The present disclosure relates to a busbar connector and a power terminal with cables, and more particularly to a busbar connector and a power terminal with cables capable of improving the current carrying capacity.
Generally, the heat dissipation effect of busbar connectors which are used to transmit large currents directly affects the current carrying capacity. In the existing busbar connectors, when a power terminal is connected to multiple cables, the exposed copper wires of the multiple cables are stacked in multiple rows and are placed on a crimping portion of the power terminal. However, while the multiple cables are being crimped in multiple rows, a large force needs to be applied to the crimping portion for crimping the exposed copper wires therein, so as to avoid insufficient crimping and causing the cable to fall off. In addition, after crimping, the crimped portions of the power terminal form a cylindrical or ring-cylindrical shape, and there are gaps between the copper wires and between the crimped portion and the copper wires. Therefore, the contact resistance between the power terminal and the cables is not easily reduced, thereby lowering the current carrying capacity of the busbar connectors.
Therefore, how to improve structural design and overcome the above-mentioned inadequacies has become an important issue to be addressed in the relevant art.
In response to the above-referenced technical inadequacies, the present disclosure provides a busbar connector and a power terminal with cables capable of improving the current carrying capacity.
In order to solve the above-mentioned problems, one of the technical aspects adopted by the present disclosure is to provide a busbar connector, which includes a housing, two terminal sets, and a plurality of cables. The housing includes two upright portions, and the two upright portions are opposite to each other and jointly form the socket. The two terminal sets are inserted into the housing. Each of the terminal sets includes at least one power terminal. The at least one power terminal includes a contact portion, a fixing portion, and a crimping portion. The fixing portion is connected between the contact portion and the crimping portion. The plurality of cables are arranged in a single row, and one end of the plurality of cables is fixedly connected to the crimping portion. The crimping portion has a cross section that is perpendicular to an extending direction of the plurality of cables, and an aspect ratio of the cross section is greater than or equal to 3.
In order to solve the above-mentioned problems, another one of the technical aspects adopted by the present disclosure is to provide a power terminal with cables, which includes a power terminal and at least three cables. The power terminal includes a contact portion, a fixing portion, and a crimping portion. The fixing portion is connected between the contact portion and the crimping portion. The at least three cables are arranged in a single row, and one end of the at least three cables is fixedly connected to the crimping portion. The crimping portion has a cross section that is perpendicular to an extending direction of the at least three cables, and an aspect ratio of the cross section is greater than or equal to 3.
Therefore, in the busbar connector and the power terminal with cables provided by the present disclosure, by virtue of “the plurality of cables being arranged in a single row, and one end of the plurality of cables being fixedly connected to the crimping portion” and “the crimping portion having a cross section that is perpendicular to an extending direction of the plurality of cables, and an aspect ratio of the cross section being greater than or equal to 3,” the plurality of cables are connected to the power terminal in a single row arrangement, such that contact areas between the crimp portion of the power terminal and the cables can be increased to reduce contact resistance, and surface areas of each of the cables that are in contact with the air can be increased (i.e., the heat dissipation area are increased), thereby improving heat dissipation efficiency and increasing current carrying capacity.
These and other aspects of the present disclosure will become apparent from the following description of the embodiment taken in conjunction with the following drawings and their captions, although variations and modifications therein may be affected without departing from the spirit and scope of the novel concepts of the disclosure.
The described embodiments may be better understood by reference to the following description and the accompanying drawings, in which:
The present disclosure is more particularly described in the following examples that are intended as illustrative only since numerous modifications and variations therein will be apparent to those skilled in the art. Like numbers in the drawings indicate like components throughout the views. As used in the description herein and throughout the claims that follow, unless the context clearly dictates otherwise, the meaning of “a,” “an” and “the” includes plural reference, and the meaning of “in” includes “in” and “on.” Titles or subtitles can be used herein for the convenience of a reader, which shall have no influence on the scope of the present disclosure.
The terms used herein generally have their ordinary meanings in the art. In the case of conflict, the present document, including any definitions given herein, will prevail. The same thing can be expressed in more than one way. Alternative language and synonyms can be used for any term(s) discussed herein, and no special significance is to be placed upon whether a term is elaborated or discussed herein. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification including examples of any terms is illustrative only, and in no way limits the scope and meaning of the present disclosure or of any exemplified term. Likewise, the present disclosure is not limited to various embodiments given herein. Numbering terms such as “first,” “second” or “third” can be used to describe various components, signals or the like, which are for distinguishing one component/signal from another one only, and are not intended to, nor should be construed to impose any substantive limitations on the components, signals or the like.
Referring to
The housing 1 includes two upright portions 11. The two upright portions 11 are opposite to each other and jointly form a socket C1. As shown in
Each of the terminal sets 2 includes one or more power terminals, and a quantity of the power terminal is not limited in the present disclosure. Referring to
Referring to
Referring to
Each of the cables 3 is a plurality of conductors covered with an insulating sheath, and one ends of the conductors are not covered by the insulating sheath and are exposed as a plurality of conductive wires 30. Referring to
Referring to
Referring to
Each of the terminal sets further includes a snap-fitting member 24. A slot 2120 is formed on one side of the fixing portion 212 of the first power terminal 21. A slot 2220 is formed on one side of the fixing portion 222 of the second power terminal 22. A slot 2320 is formed on one side of the fixing portion 232 of the support terminal 23. When the support terminal 23, the first power terminal 21, and the second power terminal 22 are stacked to each other, the slots 2120, 2220, and 2320 are also stacked to each other. Furthermore, the snap-fitting member 24 is snapped into the slots 2120, 2220, and 2320. A quantity of the snap-fitting member 24 is not limited in the present disclosure. As shown in
Moreover, the snap-fitting member 24 includes a U-shaped beam 241. The housing 1 includes a fastening hole V. When each of the terminal sets 2 is inserted into the housing 1, the U-shaped beam 241 is snapped on the fastening hole V. Therefore, the first power terminal 21, the second power terminal 22, and the support terminal 23 can be locked up through the snap-fitting member 24, and fixed in the housing 1 to prevent the terminal set 2 from being detached from the housing 1.
Each of the terminal sets 2 further includes a plurality of fixing pins 26. The fixing portion 212 of the first power terminal 21 has a plurality of through holes 212H corresponding to the plurality of fixing pins 26. The fixing portion 222 of the second power terminal 22 has a plurality of through holes 222H corresponding to the plurality of fixing pins 26. The fixing portion 232 of the support terminal 23 has a plurality of through holes 232H corresponding to the plurality of fixing pins 26. Therefore, each of the fixing pins 26 passes through the plurality of through holes 212H, 222H, and 232H to connect the first power terminal 21, the second power terminal 22, and the support terminal 23 together.
Referring to
The housing 1 further includes two wing portions 12, which respectively correspond to the two upright portions 11. Each of the wing portions 12 is perpendicular to a corresponding one of the upright portions 11. The housing 1 has a plurality of first fastener portions 111 respectively corresponding to the plurality of first engaging members 2511 at a top edge of each of the upright portions 11, and the housing 1 has a plurality of second fastener portions 121 respectively corresponding to the plurality of second engaging members 2521 at an edge of each of the wing portions 12.
When the two grounding terminals 25 are respectively disposed at the two sides of the housing 1, the two first sections 251 of the two grounding terminals 25 are respectively disposed at the two upright portions 11, such that the plurality of first engaging members 2511 are respectively snapped on the plurality of first fastener portions 111, and the plurality of second engaging members 2521 are respectively snapped on the plurality of second fastener portions 121, so as to fix the two grounding terminals 25 on the housing 1.
For example, each of the first engaging members 2511 is a hook, and each of the first fastener portions 111 is a slot. Each of the second engaging members 2521 is a perforated fixing piece, and each of the second fastener portions 121 is a protruding rib. In addition, the second section 252 of each of the grounding terminals 25 includes at least one locking hole 250, and each of the wing portions 12 of the housing 1 includes at least one positioning pad P corresponding to the at least one locking hole 250. When each of the grounding terminals 25 is disposed on the housing 1, the at least one locking hole 250 is snapped on the at least one positioning pad P. As shown in
Referring to
Moreover, the fixing portion 212 of the first power terminal 21 includes a first fixing section 2121 and a second fixing section 2122 that are separable from each other. The first fixing section 2121 is connected to the contact portion 211, the second fixing section 2122 is connected to the crimping portion 213, and the first fixing section 2121 can be connected to the second fixing section 2122 through the fixing pins 26 Similarly, the fixing portion 222 of the second power terminal 22 includes a first fixing section 2221 and a second fixing section 2222 that are separable from each other. The first fixing section 2221 is connected to the contact portion 221, and the second fixing section 2222 is connected to the crimping portion 223. In other words, in the second embodiment, each of the power terminals can be divided into a plurality of parts. In addition, in the second embodiment, the power terminals have no support terminals.
Moreover, the first fixing section 2121 and the second fixing section 2122 of the first power terminal 21 have a plurality of through holes 212H, and the first fixing section 2221 and the second fixing section 2222 of the second power terminal 22 have a plurality of through holes 222H. The first power terminal 21 and the second power terminal 22 are assembled through the plurality of fixing pins 26 passing through the plurality of through holes 212H and 222H.
As shown in
In the busbar connector and the power terminal with cables provided by the present disclosure, by virtue of “the plurality of cables being arranged in a single row, and one end of the plurality of cables being fixedly connected to the crimping portion” and “the crimping portion having a cross section that is perpendicular to an extending direction of the plurality of cables, and an aspect ratio of the cross section being greater than or equal to 3,” the plurality of cables are connected to the power terminal in a single row arrangement, such that contact areas between the crimp portion of the power terminal and the cables can be increased to reduce contact resistance, and surface areas of each of the cables in contact with the air can be increased (i.e., the heat dissipation area are increased), thereby improving heat dissipation efficiency and increasing current carrying capacity.
Moreover, in the present disclosure, the plurality of power terminals (i.e., the first power terminal 21 and the second power terminal 22) are connected to the plurality of cables. Each of the power terminals is connected to the plurality of cables arranged in a single row. The crimping portions of the power terminals are spaced apart from and not in contact with each other, so as to increase the airflow space and improving heat dissipation efficiency and current carrying capacity. In addition, through the staggered arrangement of the plurality of first contact arms 2111 of the first power terminal 21 and the plurality of second contact arms 2211 of the second power terminal 22, the quantities of electrical contact points can be increased to enhance the conductive areas as much as possible, thereby reducing contact resistance.
The foregoing description of the exemplary embodiments of the disclosure has been presented only for the purposes of illustration and description and is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching.
The embodiments were chosen and described in order to explain the principles of the disclosure and their practical application so as to enable others skilled in the art to utilize the disclosure and various embodiments and with various modifications as are suited to the particular use contemplated. Alternative embodiments will become apparent to those skilled in the art to which the present disclosure pertains without departing from its spirit and scope.
This application claims the benefit of priority to the U.S. Provisional Patent Application Ser. No. 63/472,640, filed on Jun. 13, 2023, which application is incorporated herein by reference in its entirety. Some references, which may include patents, patent applications and various publications, may be cited and discussed in the description of this disclosure. The citation and/or discussion of such references is provided merely to clarify the description of the present disclosure and is not an admission that any such reference is “prior art” to the disclosure described herein. All references cited and discussed in this specification are incorporated herein by reference in their entireties and to the same extent as if each reference was individually incorporated by reference.
Number | Date | Country | |
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63472640 | Jun 2023 | US |