CN116528535B - Electric connector assembly structure, distribution box and preparation method of distribution box - Google Patents
Electric connector assembly structure, distribution box and preparation method of distribution box Download PDFInfo
- Publication number
- CN116528535B CN116528535B CN202310805437.1A CN202310805437A CN116528535B CN 116528535 B CN116528535 B CN 116528535B CN 202310805437 A CN202310805437 A CN 202310805437A CN 116528535 B CN116528535 B CN 116528535B
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- shell
- electric
- relay
- shell body
- electric connector
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- 238000009826 distribution Methods 0.000 title claims abstract description 39
- 238000002360 preparation method Methods 0.000 title abstract description 7
- 238000001746 injection moulding Methods 0.000 claims abstract description 16
- 238000002347 injection Methods 0.000 claims description 10
- 239000007924 injection Substances 0.000 claims description 10
- 239000000463 material Substances 0.000 claims description 10
- 238000004080 punching Methods 0.000 claims description 5
- 229920001169 thermoplastic Polymers 0.000 claims description 5
- 229920001187 thermosetting polymer Polymers 0.000 claims description 5
- 239000004416 thermosoftening plastic Substances 0.000 claims description 5
- 238000004519 manufacturing process Methods 0.000 claims description 3
- 230000017525 heat dissipation Effects 0.000 abstract description 10
- 230000005540 biological transmission Effects 0.000 abstract description 3
- 238000001816 cooling Methods 0.000 description 11
- 238000009434 installation Methods 0.000 description 7
- 239000012778 molding material Substances 0.000 description 5
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 4
- 229910052802 copper Inorganic materials 0.000 description 4
- 239000010949 copper Substances 0.000 description 4
- 238000013461 design Methods 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 238000010030 laminating Methods 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 238000012423 maintenance Methods 0.000 description 3
- 238000000465 moulding Methods 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 229920003023 plastic Polymers 0.000 description 3
- 239000003507 refrigerant Substances 0.000 description 3
- 238000005070 sampling Methods 0.000 description 3
- 206010011469 Crying Diseases 0.000 description 2
- 238000004146 energy storage Methods 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 230000005855 radiation Effects 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 238000009825 accumulation Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 239000011435 rock Substances 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K5/00—Casings, cabinets or drawers for electric apparatus
- H05K5/02—Details
- H05K5/0247—Electrical details of casings, e.g. terminals, passages for cables or wiring
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
- B60L3/0023—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train
- B60L3/0046—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train relating to electric energy storage systems, e.g. batteries or capacitors
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/28—Clamped connections, spring connections
- H01R4/30—Clamped connections, spring connections utilising a screw or nut clamping member
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
- H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
- H02J7/0042—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries characterised by the mechanical construction
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/02—Arrangements of circuit components or wiring on supporting structure
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/20218—Modifications to facilitate cooling, ventilating, or heating using a liquid coolant without phase change in electronic enclosures
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/2039—Modifications to facilitate cooling, ventilating, or heating characterised by the heat transfer by conduction from the heat generating element to a dissipating body
- H05K7/20436—Inner thermal coupling elements in heat dissipating housings, e.g. protrusions or depressions integrally formed in the housing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/70—Energy storage systems for electromobility, e.g. batteries
Abstract
The invention provides an electric connector assembly structure, a distribution box and a preparation method thereof, wherein the electric connector assembly structure comprises an electric connector and a shell, the electric connector and the shell are in an injection molding integrated structure, the electric connector comprises a first part and at least one second part, the shell comprises a shell body and a fixing part, and the first part is attached to the outer wall of the shell body; the second part is formed by stamping the first part, protrudes into the shell body to form a groove, penetrates through the shell body, is provided with a notch at one side, and is used for connecting an electric element; the shell body extends into the groove through the notch to form a fixing part. According to the structure, the electric connecting piece and the shell are in an integrated structure through injection molding, the second part of the electric connecting piece stretches into the shell, and the first part is positioned on the outer side of the shell, so that when the electric connecting piece and the electric element generate heat due to transmission current, heat can be emitted to the outside of the shell through the first part, and effective heat dissipation is achieved.
Description
Technical Field
The invention relates to the technical field of power distribution, in particular to an electric connector assembly structure, a distribution box and a preparation method of the distribution box.
Background
The distribution box is a battery energy distribution unit, is an important part on a high-voltage loop of an electric automobile, is usually arranged in a battery box, is directly connected with a power battery through a high-voltage plug-in unit, is used for controlling the charge and discharge of the battery box, and is important for the safety of the whole automobile; as an electrical component, the heat-dissipating device has good heat-dissipating performance, and is directly related to the working stability and service life of the device.
The invention patent application with the prior application publication number of CN113829882A discloses a high-voltage distribution box electric automobile, in the technical scheme, a large number of copper bars are adopted for connection among electric elements, the distribution box is used as an electric energy distribution unit, heat is generated by the copper bars and the electric elements during operation, the copper bars and the electric elements are arranged in a box body, heat cannot be dissipated, the temperature of the distribution box is seriously increased, and the normal operation of the distribution box is easily affected;
the invention patent application with the publication number of CN115474416A discloses a BDU integrated heat dissipation device and an electric vehicle, and relates to the technical field of batteries. According to the technical scheme, the liquid cooling plate substrate is fixedly arranged on the surface of the BDU body assembly so as to radiate BDU, and the electrical elements of the BDU need to transfer heat to the BDU body through air and then to the liquid cooling plate, so that the radiation efficiency is low;
the invention patent application with the prior application publication number of CN116131047A provides an automobile BDU electric connector, an automobile BDU and a BDU heat dissipation method, wherein a flow channel is arranged in a bus, and a connector communicated with the flow channel is arranged on the bus, so that the temperature of the BDU is reduced in a mode of feeding a refrigerant into the bus. But this kind of radiating mode, its one needs to lay refrigerant conveying line, this structural layout in can influencing BDU block terminal, has improved the design degree of difficulty, has improved the assembly degree of difficulty simultaneously, and has the weeping risk, even adopts insulating refrigerant, also easily produces conductive short circuit because of dissolving into impurity when the weeping, is unfavorable for subsequent maintenance work.
Disclosure of Invention
In view of the above, the invention provides an electric connector assembly structure, a distribution box and a preparation method thereof, which can improve convenience in assembly and disassembly of components while ensuring good heat dissipation efficiency, so as to solve the problems of low heat dissipation efficiency, inconvenient disassembly and maintenance and the like of the existing distribution box heat dissipation structure.
The technical scheme of the invention is realized as follows:
in one aspect, the invention provides an electrical connector assembly structure comprising an electrical connector and a housing, the electrical connector and the housing being injection molded as a unitary structure, wherein,
the electrical connector comprises a first portion and at least one second portion, the housing comprises a housing body and a securing portion, wherein,
a first part which is attached to the outer wall of the shell body;
the second part is formed by stamping the first part, protrudes into the shell body to form a groove, penetrates through the shell body, is provided with a notch at one side, and is used for connecting an electric element;
the shell body extends into the groove through the notch to form a fixing part.
On the basis of the above technical scheme, preferably, the fixing portion is of a U-shaped plate structure, and the fixing portion is attached to the side wall of the second portion perpendicular to the shell body.
On the basis of the above technical scheme, preferably, the connection part of the second part and the first part is provided with a first arc-shaped chamfer part, and the fixing part extends to the first part and is attached to the first arc-shaped chamfer part.
On the basis of the technical scheme, preferably, the shell further comprises an end plate, the end plate is arranged at the notch, and the end plate, the shell body and the fixing part are in an injection molding integrated structure.
On the basis of the above technical scheme, preferably, the edge of the side of the second part protruding to the inside of the shell body is provided with a second arc chamfer part, the shell further comprises an insulating part, the insulating part is positioned at the outer side of the groove and is in an integral structure with the shell in an injection molding way, and the insulating part is attached to the second arc chamfer part.
On the basis of the technical proposal, the heat-conducting shell also preferably comprises an insulating film and a heat-conducting pad, the outer wall of the shell body is provided with a containing groove, wherein,
the accommodating groove is used for accommodating the first part;
an insulating film adhering the first portion to the case body;
and the heat conducting pad is attached to one surface of the insulating film, which is far away from the shell body.
On the basis of the technical proposal, the novel screw bolt is preferable to further comprise a bolt, wherein the bolt comprises a head part and a screw part, the head part and the screw part are of an integrated structure, and the screw part is provided with a screw hole,
a head located within the recess;
the screw rod part penetrates through the shell body and the second part, extends into the shell body and is in threaded connection with the electric element.
On the other hand, the invention provides a distribution box, which comprises the electric connecting piece assembling structure, wherein the shell is the shell of the distribution box, and the electric elements comprise a fuse, a main positive relay, a quick charging relay, a pre-charging resistor, a pre-charging relay, a shunt and a main negative relay, so as to form a positive pole loop, a pre-charging loop and a negative pole loop,
the fuse, the main positive relay and the quick charging relay are electrically connected in series in sequence to form a positive pole loop;
the pre-charging resistor is electrically connected with the pre-charging relay in series, and the pre-charging resistor and the pre-charging relay are electrically connected with the main positive relay in parallel to form a pre-charging loop;
the shunt is electrically connected with the main negative relay in series to form a negative pole loop.
On the basis of the technical proposal, preferably, at least two electric connecting pieces are arranged on the shell, at least two second parts are arranged on the electric connecting pieces, positioning plates are arranged on the main positive relay, the quick charging relay and the main negative relay, positioning grooves are arranged between the notch of the two electric connecting pieces,
two second parts, each for electrically connecting one electric element, so as to realize the electrical connection between the two electric elements;
the positioning groove is formed in the shell body;
the positioning plate is spliced with the positioning groove and used for mounting and positioning the electric element.
In still another aspect, the present invention provides a method for manufacturing the above-mentioned electrical box, comprising the steps of:
s1, firstly, punching a material with conductivity to form an electric connector with a first part and a second part;
s2, placing the electric connecting piece into a cavity of a mold, wherein the cavity of the mold corresponds to the shape of the shell;
s3, injecting a thermoplastic or thermosetting material into a cavity of the die, forming a shell with a shell body and a fixing part by the thermoplastic or thermosetting material, after the shell is cooled and molded, fixing the electric connector by the fixing part matched with the shell body, and then taking the electric connector out of the die;
s4, placing and fixing all the electric elements in the shell, and then completing electric connection among all the electric elements so as to form a positive pole loop, a pre-charging loop and a negative pole loop, wherein the main positive relay, the quick charging relay and the main negative relay are respectively inserted and positioned with the positioning groove through one positioning plate.
Compared with the prior art, the electric connecting piece assembly structure, the distribution box and the preparation method thereof have the following beneficial effects:
(1) The electric connector and the shell are in an integrated structure through injection molding, wherein the second part of the electric connector stretches into the shell, the first part is positioned on the outer side of the shell, when the electric connector and the electric element generate heat due to transmission current, heat can be conducted to the first part through the second part of the electric connector, so that the heat is emitted to the outside of the shell, effective heat dissipation is realized, the heat is prevented from being accumulated in the shell, meanwhile, a water cooling plate is arranged outside the shell and is used for connecting the first part of the electric connector, the heat dissipation efficiency is further improved, and the pipe orifice of the water cooling plate does not influence the electric element even if liquid leaks, and the arrangement of the structure has good use safety; the arrangement of the structure does not need to add a cooling component in the shell, reduces the design difficulty and improves the convenience of disassembly, assembly and maintenance;
(2) The second part protrudes to the inside of the shell to form a groove, so that a fixing part can be formed in the groove when the shell is injection molded, and the electric connector is clamped through the shell body and the fixing part, so that the installation stability of the electric connector is further improved;
(3) The electric element is installed through the bolt, the head of the bolt is positioned in the groove formed in the second part, and the screw rod part penetrates through the shell body and stretches into the shell and is in threaded connection with the electric element;
(4) The positioning groove is formed in the shell body, and the positioning plate is arranged on the electric element, so that when the electric element is installed, the electric element can be positioned by inserting the positioning groove through the positioning plate, the fixing bolt hole or the conductive bolt hole of the electric element is conveniently aligned with the second part, and the convenience of connection of the bolt and the electric element is improved;
(5) The first portion laminating is provided with insulating film and heat conduction pad, and this is convenient to the water-cooling subassembly heat conduction of laying at the casing external world, can be used to the insulation of electrical connection piece simultaneously.
Drawings
In order to more clearly illustrate the embodiments of the invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, it being obvious that the drawings in the following description are only some embodiments of the invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
Fig. 1 is a perspective view of a distribution box of the present invention;
fig. 2 is a top view of the electrical box of the present invention;
FIG. 3 is a cross-section taken along the direction A-A in FIG. 2 in accordance with the present invention;
FIG. 4 is an enlarged view of the structure of the point A in FIG. 3 according to the present invention;
fig. 5 is a bottom structural view of the distribution box of the present invention;
FIG. 6 is an enlarged view of the structure at point B of FIG. 5 in accordance with the present invention;
fig. 7 is a front view of the power distribution box of the present invention;
FIG. 8 is a block diagram of the bottom of the housing of the electrical connector assembly of the present invention;
fig. 9 is a structural view showing connection of electrical components of the distribution box of the present invention by means of electrical connectors;
FIG. 10 is a block diagram of an electrical connector of the electrical connector assembly structure of the present invention;
FIG. 11 is a bottom view of an electrical connector of the electrical connector assembly structure of the present invention;
FIG. 12 is a block diagram of a quick charge relay of the electrical connector assembly of the present invention;
fig. 13 is an electrical schematic of the electrical box of the present invention;
in the figure: 1. an electrical connection; 111. a first section; 112. a second section; 113. a third section; 101. a groove; 102. a notch; 103. a sidewall; 104. a first arc-shaped chamfer portion; 105. a second arc-shaped chamfer portion; 2. a housing; 21. a housing body; 22. a fixing part; 23. an end plate; 24. an insulating part; 25. a positioning part; 201. a receiving groove; 202. a positioning groove; 3. an insulating film; 4. a thermal pad; 5. a bolt; 51. a head; 52. a screw portion; 6. a fuse; 7. a main positive relay; 8. a fast charging relay; 9. pre-charging a resistor; 10. pre-charging a relay; 11. a shunt; 12. a main negative relay; 13. a sampling connector; 14. binding posts; 00. and (5) positioning the plate.
Detailed Description
The following description of the embodiments of the present invention will clearly and fully describe the technical aspects of the embodiments of the present invention, and it is apparent that the described embodiments are only some embodiments of the present invention, not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the present invention without making any inventive effort, are intended to fall within the scope of the present invention.
As shown in fig. 1 to 13, the electric connector assembly structure of the present invention includes an electric connector 1, a housing 2, an insulating film 3, a heat conducting pad 4 and a bolt 5;
the electric connector assembly structure can be applied to distribution boxes such as BDU, PDU and the like, and can also be applied to various boxes needing to be provided with electric elements;
the distribution box comprises the connecting piece assembling structure, and further comprises a fuse 6, a main positive relay 7, a quick charging relay 8, a pre-charging resistor 9, a pre-charging relay 10, a shunt 11, a main negative relay 12 and a positioning plate 00.
As shown in fig. 3 to 5, the electrical connector 1 and the housing 2 are injection molded into an integral structure;
specifically, as shown in fig. 6, 10 and 11, the electrical connector 1 includes a first portion 111 and at least one second portion 112, and the housing 2 includes a housing body 21 and a fixing portion 22;
as shown in fig. 4 to 6, the first portion 111 is provided to be bonded to the outer wall of the case body 21; a second portion 112 formed by punching the first portion 111, the second portion 112 protruding into the case body 21 to form a groove 101, the second portion 112 penetrating through the case body 21, and a slot 102 being formed at one side of the second portion 112, the second portion 112 being for connecting an electrical component; the shell body 21 extends into the groove 101 through the notch 102 to form a fixing part 22;
in the above structure, when the electric connector 1 is injection molded with the housing 2, the material for injection molding the housing 2 forms the housing body 21 to cover one surface of the electric connector 1, and the injection molding material flows into the groove 101 through the notch 102 to form the fixing portion 22, and at this time, the fixing portion 22 cooperates with the housing body 21 to clamp the protruding second portion 112, so as to realize injection molding connection between the electric connector 1 and the housing 2; the whole structure is simple, and the production is convenient;
the second part 112 protrudes into the shell 2, so that the electric elements in the shell 2 are conveniently connected for current transmission, when the electric connector 1 and the electric elements work, generated heat is conducted to the first part 111 by the second part 112, and the heat is radiated through the first part 111 positioned outside the shell 2, so that the heat accumulation in the shell 2 can be avoided, the radiating efficiency of the distribution box is effectively improved, and the high temperature is prevented from influencing the working stability and the service life of the distribution box; meanwhile, as the cooling measures such as cooling pipelines are not required to be arranged in the distribution box, the design difficulty and the assembly difficulty of the distribution box are reduced.
As shown in fig. 3 to 6, the fixing portion 22 has a U-shaped plate structure, and the fixing portion 22 is attached to the second portion perpendicular to the side wall 103 of the housing body 21;
in the above structure, the fixing portion 22 is engaged with the side wall 103 of the housing body 21 to expose the protruding surface of the second portion 112, so that the housing 2 can fix the electrical connector 1 and simultaneously electrically connect the electrical component with the protruding surface of the second portion 112, thereby avoiding the problem of connection interference.
Further, as shown in fig. 4, a first arc chamfer 104 is provided at the connection between the second portion 112 and the first portion 111, and the fixing portion 22 extends toward the first portion 111 and is attached to the first arc chamfer 104;
like above-mentioned structure, when fixed part 22 extends and laminating first arc chamfer portion 104, fixed part 22 has the turn-ups portion, namely laminating first arc chamfer portion 104's part, this stability that can further improve electric connector 1 and casing 2 injection molding, this can avoid electric connector 1 and casing 2's interface separation of moulding plastics, even the interface separation of moulding plastics, electric connector 1 also is difficult for taking place to rock by a wide margin, this has improved the structural integrity of moulding plastics, and the job stabilization nature of this structure application, make this electric connection assembly structure more be applicable to the vibration environment.
Further, as shown in fig. 4, the edge of the surface of the second portion 112 protruding toward the inside of the shell body 21 is provided with a second arc chamfer portion 105, the shell 2 further includes an insulating portion 24, the insulating portion 24 is located at the outer side of the groove 101 and is injection-molded with the shell body 21 into an integral structure, and the insulating portion 24 is attached to the second arc chamfer portion 105;
in the above structure, after the insulating portion 24 is attached to the second arc chamfer portion 105, the injection connection stability of the electric connector 1 and the housing 2 can be further improved, the insulating portion 24 and the fixing portion 22 clamp the second portion 112 from both sides, the integrity of the injection structure can be further improved, and even when the housing 2 is heated, vibrated and subjected to shearing force, the electric connector 1 and the housing 2 are not easy to separate; the insulating part 24 and the fixing part 22 are oppositely arranged and are attached to the structure of the electric connector 1, so that the stability of the installation structure of the electric connector 1 is ensured, the space is not occupied too much, the portability can be ensured, and the electric connector has important significance on the energy density of the energy storage assembly, which is not influenced as much as possible after the electric connector is applied to the electric energy storage assembly.
Further, the housing 2 further includes an end plate 23, the end plate 23 is disposed at the notch 102, and the end plate 23, the housing body 21 and the fixing portion 22 are injection molded into an integral structure;
with the above configuration, after the end plate 23 is provided, the end plate 23 and the fixing portion 22 form an annular structure, and the stability of the fixing portion 22 can be further improved.
Further, as shown in fig. 3, 4 and 8, a receiving groove 201 is formed on the outer wall of the housing body 21, and the receiving groove 201 is used for receiving the first portion 111; an insulating film 3 for bonding the first portion 111 to the case body 21; a heat conduction pad 4 attached to one surface of the insulating film 3 away from the case body 21;
in the above structure, since the first portion 111 is located on the outer wall of the case body 21, the accommodating groove 201 is provided, so that the first portion 111 is flush with the outer wall of the case body 21, which facilitates the attaching of the insulating film 3 to the outer wall of the case body 21 to cover the first portion 111, and achieves insulation protection of the first portion 111; and then the heat conducting pad 4 is attached to the insulating film 3, and heat radiating components such as a water cooling plate and the like are arranged to be connected with the heat conducting pad 4, so that active heat radiation can be performed, and the heat radiating efficiency of the electric elements and the electric connecting pieces 1 in the distribution box is effectively improved.
Further, as shown in fig. 6, 8 and 9, the housing 2 is provided with a positioning portion 25, and the electrical connector 1 further includes a third portion 113, where the positioning portion 25 and the third portion 113 are at least one, and the third portion 113 protrudes into the housing 2 as the second portion 112, and the third portion 113 and the second portion 112 are disposed opposite to each other at an edge of the first portion 111; the positioning part 25 and the shell 2 are injection molded into an integrated structure, and the positioning part 25 is propped against the third part 113, so that the phenomenon of edge warping of the electric connector 1 can be prevented;
the notch 102 is formed by arranging the second portion 112 at the edge of the first portion 111, the notch 102 facilitates the injection molding material to enter the fixing portion 22, and reduces the contact surface between the injection molding material and the electric connector 1, if the second portion 112 is arranged at the middle position of the first portion 111, the injection molding material needs to cross a part of the first portion 111 to form the fixing portion 22, but the structure is inconvenient in injection molding, uses more materials, reduces the exposed area of the first portion 111, affects heat dissipation, and interferes with the arrangement of the insulating film 3 and the heat conducting pad 4.
As shown in fig. 3 and 4, the bolt 5 includes a head 51 and a screw 52, and the head 51 and the screw 52 are integrated, wherein the head 51 is located in the groove 101; the screw portion 52 penetrates the case body 21 and the second portion 112, extends into the case 2, and is screwed with the electric element;
in order to facilitate the connection between the electrical component and the electrical connector 1, the bolt 5 is provided, after the electrical connector 1 and the housing 2 are molded into an integral structure, the bolt 5 is installed from the outside of the housing 2, the screw portion 52 of the bolt 5 passes through the housing body 21 of the housing 2 and the second portion 112 of the electrical connector 1, the head 51 is positioned in the groove 101, and then the screw portion 52 is connected with the electrical component, which realizes the fixation between the electrical component and the housing 2, and simultaneously realizes the electrical connection between the electrical component and the electrical connector 1, and no additional fixing piece is required for the installation and fixation between the electrical component and the housing 2, thereby reducing the number of the connecting pieces and simplifying the installation procedure; meanwhile, the head 51 of the bolt 5 is positioned in the groove 101, so that the flatness of the outer surface of the shell 2 is not affected, and heat dissipation components such as the insulating film 3, the heat conducting pad 4 and the water cooling plate are conveniently installed to perform insulating and cooling work, and when the electric element is connected with the installation bolt 5, the electric element is installed by using a cylindrical wrench with an inner hexagon.
In the power distribution box, a shell 2 is a shell of the power distribution box, and electric elements comprise a fuse 6, a main positive relay 7, a quick charging relay 8, a pre-charging resistor 9, a pre-charging relay 10, a shunt 11 and a main negative relay 12, and are used for forming a positive pole loop, a pre-charging loop and a negative pole loop, wherein the fuse 6, the main positive relay 7 and the quick charging relay 8 are electrically connected in series in sequence to form the positive pole loop; the pre-charging resistor 9 is electrically connected with the pre-charging relay 10 in series, and the pre-charging resistor 9 and the pre-charging relay 10 are electrically connected with the main positive relay 7 in parallel to form a pre-charging loop; the shunt 11 and the main negative relay 12 are electrically connected in series to form a negative pole loop;
as described above, referring specifically to fig. 13, the application scenario of the distribution box of the present invention includes a battery pack, and the design of the circuit is suitable for controlling the charge and discharge of a battery module in the battery pack, and the battery module is connected in series between the main positive relay 7 and the main negative relay 12;
referring to fig. 2, the shunt 11 is configured to be provided with a sampling connector 13, and the sampling connector 13 is used for connecting a detection circuit to detect current of the circuit of the power distribution box;
as shown in fig. 1, 2 and 9, a binding post 14 is further provided, one end of the binding post 14 is connected with the electric connector 1, and the other end is used for connecting with a battery module, so as to realize charge and discharge work of the battery module.
As shown in fig. 2, 6 and 8, the electrical connector 1 is provided with at least two on the housing 2, at least two second portions 112 are provided on the electrical connector 1, positioning plates 00 are provided on the main positive relay 7, the quick charge relay 8 and the main negative relay 12, and positioning grooves 202 are provided between the notches 102 of the two electrical connectors 1, wherein the two second portions 112 are respectively used for electrically connecting one electrical element so as to realize the electrical connection between the two electrical elements; a positioning groove 202 formed in the case body 21; the positioning plate 00 is spliced with the positioning groove 202 and used for mounting and positioning the electric element;
when the main positive relay 7, the quick charge relay 8 and the main negative relay 12 are installed, the main positive relay 7, the quick charge relay 8 and the main negative relay 12 are inserted into the positioning groove 202 on the shell 2 through the positioning plate 00, so that the installation and positioning of the electric elements can be realized, the fixing or conductive bolt holes of the electric elements are conveniently aligned with the second part 112 of the electric connector 1, and therefore, when the bolts 5 are installed, the screw parts 52 of the bolts 5 are conveniently aligned with the bolt holes of the electric elements, the connection and the fixation of the electric elements and the shell 2 are realized, and the convenience of the installation of the electric elements is improved;
in fact, the positioning groove 202 is located between the two end plates 23, and the positioning groove 23 can increase the supporting area of the housing 2 and the positioning plate 00, which can further increase the plugging stability of the positioning plate 00 to fix the electrical components, meanwhile, the end plate 23 is formed by the cavity of the injection mold, and the position of the end plate 23 can be conveniently matched with the notch 102 for the circulation of injection molding materials to form the fixing portion 22 in the groove 101.
Specifically, when the electrical connector 1 is applied, the fuse 6 is electrically connected with the main positive relay 7 through one electrical connector 1, and the fuse 6 is electrically connected with the second portion 112 of the main positive relay 7 respectively; the main positive relay 7 is electrically connected with the quick charging relay 8 through an electric connector 1, and the main positive relay 7 is electrically connected with the quick charging relay 8 through a second part 112 respectively; the shunt 11 is electrically connected to the main negative relay 12 via an electrical connection 1, and the shunt 11 is electrically connected to a second portion 112 of each of the main negative relays 12.
The preparation method of the distribution box comprises the following steps:
s1, firstly, punching a material with conductivity to form an electric connector 1 with a first part 111 and a second part 112;
s2, placing the electric connector 1 into a cavity of a mold, wherein the cavity of the mold corresponds to the shape of the shell 2;
s3, injecting a thermoplastic or thermosetting material into a cavity of the die, forming a shell 2 with a shell body 21 and a fixing part 22 by the thermoplastic or thermosetting material, after the shell 2 is cooled and molded, fixing the electric connector 1 by the fixing part 22 matched with the shell body 21, and then taking the electric connector out of the die;
s4, placing and fixing the electric elements in the shell 2, and then completing the electric connection among the electric elements so as to form a positive pole loop, a pre-charging loop and a negative pole loop, wherein the main positive relay 7, the quick charging relay 8 and the main negative relay 12 are respectively inserted and positioned with the positioning groove 202 through one positioning plate 00.
In the above steps, the conductive material may be metal such as copper bar, and after the electric connector 1 and the housing 2 are injection-molded and fixed, the positioning groove 202 is formed at the same time, so that the main positive relay 7, the quick charge relay 8 and the main negative relay 12 can be positioned first, and then connected with the electric connector 1, thereby improving the convenience of assembly.
The foregoing description of the preferred embodiments of the invention is not intended to be limiting, but rather is intended to cover all modifications, equivalents, alternatives, and improvements that fall within the spirit and scope of the invention.
Claims (6)
1. An electric connector assembly structure is characterized by comprising an electric connector (1), a shell (2) and a bolt (5), wherein the electric connector (1) and the shell (2) are injection molded into an integrated structure, and the electric connector assembly structure comprises a shell and a bolt,
the electrical connection (1) comprises a first part (111) and at least one second part (112), the housing (2) comprises a housing body (21) and a fixing part (22), wherein,
the first part (111) is arranged to be bonded to the outer wall of the case body (21);
the second part (112) is formed by punching the first part (111), the second part (112) protrudes into the shell body (21) to form a groove (101), the second part (112) penetrates through the shell body (21), a notch (102) is formed in one side of the second part (112), and the second part (112) is used for connecting an electric element;
a first arc-shaped chamfer part (104) is arranged at the joint of the second part (112) and the first part (111), and the fixing part (22) extends towards the first part (111) and is attached to the first arc-shaped chamfer part (104);
the edge of one surface of the second part (112) protruding towards the inside of the shell body (21) is provided with a second arc-shaped chamfer part (105), the shell (2) further comprises an insulating part (24), the insulating part (24) is positioned at the outer side of the groove (101) and is in an integrated injection molding structure with the shell body (21), and the insulating part (24) is attached to the second arc-shaped chamfer part (105);
the shell body (21) extends into the groove (101) through the notch (102) to form the fixing part (22);
the fixing part (22) is of a U-shaped plate structure, and the fixing part (22) is attached to the side wall (103) of the second part (112) perpendicular to the shell body (21);
the bolt (5) comprises a head part (51) and a screw rod part (52), wherein the head part (51) and the screw rod part (52) are of an integrated structure, and the head part (51) is positioned in the groove (101); the screw portion (52) penetrates through the case body (21) and the second portion (112) and extends into the case (2), and is in threaded connection with the electric element.
2. The electrical connector assembly structure of claim 1, wherein: the shell (2) further comprises an end plate (23), the end plate (23) is arranged at the notch (102), and the end plate (23), the shell body (21) and the fixing part (22) are in an injection molding integrated structure.
3. The electrical connector assembly structure of any one of claims 1 or 2, wherein: the heat conducting device also comprises an insulating film (3) and a heat conducting pad (4), wherein the outer wall of the shell body (21) is provided with a containing groove (201),
the accommodating groove (201) is used for accommodating the first part (111);
the insulating film (3) is attached to the first portion (111) and the case body (21);
the heat conducting pad (4) is attached to one surface, away from the shell body (21), of the insulating film (3).
4. A power distribution box, characterized in that: the electric connector assembly structure according to any one of claims 1-3, wherein the housing (2) is a housing of the distribution box, the electric element comprises a fuse (6), a main positive relay (7), a quick charging relay (8), a pre-charging resistor (9), a pre-charging relay (10), a shunt (11) and a main negative relay (12) for forming a positive pole loop, a pre-charging loop and a negative pole loop,
the fuse (6), the main positive relay (7) and the quick charging relay (8) are electrically connected in series in sequence to form the positive pole loop;
the pre-charging resistor (9) is electrically connected in series with the pre-charging relay (10), and the pre-charging resistor (9) and the pre-charging relay (10) are electrically connected in parallel with the main positive relay (7) to form a pre-charging loop;
the current divider (11) and the main negative relay (12) are electrically connected in series to form a negative pole loop.
5. The electrical box of claim 4, wherein: the electric connecting pieces (1) are at least two on the shell (2), each electric connecting piece (1) is at least provided with two second parts (112), the main positive relay (7), the quick charging relay (8) and the main negative relay (12) are all provided with positioning plates (00), positioning grooves (202) are arranged between the notch (102) of the two electric connecting pieces (1),
two second portions (112) each for electrically connecting one of the electrical components to achieve electrical connection between the two electrical components;
the positioning groove (202) is formed in the shell body (21);
the positioning plate (00) is inserted into the positioning groove (202) for mounting and positioning the electric element.
6. A method of manufacturing the electrical distribution box of claim 5, comprising the steps of:
s1, firstly punching a material with conductivity to form the electric connector (1) with the first part (111) and the second part (112);
s2, placing the electric connecting piece (1) into a cavity of a mold, wherein the cavity of the mold corresponds to the shape of the shell (2);
s3, injecting a thermoplastic or thermosetting material into the cavity of the die, forming a shell (2) with the shell body (21) and the fixing part (22), and after the shell (2) is cooled and molded, fixing the electric connector (1) by the fixing part (22) matched with the shell body (21), and then taking the electric connector out of the die;
s4, placing the electric element into the shell (2) and fixing the electric element, and then completing electric connection among the electric elements so as to form the positive pole loop, the pre-charging loop and the negative pole loop, wherein the main positive relay (7), the quick charging relay (8) and the main negative relay (12) are respectively inserted and positioned with the positioning groove (202) through one positioning plate (00).
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| CN117013285B (en) * | 2023-09-28 | 2023-12-22 | 武汉嘉晨电子技术有限公司 | High-low voltage integrated connecting piece, BDU and processing method thereof |
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