WO2024061304A1 - 电连接器 - Google Patents

电连接器 Download PDF

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Publication number
WO2024061304A1
WO2024061304A1 PCT/CN2023/120262 CN2023120262W WO2024061304A1 WO 2024061304 A1 WO2024061304 A1 WO 2024061304A1 CN 2023120262 W CN2023120262 W CN 2023120262W WO 2024061304 A1 WO2024061304 A1 WO 2024061304A1
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WO
WIPO (PCT)
Prior art keywords
electrical connector
terminal
wire harness
aluminum
shell
Prior art date
Application number
PCT/CN2023/120262
Other languages
English (en)
French (fr)
Inventor
王超
Original Assignee
吉林省中赢高科技有限公司
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Application filed by 吉林省中赢高科技有限公司 filed Critical 吉林省中赢高科技有限公司
Publication of WO2024061304A1 publication Critical patent/WO2024061304A1/zh

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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
    • H01R31/00—Coupling parts supported only by co-operation with counterpart
    • H01R31/06—Intermediate parts for linking two coupling parts, e.g. adapter
    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure

Definitions

  • the invention relates to the field of electrical technology automotive wiring harnesses, and in particular to an electrical connector.
  • the proportion of high-voltage electrical connectors (generally referring to electrical connectors with a voltage greater than 500V) used in automobiles is increasing, and the requirements for the volume and reliability of connectors are also increasing.
  • the number of squares of the wiring harness increases, the size of the high-voltage electrical connector is also increasing.
  • the flow of large currents causes the electromagnetic interference ability of the high-voltage wiring harness itself to other components to become stronger and stronger.
  • the current high-voltage electrical connector needs to add a shielding layer on the inside of the high-voltage electrical connector.
  • elbow electrical connectors i.e., electrical connectors with an angle of 90°-180° between the axial direction of the wiring harness and the length direction of the terminal at the equipment end
  • elbow electrical connectors with large square aluminum wires generally referring to connectors with a square number greater than 70 squares
  • occupy a large lateral space are large in size, and have complex connections, large weight, and high costs.
  • the object of the present invention is to provide an electrical connector that can reduce the space size of the connector, simplify the structure, have low weight and low cost.
  • the invention provides an electrical connector, which includes a pluggable male head and a female base and an electrical connection device; the male head includes at least one aluminum wire harness and at least one male terminal; the electrical connection device includes a connecting body, and both ends of the connecting body are connected Two bending structures are respectively provided, and the two bending structures extend to the same side of the connection body. The two bending structures are respectively connected to the aluminum wire harness and the male terminal, and the male terminal is inserted into the female base.
  • the electrical connector in the present invention uses an electrical connection device to realize the transfer between the aluminum wire harness and the male terminal, and the electrical connection device adopts a bending structure, which can be used for large square aluminum wire connectors. It not only has a simple structure and is easy to process, but also It can reduce the space size of the connector, reduce the volume and weight, and reduce the cost.
  • Figure 1 A perspective view of the electrical connector provided by the present invention.
  • Figure 2 is a top view of Figure 1.
  • Figure 3 is a cross-sectional view along the A-A direction in Figure 2.
  • Figure 4 Structural diagram of the cooperation between the aluminum wire harness and the insulating inner shell provided by the present invention.
  • Figure 5 Structural diagram of the aluminum wire harness provided by the present invention cooperating with the electrical connection device and the male terminal.
  • FIG. 6 Structural diagram 1 of the electrical connection device provided by the present invention.
  • FIG. 7 is a second structural diagram of the electrical connection device provided by the present invention.
  • Figure 8 Structural diagram three of the electrical connection device provided by the present invention.
  • Figure 9 Structural diagram of the transition terminal provided for the present invention.
  • this embodiment provides an electrical connector, including a pluggable male head and a female base and an electrical connector.
  • the male head includes at least one aluminum wire harness 1 and at least one male terminal 3.
  • the electrical connection device 2 includes a connecting body 21.
  • Two bending structures i.e., a first bending structure 22 and a second bending structure
  • Bending structure 23 the two bending structures extend to the same side of the connection body 21, and the two bending structures are respectively connected to (the end of) the aluminum wire harness 1 and (the end of) the male terminal 3, and the male terminal 3 is installed in the female seat.
  • the number of the electrical connection device 2, the aluminum wire harness 1 and the male terminal 3 are the same, and they are mainly suitable for elbow electrical connectors, that is, the angle between the length direction of the male terminal 3 and the axial direction of the aluminum wire harness 1 can be 90°-180°.
  • the electrical connector in this embodiment uses the electrical connection device 2 to realize the transfer between the aluminum wire harness 1 and the male terminal 3, and the electrical connection device 2 adopts a bending structure, which can be used for large square aluminum wire connectors, and is not only simple in structure , easy to process, and can reduce the space size of the connector, reduce the volume and weight, and reduce the cost.
  • the electrical connection device 2 is an integrally stamped plate-like structure.
  • the integrated and bent electrical connection device 2 when used to connect the aluminum wire harness 1 and the male terminal 3, the integrated and bent electrical connection device 2 is used at the bent connection point of the aluminum wire harness 1 and the male terminal 3, eliminating the need for secondary bolting or
  • the structure such as crimping is more simplified, reducing the size and weight, and reducing the cost; and while ensuring a small size, it also reduces the connection points of large square aluminum wire terminals, achieving a connection with a smaller contact resistance.
  • the bending structure (specifically the first bending structure 22) and the aluminum wire harness 1 are connected by friction welding.
  • Aluminum wire friction welding connection has better electrical conductivity, stronger mechanical connection performance, and can achieve the purpose of reducing cost and weight.
  • one of the bending structures ie, the first bending structure 22
  • a protrusion 221 formed by an outward recess specifically, a protrusion 221 is recessed in a direction close to the aluminum wire harness 1 .
  • the specific shape of the protrusion 221 can be determined according to actual needs.
  • the protrusion 221 is an outwardly concave round rod structure and is coaxial with the aluminum wire harness 1 .
  • the protrusion 221 and the aluminum wire harness 1 are connected by friction welding.
  • the rotating spindle of the friction welding equipment is inserted into the inner pit of the protrusion 221, and the aluminum wire harness 1 is clamped by the clamp of the friction welding equipment.
  • the aluminum wire harness 1 remains stationary during friction welding, and the first bending structure 22 rotates with the rotating spindle to achieve friction welding connection between the two; the protrusion 221 can be used to facilitate centering, ensure the concentricity of the connection between the electrical connection device 2 and the aluminum wire harness 1, and ensure the appearance and quality of the connection.
  • a plurality of embedding holes 231 are opened in another bending structure (specifically, the second bending structure 23), which can enhance the strength of the integrated injection molding.
  • a guide plug-in portion 232 whose thickness gradually decreases outward is formed at the end of another bending structure (ie, the second bending structure 23 ), which can facilitate plug-in cooperation with the male terminal 3 .
  • connection body 21 is at least partially a flexible conductor, for example, the flexible conductor is a multi-core cable or a braided wire. Flexible cable or multi-layer thin plate stacked flexible cable. When there is vibration in the male terminal 3, the connection body 21 can better absorb the vibration and reduce the vibration transmitted to the aluminum wire harness 1; at the same time, it has a better fault tolerance during assembly.
  • the specific bending angles of the above two bending structures are determined according to the angle between the length direction of the male terminal 3 in the elbow electrical connector used and the axial direction of the aluminum wire harness 1.
  • the length direction of the male terminal 3 is perpendicular to the axial direction of the aluminum wire harness 1
  • the connecting body 21 and the two bending structures are both plate-like structures, and the plate surfaces of the two bending structures are perpendicular to each other and perpendicular to the connecting body 21;
  • the plate surface of one of the bending structures i.e., the first bending structure 22
  • the plate surface of the other bending structure i.e., the second bending structure 23
  • first bending structure 22 is a circular plate
  • connecting body 21 is a right-angled triangular plate with a transition arc
  • the length direction of the connecting body 21 extends along the axial direction of the aluminum wire harness 1
  • the second bending structure 23 is a rectangular plate.
  • the distance L between the axis of the aluminum wire harness 1 and the outer surface of the connecting body 21 must be larger than the distance L between the axis of the aluminum wire harness 1 and the outer surface of another bending structure (ie, the second bending structure 23 ).
  • the spacing T between them is shown in Figures 6 to 8; and due to the friction welding process requirements of large square friction welding terminals, the value of the spacing L is relatively large and must be within a certain size range.
  • both bending structures extend along the length direction parallel to the male terminal 3, which can reduce the space occupied by the terminal compared to the existing large square friction welding terminal and ensure that the electrical connection device 2 occupies
  • the smaller lateral size (the lateral size is perpendicular to the axis of the aluminum wire harness 1 and the size of the plate surface of the male terminal 3) facilitates reducing the lateral size of the connector; especially for multi-core terminals (i.e. the aluminum wire harness 1 When the number is greater than or equal to two, each aluminum wire harness 1 is arranged parallel and side by side), the lateral size shortening is more obvious; and the second bending structure 23 can also ensure that the contact area with the male terminal 3 meets the requirement of a large square number.
  • the bending line formed between the second bending structure 23 and the connecting body 21 is arranged along the axis direction of the aluminum wire harness 1, and can be as close as possible to the center line of the aluminum wire harness 1 when meeting the requirements of the friction welding process, making the structure more compact.
  • an insulating layer is integrally injection molded and wrapped on the outside of the electrical connection device 2.
  • This insulating layer should avoid the connection position between the first bending structure 22 and the aluminum wire harness 1 and the second bending structure 23 and the male end.
  • the connection position of terminal 3, that is, the position where the electrical connection device 2 contacts the aluminum wire harness 1 and the male terminal 3 is not covered with an insulating layer.
  • the remaining positions of the electrical connection device 2 are covered with an insulating layer, which can provide insulation protection. , to prevent leakage.
  • the above-mentioned plurality of embedded holes 231 should be distributed on both sides of the first end of the male terminal 3, and the integrated injection molding strength can be enhanced by using the embedded holes 231.
  • the male terminal 3 includes a transition terminal 31 and a device terminal 32, wherein the first end of the transition terminal 31 is plugged and fixed with the electrical connection device 2 (specifically, the second bending structure 23), and the second end of the transition terminal 31 is plugged and fixed with the device terminal 32.
  • the first end of the terminal 32 is plugged and fixed.
  • the transition terminal 31 and the device terminal 32 may be parallel to each other as shown in FIG. 5 , or may adopt other shapes and be arranged in other ways as required.
  • the plate surface of the above-mentioned second bending structure 23 should be parallel to the end plate surface of the male terminal 3, that is, parallel to the plate surface of the first end of the transition terminal 31, so as to facilitate the connection between the second bending structure 23 and the first end of the transition terminal 31.
  • the connection at one end ensures that the contact area between the two meets the requirements of a large square number.
  • the male terminal 3 is composed of two parts: a transition terminal 31 and a device terminal 32. During use, the transition terminals 31 of different shapes, lengths, etc. can be combined with different shapes (can also be bent), lengths, etc. according to needs.
  • the structural form of the device terminals 32 (also known as copper bar terminals) can be connected in any combination and is more flexible and diverse, making the connector more suitable for various environments, meeting the diverse needs of the connector, and having greater versatility.
  • a first slot 311 and a second slot 312 are respectively formed at the first end and the second end of the transition terminal 31.
  • the electrical connection device 2 (specifically, the second The bending structure 23) is inserted into the first slot 311, and the first end of the device terminal 32 is inserted into the second slot 312.
  • the transition terminal 31 may be in the form of a single-chip terminal, or may be formed by stacking multiple chip-shaped terminals as shown in FIG. 5 , and then be plugged into the equipment-side terminal 32 .
  • the male head also includes a plug shell 5 and an insulating inner shell 4. Parts of the electrical connection device 2 and the aluminum wire harness 1 are penetrated in the insulating inner shell 4.
  • the insulating inner shell 4 is penetrated and fixed in the plug shell 5.
  • the insulating inner shell 4 mainly serves to insulate and protect the electrical connection device 2 and the aluminum wire harness 1.
  • the corresponding end of the aluminum wire harness 1 can extend out of the insulating inner shell 4.
  • a first clamping block 511 is protruding from the inner wall of the plug shell 5, and a first clamping slot 41 is provided on the outer wall of the insulating inner shell 4.
  • the first clamping block 511 It can be carded in the first card slot 41 .
  • the plug shell 5 and the insulating inner shell 4 are positioned and locked by buckles, which can enhance the tensile resistance of the connector.
  • a plug insulating lining 51 is also provided on the inner wall of the plug housing 5 , and the first blocking block 511 is formed on the inner wall of the plug insulating lining 51 .
  • the plug insulating lining 51 is a glue-filled structure and is filled between the plug shell 5 and the insulating inner shell 4.
  • the plug insulating lining 51 can better protect the electrical connection device 2 and the aluminum wire harness 1.
  • a connector tail shell 52 is connected to the rear end of the plug shell 5, and a shielding locking ring 53 is provided on the outer cover of the insulating inner shell 4.
  • the shielding locking ring 53 is in contact with the connector tail shell 52. to achieve external shielding access.
  • the shield locking ring 53 can be integrally connected to the insulating inner shell 4 by injection molding.
  • the female base includes a socket shell 6, the male terminal 3 is inserted into the socket shell 6, and the plug shell 5 and the socket shell 6 are locked by a secondary locking device 7.
  • the specific structure of the secondary locking device 7 can adopt any existing method, and the present invention is not limited to this.
  • a second clamping block is protruding from the inner wall of the socket shell 6, and a second clamping slot 321 is provided on the male terminal 3 (the second clamping slot 321 is specifically provided on the equipment terminal 32), the second clamping block can be clamped in the second clamping slot 321.
  • a socket insulating lining is further provided on the inner wall of the socket shell 6, and the second clamping block is formed on the inner wall of the socket insulating lining.
  • the socket insulating lining has a glue-filled structure and is filled in the socket shell 6. The socket insulating lining can better protect the male terminal 3.
  • a coating is provided at the connection between the bending structure and the aluminum wire harness 1, and the coating is a copper-aluminum transition layer.
  • the copper-aluminum transition layer is provided on the connection surface between the bending structure made of copper and the aluminum wire harness 1 made of aluminum. Under the action of heat and pressure, copper atoms and aluminum atoms mutually penetrate or combine to form a copper-aluminum transition layer, which not only avoids electrochemical corrosion between copper and aluminum, but also improves the electrical and mechanical properties of the copper-aluminum connection, so that the mechanical and electrical properties of the copper-aluminum composite terminal are significantly improved.
  • the copper-aluminum transition layer contains at least copper element, aluminum element, copper-aluminum solid solution and copper-aluminum compound.
  • the copper-aluminum compound is one or more of Cu2Al, Cu3Al2, CuAl, and CuAl2.
  • the copper-aluminum transition layer contains no less than 6.5wt% copper-aluminum solid solution.
  • the copper-aluminum transition layer contains less than 6.5wt% copper-aluminum solid solution
  • the copper-aluminum transition layer contains no less than 6.5wt% copper-aluminum solid solution.
  • Other components in the transition layer are greater than 93.5wt%.
  • the large proportion of copper and aluminum in the copper-aluminum transition layer means that the copper-aluminum welding is insufficient and the copper-aluminum elements are not fused into a copper-aluminum solid solution.
  • the copper-aluminum transition layer has a large proportion of copper-aluminum compounds.
  • the conductivity of the copper-aluminum compounds is very poor, and the copper-aluminum compounds are relatively brittle.
  • the content is high, the mechanical properties and electrical properties of the copper-aluminum composite terminals will be reduced. Therefore, the copper-aluminum transition layer of the present invention contains at least 6.5 wt% copper-aluminum solid solution.
  • Table 1 Effect of the proportion of copper-aluminum solid solution in the copper-aluminum transition layer on the pull-out force and voltage drop of the electrical connector
  • the inventor set that the copper-aluminum transition layer contains no less than 6.5 wt% solid solution of copper and aluminum.

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  • Insulated Conductors (AREA)
  • Details Of Connecting Devices For Male And Female Coupling (AREA)

Abstract

本发明为一种电连接器，包括能插合的公头和母座以及电连接装置(2)。公头包括至少一个铝线束(1)和至少一个公端端子(3)，电连接装置(2)包括连接本体(21)，连接本体(21)的两端分别设有两个折弯结构，两个折弯结构向连接本体(21)的同一侧延伸，两个折弯结构分别与铝线束(1)和公端端子(3)连接，公端端子(3)穿设在母座内。本发明能缩小连接器的空间尺寸，结构更简化，重量小，成本低。

Description

电连接器
相关申请
本申请要求专利申请号为202211150049.6、申请日为2022年9月21日、发明名称为“电连接器”的中国发明专利的优先权。
技术领域
本发明是关于电气技术汽车线束领域，尤其涉及一种电连接器。
背景技术
随着新能源汽车领域的发展，高压电连接器(一般指电压大于500V的电连接器)在汽车上应用的比例越来越高，对连接器的体积以及可靠性要求也越来越高，随着线束平方数的越来越大，高压电连接器的尺寸也越来越大。对于大平方连接器，大电流的流通导致高压线束本身电磁干扰能力对其它零部件的也越来越强，当前高压电连接器为避免对其它零部件的电磁干扰，需要在高压电连接器内侧增加屏蔽层。这样的高压电连接器相比不带屏蔽的电连接器成本高、质量重、体积大，导致线束系统制作加工成本越来越高，工艺越来越复杂。而且在一些安装场合，经常需要用到弯头电连接器(即线束的轴向与设备端端子的长度方向的夹角为90°-180°的电连接器)，但是目前的弯头电连接器中大平方铝线的连接器(一般指平方数大于70平方的连接器)所占横向空间较大，尺寸较大，且连接复杂，重量大，成本高。
发明内容
本发明的目的在于提供一种电连接器，能缩小连接器的空间尺寸，结构更简化，重量小，成本低。
本发明的上述目的可采用下列技术方案来实现：
本发明提供一种电连接器，包括能插合的公头和母座以及电连接装置；公头包括至少一个铝线束和至少一个公端端子，电连接装置包括连接本体，连接本体的两端分别设有两个折弯结构，两个折弯结构向连接本体的同一侧延伸，两个折弯结构分别与铝线束和公端端子连接，公端端子穿设在母座内。
本发明的特点及优点是：
本发明中的电连接器，利用电连接装置实现铝线束与公端端子的转接，且电连接装置采用折弯结构，可以用于大平方铝线连接器，不仅结构简单，加工方便，且能缩小连接器的空间尺寸，减小体积和重量，降低成本。
附图说明
以下附图仅旨在于对本发明做示意性说明和解释，并不限定本发明的范围。其中：
图1：为本发明提供的电连接器的立体图。
图2：为图1的俯视图。
图3：为图2中沿A-A方向的剖视图。
图4：为本发明提供的铝线束与绝缘内壳配合的结构图。
图5：为本发明提供的铝线束与电连接装置和公端端子配合的结构图。
图6：为本发明提供的电连接装置的结构图一。
图7：为本发明提供的电连接装置的结构图二。
图8：为本发明提供的电连接装置的结构图三。
图9：为本发明提供的过渡端子的结构图。
附图标号说明：
1、铝线束；
2、电连接装置；21、连接本体；22、第一折弯结构；221、凸起；23、第二折弯结
构；231、嵌入孔；232、导向插接部；
3、公端端子；31、过渡端子；311、第一插槽；312、第二插槽；32、设备端端子；
321、第二卡槽；
4、绝缘内壳；41、第一卡槽；
5、插头外壳；51、插头绝缘内衬；511、第一卡块；52、连接器尾壳；53、屏蔽锁
止环；
6、插座外壳；
7、二次锁止装置。
具体实施方式
为了对本发明的技术特征、目的和效果有更加清楚的理解，现对照附图说明本发明的具体实施方式。
如图1至图9所示，本实施例提供一种电连接器，包括能插合的公头和母座以及电 连接装置2。公头包括至少一个铝线束1和至少一个公端端子3，电连接装置2包括连接本体21，连接本体21的两端分别设有两个折弯结构(即第一折弯结构22和第二折弯结构23)，两个折弯结构向连接本体21的同一侧延伸，两个折弯结构分别与铝线束1(的端部)和公端端子3(的端部)连接，公端端子3穿设在母座内。其中，电连接装置2、铝线束1和公端端子3的数量相同，主要适用于弯头电连接器，即公端端子3的长度方向与铝线束1的轴向之间的夹角可以为90°-180°。
本实施例中的电连接器，利用电连接装置2实现铝线束1与公端端子3的转接，且电连接装置2采用折弯结构，可以用于大平方铝线连接器，不仅结构简单，加工方便，且能缩小连接器的空间尺寸，减小体积和重量，降低成本。
在具体实现方式中，电连接装置2为一体冲压的板状结构。
如此，用于连接铝线束1和公端端子3时，在铝线束1和公端端子3的弯折连接处采用一体化并折弯的电连接装置2连接，不用再进行二次螺栓连接或压接等结构，结构更加简化，减小了体积和重量，降低了成本；而且保证尺寸较小的情况下，也减少了大平方铝线端子的连接点，实现了较小接触电阻的连接。
作为优选地，折弯结构(具体是第一折弯结构22)与铝线束1之间采用摩擦焊连接。铝线摩擦焊连接具有更优异的导电性能，具有更强的机械连接性能，并可以达到降低成本、减轻重量的目的。
一般在其中一个折弯结构(即第一折弯结构22)上设有向外凹陷形成的凸起221(具体是向靠近铝线束1的方向凹陷)。具体凸起221的形状可以根据实际需要而定，例如本实施例中参照图5和图6，该凸起221为向外凹陷的圆棒结构，并与铝线束1同轴。
安装于连接器时，凸起221与铝线束1采用摩擦焊连接。加工时，摩擦焊设备的旋转主轴插接在该凸起221的内侧凹坑中，铝线束1由摩擦焊设备的夹具夹持，进行摩擦焊时铝线束1保持不动，第一折弯结构22随旋转主轴旋转，以实现两者的摩擦焊连接；利用该凸起221可以更便于定心，确保电连接装置2与铝线束1在连接处的同心度，保证连接外观和连接质量。
进一步地，在另一个折弯结构(具体是第二折弯结构23)上开设有多个嵌入孔231，可以加强一体注塑强度。
参照图6，在另一个折弯结构(即第二折弯结构23)的端部形成有厚度向外逐渐渐缩的导向插接部232，可以更便于与公端端子3插接配合。
进一步地，连接本体21至少部分为柔性导体，例如柔性导体为多芯线缆或编织线 缆或多层薄板叠加的软排。在公端端子3存在震动时，连接本体21可以更好的吸收震动，减少传递给铝线束1的震动；同时在装配时有更好的容错率。
上述两个折弯结构的具体弯折角度根据所使用的弯头电连接器中公端端子3的长度方向与铝线束1的轴向之间的夹角而定。例如应用于90°电连接器时，参照图5和图6，公端端子3的长度方向垂直于铝线束1的轴向，连接本体21和两个折弯结构均为板状结构，两个折弯结构的板面相互垂直并均垂直于连接本体21；其中一个折弯结构(即第一折弯结构22)的板面垂直于铝线束1的轴向，另一个折弯结构(即第二折弯结构23)的板面平行于公端端子3中与该折弯结构连接的端部的板面。
具体第一折弯结构22、连接本体21和第二折弯结构23的形状可以根据需要而定，例如本实施例中第一折弯结构22为圆形板，连接本体21为直角三角形板并具有过渡圆弧，且连接本体21的长度方向沿铝线束1的轴向延伸，第二折弯结构23为矩形板体。
由于冲压本身的工艺要求，铝线束1的轴线与连接本体21的外表面之间的间距L必然大于铝线束1的轴线与另一折弯结构(即第二折弯结构23)的外表面之间的间距T，如图6至图8所示；而且因大平方摩擦焊端子的摩擦焊工艺要求，间距L的值相对较大且要在一定尺寸范围内。
进一步优选地，两个折弯结构均沿平行于公端端子3的长度方向延伸，相较于现有大平方摩擦焊端子而言可以减小端子所占空间，可以保证电连接装置2所占横向尺寸较小(该横向尺寸也即垂直于铝线束1的轴线，也垂直于公端端子3的板面的尺寸)，便于缩小连接器的横向尺寸；尤其对于多芯端子(即铝线束1的数量大于等于两个时，各铝线束1平行并排布置)来说横向尺寸缩短更加明显；而且第二折弯结构23还可以保证与公端端子3的接触面积满足大平方数的要求。第二折弯结构23与连接本体21之间形成的弯折线沿铝线束1的轴线方向设置，在满足摩擦焊工艺要求时可以尽可能的靠近铝线束1的中心线，结构更加紧凑。
在可选的方式中，在电连接装置2的外侧一体注塑包裹有绝缘层，该绝缘层应避开第一折弯结构22与铝线束1的连接位置以及第二折弯结构23与公端端子3的连接位置，也即在电连接装置2与铝线束1和公端端子3接触的位置处不包裹绝缘层，电连接装置2的其余位置均包裹绝缘层，可以起到绝缘保护的作用，防止漏电。上述的多个嵌入孔231应分布在公端端子3的第一端两侧，利用嵌入孔231可以加强一体注塑强度。
作为优选地，公端端子3包括过渡端子31和设备端端子32，过渡端子31的第一端与电连接装置2(具体是指第二折弯结构23)插接固定，过渡端子31的第二端与设备 端端子32的第一端插接固定。
过渡端子31和设备端端子32可以按照图5中示出的板面相互平行，也可以根据需要采用其他的形状以及按照其他的方式布置。上述第二折弯结构23的板面应平行于公端端子3的端部板面，也即平行于过渡端子31第一端的板面，以便于第二折弯结构23与过渡端子31第一端的连接，同时便于保证两者的接触面积满足大平方数的要求。将公端端子3采用由过渡端子31和设备端端子32两部分构成，使用时，可以根据需要将不同形状、长度等不同结构形式的过渡端子31与不同形状(也可以弯曲)、长度等不同结构形式的设备端端子32(也可称为铜排端子)任意连接组合，更加灵活多样，使得连接器更适合多样的环境，满足连接器的多样化需求，通用性更强。
为了便于插接配合，参照图5和图9，在过渡端子31的第一端和第二端分别形成有第一插槽311和第二插槽312，电连接装置2(具体是指第二折弯结构23)插设在第一插槽311内，设备端端子32的第一端插设在第二插槽312内。该过渡端子31可以采用单片端子的形式，也可以按照图5中示出的由多个片状的端子叠加构成，再与设备端端子32插接。
进一步地，公头还包括插头外壳5和绝缘内壳4，电连接装置2和铝线束1的部分均穿设在绝缘内壳4内，绝缘内壳4穿设固定在插头外壳5内。该绝缘内壳4主要起到对电连接装置2和铝线束1的绝缘保护，铝线束1的相应端部可以伸出绝缘内壳4。
为了便于绝缘内壳4与插头外壳5之间的固定，插头外壳5的内壁上凸设有第一卡块511，绝缘内壳4的外壁上设有第一卡槽41，第一卡块511能卡设在第一卡槽41内。插头外壳5与绝缘内壳4之间通过卡扣定位锁紧，可以加强连接器的抗拉能力。
在可选的方式中，参照图3，在插头外壳5的内壁还设有插头绝缘内衬51，第一卡块511形成在插头绝缘内衬51的内壁上。该插头绝缘内衬51为灌胶结构，填充在插头外壳5和绝缘内壳4之间，利用插头绝缘内衬51可以对电连接装置2和铝线束1起到更好的保护作用。
参照图1和图4，在插头外壳5的后端连接有连接器尾壳52，在绝缘内壳4外套设有屏蔽锁止环53，屏蔽锁止环53与连接器尾壳52相接触，以实现外部屏蔽通路。该屏蔽锁止环53可以与绝缘内壳4一体注塑连接。
进一步地，母座包括插座外壳6，公端端子3穿设在插座外壳6内，插头外壳5和插座外壳6之间通过二次锁止装置7锁紧。二次锁止装置7的具体结构可以采用现有任一方式，本发明对此不进行限定。
为了便于公端端子3与插座外壳6的固定，插座外壳6的内壁上凸设有第二卡块，公端端子3上设有第二卡槽321(第二卡槽321具体是设在设备端端子32上)，第二卡块能卡设在第二卡槽321内。
在可选的方式中，在插座外壳6的内壁还设有插座绝缘内衬，第二卡块形成在插座绝缘内衬的内壁上。该插座绝缘内衬为灌胶结构，填充在插座外壳6内，利用插座绝缘内衬可以对公端端子3起到更好的保护作用。
在可选的方式中，所述折弯结构与所述铝线束1的连接处设置镀层，所述镀层为铜铝过渡层。铜铝过渡层设置在铜材质的折弯结构和铝材质的铝线束1的连接面上，铜原子和铝原子在热量和压力的作用下，相互渗透或相互结合形成铜铝过渡层，既避免铜铝之间发生电化学腐蚀，也提高了铜铝连接的电学性能和力学性能，使铜铝复合端子的机械性能和电学性能显著提高。
需要说明的是，所述铜铝过渡层中至少包含了铜单质、铝单质、铜铝固溶体与铜铝化合物。铜铝化合物为Cu2Al，Cu3Al2，CuAl，CuAl2中的一种或多种。
在可选的方式中，所述铜铝过渡层包含不少于6.5wt％的铜铝固溶体，当所述的铜铝过渡层包含铜铝固溶体少于6.5wt％时，则所述过铜铝过渡层内其他成分大于93.5wt％。所述铜铝过渡层中铜单质、铝单质比例大，代表铜铝焊接并不充分，铜铝单质没有融合为铜铝固溶体。所述铜铝过渡层中铜铝化合物比例大，铜铝化合物的导电性非常差，且铜铝化合物脆性较大，含量多的时候会降低铜铝复合端子的机械性能和电气性能。因此本发明所述的铜铝过渡层至少包含6.5wt％的铜铝固溶体。
为了论证不同铜铝固溶体在所述铜铝过渡层中的占比对折弯结构与铝线束1间的拉拔力和电压降的影响，考察了不同铜铝固溶体在所述铜铝过渡层中的占比的电连接器的拉拔力值、电压降值和焊接强度，结果参见表1。
表1：铜铝固溶体在铜铝过渡层中的占比对电连接器拉拔力和电压降的影响
从上表1可以看出，当铜铝过渡层中包含的铜铝固溶体小于6.5wt％时，折弯结构 与铝线束1间的拉拔力明显降低，而电压降明显上升，无法满足折弯结构与铝线束1的力学性能和电气性能要求。随着所述铜铝过渡层包含的铜铝固溶体占比逐渐增多，折弯结构与铝线束1连接的力学性能和电气性能逐渐增强，因此发明人设定，铜铝过渡层包含不少于6.5wt％的铜铝固溶体。
以上仅为本发明示意性的具体实施方式，并非用以限定本发明的范围。任何本领域的技术人员，在不脱离本发明的构思和原则的前提下所作出的等同变化与修改，均应属于本发明保护的范围。

Claims (20)

  1. 一种电连接器，其中，包括能插合的公头和母座以及电连接装置；
    所述公头包括至少一个铝线束和至少一个公端端子，所述电连接装置包括连接本体，所述连接本体的两端分别设有两个折弯结构，两个所述折弯结构向所述连接本体的同一侧延伸，两个所述折弯结构分别与所述铝线束和所述公端端子连接，所述公端端子穿设在所述母座内。
  2. 如权利要求1所述的电连接器，其中，
    所述电连接装置为一体冲压的板状结构。
  3. 如权利要求1所述的电连接器，其中，
    所述折弯结构与所述铝线束之间采用摩擦焊连接。
  4. 如权利要求1所述的电连接器，其中，
    在其中一个所述折弯结构上设有向外凹陷形成的凸起。
  5. 如权利要求1所述的电连接器，其中，
    在另一个所述折弯结构上开设有多个嵌入孔。
  6. 如权利要求1所述的电连接器，其中，
    在另一个所述折弯结构的端部形成有厚度向外逐渐渐缩的导向插接部。
  7. 如权利要求1所述的电连接器，其中，
    所述连接本体至少部分为柔性导体。
  8. 如权利要求7所述的电连接器，其中，
    所述柔性导体为多芯线缆或编织线缆或多层薄板叠加的软排。
  9. 如权利要求1所述的电连接器，其中，
    所述公端端子的长度方向垂直于所述铝线束的轴向，所述连接本体和两个所述折弯结构均为板状结构，两个所述折弯结构的板面相互垂直并均垂直于所述连接本体；其中一个所述折弯结构的板面垂直于所述铝线束的轴向，另一个所述折弯结构的板面平行于所述公端端子中与该折弯结构连接的端部的板面。
  10. 如权利要求9所述的电连接器，其中，
    所述铝线束的轴线与所述连接本体的外表面之间的间距大于所述铝线束的轴线与另一个所述折弯结构的外表面之间的间距。
  11. 如权利要求10所述的电连接器，其中，
    两个所述折弯结构均沿平行于所述公端端子的长度方向延伸。
  12. 如权利要求1所述的电连接器，其中，
    所述公端端子包括过渡端子和设备端端子，所述过渡端子的第一端与所述电连接装置插接固定，所述过渡端子的第二端与所述设备端端子的第一端插接固定。
  13. 如权利要求12所述的电连接器，其中，
    在所述过渡端子的第一端和第二端分别形成有第一插槽和第二插槽，所述电连接装置插设在所述第一插槽内，所述设备端端子的第一端插设在所述第二插槽内。
  14. 如权利要求1所述的电连接器，其中，
    所述公头还包括插头外壳和绝缘内壳，所述电连接装置和所述铝线束的部分均穿设在所述绝缘内壳内，所述绝缘内壳穿设固定在所述插头外壳内。
  15. 如权利要求14所述的电连接器，其中，
    在所述插头外壳的内壁还设有插头绝缘内衬。
  16. 如权利要求14所述的电连接器，其中，
    在所述插头外壳的后端连接有连接器尾壳，在所述绝缘内壳外套设有屏蔽锁止环，所述屏蔽锁止环与所述连接器尾壳相接触。
  17. 如权利要求14所述的电连接器，其中，
    所述母座包括插座外壳，所述公端端子穿设在所述插座外壳内，所述插头外壳和所述插座外壳之间通过二次锁止装置锁紧。
  18. 如权利要求17所述的电连接器，其中，
    在所述插座外壳的内壁还设有插座绝缘内衬。
  19. 如权利要求1所述的电连接器，其中，
    所述折弯结构与所述铝线束的连接处设置镀层，所述镀层为铜铝过渡层。
  20. 如权利要求19所述的电连接器，其中，
    所述铜铝过渡层包含不少于6.5wt％的铜铝固溶体。
PCT/CN2023/120262 2022-09-21 2023-09-21 电连接器 WO2024061304A1 (zh)

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CN115473095A (zh) * 2022-09-21 2022-12-13 吉林省中赢高科技有限公司 电连接器
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