gold-zirconium alloy.
  • the thickness of the conductive wear-resistant layer has a great influence on the overall performance and life of the plug-in terminal, and in severe cases, it will cause a sudden reduction in product life or even failure. If the thickness of the conductive wear-resistant layer is too small, the wear-resistant performance of the plug-in terminal does not meet the requirements. When the thickness of the conductive wear-resistant layer is too large, it is easy to fall off from the surface of the terminal, resulting in a decrease in wear-resistant performance, resulting in contact between the plug-in terminal and the mating terminal. The smaller the area, the higher the contact resistance, which in turn may cause a risk of fire due to an increase in temperature. Moreover, the metal of the conductive wear-resistant layer 3 is relatively expensive, and the use of a thicker conductive wear-resistant layer 3 does not improve performance and has no use value.
  • the temperature rise test in Table 3 below is to pass the same current to the mating terminal 30 and the mating terminal 30 after mating, and detect the temperature at the same position of the mating 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 number of plugging and unplugging in Table 3 below is to fix the mating terminals on the test bench respectively, and use a mechanical device to simulate the plugging and unplugging of the mating terminals, and every time after 100 plugs and pulls, stop to observe the conductivity and wear resistance of the terminal surface If the layer 3 is damaged, the conductive wear-resistant layer 3 on the surface of the terminal is scratched, and the material of the terminal itself is exposed, then the experiment is stopped, and the number of plugging and unplugging 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.
  • Table 3 The influence of different thicknesses of the bottom conductive wear-resistant layer 3 on the temperature rise and the number of plugging and unplugging of the plug-in terminal
  • the thickness of the underlying conductive wear-resistant layer 3 is 0.01 ⁇ m-15 ⁇ m.
  • the inventors found that when the thickness of the underlying conductive wear-resistant layer 3 is 0.1 ⁇ m-9 ⁇ m, the comprehensive effect of the temperature rise of the plug-in terminal and the number of times of plugging and unplugging is better. Therefore, in order to further improve the safety, reliability and practicality of the product itself
  • the thickness of the underlying conductive wear-resistant layer 3 is preferably 0.1 ⁇ m-9 ⁇ m.
  • the experimental method is the same as the above-mentioned experimental method.
  • Table 4 The influence of the thickness of the conductive wear-resistant layer 3 on the temperature rise and the number of plugging and unplugging of different surface layers
  • the thickness of the surface silver layer is greater than 55 ⁇ m, due to the thicker conductive wear-resistant layer 3 at the bottom, the heat generated by the plug-in terminal cannot be dissipated, so that the temperature rise of the plug-in terminal is unqualified, and the thicker conductive wear-resistant layer 3 is easy to burn from The surface of the terminal peels off, causing a decrease in the number of cycles of corrosion resistance.
  • the metal of the surface conductive wear-resistant layer 3 is relatively expensive, the use of a thicker conductive wear-resistant layer 3 does not improve performance and has no use value. Therefore, the inventors choose the thickness of the surface conductive wear-resistant layer 3 to be 0.1 ⁇ m-55 ⁇ m.
  • the inventors found that when the thickness of the surface conductive wear-resistant layer 3 is 1 ⁇ m-35 ⁇ m, the comprehensive effect of the temperature rise of the plug-in terminal and the number of times of plugging and unplugging is better. Therefore, in order to further improve the safety, reliability and practicability of the product itself , preferably the thickness of the surface conductive wear-resistant layer 3 is 1 ⁇ m-35 ⁇ m.
  • the inner wall of the elastic sheet 21 is provided with a plurality of conductive wear-resistant layers 3 arranged at intervals along the axial direction of the plug terminal.
  • a plurality of conductive wear-resistant layers are arranged at intervals along the axial direction of the plug terminal.
  • the inner diameter of the cavity of the plug-in terminal gradually decreases toward the direction close to the free end 22, that is, the diameter of the cavity on the side of the free end 22 of the plug-in terminal is the smallest, even if the mating terminal can be inserted Into the cavity, the elastic piece has a larger deformation space, so that the elastic unit 2 has a greater grip force after being mated with the mating terminal.
  • expansion and contraction joints 23 are formed between any two adjacent elastic sheets 21, and the width of each expansion and contraction joint 23 gradually decreases toward the direction close to the free end 22, That is, the expansion and contraction joint 23 has the smallest width on the side of the free end 22 of the plug terminal, so that the width of the front end of the elastic sheet 21 is larger, and then a conductive wear-resistant layer 3 with a larger width can be provided to increase the conductive wear-resistant layer 3
  • the expansion and contraction joint 23 has a larger width at the rear end of the elastic sheet 21 , which has good sediment and drainage performance.
  • the number of elastic pieces 21 is an even number, so that the elastic pieces 21 are symmetrically arranged to ensure that the stress after the elastic pieces 21 contact with the mating terminal is symmetrical, for example, the number of elastic pieces 21 is 4, 6, 8, 10, 12, 14 or 16.
  • the plug-in terminal also includes a scraping protrusion 4 located in the cavity and fixed on the inner wall of each elastic sheet 21, and in the axial direction of the plug-in terminal, the scraping protrusion 4 4 is located between the conductive wear-resistant layer 3 and the free end 22, so when the mating terminal is inserted, the scraping protrusion 4 first contacts the mating terminal, and removes the sundries on the mating terminal to prevent the mating terminal from The object is sandwiched between the conductive wear-resistant layer 3 and the mating terminal, so that the conductive wear-resistant layer 3 and the mating terminal maintain good electrical contact.
  • the inner surface 41 of the scraping protrusion 4 does not protrude from the inner surface 31 of the conductive wear-resistant layer 3 to prevent the scraper protrusion 4 from obstructing the contact between the conductive wear-resistant layer 3 and the mating terminal.
  • the inner surface 41 of the scraping protrusion 4 on the plurality of elastic sheets 21 and the inner surface 31 of the conductive wear-resistant layer 3 are all located on the same torus or the same conical surface, and the scraping The protrusion 4 will not hinder the contact between the conductive wear-resistant layer and the mating terminal, and can support the mating terminal.
  • the scraping protrusion 4 is provided with a chamfer or rounding on the side close to the free end 22, so as to facilitate the insertion of the mating terminal.
  • arc-shaped grooves 213 are respectively provided on the outer wall of each elastic piece 21 near the end of the connecting unit 1, and the arc-shaped grooves 213 on a plurality of elastic pieces 21 constitute a
  • the discontinuous annular groove in the circumferential direction of the terminal can eliminate the external stress of the elastic sheet 21 by setting the arc-shaped groove 213, so that the elastic sheet 21 maintains a good elastic force after continuous deformation and repeated heating, so that the elastic sheet 21 Not easily deformed.
  • the depth of the arc-shaped groove 213 is no more than one-third of the thickness of the elastic sheet 21, which can not only eliminate the external stress of the elastic sheet 21, but also prevent the elastic sheet 21 from being insufficient in strength due to too small thickness.
  • the connecting unit 1 is made of aluminum or aluminum alloy, so as to connect aluminum wires or other aluminum conductors.
  • the material of the elastic unit 2 is copper or copper alloy, so as to connect copper wires or other copper conductors.
  • the material of the connecting unit 1 is aluminum or aluminum alloy
  • the material of the elastic unit 2 is copper or copper alloy, so as to realize copper
  • the reliable connection of aluminum conductors solves the problem of difficult reliable connection of copper and aluminum conductors.
  • connection unit 1 and the elastic unit 2 are connected together by one or more of friction welding, ultrasonic welding, arc welding, laser welding and resistance welding.
  • the friction welding method refers to the method of welding by using the heat generated by the friction of the contact surface of the workpiece as the heat source to cause the workpiece to undergo plastic deformation under pressure.
  • 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 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.
  • Laser welding is an efficient and precise welding method that uses a high-energy-density laser beam as a heat source.
  • 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.

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Abstract

一种插接端子，包括沿插接端子的轴向设置并连接的连接单元和弹性单元；弹性单元包括沿插接端子的周向间隔设置的多个弹性片，多个弹性片的远离连接单元的一端构成弹性单元的自由端，多个弹性片围成一容腔，容腔供接纳自自由端插入的对配端子；插接端子还包括位于容腔内且固定于各弹性片的内壁上的导电耐磨层，导电耐磨层凸出于弹性片的内壁面，并能与对配端子的外壁接触。本申请通过设置导电耐磨层，一方面起到耐磨效果，防止弹性片的内壁被磨损，延长插接端子的使用寿命，另一方面将弹性片与对配端子电性连接，起到导电作用。

Description

一种插接端子
相关申请
本申请要求于2021年7月15日递交的申请号为202110803170.3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202121611139.1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，尤其涉及一种插接端子。
背景技术
插接端子在使用过程中，需要与对配端子插接，在频繁的插拔动作中，会对插接端子造成磨损，不仅会降低插接端子的使用寿命，还会导致插接端子接触不良，影响正常使用，严重的还会造成安全事故。
发明内容
本申请的目的是提供一种弹性插接端子，以解决现有插接端子容易磨损的问题。
为达到上述目的，本申请提出一种插接端子，其包括沿所述插接端子的轴向设置并连接的连接单元和弹性单元；所述弹性单元包括沿所述插接端子的周向间隔设置的多个弹性片，多个所述弹性片的远离所述连接单元的一端构成所述弹性单元的自由端，多个所述弹性片围成一容腔，所述容腔供接纳自所述自由端插入的对配端子；所述插接端子还包括位于所述容腔内且固定于各所述弹性片的内壁上的导电耐磨层，所述导电耐磨层凸出于所述弹性片的内壁面，并能与所述对配端子的外壁接触。
本申请的插接端子的特点和优点是：
1.本申请通过设置弹性片，使弹性单元具备弹性，能够与对配端子紧密接触，保证更多的接触面积，实现更好的电学性能和力学性能，通过设置导电耐磨层，一方面起到耐磨效果，防止弹性片的内壁被磨损，延长插接端子的使用寿命，另一方面将弹性片与对配端子电性连接，起到导电作用；
2.本申请通过在每个弹性片上设置多个导电耐磨层，每个弹性片通过多个导电耐磨层与对配端子的外壁接触，既增大了插接端子与对配端子的接触面积，又提高耐磨性；
3.本申请通过在各弹性片的内壁上设置刮削凸起，当对配端子插入时，刮削凸起首先与对配端子接触，将对配端子上的杂物去除，防止对配端子上的杂物夹在导电耐磨层与对配端子之间，使导电耐磨层与对插端子保持良好的电性接触；
4.本申请通过在各弹性片的外壁上设置弧形凹槽，能够消除弹性片的外部应力，使弹性片在持续变形、反复升温后保持较好的弹力，使弹性片不易变形；
5.本申请通过在各弹性片的内壁面上设置螺旋凸起和/或多个凸点，增大了弹性片与对配端子对插后的正压力，进而有效降低接触电阻，降低温升导致的起火风险。
附图说明
此处所说明的附图用来提供对本发明的进一步理解，构成本申请的一部分，并不构成对本发明的限定。在附图中：
图1是本申请第一实施例的插接端子的外部结构示意图；
图2是图1的插接端子的剖视图；
图3是本申请第二实施例的插接端子的剖视图；
图4是本申请第三实施例的插接端子的剖视图；
图5是本申请第四实施例的插接端子的剖视图。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚明白，下面结合附图对本发明实施例做进一步详细说明。在此，本发明的示意性实施例及其说明用于解释本发明，但并不作为对本发明的限定。
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。
如图1和图2所示，本申请提供一种插接端子，其包括沿插接端子的轴向设置并连接的连接单元1和弹性单元2，弹性单元2包括沿插接端子的周向间隔设置的多个弹性片21，多个弹性片21的远离连接单元1的一端构成弹性单元2的自由端22，多个弹性片21围成一容腔，容腔供接纳自自由端22插入的对配端子；插接端子还包括位于容腔内且固定于各弹性片21的内壁上的导电耐磨层3，导电耐磨层3凸出于弹性片21的内壁面211，并能与对配端子的外壁接触。
本申请通过设置弹性片21，使弹性单元2具备弹性，能够与对配端子紧密接触，保证更多的接触面积，实现更好的电学性能和力学性能，通过设置导电耐磨层3，一方面起到耐磨效果，防止弹性片21的内壁被磨损，延长插接端子的使用寿命，另一方面将弹性片21与对配端子电性连接，起到导电作用。
如图2所示，在一实施例中，多个弹性片21上的导电耐磨层3在插接端子的周向方向上依次对应，即多个弹性片21上的导电耐磨层3构成一沿插接端子的周向不连续延伸的耐磨环，导电耐磨层3邻近自由端22设置，以防止对配端子插入容腔时与弹性片21的自由端摩擦。
进一步，导电耐磨层3的轴向两端均为倒角或倒圆结构，以便于对配端子插入。
如图5所示，在一实施例中，每个弹性片21上设有沿其长度方向间隔设置的多个导电耐磨层3，每个弹性片21通过多个导电耐磨层3与对配端子的外壁接触，既增大了插接端子与对配端子的接触面积，又提高耐磨性。
在一实施例中，如图2所示，导电耐磨层3整体凸出于弹性片21的内壁面211，即弹性片21的内壁面为平滑状，导电耐磨层3固定在弹性片21的内壁面上，导电耐磨层3整体的凸出高度为0.5μm-70μm。
在另一实施例中，如图3所示，各弹性片21的内壁面211上分别凹设有嵌槽212，导电耐磨层3的一部分固定嵌设于嵌槽212内，导电耐磨层3的另一部分凸出于弹性片21的内壁面211，导电耐磨层3的整体凸出高度为0.5μm-70μm。
但本申请并不以此为限，导电耐磨层3还可以通过其它方式固定于弹性片21的内壁面上。
为了测试导电耐磨层3的整体凸出高度对导电耐磨层3的磨损和导电率的影响，发明人选用了十组凸出高度不同的端子组进行测试，分别测试导电耐磨层3磨损时的插拔次数以及导电率，测试结果如表1所示。
下表1中的插拔次数是将插接端子分别固定在实验台上，采用机械装置使插接端子模拟与对插端端子插拔，并且每经过100次的插拔，就要停下来观察端子导电耐磨层3破坏的情况，当端子导电耐磨层3出现划伤，并露出端子本身材质，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1中的导电率是将插接端子与对插端端子对插后，将对插端子结构通电流，检测相应的端子对插处的导电率，在本实施例中，导电率大于99％为合格。
测试结果如表1。
表1：不同的导电耐磨层3凸出高度对插接端子的插拔次数和导电率的影响
Figure PCTCN2022106038-appb-000001
从表1中可以看出，端子导电耐磨层3高度小于0.5μm时，端子对插间的导电率全部合格，但是插接端子的插拔次数不满足要求，也就是说端子导电耐磨层3很容易就被磨损，不能满足插接端子的使用寿命要求。当端子导电耐磨层3高度大于70μm时，虽然插接端子的插拔次数合格，但是由于端子导电耐磨层3高度太高，增加了接触电阻，因此端子对插间的导电率不满足要求，端子对插结构的电学性能差。因此，发明人选择凸出高度的值范围在0.5μm-70μm之间，既能满足插接端子的插拔次数要求，又能满足插接端子的导电率。极大的保证对插连接机构的电气性能，延长了用电装置的使用寿命。
在一实施例中，导电耐磨层3的内表面31为能与对配端子的外壁面贴合的圆弧面，以增大导电耐磨层与对配端子的接触面积。插接端子与对配端子的横截面一般为圆形，在插接端子的使用过程中，若插接端子的内壁与对配端子的外壁面无法完全贴合，会导致插接端子接触不良，接触电阻增大，进一步可能导致插接端子工作时温度过高而起火。本申请中导电耐磨层3的内表面31设置为可以与对配端子的外壁面贴合的圆弧面，增大导电耐磨层与对配端子的接触面积，有效降低接触电阻，进而降低因温度升高导致的起火风险。
为增大弹性片21与对配端子的接触面积，有以下三种实施例。
在第一实施例中，弹性片21的内壁面211上设有用于与对配端子接触的螺旋凸起，螺旋凸起可以增加与对配端子对插后的正压力，进而有效降低接触电阻，降低温升导致的起火风险。
在第二实施例中，弹性片21的内壁面211上设有用于与所述对配端子接触的多个凸点，凸点可以增加与对配端子对插后的正压力，进而有效降低接触电阻，降低温升导致的起火风险。
在第三实施例中，弹性片21的内壁面211上设有用于与对配端子接触的螺旋凸起和多个凸点，同时设置螺旋凸起和多个凸点，能进一步增大弹性片21与对配端子的接触面积，进一步增加与对配端子对插后的正压力，进而有效降低接触电阻，降低温升导致的起火风险。
在一实施例中，导电耐磨层3包括底层和表层，所述底层材质为金、银、镍、锡、锡铅合金和锌中的一种或多种；所述表层材质为金、银、镍、锡、锡铅合金、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。
所述导电耐磨层3材质为金、银、镍、锡、锌、锡铅合金、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。导电耐磨层3作为需要经常插拔的金属触点，是需要较好的耐磨金属作为导电耐磨层3，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，能够使插接端子获得更好的电学性能和更长的使用寿命。
为了论证不同导电耐磨层3材质对插接端子整体性能的影响，发明人使用相同规格、材质，采用不同导电耐磨层3材料的插接端子样件，利用同种规格的对配接插件做一系列插拔次数和耐腐蚀性时间测试。实验结果如下表2所示。
下表2中的插拔次数是将对插端子分别固定在实验台上，采用机械装置使对插端子模拟插拔，并且每经过100次的插拔，就要停下来观察端子表面导电耐磨层3破坏的情况，端子表面导电耐磨层3出现划伤，并露出端子本身材质，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2中的导电率是将插接端子与对插端端子对插后，将对插端子结构通电流，检测相应的端子对插处的导电率，在本实施例中，导电率大于99％为合格。
表2：不同导电耐磨层3材质对插接端子插拔次数和导电率的影响
Figure PCTCN2022106038-appb-000002
从上表2可以看出，当选用导电耐磨层3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。当选用导电耐磨层3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，发明人选择导电耐磨层3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。
导电耐磨层的厚度对插接端子的整体性能和寿命都有很大的影响，严重时会造成产品寿 命骤减甚至失效。导电耐磨层的厚度过小时，插接端子的耐磨性能不符合要求，导电耐磨层厚度过大时反而容易从端子表面脱落，造成耐磨性能下降，导致插接端子与对配端子接触面积变小，接触电阻增大，进而可能造成因温度升高的起火等风险。而且，导电耐磨层3金属较贵，使用较厚的导电耐磨层3，性能没有上升，不存在使用价值。
为了论证底层导电耐磨层3厚度变化对插接端子整体性能的影响，发明人使用相同规格、材质，采用不同镍底层厚度，相同的银表层厚度的插接端子样件，利用同种规格的对配接插件做一系列温升测试和插拔次数的测试，实验结果如下表3所示。
下表3中的温升测试是将对插后的插接端子和对配端端子30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插接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3中的插拔次数是将对插端子分别固定在实验台上，采用机械装置使对插端子模拟插拔，并且每经过100次的插拔，就要停下来观察端子表面导电耐磨层3破坏的情况，端子表面导电耐磨层3出现划伤，并露出端子本身材质，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。
表3：不同底层导电耐磨层3厚度对插接端子温升和插拔次数的影响
Figure PCTCN2022106038-appb-000003
从上表3可以看出，当底层镍层厚度小于0.01μm时，插接端子的温升虽然合格，但是由于导电耐磨层太薄，插接端子的插拔次数小于合格值，不符合插接端子的性能要求。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燃烧事故。当底层镍层厚度大于15μm时，由于底层导电耐磨层3较厚，插接端子产生的热量散发不出来，使插接端子的温升不合格，而且底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，发明人选择底层导电耐磨层3厚度为0.01μm-15μm。优选的，发明人发现底层导电耐磨层3厚度为0.1μm-9μm时，插接端子的温升及插拔次数的综合效果更好，因此，为了进一步提高产品本身的安全性可靠性及实用性，优选底层导电耐磨层3厚度为0.1μm-9μm。
为了论证表层导电耐磨层3厚度变化对插接端子整体性能的影响，发明人使用相同规格、材质，采用相同镍底层厚度，不同的银表层厚度的插接端子样件，利用同种规格的对配接插 件做一系列温升和插拔次数的测试，实验结果如下表4所示。
实验方法与上述实验方法相同。
表4：不同表层导电耐磨层3厚度对温升和插拔次数的影响
Figure PCTCN2022106038-appb-000004
从上表4可以看出，当表层银层厚度小于0.5μm时，插接端子的温升虽然合格，但是由于导电耐磨层3太薄，插接端子的插拔次数小于合格值，不符合插接端子的性能要求。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燃烧事故。当表层银层厚度大于55μm时，由于底层导电耐磨层3较厚，插接端子产生的热量散发不出来，使插接端子的温升不合格，而且导电耐磨层3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，由于表层导电耐磨层3金属较贵，因此使用较厚的导电耐磨层3，性能没有上升，不存在使用价值。因此，发明人选择表层导电耐磨层3厚度为0.1μm-55μm。
优选的，发明人发现表层导电耐磨层3厚度为1μm-35μm时，插接端子的温升及插拔次数的综合效果更好，因此，为了进一步提高产品本身的安全性可靠性及实用性，优选表层导电耐磨层3厚度为1μm-35μm。
在一实施例中，弹性片21的内壁上设有沿所述插接端子的轴向间隔排列的多个导电耐磨层3，本申请通过在每个弹性片上设置多个导电耐磨层，每个弹性片通过多个导电耐磨层与对配端子的外壁接触，既增大了插接端子与对配端子的接触面积，又提高耐磨性。
在一实施例中，插接端子的容腔的内径朝靠近自由端22的方向逐渐减小，即容腔在插接端子的自由端22一侧的孔径最小，既使对配端端子能够插入到容腔内，又使弹性片具有更大的变形空间，使弹性单元2与对配端子对插后具有更大的抓紧力。
如图1至图4所示，在一实施例中，任意相邻的两个弹性片21之间形成胀缩缝23，各胀缩缝23的宽度朝靠近自由端22的方向逐渐减小，即胀缩缝23在插接端子的自由端22一侧的宽度最小，从而使弹性片21前端的宽度较大，进而得以设置宽度较大的导电耐磨层3，增大导电耐磨层3与对配端子的接触面积，另外，胀缩缝23在弹性片21后端的宽度较大，具有良好的排泥沙和排水性能。
在一实施例中，弹性片21的数量为偶数个，以使弹性片21对称设置，保证弹性片21与 对配端子接触后的应力对称，例如弹性片21的数量为4个、6个、8个、10个、12个、14个或16个。
如图4所示，在一实施例中，插接端子还包括位于容腔内且固定于各弹性片21的内壁上的刮削凸起4，在插接端子的轴向方向上，刮削凸起4位于导电耐磨层3和自由端22之间，因此当对配端子插入时，刮削凸起4首先与对配端子接触，将对配端子上的杂物去除，防止对配端子上的杂物夹在导电耐磨层3与对配端子之间，使导电耐磨层3与对插端子保持良好的电性接触。
在一种可行的技术方案中，刮削凸起4的内表面41不凸出于导电耐磨层3的内表面31，以避免刮削凸起4妨碍导电耐磨层3与对配端子的接触。
在另一种可行的技术方案中，多个弹性片21上的刮削凸起4的内表面41和导电耐磨层3的内表面31均位于同一个圆环面或同一个圆锥面上，刮削凸起4既不会妨碍导电耐磨层与对配端子接触，又能支撑对配端子。
进一步，刮削凸起4在靠近自由端22的一侧内部设有倒角或倒圆，以便于对配端子插入。
如图4所示，在一实施例中，各弹性片21的靠近连接单元1的一端外壁上分别设有弧形凹槽213，多个弹性片21上的弧形凹槽213构成一个沿插接端子的周向不连续的环形凹槽，通过设置弧形凹槽213，能够消除弹性片21的外部应力，使弹性片21在持续变形、反复升温后保持较好的弹力，使弹性片21不易变形。
进一步，弧形凹槽213的深度不大于弹性片21厚度的三分之一，既能消除弹性片21的外部应力，又防止弹性片21因厚度太小而强度不足。
在一实施例中，连接单元1的材质为铝或铝合金，以便连接铝线或其它铝导体。
在一实施例中，弹性单元2的材质为铜或铜合金，以便连接铜线或其它铜导体。
电动汽车的线缆由于电压高，电流大，都需要使用大线径的铜导线进行电流的传导，但是，随着铜价日益上涨，使用铜材作为导线的材料成本会越来越高。为此，人们开始寻找金属铜的替代品来降低成本。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，在汽车电气连接领域中以铝代铜是发展趋势。
但是由于铜铝之间的电极电位差较大，铜导线和铝导线直接连接后，铜铝导线之间会产生电化学腐蚀，铝易受腐蚀而导致连接区域电阻增大，易在电气连接中产生严重的后果，例如功能失效、火灾等。
为解决现有技术中铜铝导线难以可靠连接的问题，在一些实施例中，所述连接单元1的材质为铝或铝合金，所述弹性单元2的材质为铜或铜合金，从而实现铜铝导线的可靠连接， 解决了铜铝导线难以可靠连接的问题。
进一步，连接单元1和弹性单元2通过摩擦焊方式、超声波焊接方式、弧焊方式、激光焊方式、电阻焊方式的一种或几种连接在一起。
摩擦焊方式，是指利用工件接触面摩擦产生的热量为热源，使工件在压力作用下产生塑性变形而进行焊接的方法。
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。
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。
激光焊方式，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。
电阻焊方式，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。
采用以上的加工方式或组合，能够有效的将铜/铜合金材质的弹性单元2和铝/铝合金材质的连接单元1进行连接，保证插接端子具有良好的力学性能和电学性能。
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 (19)

  1. 一种插接端子，其中，所述插接端子包括沿所述插接端子的轴向设置并连接的连接单元(1)和弹性单元(2)；
    所述弹性单元(2)包括沿所述插接端子的周向间隔设置的多个弹性片(21)，多个所述弹性片(21)的远离所述连接单元(1)的一端构成所述弹性单元(2)的自由端(22)，多个所述弹性片(21)围成一容腔，所述容腔供接纳自所述自由端(22)插入的对配端子；
    所述插接端子还包括位于所述容腔内且固定于各所述弹性片(21)的内壁上的导电耐磨层(3)，所述导电耐磨层(3)凸出于所述弹性片(21)的内壁面(211)，并能与所述对配端子的外壁接触。
  2. 如权利要求1所述的插接端子，其中，多个所述弹性片(21)上的导电耐磨层(3)在所述插接端子的周向方向上依次对应，所述导电耐磨层(3)邻近所述自由端(22)设置。
  3. 如权利要求1所述的插接端子，其中，所述导电耐磨层(3)整体凸出于所述弹性片(21)的内壁面(211)，或者，
    各所述弹性片(21)的内壁面(211)上分别凹设有嵌槽(212)，所述导电耐磨层(3)的一部分位于所述嵌槽(212)内，且另一部分凸出于所述弹性片(21)的内壁面(211)。
  4. 如权利要求3所述的插接端子，其中，所述导电耐磨层(3)的整体凸出高度为0.5μm-70μm。
  5. 如权利要求1所述的插接端子，其中，所述导电耐磨层(3)的内表面(31)为能与所述对配端子的外壁面贴合的圆弧面。
  6. 如权利要求1所述的插接端子，其中，所述弹性片(21)的内壁面(211)上设有用于与所述对配端子接触的螺旋凸起；且/或，
    所述弹性片(21)的内壁面(211)上设有用于与所述对配端子接触的多个凸点。
  7. 如权利要求1所述的插接端子，其中，所述导电耐磨层(3)包括底层和表层，所述底层材质为金、银、镍、锡、锡铅合金和锌中的一种或多种；所述表层材质为金、银、镍、锡、锡铅合金、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。
  8. 如权利要求7所述的插接端子，其中，所述底层厚度为0.01μm-15μm。
  9. 如权利要求7所述的插接端子，其中，所述底层厚度为0.1μm-9μm。
  10. 如权利要求7所述的插接端子，其中，所述表层厚度为0.5μm-55μm。
  11. 如权利要求7所述的插接端子，其中，所述底层厚度为1μm-35μm。
  12. 如权利要求1至11任一项所述的插接端子，其中，所述弹性片(21)的内壁上设有沿所述插接端子的轴向间隔排列的多个导电耐磨层(3)。
  13. 如权利要求1至11任一项所述的插接端子，其中，所述容腔的内径朝靠近所述自由端(22)的方向逐渐减小。
  14. 如权利要求1至11任一项所述的插接端子，其中，所述插接端子还包括位于所述容腔内且固定于各所述弹性片(21)的内壁上的刮削凸起(4)，在所述插接端子的轴向方向上，所述刮削凸起(4)位于所述所述导电耐磨层(3)和所述自由端(22)之间。
  15. 如权利要求14所述的插接端子，其中，所述刮削凸起(4)的内表面(41)不凸出于所述导电耐磨层(3)的内表面(31)。
  16. 如权利要求14所述的插接端子，其中，多个所述弹性片(21)上的刮削凸起(4)的内表面(41)和导电耐磨层(3)的内表面(31)均位于同一个圆环面或同一个圆锥面上。
  17. 如权利要求1至11任一项所述的插接端子，其中，所述弹性片(21)的靠近所述连接单元(1)的一端外壁上设有弧形凹槽(213)。
  18. 如权利要求1至11任一项所述的插接端子，其中，所述连接单元(1)的材质为铝或铝合金。
  19. 如权利要求1至11任一项所述的插接端子，其中，所述弹性单元(2)的材质为铜或铜合金。
PCT/CN2022/106038 2021-07-15 2022-07-15 一种插接端子 WO2023284865A1 (zh)

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CN112290265A (zh) * 2019-07-22 2021-01-29 Aptiv技术有限公司 母电源触头
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CN105580213A (zh) * 2013-09-27 2016-05-11 株式会社自动网络技术研究所 端子配件
CN205178083U (zh) * 2015-11-10 2016-04-20 连展科技（深圳）有限公司 插头端子
US20190006797A1 (en) * 2017-06-29 2019-01-03 Commscope Technologies Llc Inner contact for coaxial cable
CN209045850U (zh) * 2018-11-23 2019-06-28 广东纳特康电子股份有限公司 稳定性可靠的连接器母座
CN112290265A (zh) * 2019-07-22 2021-01-29 Aptiv技术有限公司 母电源触头
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