WO2023098850A1 - 充电端子与线缆连接结构及充电座结构 - Google Patents

充电端子与线缆连接结构及充电座结构 Download PDF

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Publication number
WO2023098850A1
WO2023098850A1 PCT/CN2022/136090 CN2022136090W WO2023098850A1 WO 2023098850 A1 WO2023098850 A1 WO 2023098850A1 CN 2022136090 W CN2022136090 W CN 2022136090W WO 2023098850 A1 WO2023098850 A1 WO 2023098850A1
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Prior art keywords
terminal
charging
charging terminal
cable
transition
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PCT/CN2022/136090
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English (en)
French (fr)
Inventor
王超
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长春捷翼汽车科技股份有限公司
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Publication of WO2023098850A1 publication Critical patent/WO2023098850A1/zh

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/26—End pieces terminating in a screw clamp, screw or nut
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
    • H01R24/28—Coupling parts carrying pins, blades or analogous contacts and secured only to wire or cable
    • 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
    • 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
    • H01R4/32—Conductive members located in slot or hole in screw
    • 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

Definitions

  • the present application relates to the field of electrical connection technology, and in particular to a charging terminal and cable connection structure and a charging stand structure for a new energy vehicle charging system.
  • the charging stand in the current charging system is directly connected to the terminal and the cable, or multiple terminals are integrated into one module and installed on the housing.
  • Parts (terminals) will be worn to varying degrees due to the environment and working conditions.
  • a terminal fails or a wire connection problem occurs, it is necessary to remove the parts from the housing for repair or replacement. , time-consuming and labor-intensive, and it is easy to cause secondary damage to the terminal or the housing during replacement.
  • the existing terminal screw connection method is not stable, and the phenomenon of terminal loosening will occur after a long time.
  • the inventor proposes a charging terminal and cable connection structure and a charging stand structure to overcome the defects of the prior art.
  • the purpose of this application is to provide a charging terminal and cable connection structure and a charging stand structure, which can realize the detachable connection between the charging terminal and the cable, and facilitate the replacement of the terminal or cable separately.
  • the maintenance and replacement are simple, time-saving and labor-saving, and can effectively Improve product life.
  • a charging terminal and cable connection structure including a transition terminal and a charging terminal, the first end of the charging terminal is provided with a screw connection structure and a clamping structure, and the transition terminal A screw connection hole and a clamping part are provided, the clamping part is clamped with the clamping structure, the screw connection hole is connected with the screw connection structure through a screw connection, so that the transition terminal and the charging The terminals are fixedly connected, and the second end of the transition terminal is used for electrically connecting cables.
  • the charging terminal and cable connection structure and the charging stand structure provided by the present application have the following beneficial effects:
  • the transition terminal and the charging terminal are detachably connected.
  • the terminal of the charging stand fails or there is a problem with the connection of a certain wire, only the faulty parts need to be disassembled separately for maintenance and replacement. Simple, time-saving and labor-saving, and can effectively improve the life of the product;
  • the first end of the transition terminal is connected to the charging terminal through a thread.
  • the threaded connection provides the possibility for individual replacement of parts and improves the life of the product; in addition, the current connection between the charging terminal (connector) and the cable (or wire) is mostly by crimping. Or welding method, crimping or welding connection requires higher precision control and higher assembly time, threaded connection reduces assembly accuracy while meeting the product's assemblability and manufacturability requirements;
  • the charging terminal and the transition terminal are clamped first and then screwed to make the connection between the two more stable and less likely to loosen;
  • the detachable connection between the charging terminal and the cable is realized by using the connection structure between the charging terminal and the cable, which is convenient for replacing the terminal or the cable separately, and at the same time, the connection between the terminals is made more convenient by using the clamping and screwing methods. Stablize. It is also possible to set different numbers of charging terminal connection parts in the seat shell according to specific needs, so as to realize different numbers of cable connections; in the charging stand structure of the present application, the cables are welded outside the seat shell, and the welding angle can be adjusted according to needs to meet different requirements. The outlet angle and welding requirements.
  • Fig. 1 It is a structural schematic diagram of Embodiment 1 of the charging terminal and cable connection structure of the present application.
  • FIG. 2 is a structural schematic diagram of a transition terminal in Embodiment 1 of the charging terminal and cable connection structure of the present application.
  • FIG. 3 is a schematic structural view of the charging terminal in Embodiment 1 of the connection structure between the charging terminal and the cable of the present application.
  • FIG. 4 is a structural schematic diagram of Embodiment 2 of the charging terminal and cable connection structure of the present application.
  • Fig. 5 It is a schematic diagram when the transition terminal of the present application is a straight plate structure.
  • Figure 6 An exploded schematic view of the structure of the charging stand of the present application.
  • the screw connection hole 11 and the clamping part, the clamping part is clamped with the clamping structure, the screw connection hole 11 and the screw connection structure are connected through a screw connection, so that the transition terminal 1 is fixedly connected with the charging terminal 2, and the transition terminal The second end of 1 is used to electrically connect the cable 3 .
  • the clamping structure and the clamping part are clamped first, which can prevent the transition terminal 1 and the charging terminal 2 from rotating relative to each other, and then the screw connection can completely fix the charging terminal 2 and the transition terminal 1 .
  • the screw connection can completely fix the charging terminal 2 and the transition terminal 1 .
  • the locking structure is a first locking groove 22 provided on the side wall of the charging terminal 2, and the locking part is arranged on the
  • the screw connection structure is a stud 21 arranged on the first end face, the screw connection Be the nut 4 that is screwed with the stud 21.
  • the first locking groove is L-shaped, and the first locking protrusion 12 has an extension 121 toward the center of the screw hole 11.
  • the extension 121 is first parallel to the charging terminal 2 in the L-shape. One side of the axial direction is clamped, and then rotated along the circumferential direction of the charging terminal 2 to complete the clamping.
  • the snap-in structure is a second snap-in protrusion 23 arranged on the first end surface, and the snap-in portion is arranged on a threaded joint.
  • the second clamping groove 13 next to the hole 11 has a screw connection structure as an internally threaded hole 24 provided on the first end face, and the screw connection member is a screw.
  • the inner threaded hole 24 is concentric with the threaded hole 11.
  • the screw connection torque of the screw connection structure and the screw connection member is 0.1N ⁇ m-17N ⁇ m.
  • the vibration test is to place the connected sample on the vibration test bench. After 300 vibration cycles, each cycle requires vibration in 6 directions, the frequency is 100Hz, and the acceleration in one direction is 40m/s2, and then the transition terminal 1 is observed. and charging terminal 2 is loose. Loose is unqualified. The results are shown in Table 1.
  • the transition terminal 1 may adopt a straight plate structure, the first end of the transition terminal 1 is provided with a boss 14 , and the end surface of the screw connection is against the boss 14 .
  • the thickness of the boss 14 is greater than the thickness of the connection with the cable 3 , and the thickness difference facilitates the connection between the transition terminal 1 and the screw connector, and at the same time facilitates the connection of the cable 3 .
  • the transition terminal 1 may be an integral molding structure.
  • the transition terminal 1 can also adopt a bent plate structure, the first end of the bent plate structure and the second end of the bent plate structure are set at an included angle, and the angle range of the included angle is 0-360° .
  • the curved plate structure can meet the requirement of the cable outlet angle of the cable 3 to a certain extent.
  • connection manner between the second end of the transition terminal 1 and the cable 3 is one of crimping, plugging, clamping, bolting, riveting, welding, bundling or locking.
  • a crimping structure can be used, for example, a crimping surface is provided on the transition terminal 1 and the charging terminal 2, and the charging terminal 2 is fixedly connected to the transition terminal 1 by crimping.
  • a plug-in structure can be used, for example, a pin is provided on the end surface of the transition terminal 1, and a slot is provided on the charging terminal 2, and the plug is inserted into the slot and fixedly connected.
  • a clamping structure can be adopted, for example, a buckle is provided on the surface of the transition terminal 1 to be spliced, and a clamping slot is provided on the charging terminal 2 to complete the clamping.
  • a bolt connection structure can be adopted, the transition terminal 1 is provided with external threads, and the charging terminal 2 is provided with internal threads to complete the screw connection.
  • a riveting structure may be used, and the riveting structure includes a rivet and a fixing hole, the fixing hole is set on the transition terminal 1, and the rivet is set on the charging terminal 2 to complete the riveting.
  • a welded structure can be used.
  • the second end of the transition terminal 1 is connected to the cable 3 through friction welding, ultrasonic welding, arc welding, laser welding or resistance welding.
  • the friction welding method refers to the method of welding by using the heat generated by the friction of the contact surface of the workpiece as the heat source to cause the workpiece to undergo plastic deformation under pressure.
  • the ultrasonic welding method is to use high-frequency vibration waves to transmit to the surfaces of two objects to be welded. Under pressure, the surfaces of the two objects are rubbed against each other to form fusion between molecular layers.
  • the arc welding method refers to using the arc as a heat source and using the physical phenomenon of air discharge to convert electrical energy into thermal energy and mechanical energy required for welding, so as to achieve the purpose of connecting metals.
  • the main methods are electrode arc welding, submerged arc welding, and gas protection. welding etc.
  • Laser welding is an efficient and precise welding method that uses a high-energy-density laser beam as a heat source.
  • the resistance welding method refers to a method that uses a strong current to pass through the contact point between the electrode and the workpiece, and generates heat from the contact resistance to achieve welding.
  • a bundling structure can be adopted, and the bundling structure includes a bundling piece, and grooves are provided on the surface of the transition terminal 1 and the charging terminal 2, and the bundling piece is used to connect the transition terminal 1 and the charging terminal 2 bundled together.
  • Binding parts include cable ties, pipe hoops, hook locks, etc.
  • a locking structure can be adopted, and the locking structure includes locking parts, which are respectively arranged on the surfaces of the transition terminal 1 and the charging terminal 2 to complete the locking connection.
  • transition terminal 1 is a tellurium-copper alloy, wherein the content of tellurium is 0.1%-5%.
  • the transition terminal 1 when the transition terminal 1 is made of tellurium-copper alloy, it can make the transition terminal 1 have good electrical conductivity and easy cutting performance, ensure electrical performance and improve workability, and at the same time, the elasticity of tellurium-copper alloy is also very good. .
  • the tellurium content in the tellurium-copper alloy is 0.2%-1.2%.
  • the inventor selected 10 transition terminals 1 of the same shape for testing, and each transition terminal 1 is a tellurium-copper alloy, and the content of tellurium is 0.05%, 0.1%, 0.2%, 1%, 1.2%, and 1.8%, respectively. %, 3%, 5%, 6%, 7%.
  • the test results are shown in Table 2.
  • the electrical conductivity of the tellurium-copper alloy is greater than 99%, which is an ideal value.
  • Table 2 The effect of tellurium copper alloys with different tellurium contents on electrical conductivity.
  • the transition terminal 1 is provided with a plated layer.
  • the purpose of the coating is to improve corrosion resistance, improve electrical conductivity, increase the number of times of use, and better prolong the service life of the transition terminal 1 .
  • the plating layer can adopt methods such as electroplating, chemical plating, magnetron sputtering or vacuum plating.
  • the electroplating method is the process of plating a thin layer of other metals or alloys on some metal surfaces by using the principle of electrolysis.
  • the electroless plating method is a process of metal deposition through a controllable oxidation-reduction reaction under the catalysis of metals.
  • the magnetron sputtering method uses the interaction between the magnetic field and the electric field to make electrons run in a spiral shape near the target surface, thereby increasing the probability of electrons colliding with argon to generate ions.
  • the generated ions hit the target surface under the action of the electric field to sputter out the target material.
  • the vacuum plating method is to deposit various metal and non-metal films on the surface of plastic parts by distillation or sputtering under vacuum conditions.
  • the coating material is one or more of gold, silver, nickel, tin, zinc, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver and silver-gold-zirconium alloy.
  • Copper or aluminum as an active metal, will undergo oxidation reaction with oxygen and water during use, so one or several inert metals are required as a coating to prolong the service life of the transition terminal 1 .
  • a better wear-resistant metal is also required as a coating, which can greatly increase the service life of the contacts.
  • the transition terminal 1 needs good electrical conductivity.
  • the conductivity and stability of the above-mentioned metals are better than copper or copper alloy and Lu or aluminum alloy, which can make the transition terminal 1 obtain better electrical properties and longer life. service life.
  • transition terminal 1 In order to demonstrate the impact of different coating materials on the overall performance of the transition terminal 1, the inventor used the same specifications and materials, and used transition terminal 1 samples of different coating materials to do a series of tests on the number of insertions and extractions and corrosion resistance time. The advantages and disadvantages of other commonly used electroplating materials, the inventor also selects tin, nickel, zinc as the coating material of experiment. The experimental results are shown in Table 3 below.
  • the number of plugging and unplugging in Table 3 below is to fix the transition terminal 1 on the test bench respectively, and use a mechanical device to simulate the plugging and unplugging of the transition terminal 1, and stop to observe the surface coating of the transition terminal 1 after every 100 times of plugging and unplugging
  • the surface coating of the terminal is scratched, and the material of the terminal itself is exposed, the experiment is stopped, and the number of insertions and extractions at that time is recorded. Insertion times less than 8000 times are unqualified.
  • the corrosion resistance time test in Table 3 below is to put the transition terminal 1 into the salt spray test box, spray salt spray on each position of the transition terminal 1, take it out and clean it every 20 hours to observe the surface corrosion, That is, one cycle, until the surface corrosion area of the transition terminal 1 is greater than 10% of the total area, stop the test, and record the number of cycles at that time. In this embodiment, the number of cycles less than 80 is considered unqualified.
  • the coating material is gold, silver, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, and silver-gold-zirconium alloy
  • the experimental results exceed the standard value and the performance is relatively stable.
  • the coating material is gold, silver, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, and silver-gold-zirconium alloy
  • the coating material is gold, silver, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver and silver-gold-zirconium alloy.
  • the present application also provides a charging stand structure 200, including a charging stand body 5, at least one charging terminal connection part (prior art) is arranged in the charging stand body 5, and each charging terminal connection part is conductively connected to the charging terminal.
  • the first end of the charging terminal 2 can be detachably connected to the first end of the aforementioned charging terminal and cable connection structure 100 (the first end of the transition terminal constitutes the first end of the charging terminal and cable connection structure 100
  • the second end of the charging terminal and the cable connection structure 100 (the second end of the transition terminal constitutes the second end of the charging terminal and the cable connection structure 100 ) is fixed and conductively connected to the cable 3 .
  • the charging base body 5 includes a base housing 51, the base housing 51 includes a detachable rear cover 52; the charging terminal and cable connection structure 100 includes a transition terminal 1, the charging terminal 2 is located in the base housing 51, and the transition terminal 1 The first end of the transition terminal 1 is located in the seat housing 51 , and the second end of the transition terminal 1 is exposed to the seat housing 51 . The second end of the transition terminal 1 is exposed to the seat housing 51, and the welding angle with the cable 3 can be adjusted to facilitate adjustment of the outlet angle of the cable 3.
  • the charging terminal 2 needs to be replaced, only the rear cover 52 needs to be disassembled, and the charging terminal 2 can be removed for replacement, which is convenient and quick.
  • the second end of the transition terminal 1 is exposed at the bottom of the seat housing 51, and the bottom of the seat housing 51 is provided with at least one through slot, and the second end of the transition terminal 1 passes through the through slot exposed to the seat case 51 .
  • the charging terminal and cable connection structure and the charging stand structure provided by the present application have the following beneficial effects:
  • the transition terminal and the charging terminal are detachably connected.
  • the terminal of the charging stand fails or there is a problem with the connection of a certain wire, only the faulty parts need to be disassembled separately for maintenance and replacement. Simple, time-saving and labor-saving, and can effectively improve the life of the product;
  • the first end of the transition terminal is connected to the charging terminal through a thread.
  • the threaded connection provides the possibility for individual replacement of components and improves the life of the product; in addition, the current connection between the charging terminal (connector) and the cable (or wire) is mostly by crimping. Or welding method, crimping or welding connection requires higher precision control and higher assembly time, threaded connection reduces assembly accuracy while meeting the product's assemblability and manufacturability requirements;
  • the charging terminal and the transition terminal are clamped first and then screwed to make the connection between the two more stable and less likely to loosen;
  • the detachable connection between the charging terminal and the cable is realized by using the connection structure between the charging terminal and the cable, which is convenient for replacing the terminal or the cable separately, and at the same time, the connection between the terminals is made more convenient by using the clamping and screwing methods. Stablize. It is also possible to set different numbers of charging terminal connection parts in the seat shell according to specific needs, so as to realize different numbers of cable connections; in the charging stand structure of the present application, the cables are welded outside the seat shell, and the welding angle can be adjusted according to needs to meet different requirements. The outlet angle and welding requirements.

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Abstract

本申请为一种充电端子与线缆连接结构及充电座结构，充电端子与线缆连接结构包括过渡端子(1)和充电端子(2)，充电端子(2)的第一端上设置有螺接结构和卡接结构，过渡端子(1)上设置有螺接孔(11)和卡接部，卡接部与卡接结构卡接，螺接孔(11)与螺接结构通过螺接件连接，使过渡端子(1)与充电端子(2)固定连接，过渡端子(1)的第二端用于电性连接线缆(3)。本申请的充电端子与线缆连接结构及充电座结构，实现充电端子与线缆的可拆卸连接，方便单独更换端子或者线缆，维修更换简单，省时省力，且能有效提高产品的寿命。

Description

充电端子与线缆连接结构及充电座结构
相关申请
本申请要求专利申请号为202123018657.5、申请日为2021年12月03日、发明名称为“充电端子与线缆连接结构及充电座结构”的中国发明专利的优先权。
技术领域
本申请涉及电气连接技术领域，尤其涉及一种用于新能源汽车充电系统的充电端子与线缆连接结构及充电座结构。
背景技术
随着汽油燃料的资源减少和环境保护的原因，越来越多的国家将新能源汽车作为未来汽车的发展方向，新能源汽车的普及程度越来越高，为新能源电池补充能量的充电系统也越来越快的发展。
但是目前的充电系统中的充电座都是直接连接端子及线缆，或者多个端子集成一个模块安装在壳体上，当新能源车主日常进行车辆充电时，随着反复插拔，接触的连接件(端子)会因环境及使用的工况产生不同程度的磨损，在某一个端子出现故障，或者某一处导线连接出现问题时，都需要将零件从壳体上卸下，进行维修或者更换，费时费力，且更换时容易对端子或壳体造成二次损坏。同时，现有的端子螺接方式并不稳固，时间长了会出现端子松动的现象。
由此，本发明人凭借多年从事相关行业的经验与实践，提出一种充电端子与线缆连接结构及充电座结构，以克服现有技术的缺陷。
发明内容
本申请的目的在于提供一种充电端子与线缆连接结构及充电座结构，实现充电端子与线缆的可拆卸连接，方便单独更换端子或者线缆，维修更换简单，省时省力，且能有效提高产品的寿命。
本申请的目的是这样实现的，一种充电端子与线缆连接结构，包括过渡端子和充电端子，所述充电端子的第一端上设置有螺接结构和卡接结构，所述过渡端子上设置有螺接孔和卡接部，所述卡接部与所述卡接结构卡接，所述螺接孔与所述螺接结构通过螺接件连接，使所述过渡端子与所述充电端子固定连接，所述过渡端子的第二端用于电性连 接线缆。
由上所述，本申请提供的充电端子与线缆连接结构及充电座结构具有如下有益效果：
本申请的充电端子与线缆连接结构中，过渡端子与充电端子能拆卸地连接，在充电座的端子出现故障，或者某一处导线连接出现问题时，只需单独拆卸故障零部件，维修更换简单，省时省力，且能有效提高产品的寿命；
过渡端子的第一端通过螺纹连接充电端子，螺纹连接为部件单独更换提供了可能性，提高产品的寿命；另外，当前充电端子(插接件)同线缆(或导线)连接多采用压接或焊接方式，压接或焊接连接需要较高的精度控制以及更高的装配时长，螺纹连接降低装配精度的同时满足产品的可装配性、可制造性需要；
充电端子和过渡端子先卡接再螺接的方式，使两者的连接更稳固，不易发生松动；
本申请的充电座结构中，采用充电端子与线缆连接结构实现充电端子与线缆的可拆卸连接，方便单独更换端子或者线缆，同时使用卡接和螺接的方式使端子之间连接更稳定。还可以根据具体需要在座壳体中设置不同数量的充电端子连接部，实现不同数量的线缆连接；本申请的充电座结构中，在座壳体外焊接线缆，能够根据需要调整焊接角度，满足不同的出线角度和焊接需求。
附图说明
为了更清楚地说明本发明实施例中的技术方案，下面将对实施例描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
其中：
图1：为本申请的充电端子与线缆连接结构的实施例一的结构示意图。
图2：为本申请的充电端子与线缆连接结构的实施例一的过渡端子的结构示意图。
图3：为本申请的充电端子与线缆连接结构的实施例一的充电端子的结构示意图。
图4：为本申请的充电端子与线缆连接结构的实施例二的结构示意图。
图5：为本申请的过渡端子为直板结构时的示意图。
图6：为本申请的充电座结构的分解示意图。
具体实施方式
为了对本申请的技术特征、目的和效果有更加清楚的理解，现对照附图说明本申请的具体实施方式。
在此描述的本申请的具体实施方式，仅用于解释本申请的目的，而不能以任何方式理解成是对本申请的限制。在本申请的教导下，技术人员可以构想基于本申请的任意可能的变形，这些都应被视为属于本申请的范围。需要说明的是，当元件被称为“设置于”另一个元件，它可以直接在另一个元件上或者也可以存在居中的元件。当一个元件被认为是“连接”另一个元件，它可以是直接连接到另一个元件或者可能同时存在居中元件。术语“安装”、“相连”、“连接”应做广义理解，例如，可以是机械连接或电连接，也可以是两个元件内部的连通，可以是直接相连，也可以通过中间媒介间接相连，对于本领域的普通技术人员而言，可以根据具体情况理解上述术语的具体含义。本文所使用的术语“垂直的”、“水平的”、“上”、“下”、“左”、“右”以及类似的表述只是为了说明的目的，并不表示是唯一的实施方式。
除非另有定义，本文所使用的所有的技术和科学术语与属于本申请的技术领域的技术人员通常理解的含义相同。本文中在本申请的说明书中所使用的术语只是为了描述具体的实施方式的目的，不是旨在于限制本申请。本文所使用的术语“和/或”包括一个或多个相关的所列项目的任意的和所有的组合。
一种充电端子与线缆连接结构100，如图1所示，包括过渡端子1和充电端子2，充电端子2的第一端上设置有螺接结构和卡接结构，过渡端子1上设置有螺接孔11和卡接部，卡接部与卡接结构卡接，螺接孔11与螺接结构通过螺接件连接，使所述过渡端子1与所述充电端子2固定连接，过渡端子1的第二端用于电性连接线缆3。
卡接结构和卡接部先行卡接，能够防止过渡端子1与充电端子2相对转动，再进行螺接能够使充电端子2和过渡端子1完全固定。而需要对某个端子单独更换时，只需要先解除螺接再取下需要更换的端子。或者某一处导线连接出现问题时，只需单独拆卸故障零部件，维修更换简单，省时省力，且能有效提高产品的寿命。
在一个具体的实施例(实施例一)中，如图1、图2、图3所示，卡接结构为充电端子2侧壁上设置的第一卡接槽22，卡接部为设置在螺接孔11旁的第一卡接凸起12，第一卡接凸起12与第一卡接槽22相匹配，螺接结构为设置在第一端端面 上的螺柱21，螺接件为与螺柱21螺接的螺母4。安装时，先将螺接孔11套设在螺柱21上，然后使第一卡接凸起12与第一卡接槽22卡接，最后将螺母4螺接在螺柱21上，使充电端子2与过渡端子1固定在一起。
进一步的，如图2所示，第一卡槽为L型，第一卡接凸起12具有向螺接孔11圆心方向的延伸部121，延伸部121先与L型中平行于充电端子2轴向的一边卡接，再沿着充电端子2的周向旋转，完成卡接。
在另一个具体的实施例(实施例二)中，如图4所示，所述卡接结构为设置在第一端端面上的第二卡接凸起23，卡接部为设置在螺接孔11旁的第二卡接槽13，螺接结构为设置在第一端端面上的内螺纹孔24，螺接件为螺钉。内螺纹孔24与螺接孔11同心，在安装时，先将第二卡接凸起23与第二卡接槽13卡接，再用螺钉与内螺纹孔螺接，从而使充电端子2与过渡端子1固定在一起。
在优选的实施方式中，螺接结构与螺接件螺接的扭矩为0.1N·m-17N·m。
为了验证螺接结构与螺接件的螺接的扭矩范围，对过渡端子1与充电端子2连接情况的影响，发明人选用相同的过渡端子1、充电端子2、螺接结构与螺接件，采用不同的扭矩将其拧紧到一起，测试经过振动试验的过渡端子1与充电端子2的连接情况。试验结果如表1所示。
振动试验是将连接后的样件放置在振动试验台上，经过300个振动循环，每个循环都需要6个方向的振动，频率为100Hz，单方向加速度为40m/s2，然后观察过渡端子1和充电端子2是否有松脱现象。有松脱为不合格。结果如表1所示。
表1不同的扭矩对连接情况的影响
Figure PCTCN2022136090-appb-000001
从上表1中可以看出，当螺接结构与螺接件的扭矩值小于0.1N·m时，充电端子2与过渡端子1经过振动试验后松脱，当扭矩值大于17N·m时，由于扭矩过大，施加于过渡端子1与充电端子2的扭力太大，导致过渡端子1受到较大的压力变形，从而无法实现充电座的基本功能。因此，发明人将螺接结构与螺接件螺接的扭矩范 围确定为0.1N·m-17N·m。
进一步，如图5所示，过渡端子1可以采用直板结构，过渡端子1的第一端设置凸台14，螺接件的端面顶抵于凸台14上。凸台14处的厚度尺寸大于与线缆3连接处的厚度尺寸，厚度差方便过渡端子1与螺接件的连接，同时方便线缆3的连接。过渡端子1可以是整体成型结构。
进一步，根据实际工况需求，过渡端子1还可以采用弯板结构，弯板结构的第一端和弯板结构的第二端之间呈夹角设置，夹角的角度范围为0～360°。弯板结构可以一定程度上满足线缆3的出线角度需求。
优选地，过渡端子1的第二端与线缆3的连接方式为压接、插接、卡接、螺栓连接、铆接、焊接、捆扎或锁扣连接中的一种。
在第一种可行的技术方案中，可以采用压接结构，如在过渡端子1和充电端子2上设置压接面，充电端子2通过压接的方式与过渡端子1固定连接。
在第二种可行的技术方案中，可以采用插接结构，如在过渡端子1的端部表面设置插销，充电端子2设置插槽，插销插入插槽后固定连接。
在第三种可行的技术方案中，可以采用卡接结构，如在过渡端子1的待拼接表面上设置卡扣，充电端子2上设置卡槽，完成卡接。
在第四种可行的技术方案中，可以采用螺栓连接结构，过渡端子1上设置外螺纹，充电端子2上设置内螺纹，完成螺接。
在第五种可行的技术方案中，可以采用铆接结构，铆接结构包括铆钉和固定孔，固定孔设置在过渡端子1上，铆钉设置在充电端子2上，完成铆接。
在第六种可行的技术方案中，可以采用焊接结构。
具体的，所述过渡端子1的第二端与所述线缆3通过摩擦焊方式、超声波焊接方式、弧焊方式、激光焊方式或电阻焊方式连接在一起。
摩擦焊方式，是指利用工件接触面摩擦产生的热量为热源，使工件在压力作用下产生塑性变形而进行焊接的方法。
超声波焊接方式，是利用高频振动波传递到两个需焊接的物体表面，在加压的情况下，使两个物体表面相互摩擦而形成分子层之间的熔合。
弧焊方式，是指以电弧作为热源，利用空气放电的物理现象，将电能转换为焊接所需的热能和机械能，从而达到连接金属的目的，主要方法有焊条电弧焊、埋弧焊、气体保护焊等。
激光焊方式，是利用高能量密度的激光束作为热源的一种高效精密焊接方法。
电阻焊方式，是指一种利用强大电流通过电极和工件间的接触点，由接触电阻产生热量而实现焊接的一种方法。
在第七种可行的技术方案中，可以采用捆扎结构，捆扎结构包括捆扎件，在过渡端子1和充电端子2的表面上设置凹槽，使用捆扎件在凹槽位置将过渡端子1和充电端子2捆扎在一起。捆扎件包括扎带、管箍、钩锁等。
在第八种可行的技术方案中，可以采用锁扣结构，锁扣结构包括锁扣件，锁扣件分别设于过渡端子1和充电端子2表面上，完成锁扣连接。
进一步的，所述过渡端子1为碲铜合金，其中碲的含量为0.1％-5％。
也就是说，所述过渡端子1的材质为碲铜合金时能使过渡端子1具有良好的导电性和易切削性能，保证电学性能也能提高加工性，同时，碲铜合金的弹性也很优良。优选的，碲铜合金中碲的含量为0.2％-1.2％。
发明人选用了10个相同形状的过渡端子1进行测试，每个过渡端子1均为碲铜合金，其中碲的含量占比分别为0.05％、0.1％、0.2％、1％、1.2％、1.8％、3％、5％、6％、7％。测试结果如表2所示，在本实施例中，碲铜合金的导电率大于99％为理想值。
表2：不同碲含量的碲铜合金对导电率的影响。
碲含量 0.05％ 0.1％ 0.2％ 1％ 1.2％ 1.8％ 3％ 5％ 6％ 7％
导电率 98.6％ 99.1％ 99.3％ 99.6％ 99.8％ 99.5％ 99.3％ 99.1％ 98.9％ 98.7％
由表2可知，当碲的含量占比小于0.1％时或者大于5％时，导电率明显下降，不能满足理想值要求。当碲的含量占比大于等于0.2％且小于等于1.2时，导电性能最好，因此发明人选用碲的含量为0.1％-5％的碲铜合金。在最理想的情况下选用含量为0.2％-1.2％的碲铜合金。
在优选的实施例中，所述过渡端子1上设置有镀层。
镀层是为了提高耐腐蚀性，提高导电性能，增加使用次数，能够更好的延长过渡端子1的使用寿命。
镀层可采用电镀、化学镀、磁控溅射或者真空镀等方法。
电镀方法，就是利用电解原理在某些金属表面上镀上一薄层其它金属或合金的过程。
化学镀方法，是在金属的催化作用下，通过可控制的氧化还原反应产生金属的沉积过程。
磁控溅射方法，是利用磁场与电场交互作用，使电子在靶表面附近成螺旋状运行，从而增大电子撞击氩气产生离子的概率。所产生的离子在电场作用下撞向靶面从而溅射出靶材。
真空镀方法，是采用在真空条件下，通过蒸馏或溅射等方式在塑件表面沉积各种金属和非金属薄膜。
所述镀层材质为金、银、镍、锡、锌、锡铅合金、银锑合金、钯、钯镍合金、石墨银、石墨烯银和银金锆合金中的一种或多种。
铜或铝作为活泼金属，在使用过程中会与氧气和水发生氧化反应，因此需要一种或几种不活泼金属作为镀层，延长过渡端子1的使用寿命。另外，也是需要较好的耐磨金属作为镀层，能够极大的增加触点的使用寿命。还有过渡端子1需要很好的导电性能，上述金属的导电性和稳定性，都要优于铜或铜合金及吕或铝合金，能够使过渡端子1获得更好的电学性能和更长的使用寿命。
为了论证不同镀层材质对过渡端子1整体性能的影响，发明人使用相同规格、材质，采用不同镀层材料的过渡端子1样件做一系列插拔次数和耐腐蚀性时间测试，为了证明选用材料和其他常用电镀材料的优缺点，发明人也选用了锡、镍、锌作为实验的镀层材质。实验结果如下表3所示。
下表3中的插拔次数是将过渡端子1分别固定在实验台上，采用机械装置使过渡端子1模拟插拔，并且每经过100次的插拔，就要停下来观察过渡端子1表面镀层破坏的情况，端子表面镀层出现划伤，并露出端子本身材质，则实验停止，记录当时的插拔次数。插拔次数小于8000次为不合格。
下表3中的耐腐蚀性时间测试，是将过渡端子1放入到盐雾喷淋试验箱内，对过渡端子1的各个位置喷淋盐雾，每隔20小时取出清洗观察表面腐蚀情况，即为一个周期，直到过渡端子1表面腐蚀面积大于总面积的10％的时候，停止测试，并记录当时的周期数。在本实施例中，周期数小于80次认为不合格。
表3：不同镀层材质对过渡端子插拔次数和耐腐蚀性的影响
Figure PCTCN2022136090-appb-000002
从上表可以看出，当选用镀层材质为金、银、银锑合金、钯、钯镍合金、石墨银、石墨烯银和银金锆合金时，实验结果超过标准值较多，性能比较稳定。当选用镀层材质为镍、锡、锡铅合金、锌时，实验结果也是能够符合要求的，因此，发明人选择镀层材质为金、银、镍、锡、锡铅合金、锌、银锑合金、钯、钯镍合金、石墨银、石墨烯银和银金锆合金中的一种或多种组合。
如图6所示，本申请还提供一种充电座结构200，包括充电座本体5，充电座本体5内设置至少一个充电端子连接部(现有技术)，各充电端子连接部导电连接充电端子2的第二端，充电端子2的第一端能拆卸地连接前述的充电端子与线缆连接结构100的第一端(过渡端子的第一端构成充电端子与线缆连接结构100的第一端)，充电端子与线缆连接结构100的第二端(过渡端子的第二端构成充电端子与线缆连接结构100的第二端)固定且导电连接线缆3。
进一步，充电座本体5包括座壳体51，座壳体51包括可拆卸的后盖52；充电端子与线缆连接结构100包括过渡端子1，充电端子2位于座壳体51内，过渡端子1的第一端位于座壳体51内，过渡端子1的第二端外露于座壳体51。过渡端子1的第二端外露于座壳体51，可以调节选择与线缆3的焊接角度，方便调整线缆3的出线角度。当需要更换充电端子2时，只需要拆卸后盖52，就可以将充电端子2拆下进行更换，方便快捷。
在本申请的一具体实施例中，过渡端子1的第二端外露于座壳体51的底部，座壳体51的底部设置至少一个贯通槽孔，过渡端子1的第二端通过贯通槽孔外露于座壳体51。
由上所述，本申请提供的充电端子与线缆连接结构及充电座结构具有如下有益效果：
本申请的充电端子与线缆连接结构中，过渡端子与充电端子能拆卸地连接，在充电座的端子出现故障，或者某一处导线连接出现问题时，只需单独拆卸故障零部件，维修更换简单，省时省力，且能有效提高产品的寿命；
过渡端子的第一端通过螺纹连接充电端子，螺纹连接为部件单独更换提供了可能性，提高产品的寿命；另外，当前充电端子(插接件)同线缆(或导线)连接多采用压接或焊接方式，压接或焊接连接需要较高的精度控制以及更高的装配时长，螺纹连接降低装配精度的同时满足产品的可装配性、可制造性需要；
充电端子和过渡端子先卡接再螺接的方式，使两者的连接更稳固，不易发生松动；
本申请的充电座结构中，采用充电端子与线缆连接结构实现充电端子与线缆的可拆卸连接，方便单独更换端子或者线缆，同时使用卡接和螺接的方式使端子之间连接更稳定。还可以根据具体需要在座壳体中设置不同数量的充电端子连接部，实现不同数量的线缆连接；本申请的充电座结构中，在座壳体外焊接线缆，能够根据需要调整焊接角度，满足不同的出线角度和焊接需求。
以上所述仅为本申请示意性的具体实施方式，并非用以限定本申请的范围。任何本领域的技术人员，在不脱离本申请的构思和原则的前提下所作出的等同变化与修改，均应属于本申请保护的范围。

Claims (10)

  1. 一种充电端子与线缆连接结构，其中，包括过渡端子和充电端子，所述充电端子的第一端上设置有螺接结构和卡接结构，所述过渡端子上设置有螺接孔和卡接部，所述卡接部与所述卡接结构卡接，所述螺接孔与所述螺接结构通过螺接件连接，使所述过渡端子与所述充电端子固定连接，所述过渡端子的第二端用于电性连接线缆。
  2. 如权利要求1所述的充电端子与线缆连接结构，其中，所述卡接结构为充电端子侧壁上设置的第一卡接槽，所述卡接部为设置在所述螺接孔旁的第一卡接凸起，所述第一卡接凸起与所述第一卡接槽相匹配，所述螺接结构为设置在第一端端面上的螺柱，所述螺接件为与所述螺柱螺接的螺母。
  3. 如权利要求1所述的充电端子与线缆连接结构，其中，所述卡接结构为设置在第一端端面上的第二卡接凸起，所述卡接部为设置在所述螺接孔旁的第二卡接槽，所述螺接结构为设置在第一端端面上的内螺纹孔，所述螺接件为螺钉。
  4. 如权利要求1所述的充电端子与线缆连接结构，其中，所述螺接结构与所述螺接件螺接的扭矩为0.1N·m-17N·m。
  5. 如权利要求1所述的充电端子与线缆连接结构，其中，所述过渡端子为直板结构，过渡端子的第一端设置凸台，所述螺接件的端面顶抵于所述凸台上。
  6. 如权利要求1所述的充电端子与线缆连接结构，其中，所述过渡端子为弯板结构，弯板结构的第一端和弯板结构的第二端之间呈夹角设置，夹角的角度范围为0°-360°。
  7. 如权利要求1所述的充电端子与线缆连接结构，其中，所述过渡端子的第二端与线缆的连接方式为压接、插接、卡接、螺栓连接、铆接、焊接、捆扎或锁扣连接中的一种。
  8. 一种充电座结构，包括充电座本体，其中，所述充电座本体内设置至少一个充电端子连接部，各所述充电端子连接部导电连接充电端子的第二端，充电端子的第一端能拆卸地连接如权利要求1至7任一项所述的充电端子与线缆连接结构的第一端，所述充电端子与线缆连接结构的第二端固定且导电连接线缆。
  9. 如权利要求8所述的充电座结构，其中，所述充电座本体包括座壳体，所述座壳体包括可拆卸的后盖；所述充电端子与线缆连接结构包括过渡端子，所述充电端子位于所述座壳体内，过渡端子的第一端位于所述座壳体内，过渡端子的第二端外露于所述座壳体。
  10. 如权利要求9所述的充电座结构，其中，所述过渡端子的第二端外露于所述座壳体的底部，所述座壳体的底部设置至少一个贯通槽孔。
PCT/CN2022/136090 2021-12-03 2022-12-02 充电端子与线缆连接结构及充电座结构 WO2023098850A1 (zh)

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CN216354822U (zh) * 2021-12-03 2022-04-19 长春捷翼汽车零部件有限公司 充电端子与线缆连接结构及充电座结构
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