TW202602013A - Power connector and its assembly method - Google Patents

Abstract

A power connector and a method of assembling the same are provided. The power connector includes a socket and a plug that can be connected together. The socket includes an insulated socket housing, a conductive body, and a locking member attached to the body but movable relative to the body. The body and the locking member are located within the socket housing. The locking member has a top portion and a rear portion angled relative to each other, and the rear portion has an opening therethrough. The plug includes a plug housing and a conductive pin. The pin passes through the body and engages with the rear portion of the locking member in a locked state.

Description

Power connector and its assembly method

Power connectors are used in high-current, high-voltage energy storage and distribution units. Such power connectors can be used in high-power applications such as computers, data servers, bus applications, and electric vehicle (EV) systems.

A power connector and its assembly method are provided.

In one embodiment, the power connector includes a socket and a plug that can be connected together. The socket includes an insulated socket housing, a conductive body, and a locking member attached to the body but movable relative to the body. The body and the locking member are located within the socket housing. The locking member has a top portion and a rear portion angled relative to each other, and the rear portion has an opening therethrough. The plug includes a plug housing and a conductive pin. The pin engages with the rear portion of the locking member in a locked state through the body.

In one embodiment, the pin can be released from the locking element.

A method for assembling a power connector is provided. The method includes: inserting a conductive pin into a channel of a conductive body having a flexible locking member thereon, the locking member having a top portion and a rear portion angled relative to each other, the top portion engaging the body, the rear portion having an opening therethrough that partially obscures the channel; engaging a free end of the pin with the rear portion of the locking member, thereby moving the locking member relative to the body; passing the free end of the pin through the locking member; and engaging the locking member with a shank of the pin.

Although the invention can readily be embodied in various forms, the embodiments shown in the drawings and described in detail herein are specific examples. It is understood that the invention should be considered as an example of its principles and is not intended to limit the invention to what is shown and described herein. Thus, unless otherwise stated, features of the invention may be combined to form other combinations not given for simplicity. It will be further appreciated that in some embodiments, one or more components shown by way of example in the drawings may be removed and/or replaced with alternative components within the scope of the invention.

This invention relates to a power connector 20 for high-current, high-voltage energy storage and distribution units. The power connector 20 can be used in high-power applications such as computers, data servers, bus applications, and electric vehicle (EV) systems.

As shown in Figures 1 and 2, the power connector 20 includes a socket 22 having a terminal 24 therein and a plug 26 configured to mate with the terminal 24. The socket 22 includes an insulated socket housing 28, a conductive socket 30, and a locking element 32. The plug 26 includes an insulated plug housing 34 and a conductive pin 36. The pin 36 is located within the terminal 24 and is releasably locked to the socket 30 by the locking element 32.

As shown in Figures 2 and 3, the socket housing 28 has a top wall 38, a front wall 40 and a rear wall 42 extending downward from the top wall 38, and opposing side walls 44, 46 extending between the front wall 40 and the rear wall 42. The top wall 38, the front wall 40 and the rear wall 42, and the opposing side walls 44, 46 define a cavity 48 that is open at one end. The cavity 48 opens at the bottom of the socket housing 28. The top wall 38 includes a fastener 50, which can be pressed into the cavity 48 to cause the fastener 50 to bend inward relative to the remainder of the top wall 38. The fastener 50 is separated from the remainder of the top wall 38 by gaps 52 surrounding the fastener 50 on three sides. The front wall 40 has an opening 54 extending through it, which communicates with the cavity 48. A chamfer 56 extends from the front surface of the front wall 40 to the opening 54. Both side walls 44 and 46 have fasteners 58 thereon, each fastener 58 having an inwardly extending barb 60 extending into the cavity 48 (shown in dashed lines in FIG. 1). The fasteners 58 are disengaged from the remainder of the side walls 44 and 46 through a gap 62. The fasteners 58 are capable of bending outward relative to the remainder of the side walls 44 and 46.

As best shown in Figure 4, the socket 30 includes an upper portion 64 and a lower portion 66 extending from a lower end of the upper portion 64. The upper portion 64 has a top surface 68, an opposing bottom surface 70, a front surface 72, an opposing rear surface 74, and two side surfaces 76, 78 extending between the front surface 72 and the rear surface 74. Each side surface 76, 78 has an elongated slot 80 extending from the rear surface 74 at its lower end. The lower portion 66 may be a threaded shank. An elongated slot 82 is provided on the top surface 68 and extends parallel to the front surface 72. The slot 82 may extend between the two side surfaces 76, 78. A step 84 is disposed in a middle portion of the slot 82. A pin receiving channel 86 may be formed on one side of the cylindrical surface, extending from the front surface 72 to the rear surface 74 and passing through the socket 30. An axial centerline of the socket 30 is defined between the front surface 72 and the rear surface 74. A chamfer 88 may be provided at the entrance on the front surface 72 of the pin receiving channel 86. A countersunk hole 90 is provided on the rear surface 74 surrounding the exit of the pin receiving channel 86.

The locking member 32 is formed as a flexible spring and may be made of stainless steel. The locking member 32 has a rear portion 92 and a top portion 94 extending from an upper end of the rear portion 92. The top portion 94 has a front lip 96 extending from its front end. Before assembly with the socket 30, as shown in FIG. 5, the rear portion 92 and the top portion 94 are preferably at a non-orthogonal angle A relative to each other, for example, eighty-two (82) degrees, but may also be orthogonal to each other, with the front lip 96 orthogonal to the top portion 94. The rear portion 92 includes an opening 98 extending through it. A top edge 100 of the opening 98 may be a straight line, and a bottom edge 102 of the opening 98 is generally U-shaped, see FIG. 2. The bottom edge 102 has a bend 104 on the front side of the rear portion 92, see Figure 4. The front lip 96 has a central notch 106 that generally reflects the shape of the step 84.

As shown in Figures 2 and 3, terminal 24 includes a conductive contact 108 and may include a conductive cap 110. Contact 108 may be formed from an annular connection 112, such that a plurality of spaced, flexible beams 114 are cantilevered from the annular connection 112, thereby forming a channel 116 extending from a front end to a rear end of contact 108 within them. The plurality of flexible beams 114 extend from one end of the connection 112, and each beam 114 is generally parallel to and radially spaced from an axial centerline of contact 108. The plurality of beams 114 are spaced apart from each other around the circumference of the connection 112. Each beam 114 may have: a first portion extending at an angle from the connection 112 at a corner; and a second portion extending at an angle from one end of the first portion at a corner. The first portion is inclined inward toward the axial centerline, and the second portion is inclined outward relative to the axial centerline. Multiple corners may be rounded and aligned around the circumference of the contact 108, defining an inner diameter. The cap 110 has: an annular first wall 118 defining an opening forming part of the channel 116; and a second wall 120 extending radially outward from and perpendicular to the first wall 118. Other forms of the contact 108 are within the scope of the invention.

As shown in Figure 6, the contact 108 is situated within the channel 86 of the socket 30 such that the rear end of the contact 108 is substantially aligned with the rear end of the socket 30, the front end of the contact 108 is spaced apart from the front end of the socket 30, and the axial centerline of the socket 30 is aligned with the axial centerline of the contact 108. An outer surface of the connecting portion 112 abuts against an inner surface of the wall forming the pin receiving channel 86 of the socket 30. A cap 110 secures the socket 30 and the contact 108 together. In one embodiment, the cap 110 is press-fitted to both the socket 30 and the contact 108. In another embodiment, the cap 110 is press-fitted into both the socket 30 and the contact 108. The wall 118 of the cap 110 abuts against the inner surface of the connector 112. The wall 120 is located within the countersunk hole 90. Other means for attaching the contact 108 to the socket 30 are within the scope of the invention. The cap 110 can be eliminated and the contact 108 can be directly attached to the socket 30.

Locking member 32 is seated on socket 30. The rear portion 92 of locking member 32 extends along and engages with the rear surface 74 of socket 30, the top portion 94 of locking member 32 extends close to the top surface 68 of socket 30, and the front lip 96 of locking member 32 is seated within groove 82. The rear portion 92 and the top portion 94 form an angle greater than ninety (90) degrees relative to each other. The central notch 106 of the front lip 96 engages with the step 84 of groove 82 with an interference fit to secure locking member 32 to socket 30. If wall 120 is provided, it is located between the rear portion 92 of locking member 32 and the rear surface 74 of socket 30.

A socket 30, having terminals 24 and a locking member 32 mounted thereon, is inserted into the cavity 48 of a socket housing 28 through its open bottom end. The socket 30 and terminals 24 form a conductive body. A fastener 58 bends outward to allow the upper portion 64 of the socket 30 to slide into the cavity 48. After the upper portion 64 of the socket 30 passes over the barb 60 on the fastener 58, the fastener 58 returns to its initial state and the barb 60 engages within the groove 80 of the upper portion 64 to prevent the socket 30 from moving within the cavity 48. A lower portion 66 extends downward from the socket housing 28. The lower surface of the fastener 50 on the top wall 38 of the socket housing 28 can engage with the upper surface of the top portion 94 of the locking member 32. The front surface 72 of the upper portion 64 of the socket 30 rests against the front wall 40 of the socket housing 28, and the axial channel 86 of the socket 30 is aligned with the opening 54 on the socket housing 28. A space 122 is provided between the rear portion 92 and the rear wall 42 of the socket 22.

Figures 7 and 8 illustrate a modification that can be mounted on an insulated socket housing 28. A front rib 124 extends upward from the top wall 38 and from the front wall 40; a first side rib 126 extends upward from the top wall 38 and from the side wall 44 and is located on the first side of the fastener 50 near the gap 52; and a second side rib 128 extends upward from the top wall 38 and from the side wall 46 and is located on the second side of the fastener 50 near the gap 52. The three ribs 124, 126, and 128 increase the distance between the uppermost surface of the socket housing 28 and the conductive components within the socket housing 28 to minimize arcing. The front rib 124 may be located only in front of the gap 52. No rib is provided at the rear end of the fastener 50 to allow easy access to the fastener 50 by the operator's fingers. Each fastener 58 has been modified to include multiple recesses 130 extending from one bottom end of its outer surface. Each fastener 58, its two gaps 62, and the multiple recesses 130 face and are covered by the cover portion 132, which extends outward from its respective sidewalls 44, 46. The cover portion 132 has an open upper end 134 and an open lower end 136. The cover portion 132 covers the gap 62 between the fastener 58 and the remaining portions of the sidewalls 44, 46. The upper end 134 and the lower end 136 of the opening allow airflow through the cover portion 132. The cover 132 prevents contact with the conductive components in the socket housing 28.

As shown in Figure 6, before assembly with the plug 26, a portion of the opening 98 on the rear 92 of the locking member 32 is aligned with the channel 116 of the terminal 24, and a bottom portion of the bottom edge 102 of the opening 98 is above a bottom of the channel 116 of the terminal 24, so that a portion of the channel 116 of the terminal 24 is partially obscured in the axial direction.

As shown in Figures 1 and 2, the plug housing 34 includes a front wall 138 and a side wall 140 extending rearward from the front wall 138. The front wall 138 has an opening 142 extending through it, and the two walls 138, 140 define a cavity 144 within them that opens to a rear end of the plug housing 34, see Figure 9. An axial centerline extends from the front wall 138 to the rear end of the plug housing 34. The opening 142 communicates with the cavity 144. The side wall 140 is shown in a cylindrical shape, but the side wall 140 can take other forms, such as, for example, a square cross-section. Referring to Figure 9, a plurality of spaced, flexible arms 146 extend inwardly from the side wall 140 into the cavity 144. The plurality of flexible arms 146 extend in the direction of the axial centerline of the plug housing 34.

In one embodiment, the pin 36 has a shank formed by a front portion 148 and a rear portion 150 extending from a rear end of the front portion 148. Each of the front portion 148 and the rear portion 150 may be cylindrical. A flange 152 extends radially outward from the front end of the rear portion 150. The front portion 148 has a diameter smaller than the diameter of the rear portion 150. The inner diameter defined by the corner of the contact 108 is smaller than the diameter of the front portion 148 of the pin 36. The front portion 148 has a circular free end 154, which may be hemispherical. A groove 156, which may be annular, extends around at least a portion of the circumference of the front portion 148 near the circular free end 154. The rear portion 150 may have a cavity therein extending from its rear end.

To assemble the pin 36 with the plug housing 34, the free end 154 of the pin 36 is inserted through the rear end of an opening, through a cavity 144, and then through a front opening 142. The front portion 148 extends in front of the front wall 138 of the plug housing 34. A flange 152 engages multiple arms 146 and causes the multiple arms 146 to move toward the side wall 140. Once the flange 152 has passed the multiple arms 146, the multiple arms 146 return to their initial position and engage the rear end of the flange 152. This secures the pin 36 to the plug housing 34.

To form the power connector 20, the plug 26 is inserted into the socket 22, as shown in Figures 9 to 12. The locking member 32 is initially in an unbent state, as shown in Figures 6 and 9. The free end 154 of the pin 36 passes through the opening 54 on the front end of the socket 22 and through the entrance of the pin receiving channel 86. Two chamfers 56 and 88 assist in guiding the pin 36 into the channel 116 of the terminal 24. As the pin 36 is further pushed into the socket 22, the free end 154 of the pin 36 engages with multiple bendable beams 114 and causes the multiple beams 114 to bend outward, see Figure 10. As the pin 36 is further pushed into the socket 22, with the multiple corners engaging the front portion 148, the front portion 148 of the pin 36 passes through multiple beams 114, and the rounded free end 154 engages with the bottom edge 102 of the rear portion 92 of the locking member 32, see Figure 10. As the pin 36 is further pushed into the socket 22, the rounded free end 154 causes the rear portion 92 of the locking member 32 to move vertically downward and place the locking member 32 in a flexed state, see Figure 11. The upper surface of the top portion 94 of the locking member 32 remains engaged with the lower surface of the fastener 50 against the top wall 38 of the socket housing 28, or may disengage from the lower surface of the fastener 50 as shown. The opening on the rear portion 92 is sized such that the top edge 100 of the opening 98 does not engage with the rounded end 154 of the pin 36. The rounded edge at the front of the bottom edge 102 assists in this movement of the rear portion 92. The rounded end 154 passes through the opening 98, and once the slot 156 aligns with the rear portion 92, the locking member 32 returns to its unbent state, and the bottom edge 102 rests within the slot 156, see FIG. 12, so that the locking member 32 moves into a locked state. The rounded end 154 rests within the space 122. As a result, the locking member 32 locks the plug 26 to the socket 22.

By pressing down the latch 50 on the socket housing 28, the plug 26 can be released from the socket 22, as shown in Figures 12 and 13. The pressed latch 50 engages the top 94 of the locking member 32, causing the rear 92 of the locking member 32 to move downward and out of the slot 156, see Figure 13, and enter a locked-out state. The top edge 100 of the opening 98 does not engage with the pin 36. Once the bottom edge 102 of the opening 98 on the rear 92 of the locking member 32 is no longer in the slot 156, the pin 36 can be axially pulled out of the socket 22, see Figure 14.

The lower portion 66 of the connector 30 is mounted on a substrate 158, such as a printed circuit board or a bus. In Figure 2, the substrate 158 is shown as a printed circuit board, wherein a conductive contact pad 160 on the upper surface of the substrate 158 surrounds a plated conductive through-hole 162. In the case of the printed circuit board, the bottom surface 70 of the connector 30 contacts the contact pad 160 and the lower portion 66 of the connector 30 extends into the through-hole 162. If a bus is provided as the substrate 158, the bus has a through-hole (similar to through-hole 162), the lower portion 66 of the connector 30 extends through the through-hole, and the bottom surface 70 of the connector 30 contacts a mating surface of the bus surrounding the through-hole. If the lower part 66 of the socket 30 is threaded, a washer 164 and a nut 166 can be secured to the opposite side of the substrate 158 to mount the socket 22 onto the substrate 158. The pins 36 of the plug 26 are electrically connected to another component (not shown). Current flows through the pins 36 of the plug 26, through the terminal 24, through the socket 30, and onto the substrate 158. The contact between the bottom surface 70 of the socket 30 and the contact pad 160 provides a large contact surface between the socket 30 and the substrate 158 for current transmission.

Although the socket 30 and the terminal 24 are described and shown as two separate components forming a conductive body, the socket 30 and the terminal 24 can be formed as a single piece.

Although terminal 24 and cap 110 are described and shown as two separate parts, terminal 24 and cap 110 can be formed as a single piece. Furthermore, in several embodiments of contact 108, countersunk hole 90 and wall 120 can be omitted.

This invention can be used to provide right-angle screw mounting for power connector 20.

Directional terms such as front, back, horizontal, and vertical are used for ease of explanation, but do not indicate the posture required when using them.

Although specific embodiments are shown and illustrated in the drawings, it is conceivable that those skilled in the art can devise various modifications without departing from the scope of the claims. Therefore, it will be appreciated that the scope of the invention and the claims is not limited to the specific embodiments shown and illustrated in the drawings, and modifications and other embodiments will be included within the scope of the invention and the appended drawings. Furthermore, although the foregoing description and associated drawings illustrate exemplary embodiments in the context of certain exemplary combinations of elements and/or functions, it should be appreciated that different combinations of elements and/or functions may be provided by alternative embodiments without departing from the scope of the invention and the claims. In addition, the foregoing describes a method for performing multiple steps. Unless otherwise stated, one or more steps in a method may be optional, one or more steps may be performed in a different order than described, and one or more steps may be formed substantially simultaneously. Finally, the diagrams are not necessarily drawn to scale.

20: Power connector 22: Socket/receptacle 24: Terminal 26: Plug 28: Socket/receptacle housing 30: Socket 32: Locking element 34: Plug housing 36: Pin 38: Top wall 40: Front wall 42: Rear wall 44, 46: Side wall 48: Cavity 50: Fastener 52: Gap 54: Opening 56: Chamfer 58: Side fastener 60: Barb 62: Gap 66: Lower part 64: Upper part 68: Top surface 70: Bottom surface 72: Front surface 74: Rear surface 76, 78: Side surface 80: Narrow groove 82: Groove 84: Step 86: Pin receiving channel 88: Chamfer 90: Countersunk hole 92: Rear part 94: Top part 96: Front lip part 98: Opening 100: Top edge 102: Bottom edge 104: Curved part 106: Central notch 108: Contact part 110: Cap body 112: Connecting part 114: Beam 116: Channel 118: First wall 120: Second wall 122: Space 124: Front rib 126: First side rib 128: Second side rib 130: Recess 132: Covering part 134: Upper end 136: Lower end 138: Front wall 140: Side wall 142: Opening 144: Cavity 146: Arm part 148: Front part 150: Rear part 152: Flange 154: Free end; 156: Groove; 158: Substrate; 160: Conductive contact pad; 162: Through hole; 164: Washer; 166: Nut; A: Angle

Referring to the drawings can help to better understand many aspects of the invention. The components in the drawings are not necessarily drawn to scale, but the focus is on clearly illustrating the principles of the invention. In addition, in the drawings, the same graphic symbols indicate corresponding parts across several views. Figure 1 shows a perspective view of a power connector according to various aspects of the present invention, the power connector shown mounted on a substrate; Figure 2 shows an exploded perspective view of the power connector and a substrate to which the power connector can be attached; Figure 3 shows an exploded perspective view of a socket and a terminal of the power connector; Figure 4 shows a perspective view of an assembled socket body of the socket and terminal, wherein a locking member is disassembled from the assembled socket body; Figure 5 shows a side view of the locking member; Figure 6 shows a cross-sectional view of the socket and terminal before assembly with a plug of the power connector; Figure 7 shows a perspective view of the socket, wherein the socket shows a modification thereof; Figure 8 shows a perspective view of the socket of Figure 7, shown in partial cross-section; Figures 9 to 12 show cross-sectional views of the socket, terminal, and plug during assembly; and Figures 13 and 14 show cross-sectional views of the socket, terminals, and plugs during disassembly.

20: Power connector

22: Sockets and outlets

26: Plug

28: Socket housing

34: Plug housing

46: Side wall

50: Fasteners

52: Gap

58: Side fasteners

60: Reverse Hook

62: Gap

138: Anterior Wall

140: Side Wall

158:Substrate

166: Nut

Claims (22)

A socket includes: a conductive body having a channel therethrough; a locking member connected to and movable relative to the body, the locking member having a top portion and a rear portion angled relative to each other, the top portion engaging the body, the rear portion having an opening therethrough, the opening at least partially aligned with the channel in the body; and a socket housing including an opening and a cavity extending from the opening, wherein the body and the locking member are situated within the cavity and the opening is aligned with the channel in the body. The socket as described in claim 1 is combined with a conductive pin, the pin being situated within a channel of the body and passing through an opening of the locking member to engage with the rear portion of the locking member in a locked state, wherein, prior to the assembly of the pin with the locking member, the rear portion of the locking member partially obscures a rear end of the channel. The combination as described in claim 2, wherein a bottom edge of the opening through the locking member has a chamfer thereon. The combination as described in claim 2, wherein the pin includes a groove in which the rear portion of the locking member sits when the locking member is in the locked state. The combination as described in claim 2, wherein the socket housing includes a depressable fastener that engages with the top of the locking member when the locking member is moved to a locked-out state. The combination as described in claim 5, wherein the pressable fastener is located on a top wall of the socket housing and separated from the top wall by a plurality of gaps, and wherein the socket housing further includes a plurality of ribs extending upward from the top wall, wherein the plurality of gaps are located between the plurality of ribs and the pressable fastener. As claimed in claim 2, the socket is wherein the rear end of the body and the rear end of the locking member are separated from a rear wall of the socket housing by a space, and wherein, in the locked state, a free end of the pin rests within the space. As claimed in claim 1, the socket housing includes a depressable fastener that engages with the top of the locking member when the locking member is moved to a locked-out state. As claimed in claim 8, the socket housing, wherein the retractable fastener is located on a top wall of the socket housing and separated from the top wall by a plurality of gaps, and wherein the socket housing further includes a plurality of ribs extending upward from the top wall, wherein the plurality of gaps are located between the plurality of ribs and the retractable fastener. The socket as claimed in claim 1, wherein the body includes a socket and a separate terminal disposed within the socket. The socket as claimed in claim 1, wherein the socket housing is formed of an insulating material and the locking member is formed of stainless steel. As described in claim 1, the socket is wherein, prior to assembly with the body, the top and rear portions of the locking member are angled relative to each other at an angle of 82 degrees. The socket as claimed in claim 1, wherein before being assembled with the body, the top and the rear are angled relative to each other at an angle of less than 90 degrees, and after being assembled with the body, the top and the rear are angled relative to each other at an angle of greater than 90 degrees. The socket as claimed in claim 1, wherein the top portion further includes a front lip that extends downward and engages within a groove in the body. The socket as claimed in claim 1, wherein the body has a lower portion that can be connected to a substrate. The socket as described in claim 1, wherein the locking element is a spring. As claimed in claim 1, the socket housing includes: a top wall; a front wall extending downward from the top wall, with the opening penetrating the front wall; a rear wall opposite the front wall; two side walls extending between the front wall and the rear wall; a plurality of ribs extending upward from the top wall; a depressable fastener located on the top wall, engaging with the locking member and separated from the top wall and the plurality of ribs through a plurality of gaps; side fasteners located on each side wall, engaging with the body and separated from their respective side walls through a plurality of gaps; and covers extending from each side wall and covering the exterior of each side fastener and the plurality of gaps. As claimed in claim 1, the socket housing includes: a top wall; a front wall extending downward from the top wall, with the opening penetrating the front wall; a rear wall opposite the front wall; two side walls extending between the front wall and the rear wall; side fasteners located on each side wall, engaging with the body and separating from each side wall through a plurality of gaps; and covers extending from each side wall and covering the exterior of each side fastener and the plurality of gaps. The socket as described in claim 1, wherein each cover has an upper opening and a lower opening. The socket as claimed in claim 1, wherein each side fastener has a plurality of recesses on its outer surface facing the cover. A method of assembling a power connector includes: inserting a conductive pin into a channel of a conductive body, the body having a flexible locking member thereon, the locking member having a top portion and a rear portion angled relative to each other, the top portion engaging the body, the rear portion having an opening therethrough that partially obscures the channel; engaging a free end of the pin with the rear portion of the locking member, thereby moving the locking member relative to the body; passing the free end of the pin through the locking member; and engaging the locking member with a shank of the pin. The method of claim 21 further includes removing the pin from the body by pressing down a fastener engaged with the locking member.