WO2023174245A1 - 一种具有液冷功能的连接器总成及一种车辆 - Google Patents

一种具有液冷功能的连接器总成及一种车辆 Download PDF

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Publication number
WO2023174245A1
WO2023174245A1 PCT/CN2023/081258 CN2023081258W WO2023174245A1 WO 2023174245 A1 WO2023174245 A1 WO 2023174245A1 CN 2023081258 W CN2023081258 W CN 2023081258W WO 2023174245 A1 WO2023174245 A1 WO 2023174245A1
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WO
WIPO (PCT)
Prior art keywords
connector
electrical connection
connector assembly
cooling function
function according
Prior art date
Application number
PCT/CN2023/081258
Other languages
English (en)
French (fr)
Inventor
王超
Original Assignee
长春捷翼汽车科技股份有限公司
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Publication of WO2023174245A1 publication Critical patent/WO2023174245A1/zh

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R31/00—Coupling parts supported only by co-operation with counterpart
    • H01R31/06—Intermediate parts for linking two coupling parts, e.g. adapter
    • 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
    • B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/10—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
    • B60L53/14—Conductive energy transfer
    • B60L53/16—Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
    • 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
    • B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/10—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
    • B60L53/14—Conductive energy transfer
    • B60L53/18—Cables specially adapted for charging electric vehicles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
    • H01B7/041—Flexible cables, conductors, or cords, e.g. trailing cables attached to mobile objects, e.g. portable tools, elevators, mining equipment, hoisting cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/40—Insulated conductors or cables characterised by their form with arrangements for facilitating mounting or securing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/42—Insulated conductors or cables characterised by their form with arrangements for heat dissipation or conduction
    • H01B7/421—Insulated conductors or cables characterised by their form with arrangements for heat dissipation or conduction for heat dissipation
    • H01B7/423—Insulated conductors or cables characterised by their form with arrangements for heat dissipation or conduction for heat dissipation using a cooling fluid
    • 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
    • H01R13/40—Securing contact members in or to a base or case; Insulating of contact members
    • H01R13/405—Securing in non-demountable manner, e.g. moulding, riveting
    • 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
    • H01R13/648—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding  
    • H01R13/658—High frequency shielding arrangements, e.g. against EMI [Electro-Magnetic Interference] or EMP [Electro-Magnetic Pulse]
    • H01R13/6581—Shield structure
    • 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
    • H01R13/73—Means for mounting coupling parts to apparatus or structures, e.g. to a wall
    • 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
    • Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/10—Technologies relating to charging of electric vehicles
    • Y02T90/14—Plug-in electric vehicles

Definitions

  • the present invention relates to the technical field of automotive electrical appliances, and more specifically, to a connector assembly with a liquid cooling function and a vehicle.
  • the purpose of the present invention is to provide a connector assembly with a liquid cooling function and a new technical solution for vehicles.
  • the connector assembly with liquid cooling function of the present invention can reduce the failure of the electrical connection frame and the connection terminal due to the high temperature generated by electricity, prolong the service life of the connector, and improve the safety of the entire vehicle.
  • a connector assembly with a liquid cooling function including at least one electrical connection frame and a connector.
  • the connector includes connection terminals. Both ends of the electrical connection frame are respectively Electrically connected to the connection terminal, the electrical connection frame has at least one hollow inner cavity, and the hollow inner cavity circulates cooling liquid.
  • the cooling liquid is made of insulating material.
  • the electrical connection skeleton is made of a rigid hollow conductor material.
  • the electrical connection frame is electrically connected to the connection terminal by welding or crimping.
  • the cross-sectional shape of the outer contour of the electrical connection skeleton is circular, elliptical, rectangular, polygonal, A-shaped, B-shaped, D-shaped, M-shaped, N-shaped, O-shaped, S-shaped, E-shaped, One of F shape, H shape, K shape, L shape, T shape, U shape, V shape, W shape, X shape, Y shape, Z shape, P shape, semi-arc shape, arc shape, wavy shape or Several kinds.
  • the wall thickness of the hollow conductor material is uniform.
  • the cross-sectional area of the hollow conductor material is 1.5mm 2 -240mm 2 .
  • the sum of the cross-sectional areas of the hollow inner cavities accounts for 3.7%-75% of the cross-sectional area of the circumscribed circle of the electrical connection skeleton.
  • the connector further includes a shielding inner shell, and the shielding inner shell is made of conductive material.
  • the shielding inner shell is made of conductive metal or conductive plastic.
  • the conductive plastic is a polymer material containing conductive particles, and the conductive particle material contains one or more of metal, conductive ceramics, carbon-containing conductors, solid electrolytes, and mixed conductors;
  • the polymer material Materials include tetrastyrene, polyvinyl chloride, polyethylene, polyamide, polytetrafluoroethylene, tetrafluoroethylene/hexafluoropropylene copolymer, ethylene/tetrafluoroethylene copolymer, polypropylene, polyvinylidene fluoride, polyurethane, poly Terephthalic acid, polyurethane elastomer, styrenic block copolymer, perfluoroalkoxyalkane, chlorinated polyethylene, polyphenylene sulfide, polystyrene, cross-linked polyolefin, ethylene-propylene rubber, ethylene/ Vinyl acetate copolymer, chloroprene rubber, natural rubber, st
  • the metal material contains one or more of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium, and beryllium.
  • the carbon-containing conductor contains one or more of graphite silver, graphene silver, graphite powder, carbon nanotube material, and graphene material.
  • the transfer impedance of the shielded inner shell is less than 100 m ⁇ .
  • the electrical connection frame is covered with an insulating layer around its periphery.
  • an insulating layer is placed around the electrical connection skeleton, and a shielding layer and an outer insulating layer are also placed around the insulating layer.
  • the shielding layer is electrically connected to the shielding inner shell.
  • the connector includes a first connector and a second connector connecting both ends of the electrical connection frame, so A rotary cavity is provided inside the first connector, and a transfer cavity is provided inside the second connector.
  • the rotary cavity and the transfer cavity are respectively connected with the hollow inner cavity, and the first connection
  • One of the first connector and the second connector is provided with an inlet pipe, which communicates with one of the rotary cavity and the transfer cavity; the first connector and the second connector
  • the other one is provided with a derivation pipe, which is in communication with the other one of the rotary cavity and the transfer cavity.
  • the electrical connection skeleton is provided with through holes in a radial direction in both the rotary cavity and the adapter cavity, and the cooling liquid flows through the through holes.
  • one end of the inlet pipe and the outlet pipe is matched with the through hole, and the other end passes through the outer wall of the first connector and the second connector and extends to the first connector and the outside of the second connector.
  • a first sealing structure is provided between the introduction pipe and one of the first connector and the second connector;
  • a second sealing structure is provided between the derivation tube and the other one of the first connector and the second connector.
  • the boiling point of the cooling liquid is greater than or equal to 100°C.
  • the cooling liquid is water, glycol, silicone oil, fluoride, castor oil, coconut oil, corn oil, cottonseed oil, linseed oil, olive oil, palm oil, peanut oil, grapeseed oil, rapeseed Oil, safflower oil, sunflower oil, soybean oil, high oleic acid variants of various vegetable oils, decene-4-acid, decenoic acid, myrcene acid, argentine acid, tetradecanoic acid, spermacetic acid , Crude acid, palmitoleic acid, celerynic acid, oleic acid, stearic acid, codenoic acid, cetacetic acid, cetearylic acid, erucic acid, and nervonic acid, glycerin, transformer oil, axle oil, One or more types of internal combustion engine oil or compressor oil.
  • the cooling rate of the cooling liquid on the electrical connection skeleton is 0.05K/s-5K/s.
  • one of the connectors is a charging stand.
  • part of the electrical connection skeleton is flexible.
  • the electrical connection skeleton includes at least one bent portion.
  • a vehicle including the connector assembly with liquid cooling function, a circulation pump and a cooling device according to any of the above embodiments, and the hollow inner cavity is in contact with the circulation pump and the cooling device.
  • the cooling device is connected.
  • the inlet pipe connected with the hollow inner cavity is connected with the liquid inlet of the circulation pump
  • the liquid outlet of the circulation pump is connected with the liquid inlet of the cooling device
  • the outlet of the cooling device is connected with the liquid inlet of the cooling device.
  • the liquid port is connected to the outlet pipe, and the outlet pipe is connected to the hollow inner cavity.
  • the electrical connection skeleton can be arranged to follow the shape of the car body, but can be at a certain distance from the car body to ensure that it does not rub with the car shell, thereby ensuring that the electrical connection is The service life of the connecting frame.
  • a shielded inner shell is installed inside the connector, which can effectively prevent electromagnetic interference generated by the connector terminals.
  • the shielded inner shell made of conductive plastic can be integrally molded with the connector by integral injection molding, saving processing time and improving production. efficiency and reduce production costs.
  • the electrical connection skeleton is also equipped with flexible parts and curved parts.
  • the structure of the connector assembly can be reasonably designed according to the installation environment of the vehicle body, making it easier to install the connector assembly on the vehicle body and saving assembly time.
  • Figure 1 is a schematic structural diagram of a connector assembly with liquid cooling function according to the present invention.
  • FIG. 2 is a schematic cross-sectional view of the electrical connection skeleton according to the first embodiment of the present invention.
  • FIG. 3 is a schematic cross-sectional view of an electrical connection skeleton according to a second embodiment of the present invention.
  • Figure 4 is a schematic cross-sectional view of an electrical connection skeleton according to a third embodiment of the present invention.
  • FIG. 5 is a schematic cross-sectional view of an electrical connection skeleton according to the fourth embodiment of the present invention.
  • FIG. 6 is a schematic cross-sectional view of an electrical connection skeleton according to the fifth embodiment of the present invention.
  • FIG. 7 is a schematic structural diagram of the connection between the electrical connection skeleton and the first connector and the second connector of the connector assembly with liquid cooling function according to the preferred embodiment of the present invention.
  • any specific values are to be construed as illustrative only and not as limiting. Accordingly, other examples of the exemplary embodiments may have different values.
  • a connector assembly with liquid cooling function includes at least one electrical connection frame 2 and a connector.
  • the connector contains connection terminals 7, and both ends of the electrical connection frame 2 are connected to The terminals 7 are electrically connected, and the electrical connection frame 2 has at least one hollow inner cavity 3, and the hollow inner cavity 3 circulates cooling liquid.
  • the connector assembly with liquid cooling function includes two electrical connection skeletons 2.
  • the connectors include a first connector 11 and a second connector 12.
  • the first connector 11 and the second connector 12 are Both include connection terminals 7, and both ends of each electrical connection frame 2 are electrically connected to the connection terminals 7 respectively.
  • one of the above-mentioned connectors may be a charging stand.
  • the cooling liquid is made of insulating material.
  • the connector assembly with liquid cooling function of the present invention uses liquid cooling technology, which not only solves the current problem of thick wire diameter of high-voltage wire harness, but also reduces the heat generation of the electrical connection skeleton, so that the electrical connection skeleton can be Smaller wire diameters conduct larger currents. Moreover, it also solves the current problem of low cooling efficiency of liquid-cooled wire harnesses.
  • the liquid-cooled wire harnesses in the prior art are cooled through liquid-cooled tubes.
  • the cooling liquid directly contacts the electrical connection skeleton, which can quickly reduce the cooling efficiency of the electrical connection skeleton. temperature to achieve large current conduction.
  • the electrical conductivity of aluminum is second only to copper, and aluminum resources are abundant and cheap, making it one of the main materials to replace copper cables.
  • the cable form of the electrical connection frame 2 can be used to replace the multi-core cable structure, so that the cable can be fixed on the car shell and will not rub with the car shell due to the vibration of the car, thereby extending the service life of the connector assembly and reducing accident happened Rate.
  • the electrical connection frame 2 connects the first connector 11 and the second connector 12, and the second connector 12 is connected to the vehicle battery, thereby completing the electrical transmission from the first connector 11 to the vehicle battery.
  • the electrical connection frame 2 has at least one hollow inner cavity 3, and the hollow inner cavity 3 circulates coolant to the electrical connection frame. 2 plays a cooling role, thereby cooling the heated electrical connection skeleton 2 so that the connector assembly can work at a safe temperature.
  • the material of the electrical connection frame 2 can be a rigid hollow conductor material to form the hollow inner cavity 3 .
  • the use of the hard electrical connection skeleton 2 can realize automated assembly and assembly of the wire harness. At the same time, it also solves the problem of the contact and friction between the flexible cable and the car body, resulting in damage to the insulation layer and short circuit.
  • the rigid electrical connection frame 2 can be arranged to follow the shape of the car body, but can be at a certain distance from the car body to ensure that it does not rub against the car shell. , thereby ensuring the service life of the electrical connection skeleton 2.
  • cooling liquid or cooling oil is also circulated in the hollow inner cavity 3 .
  • the electrical connection skeleton 2 has a hollow inner cavity 3, and the wall thickness of the hollow conductor material is consistent.
  • the electrical connection skeleton 2 has a plurality of hollow inner cavities 3 , and the hollow inner cavities 3 are distributed in the electrical connection skeleton 2 .
  • the electrical connection skeleton 2 has four hollow inner cavities 3 , and the four hollow inner cavities 3 are distributed in the electrical connection skeleton 2 along the circumferential direction.
  • the hollow inner cavities 3 can be evenly distributed in the electrical connection skeleton 2 .
  • the number of hollow inner cavities 3 is not limited to four, and the number of hollow inner cavities 3 can be set according to actual needs.
  • the cross-sectional area of the electrical connection skeleton 2 is 1.5mm 2 -240mm 2 .
  • the cross-sectional area of the electrical connection skeleton 2 determines the current that the electrical connection skeleton 2 can conduct.
  • the electrical connection skeleton 2 that realizes signal conduction has a smaller current and the cross-sectional area of the electrical connection skeleton 2 is also smaller.
  • the minimum cross-sectional area of the electrical connection skeleton 2 for transmitting signals can reach 1.5mm 2
  • the electrical connection skeleton 2 for realizing power conduction has a larger current and a larger cross-sectional area.
  • the conductor has a maximum cross-sectional area The area reaches 240mm 2 .
  • the total cross-sectional area of the hollow inner cavity 3 accounts for 3.7%-75% of the cross-sectional area of the circumscribed circle of the electrical connection skeleton 2 .
  • the inventor has conducted relevant Test, the experimental method is to select the electrical connection skeleton 2 with different numbers of hollow inner cavities 3, apply a force of 80N, and observe whether the electrical connection skeleton 2 bends. If the bending is unqualified. In a closed environment, the same current is conducted to the electrical connection skeleton 2 with different numbers of hollow inner cavities 3, and the temperature rise is less than 50K as a qualified value. The results are shown in Table 1.
  • Table 1 The influence of the ratio of the sum of the cross-sectional area of the hollow inner cavity 3 to the cross-sectional area of the circumscribed circle of the electrical connection frame 2 on the support and temperature rise of the electrical connection frame 2
  • the cross-sectional shape of the outer contour of the electrical connection skeleton 2 is circular, elliptical, rectangular, polygonal, A-shaped, B-shaped, D-shaped, M-shaped, N-shaped, O-shaped, S-shaped, E-shaped , F shape, H shape, K shape, L shape, T shape, U shape, V shape, W shape, X shape, Y shape, Z shape, P shape, semi-arc shape, arc shape, wavy shape Or several.
  • part of the cross-section of the electrical connection skeleton 2 may be a circular structure, and the other part may be an elliptical structure.
  • the electrical connection skeleton 2 is specifically a large-diameter rod-shaped conductor.
  • the design of this structure It can better adapt to the vehicle wiring path without changing the power transmission effect.
  • two different wires are often used for transfer methods such as welding or crimping. Therefore, the design of this solution effectively reduces costs, can better match the body contour, simplifies the wiring process, reduces wiring consumables, and improves installation efficiency.
  • part of the electrical connection frame 2 is flexible.
  • the flexible material can be a multi-core cable or a braided cable or a flexible cable composed of multiple layers of sheets. Flexible materials are easy to bend and have excellent electrical conductivity. Thin sheets are soft and easy to shape. It is suitable for use as a flexible conductor. The superposition of multiple layers of thin plates can not only ensure flexibility but also ensure the efficiency of electrification.
  • the electrical connection skeleton 2 is connected by a combination of rigid materials and flexible materials. It can better match the outline of the vehicle body according to the installation environment of the vehicle body, and rationally design the structure of the connector assembly to make the installation of the connector assembly on the vehicle body easier. , save material and space.
  • the electrical connection frame 2 includes at least one bent portion.
  • the bending portion can be set according to the specific needs during the wiring process to facilitate the operator's wiring.
  • the electrical connection frame 2 is surrounded by an insulating layer 14 .
  • the insulating layer 14 can prevent the electrical connection frame 2 from being in contact with the vehicle body and causing a short circuit.
  • a shielding layer 5 and an outer insulating layer 13 are arranged outside the insulating layer 14 in sequence.
  • the shielding layer 5 can reduce the interference of the electromagnetic radiation generated by the electrical connection frame 2 to other electrical devices in the car.
  • the shielding layer 5 is made of a conductor and needs to be grounded, so an insulation layer 14 is provided between the shielding layer 5 and the electrical connection frame 2 , to prevent contact between the two.
  • the outer insulating layer 13 can prevent the shielding layer 5 from contacting the vehicle shell and causing a short circuit.
  • the first connector 11 and the second connector 12 further include a shielding inner shell 4 inside, and the shielding inner shell 4 is made of conductive material. Therefore, the shielding inner shell 4 is provided inside the connector, which can effectively prevent electromagnetic interference generated by the terminals of the connector.
  • the shielding inner shell 4 made of conductive material is electrically connected to the shielding layer 5 to form a complete shielding device.
  • the shielding layer 5 is made of rigid conductive material. Furthermore, the material of the shielding layer 5 may be metal or conductive plastic. Therefore, the shielding inner shell 4 and the shielding layer 5 can play a shielding role, effectively shielding the electromagnetic interference generated by the electrical connection skeleton 2, saving the use of the shielding net, and reducing the cost of the connector assembly.
  • the transfer impedance of the shielded inner shell 4 is less than 100 m ⁇ .
  • the inventor selected the same specifications of electrical connection skeletons 2, connectors and connection terminals 7, and used shielding inner shells 4 with different transfer impedance values to produce a series of Samples were used to test the shielding effect respectively.
  • the experimental results are shown in Table 2 below. In this embodiment, a shielding performance value greater than 40dB is an ideal value.
  • the inventor sets the transfer impedance of the shielding inner shell 4 to be less than 100m ⁇ .
  • the material of the shielding inner shell 4 contains metal or conductive plastic.
  • the conductive plastic can be a polymer material containing conductive particles.
  • the conductive particle material contains one or more of metal, conductive ceramics, carbon-containing conductors, solid electrolytes, and mixed conductors;
  • the polymer material contains tetrastyrene, polyvinyl chloride , polyethylene, polyamide, polytetrafluoroethylene, tetrafluoroethylene/hexafluoropropylene copolymer, ethylene/tetrafluoroethylene copolymer, polypropylene, polyvinylidene fluoride, polyurethane, polyterephthalic acid, polyurethane elastomer, Styrene block copolymer, perfluoroalkoxyalkane, chlorinated polyethylene, polyphenylene sulfide, polystyrene, cross-linked polyolefin, ethylene propylene rubber, ethylene/vinyl a
  • the advantage of using conductive plastic is that it can be easily injection molded, and the user can choose a suitable material for the shielding inner shell 4 according to needs.
  • the metal material in the material of the conductive particles contains one or more of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium, and beryllium. .
  • the inventor conducted experiments, using metal particles of the same size and different materials to make samples of the shielding inner shell 4, and tested the conductivity of the shielding inner shell 4 respectively. rate, the experimental results are shown in Table 3 below.
  • the conductivity of the shielding inner shell 4 is greater than 99%, which is an ideal value.
  • the conductivity of conductive plastics made of different metal particles is within the ideal range.
  • phosphorus is a non-metallic material and cannot be directly used as a material for conductive plating, but it can be added to other metals to form Alloys improve the electrical conductivity and mechanical properties of the metal itself. Therefore, the inventor determined that the material of the metal particles contains one or more of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium, and beryllium.
  • the carbon-containing conductor in the material of the conductive particles may contain one or more of graphite silver, graphene silver, graphite powder, carbon nanotube materials, and graphene materials.
  • Graphite powder is a mineral powder, the main component is carbon, soft, black gray; graphite powder is a good non-metallic conductive substance.
  • Carbon nanotubes have good electrical conductivity. Since the structure of carbon nanotubes is the same as the lamellar structure of graphite, they have good electrical properties. Graphene has extremely high electrical properties. Carbon-containing conductors containing these three materials have high conductivity and good shielding properties, and can effectively achieve electromagnetic shielding of the electrical connection skeleton 2.
  • the shielding inner shell 4 made of conductive plastic can be integrally molded with the connector by integral injection molding, which saves processing time, improves production efficiency, and reduces production costs.
  • connection terminal 7 is made of copper or copper alloy
  • electrical connection frame 2 is made of aluminum or aluminum alloy
  • the electrical connection frame 2 is electrically connected to the connection terminal 7 by welding or crimping.
  • connection terminals 7 made of copper or copper alloy for plug-in and pull-out connections.
  • the connection terminal 7 It can be widely used in various electrical transmission scenarios.
  • the electrical connection skeleton 2 made of aluminum or aluminum alloy has the advantages of good rigidity, light weight and high transmission efficiency, and is particularly suitable for the transmission of large currents.
  • connection terminal 7 and the electrical connection frame 2 are connected by welding, and the welding method used includes one or more of resistance welding, friction welding, ultrasonic welding, arc welding, laser welding, electron beam welding, pressure diffusion welding, and magnetic induction welding. , uses concentrated heat energy or pressure to create a molten connection at the contact position between the connection terminal 7 and the electrical connection frame 2, and the connection is stable by welding.
  • the metal inertness of copper is greater than that of aluminum.
  • the electrode potential difference between copper and aluminum is 1.9997V.
  • Resistance welding refers to a method that uses strong current to pass through the contact point between the electrode and the workpiece, and generates heat due to the contact resistance to achieve welding.
  • Friction welding refers to a method that uses the heat generated by friction on the contact surface of the workpiece as a heat source to cause plastic deformation of the workpiece under pressure for welding.
  • Ultrasonic welding uses high-frequency vibration waves to transmit to the surfaces of two objects to be welded. Under pressure, the surfaces of the two objects rub against each other to form fusion between the molecular layers.
  • the arc welding method refers to using the arc as a heat source and utilizing the physical phenomenon of air discharge to convert electrical energy into the thermal energy and mechanical energy required for welding, thereby achieving the purpose of joining metals.
  • the main methods include electrode arc welding, submerged arc welding, and gas shielding. Welding etc.
  • Laser welding is an efficient and precise welding method that uses high-energy-density laser beams as heat sources.
  • Friction welding refers to a method that uses the heat generated by friction on the contact surface of the workpiece as a heat source to cause plastic deformation of the workpiece under pressure for welding.
  • Electron beam welding refers to the use of accelerated and focused electron beams to bombard the welding surface placed in a vacuum or non-vacuum, so that the workpiece to be welded melts to achieve welding.
  • Pressure welding is a method of applying pressure to the weldment to bring the joint surfaces into close contact to produce a certain degree of plastic deformation to complete the welding.
  • Crimping is a production process in which after assembling the electrical connection frame 2 and the connection terminal 7, a crimping machine is used to stamp the two into one body.
  • the advantage of crimping is mass production. By using an automatic crimping machine, products of stable quality can be manufactured quickly and in large quantities.
  • the shielding layer 5 is electrically connected to the shielding inner shell 4 by crimping or welding.
  • Aluminum or aluminum alloy materials have good electrical conductivity, are light in weight and have low prices. Using aluminum or aluminum alloy to make the shielding inner shell 4 can achieve a good shielding effect and prevent the electromagnetic radiation from the connection terminal 7 and the electrical connection frame 2 from affecting other equipment.
  • Crimping is a production process in which after assembling the shielding inner shell 4 and the shielding layer 5, a crimping machine is used to stamp the two into one body.
  • the advantage of crimping is mass production. By using an automatic crimping machine, products of stable quality can be manufactured quickly and in large quantities.
  • the welding or crimping method is basically the same as the welding method of the connection terminal 7 and the electrical connection frame 2 and will not be described again.
  • the electrical connector assembly with liquid cooling function of the present invention has an electrical The connecting frame 2, and the first connector 11 and the second connector 12 connected to both ends of the electrical connecting frame 2, the first connector 11 is provided with a rotary cavity 94 inside, and the second connector 12 is provided with a transfer cavity 95 inside , the rotary cavity 94 and the switching cavity 95 are respectively connected with a hollow inner cavity 3 of the electrical connection frame 2 .
  • one of the first connector 11 and the second connector 12 is provided with an introduction pipe 91, which communicates with one of the rotary cavity 94 and the adapter cavity 95;
  • the other of the two connectors 12 is provided with a derivation pipe 92 communicating with the other of the rotary cavity 94 and the transfer cavity 95 .
  • the inlet pipe 91 is provided on the second connector 12 and communicates with the switching cavity 95;
  • the outlet pipe 92 is provided on the first connector 11 and communicates with the rotation
  • the cavity is connected to 94.
  • the inlet pipe 91 is provided on the first connector 11 and communicates with the rotary cavity 94 ; and the outlet pipe 92 is provided on the second connector 12 and communicates with the transfer cavity 95 .
  • the coolant can be driven by the circulation pump, through the inlet pipe 91 from one end of the electrical connection frame 2, such as the second connector 12, into the hollow inner cavity 3 of the electrical connection frame 2, and then flows through the hollow inner cavity 3 , then flows out through the outlet pipe 92, and is cooled by the cooling system, and then enters the hollow inner cavity 3 again by the circulation pump, forming a complete cooling cycle.
  • the electrical connection skeleton 2 is provided with radial through holes 93 in both the rotary cavity 94 and the adapter cavity 95 , and the cooling liquid flows through the rotary cavity 94 through the through holes 93 , the hollow inner cavity 3 and the transfer cavity 95.
  • the portion of the electrical connection frame 2 inside the rotary cavity 94 is provided with a through hole 93 in the radial direction, and the cooling liquid flows through the hollow inner cavity 3 and the rotary cavity 94 through the through hole 93 .
  • the portion of the electrical connection skeleton 2 inside the transfer cavity 95 is provided with a through hole 93 in the radial direction, and the cooling liquid flows through the hollow inner cavity 3 and the transfer cavity 95 through the through hole 93 .
  • the coolant can flow through the rotation cavity 94 , the hollow inner cavity 3 and the transfer cavity 95 through the through hole 93 .
  • the introduction tube 91 is inserted into the switching cavity 95 of the second connector 12 and communicates with the hollow inner cavity 3 ; the lead-out tube 92 is inserted into the rotation cavity 94 of the first connector 11 and communicates with it. Connected with hollow inner cavity 3.
  • one end of the inlet pipe and the outlet pipe can be matched and connected with the through hole of the electrical connection frame, and the other end passes through the outer wall of the first connector and the second connector and extends to the first connector. connector and the outside of the second connector. Therefore, the coolant does not need to fill the rotary cavity and the transfer cavity 95 to achieve communication with the hollow inner cavity.
  • the electrical connector assembly with liquid cooling function of the present invention may have two (or more) electrical connection skeletons, and be connected to both ends of the electrical connection skeleton. the first connector and the second connector. Both the first connector and the second connector are provided with connectors respectively connected to both ends of each electrical connection frame. Connect the terminals.
  • the electrical connection skeleton may have only one hollow inner cavity 3 as shown in FIG. 2 .
  • the electrical connection skeleton may also have multiple hollow inner cavities 3 as shown in FIG. 5 . Therefore, in the case where the electrical connection frame has multiple hollow cavities, in order to ensure that the cooling liquid flows in each hollow cavity in an electrical connection frame, as shown in Figure 6, it is possible to dispose between the hollow cavities 3 Interconnected through holes 93 are provided.
  • connection holes can be provided between each electrical connection skeleton 2. Therefore, the coolant flows through the hollow inner cavities through the connection holes and the through holes 93. 3.
  • a first sealing structure is provided between the introduction pipe 91 and one of the first connector 11 and the second connector 12;
  • a second sealing structure is provided between the derivation pipe 92 and the other one of the first connector 11 and the second connector 12 .
  • a first sealing structure may be provided between the introduction tube 91 and the second connector 12 .
  • the first sealing structure may be a sealing ring.
  • a second sealing structure may be provided between the outlet tube 92 and the first connector 11 .
  • the second sealing structure may be the same as the first sealing structure.
  • the second sealing structure is different from the first sealing structure.
  • a third sealing structure is provided between the connector and the shielding layer 5 .
  • a sealing ring 8 (can be understood as a third sealing structure) is provided between the first connector 11 or the second connector 12 and the shielding layer 5 .
  • the sealing ring 8 seals the rotary cavity 94 and the transfer cavity 95 .
  • the sealing ring 8 can prevent the cooling liquid from leaking from the connection between the first connector 11 or the second connector 12 and the shielding layer 5 .
  • the cooling medium is a cooling gas or a cooling liquid.
  • the cooling gas can be refrigerated air.
  • the cooling liquid can be water, glycol, silicone oil, fluoride, castor oil, coconut oil, corn oil, cottonseed oil, linseed oil, olive oil, palm oil, peanut oil, grapeseed oil, rapeseed oil, safflower oil , sunflower oil, soybean oil, high oleic acid variants of various vegetable oils, decene-4-acid, decenoic acid, myrcene acid, ebony acid, tetradecenic acid, sperm acid, crude acid, Palmitoleic acid, celerynic acid, oleic acid, octadecenoic acid, codenoic acid, cetoleic acid, cetearylic acid, erucic acid, and nervonic acid, glycerin, transformer oil, axle oil, internal combustion engine oil, or compressor One or more types of oil; additives can also be added to the cool
  • the boiling point of the coolant can be set to 100°C or greater.
  • Cooling oil has sensitive heat balance capability, super heat conductivity, and a wide operating temperature range, which eliminates boiling and boiling, and micro-pressure in the cooling system. There is no need to add antifreeze in low-temperature environments, and it avoids corrosion damage such as cavitation, liquid scale, and electrolysis. advantage.
  • the cooling rate of the electrical connection skeleton 2 by the cooling liquid is 0.05K/s-5K/s.
  • the connection skeleton 2 is cooled, and the temperature rise value of each electrical connection skeleton 2 is read and recorded in Table 4.
  • the experimental method is to conduct the same current through the electrical connection skeleton 2 using coolants with different cooling rates in a closed environment, record the temperature before power on and the temperature after power on when the temperature is stable, and take the absolute value of the difference.
  • a temperature rise of less than 50K is considered a qualified value.
  • one of the connectors is a charging dock. Both ends of the electrical connection frame 2 are respectively connected to a connector.
  • one of the connectors (for example, the first connector 11 ) can be a charging base, and the electrical connection frame 2 is used as a connector at the other end (for example, the first connector 11 ). Second connector 12) for charging.
  • part of the electrical connection frame 2 is flexible.
  • the flexible body can ensure that the electrical connection frame 2 can make a larger bending angle to facilitate installation in a car body with a relatively large corner. At the same time, the flexible body can absorb the vibration of the electrical connection frame 2 so that the vibration of the electrical connection frame 2 will not affect the connector and other corresponding electrical devices on the vehicle body.
  • the electrical connection frame 2 includes at least one bent portion to meet the need for the electrical connection frame 2 to be installed on the vehicle body.
  • the invention also provides a vehicle, which includes the connector assembly with liquid cooling function, a circulation pump and a cooling device as mentioned above.
  • the hollow inner cavity 3 is connected with the circulation pump and the cooling device.
  • the inlet pipe 91 is connected with the liquid inlet of the circulation pump
  • the liquid outlet of the circulation pump is connected with the liquid inlet of the cooling device
  • the liquid outlet of the cooling device is connected with the outlet pipe 92
  • the outlet pipe 92 is connected with the liquid inlet of the cooling device.
  • 92 is connected with the hollow inner cavity 3.

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Abstract

一种具有液冷功能的连接器总成和一种车辆，连接器总成包括至少一根电连接骨架和包含连接端子的连接器，电连接骨架两端分别与连接端子电连接，电连接骨架具有至少一个中空内腔，中空内腔流通冷却液。该连接器总成使用液冷技术，降低电连接骨架发热量，使电连接骨架的能够以较小线径导通较大电流，保证高压装置正常使用。

Description

一种具有液冷功能的连接器总成及一种车辆
交叉引用信息
本申请要求于2022年03月14日提交中国专利局、申请号为202210250055.2、发明名称为“一种具有液冷功能的连接器总成及一种车辆”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本发明涉及汽车电器技术领域，更具体地，涉及一种具有液冷功能的连接器总成及一种车辆。
背景技术
随着新能源汽车的越来越普及，为新能源汽车导通电流的设备和设施也随之发展起来，新能源汽车上的连接器总成由于要达到驱动大功率电机的要求，传输电流都比较大，连接器总成上的高压线缆的直径也随之增大，在车身上的装配也只能手工安装，浪费人力成本及时间成本。
另外，在正常使用的过程中，高压线缆会流经非常大的电流，因此高压线缆和连接接头都会产生大量的热量，由于热量过大将导致高温，高压线缆连接位置以及周边的连接件、固定件会因为高温而失效，影响高压装置的正常使用，产生短路及断路，甚至产生触电危险，危及生命。
以上问题目前还没有切实的解决方案，因此，汽车电器技术领域急需一种线径较小，线缆发热量较低，可以实现自动化生产和装配的连接器总成。
发明内容
本发明的目的是提供一种具有液冷功能的连接器总成及一种车辆的新技术方案。本发明的具有液冷功能的连接器总成能够降低电连接骨架和连接端子因通电产生高温导致的失效，延长连接器的使用寿命，提高整车安全性。
根据本发明的第一方面，提供了一种具有液冷功能的连接器总成，包括至少一根电连接骨架和连接器，所述连接器中包含连接端子，所述电连接骨架两端分别与连接端子电连接，所述电连接骨架具有至少一个中空内腔，所述中空内腔流通冷却液。
可选地，所述冷却液的材质为绝缘材料。
可选地，所述电连接骨架的材质含有刚性的空心导体材料。
可选地，所述电连接骨架通过焊接或压接的方式与所述连接端子电连接。
可选地，所述电连接骨架外轮廓的横截面形状为圆形、椭圆形、矩形、多边形、A形、B形、D形、M形、N形、O形、S形、E形、F形、H形、K形、L形、T形、U形、V形、W形、X形、Y形、Z形、P形、半弧形、弧形、波浪形中的一种或几种。
可选地，当所述电连接骨架具有一个中空内腔时，所述空心导体材料的壁厚一致。
可选地，所述空心导体材料的横截面积为1.5mm2-240mm2。
可选地，所述中空内腔的截面积之和占所述电连接骨架外切圆的截面积的3.7％-75％。
可选地，所述连接器内部还包含屏蔽内壳，所述屏蔽内壳的材质含有导电材料。
可选地，所述屏蔽内壳的材质含有导电金属或导电塑胶。
可选地，所述导电塑胶为包含导电颗粒的高分子材料，所述导电颗粒材质含有金属、导电陶瓷、含碳导体、固体电解质、混合导体的一种或几种；所述高分子材料的材质含有四苯乙烯、聚氯乙烯、聚乙烯、聚酰胺、聚四氟乙烯、四氟乙烯/六氟丙烯共聚物、乙烯/四氟乙烯共聚物、聚丙烯、聚偏氟乙烯、聚氨酯、聚对苯二甲酸、聚氨酯弹性体、苯乙烯嵌段共聚物、全氟烷氧基烷烃、氯化聚乙烯、聚亚苯基硫醚、聚苯乙烯、交联聚烯烃、乙丙橡胶、乙烯/醋酸乙烯共聚物、氯丁橡胶、天然橡胶、丁苯橡胶、丁腈橡胶、硅橡胶、顺丁橡胶、异戊橡胶、乙丙橡胶、氯丁橡胶、丁基橡胶、氟橡胶、聚氨酯橡胶、聚丙烯酸酯橡胶、氯磺化聚乙烯橡胶、氯醚橡胶、氯化聚乙烯橡胶、氯硫橡胶、苯乙烯丁二烯橡胶、丁二烯橡胶、氢化丁腈橡胶、聚硫橡胶、交联聚乙烯、聚碳酸酯、聚砜、聚苯醚、聚酯、酚醛树脂、脲甲醛、苯乙烯-丙烯腈共聚物、聚甲基丙烯酸酯、聚甲醛树酯中的一种或几种。
可选地，所述金属的材质含有镍、镉、锆、铬、钴、锰、铝、锡、钛、锌、铜、银、金、磷、碲、铍中的一种或几种。
可选地，所述含碳导体含有石墨银、石墨烯银、石墨粉、碳纳米管材料、石墨烯材料中的一种或多种。
可选地，所述屏蔽内壳的转移阻抗为小于100mΩ。
可选地，所述电连接骨架的外周套设绝缘层。
可选地，所述电连接骨架的外周套设绝缘层，所述绝缘层外周还套设屏蔽层和外绝缘层。
可选地，所述屏蔽层与所述屏蔽内壳电连接。
可选地，所述连接器包括连接所述电连接骨架两端的第一连接器和第二连接器，所 述第一连接器内部设置回转腔体，所述第二连接器内部设置转接腔体，所述回转腔体、所述转接腔体分别与所述中空内腔联通，所述第一连接器和所述第二连接器中的一者上设置有导入管，与所述回转腔体和所述转接腔体中的一者联通；所述第一连接器和所述第二连接器中的另一者上设置有导出管，与所述回转腔体和所述转接腔体中的另一者联通。
可选地，所述电连接骨架在所述回转腔体的部分以及在所述转接腔体的部分，均设置有径向方向的通孔，所述冷却液通过所述通孔流经所述回转腔体、所述中空内腔和所述转接腔体。
可选地，所述导入管与所述导出管一端与所述通孔匹配连接，另一端穿过所述第一连接器和所述第二连接器外壁并伸出到所述第一连接器和所述第二连接器外侧。
可选地，所述导入管与所述第一连接器、所述第二连接器两者中的一者之间设置第一密封结构；
所述导出管与所述第一连接器、所述第二连接器两者中的另一者之间设置第二密封结构。
可选地，所述冷却液的沸点大于等于100℃。
可选地，所述冷却液为水、乙二醇、硅油、氟化物、蓖麻油、椰子油、玉米油、棉籽油、亚麻子油、橄榄油、棕榈油、花生油、葡萄籽油、菜籽油、红花油、向日葵油、大豆油、各种植物油的高油酸变体、癸烯-4-酸、癸烯酸、月桂烯酸、天台乌药酸、十四碳烯酸、抹香鲸酸、粗租酸、棕榈油酸、芹岩酸、油酸、十八碳烯酸、鳕烯酸、巨头鲸鱼酸、鲸蜡烯酸、芥酸、和神经酸、甘油、变压器油、车轴油、内燃机油或压缩机油的一种或几种。
可选地，所述冷却液对所述电连接骨架的冷却速率为0.05K/s-5K/s。
可选地，其中一个所述连接器为充电座。
可选地，所述电连接骨架的部分区域为柔性。
可选地，所述电连接骨架包括至少一个弯折部。
根据本发明的第二方面，还提供一种车辆，包括上述任一实施例所述的具有液冷功能的连接器总成、循环泵和冷却装置，所述中空内腔与所述循环泵和所述冷却装置联通。
可选地，与所述中空内腔联通的导入管与所述循环泵的进液口联通，所述循环泵的出液口与所述冷却装置的进液口联通，所述冷却装置的出液口与导出管联通，所述导出管与所述中空内腔联通。
本发明的有益效果是：
1.解决了目前高压线束线径较粗的问题，使用液冷技术，降低电连接骨架的发热量，使电连接骨架的能够以较小的线径导通较大的电流。
2.解决了目前高压线束使用柔性线缆，无法实现自动化生产及装配的问题，使用至少部分硬质的电连接骨架，可以实现线束的自动化装配和组装。
3.解决目前液冷线束冷却效率低的问题，目前的液冷线束都是通过液冷管进行冷却，本发明是冷却液直接与电连接骨架接触，能够迅速降低电连接骨架的温度，实现大电流导通。
4.解决了柔性线缆与车壳接触摩擦，导致绝缘层破损短路的问题，电连接骨架能够跟随车身形状布置，但又可以与车身有一定距离，能够保证不与车壳摩擦，从而保证电连接骨架的使用寿命。
5.连接器内部设置屏蔽内壳，可以有效的阻止连接器的端子产生的电磁干扰，导电塑料制成的屏蔽内壳，可以采用一体注塑的方式与连接器一体成型，节省加工时间，提高生产效率，降低生产成本。
6.电连接骨架还设置了柔性部分和弯曲部分，可以根据车身的安装环境，合理设计连接器总成的结构，使连接器总成在车身上的安装更加容易，节省装配时间。
附图说明
被结合在说明书中并构成说明书的一部分的附图示出了本发明的实施例，并且连同其说明一起用于解释本发明的原理。
图1为本发明具有液冷功能的连接器总成的结构示意图。
图2为本发明第一实施例的电连接骨架的截面示意图。
图3为本发明第二实施例的电连接骨架的截面示意图。
图4为本发明第三实施例的电连接骨架的截面示意图。
图5为本发明第四实施例的电连接骨架的截面示意图。
图6为本发明第五实施例的电连接骨架的截面示意图。
图7为本发明优选实施例的具有液冷功能的连接器总成的电连接骨架与第一连接器、第二连接器之间连接的结构示意图。
主要组件符号说明：
11-第一连接器、12-第二连接器、2-电连接骨架、3-中空内腔、4-屏蔽内壳、5-屏蔽层、14-绝缘层、7-连接端子、8-密封环、91-导入管、92-导出管、93-通孔、94-回转腔 体、95-转接腔体、13-外绝缘层。
具体实施方式
现在将参照附图来详细描述本发明的各种示例性实施例。应注意到：除非另外具体说明，否则在这些实施例中阐述的部件和步骤的相对布置、数字表达式和数值不限制本发明的范围。
以下对至少一个示例性实施例的描述实际上仅仅是说明性的，决不作为对本发明及其应用或使用的任何限制。
对于相关领域普通技术人员已知的技术、方法和设备可能不作详细讨论，但在适当情况下，所述技术、方法和设备应当被视为说明书的一部分。
在这里示出和讨论的所有例子中，任何具体值应被解释为仅仅是示例性的，而不是作为限制。因此，示例性实施例的其它例子可以具有不同的值。
一种具有液冷功能的连接器总成，如图1至图7所示，包括至少一根电连接骨架2和连接器，连接器中包含连接端子7，电连接骨架2两端分别与连接端子7电连接，电连接骨架2具有至少一个中空内腔3，中空内腔3流通冷却液。在具体实施例中，具有液冷功能的连接器总成包括两根电连接骨架2，连接器包括第一连接器11和第二连接器12，第一连接器11和第二连接器12中均包含连接端子7，每根电连接骨架2两端分别与连接端子7电连接。在一些实施例中，上述的其中一个连接器可以为充电座。优选地，所述冷却液的材质为绝缘材料。
由此，本发明的具有液冷功能的连接器总成使用液冷技术，既解决了目前高压线束线径较粗的问题，也降低了电连接骨架的发热量，使电连接骨架的能够以较小的线径导通较大的电流。并且，也解决了目前液冷线束冷却效率低的问题，现有技术的液冷线束都是通过液冷管进行冷却，本发明是冷却液直接与电连接骨架接触，能够迅速降低电连接骨架的温度，实现大电流导通。
目前大部分连接器总成上的高压线缆都使用多芯的铜线缆，重量大，价格高，成为限制新能源汽车普及的障碍。另外，多芯的线缆虽然较柔软，能够方便加工和布线，都是由于线径过粗，重量较大，在汽车行驶过程中线缆会频繁摩擦车壳，导致线缆的绝缘层破损，造成高压放电，轻则损坏车辆，重则会造成严重的交通事故。
铝的导电性仅次于铜，并且铝资源储存量大，价格便宜，成为代替铜线缆的主要材料之一。并且，可以使用电连接骨架2的线缆形式替代多芯线缆结构，使线缆能够固定在车壳上，不会随着汽车振动与车壳摩擦，延长连接器总成的使用寿命，减少事故发生 率。
但是由于铝材质的线缆导电率不如铜材质的线缆，必须要增大线缆的截面积，才能保证流通正常的电流值，因此铝材质的线缆直径较粗，在加工和安装过程中都需要占用较大的空间。
电连接骨架2连接第一连接器11和第二连接器12，第二连接器12再与车载电池连接，从而完成从第一连接器11到车载电池的电传输。在汽车充电时，流经电连接骨架2的电流非常的大，电连接骨架2的温度快速升高，电连接骨架2具有至少一个中空内腔3，中空内腔3流通冷却液对电连接骨架2起到冷却作用，从而对发热的电连接骨架2进行降温，使连接器总成能在安全的温度下工作。并且，由于电连接骨架2具有至少一个中空内腔3，因此，电连接骨架2的材质可以为刚性的空心导体材料，以形成中空内腔3。由此，解决了目前高压线束使用柔性线缆，无法实现自动化生产及装配的问题，使用硬质的电连接骨架2，可以实现线束的自动化装配和组装。同时，也解决了柔性线缆与车壳接触摩擦，导致绝缘层破损短路的问题，刚性的电连接骨架2能够跟随车身形状布置，但又可以与车身有一定距离，能够保证不与车壳摩擦，从而保证电连接骨架2的使用寿命。
进而为了降低电连接骨架2的发热程度，在中空内腔3中也流通冷却液或冷却油。
在一些实施例中，如图2所示，电连接骨架2具有一个中空内腔3，空心导体材料的壁厚一致。
在一些实施例中，电连接骨架2具有多个中空内腔3，中空内腔3分布在电连接骨架2中。具体地，如图5所示，电连接骨架2具有四个中空内腔3，四个中空内腔3沿圆周方向分布在电连接骨架2中。优选地，中空内腔3可以均匀分布在电连接骨架2中。当然可以理解，在其他实施例中，中空内腔3的数量不限于四个，且中空内腔3的数量可以根据实际需求进行设定。
进一步地，在一些实施例中，电连接骨架2的横截面积为1.5mm2-240mm2。电连接骨架2的截面积决定电连接骨架2所能导通的电流，一般情况下，实现信号导通的电连接骨架2，电流较小，电连接骨架2截面积也较小，例如用于传输信号的线电连接骨架2最小截面积可达到1.5mm2，而实现电源导通的电连接骨架2，电流较大，电连接骨架2截面积也较大，例如汽车蓄电池线束，导体最大截面积达到240mm2。
在一些实施例中，中空内腔3的截面积之和占电连接骨架2外切圆的截面积的3.7％-75％。
如果截面积之和过大，则电连接骨架2的支撑力不足，如果截面积之和过小，则冷却效果不足，为了选择合理的中空内腔3的截面积之和，发明人进行了相关测试，实验方法是选择具有不同个数的中空内腔3的电连接骨架2，施加80N的力，观察电连接骨架2是否折弯，如果折弯为不合格。在封闭的环境中，对具有不同个数的中空内腔3的电连接骨架2导通相同的电流，温升小于50K为合格值。结果如表1所示。
表1：中空内腔3的截面积之和占电连接骨架2外切圆的截面积的比对电连接骨架2的支撑及温升的影响
从上表1中可以看出，当中空内腔3的截面积之和占电连接骨架2外径所在截面积的比小于3.7％后，电连接骨架2的温升大于50K，为不合格；当中空内腔3的截面积之和占电连接骨架2外径所在截面积的比大于75％后，电连接骨架2在80N的作用力下会出现变形，很容易导致冷却液泄露，因此，发明人优选中空内腔3的截面积之和占电连接骨架2外径所在的截面积的3.7％-75％。
在一些实施例中，电连接骨架2外轮廓的横截面形状为圆形、椭圆形、矩形、多边形、A形、B形、D形、M形、N形、O形、S形、E形、F形、H形、K形、L形、T形、U形、V形、W形、X形、Y形、Z形、P形、半弧形、弧形、波浪形中的一种或几种。
具体地，电连接骨架2横截面的一部分可以是圆形结构，另一部分是椭圆形结构，电连接骨架2具体为大直径的棒状导体，当在布线遇到狭窄的空间时，此结构的设计在不改变电能传输效果的同时还能够更好的与车辆的布线路径相适应。而传统的两导线进行车身匹配时，往往采用两条不同的导线进行焊接或压接等转接方式。因此，本方案的设计有效的降低了成本，能够更好的匹配车身轮廓，简化布线工艺，减少布线耗材，提高了安装效率。
在一些实施例中，电连接骨架2的部分区域为柔性。柔性材料可以为多芯线缆或编织线缆或多层薄板叠加的软排。柔性材料易折弯且导电性能优良，薄板质地较软容易形 变，适合作为柔性导体，多层薄板叠加既能保证柔性，又能保证通电的效率。电连接骨架2由刚性材料和柔性材料组合连接，可以根据车身的安装环境，更好地与车身轮廓相匹配，合理设计连接器总成的结构，使连接器总成在车身上的安装更加容易，节省材料和空间。
在一些实施例中，电连接骨架2包括至少一个弯折部。由此，可以根据布线过程中的具体需求设置弯折部，方便操作人员布线。
在一些实施例中，如图3所示，电连接骨架2外周套设绝缘层14。绝缘层14能够防止电连接骨架2与车壳接触发生短路。
进一步的，如图4所示，绝缘层14外还依次套设屏蔽层5和外绝缘层13。屏蔽层5能够降低电连接骨架2产生的电磁辐射对车内其他用电装置的干扰，屏蔽层5材质为导体，并且需要接地，所以在屏蔽层5和电连接骨架2之间设置绝缘层14，防止两者接触。外绝缘层13能够防止屏蔽层5和车壳接触发生短路。
在一些实施例中，第一连接器11和第二连接器12内部还包含屏蔽内壳4，屏蔽内壳4的材质为导电材料。由此，连接器内部设置屏蔽内壳4，可以有效的阻止连接器的端子产生的电磁干扰。
为了降低电磁干扰的影响，导电线缆通常采用屏蔽网进行电磁干扰的屏蔽，目前常用的屏蔽网是采用金属丝编制而成，需要在线缆生产设备中增加屏蔽编织机，设备价格高，占地面积大，导致连接器的屏蔽线缆价格居高不下。而本发明中采用导电材料制成的屏蔽内壳4与屏蔽层5电连接形成一个完全的屏蔽装置。屏蔽层5材质为刚性的导电材料。进一步地，屏蔽层5的材质可以为金属或导电塑胶。因此，屏蔽内壳4和屏蔽层5可以起到屏蔽的作用，有效的屏蔽电连接骨架2通电产生的电磁干扰，节省了屏蔽网的使用，降低了连接器总成的成本。
在一些实施例中，屏蔽内壳4的转移阻抗为小于100mΩ。为了验证不同转移阻抗值的屏蔽内壳4对屏蔽效果的影响，发明人选用相同规格的电连接骨架2、连接器和连接端子7，采用不同转移阻抗值的屏蔽内壳4，制作了一系列的样件，分别测试屏蔽效果，实验结果如下表2所示，在本实施例中，屏蔽性能值大于40dB为理想值。
屏蔽性能值测试方法为：测试仪器对电连接骨架2输出一个信号值(此数值为测试值2)，在屏蔽内壳4外侧设置探测装置，此探测装置探测到一个信号值(此数值为测试值1)。屏蔽性能值＝测试值2-测试值1。
表2：屏蔽内壳4的转移阻抗对屏蔽性能的影响
从上表2可以看出，当屏蔽内壳4的转移阻抗值大于100mΩ时，屏蔽内壳4的屏蔽性能值小于40dB，不符合理想值要求，而屏蔽内壳4的转移阻抗值为小于100mΩ时，屏蔽内壳4的屏蔽性能值全部符合理想值要求，而且趋势越来越好，因此，发明人设定屏蔽内壳4的转移阻抗为小于100mΩ。
进一步的，屏蔽内壳4的材质含有金属或导电塑胶。导电塑胶可以为包含导电颗粒的高分子材料，导电颗粒材质含有金属、导电陶瓷、含碳导体、固体电解质、混合导体的一种或几种；高分子材料的材质含有四苯乙烯、聚氯乙烯、聚乙烯、聚酰胺、聚四氟乙烯、四氟乙烯/六氟丙烯共聚物、乙烯/四氟乙烯共聚物、聚丙烯、聚偏氟乙烯、聚氨酯、聚对苯二甲酸、聚氨酯弹性体、苯乙烯嵌段共聚物、全氟烷氧基烷烃、氯化聚乙烯、聚亚苯基硫醚、聚苯乙烯、交联聚烯烃、乙丙橡胶、乙烯/醋酸乙烯共聚物、氯丁橡胶、天然橡胶、丁苯橡胶、丁腈橡胶、硅橡胶、顺丁橡胶、异戊橡胶、乙丙橡胶、氯丁橡胶、丁基橡胶、氟橡胶、聚氨酯橡胶、聚丙烯酸酯橡胶、氯磺化聚乙烯橡胶、氯醚橡胶、氯化聚乙烯橡胶、氯硫橡胶、苯乙烯丁二烯橡胶、丁二烯橡胶、氢化丁腈橡胶、聚硫橡胶、交联聚乙烯、聚碳酸酯、聚砜、聚苯醚、聚酯、酚醛树脂、脲甲醛、苯乙烯-丙烯腈共聚物、聚甲基丙烯酸酯、聚甲醛树酯中的一种或几种。
采用导电塑胶的好处是可以方便注塑成型，使用者可以根据需要选择合适材质的屏蔽内壳4。
进一步地，导电颗粒的材质中金属的材质含有镍、镉、锆、铬、钴、锰、铝、锡、钛、锌、铜、银、金、磷、碲、铍中的一种或几种。
为了论证不同金属的材质对屏蔽内壳4的导电率的影响，发明人进行了试验，使用相同规格尺寸、不同材质的金属颗粒制作屏蔽内壳4的样件，分别测试屏蔽内壳4的导电率，实验结果如下表3所示，在本实施例中，屏蔽内壳4的导电率大于99％为理想值。
表3：不同材质的金属颗粒对屏蔽内壳4的导电率的影响

从上表3可以看出，选用的不同金属颗粒制作的导电塑料，导电率都在理想值范围内，另外，磷是非金属材料，不能直接作为导电镀层的材质，但是可以添加到其他金属中形成合金，提高金属本身的导电和机械性能。因此，发明人设定金属颗粒的材质含有镍、镉、锆、铬、钴、锰、铝、锡、钛、锌、铜、银、金、磷、碲、铍中的一种或几种。
进一步地，导电颗粒的材质中含碳导体可以含有石墨银、石墨烯银、石墨粉、碳纳米管材料、石墨烯材料中的一种或多种。石墨粉是一种矿物粉末，主要成分为碳单质，质软，黑灰色；石墨粉是很好的非金属导电物质。碳纳米管具有良好的导电性能，由于碳纳米管的结构与石墨的片层结构相同，所以具有很好的电学性能。石墨烯更是具有极高的电学性能，含有这三种材料的含碳导体导电率高，屏蔽性能好，能够很好的实现对电连接骨架2的电磁屏蔽。
在一些实施例中，导电塑料制成的屏蔽内壳4，可以采用一体注塑的方式与连接器一体成型，节省加工时间，提高生产效率，降低生产成本。
在一些实施例中，连接端子7的材质为铜或铜合金，电连接骨架2材质为铝或铝合金，电连接骨架2通过焊接或压接的方式与连接端子7电连接。
铜或铜合金导电率高，并且耐摩擦，而且目前大多数的用电装置的接电部分材质都是铜，因此需要使用材质为铜或铜合金的连接端子7进行插拔连接，连接端子7可以广泛应用于各种电传输场景。
采用铝或铝合金材质的电连接骨架2，具有刚性好、质量轻、传输效率高的优点，特别适合大电流的传输。
连接端子7和电连接骨架2通过焊接连接，所采用的焊接方式，包括电阻焊接、摩擦焊接、超声波焊接、弧焊、激光焊接、电子束焊接、压力扩散焊接、磁感应焊接的一种或几种，是采用集中热能或压力，使连接端子7和电连接骨架2接触位置产生熔融连接，焊接方式连接稳固。
另外，铜的金属惰性要大于铝，铜与铝之间的电极电位差为1.9997V，这两种金属连接通电后会发生电化学反应，导致铝线逐渐被氧化，降低铝线的机械强度和导电性，采用焊接的方式可以实现异种材料的连接，由于接触位置相融，导电效果更好。
电阻焊接方式，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。
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。
激光焊接方式，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。
摩擦焊接方式，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。
电子束焊接方式，是指利用加速和聚焦的电子束轰击置于真空或非真空中的焊接面，使被焊工件熔化实现焊接。
压力焊接方式，是对焊件施加压力，使接合面紧密地接触产生一定的塑性变形而完成焊接的方法。
磁感应焊接方式，是两个被焊工件在强脉冲磁场作用下，产生瞬间高速碰撞，材料表层在很高的压力波作用下，使两种材料的原子在原子间距离内相遇，从而在界面上形成稳定的冶金结合。是固态冷焊的一种，可以将属性相似或不相似的传导金属焊接在一起。
压接方式，压接是将电连接骨架2和连接端子7装配后，使用压接机，将两者冲压为一体的生产工艺。压接的优点是量产性，通过采用自动压接机能够迅速大量的制造稳定品质的产品。
在一些实施例中，屏蔽层5通过压接或焊接的方式与屏蔽内壳4电连接。铝或铝合金材质的导电性能好，重量轻，价格较低。用铝或铝合金制作屏蔽内壳4，可以起到很好的屏蔽效果，防止连接端子7和电连接骨架2的电磁辐射影响其他设备。
压接是将屏蔽内壳4与屏蔽层5装配后，使用压接机，将两者冲压为一体的生产工艺。压接的优点是量产性，通过采用自动压接机能够迅速大量的制造稳定品质的产品。
焊接或压接的方式与连接端子7和电连接骨架2的焊接方式基本相同，不再赘述。
在一些实施例中，如图7所示，本发明的具有液冷功能的电连接器总成具有一根电 连接骨架2，以及与电连接骨架2两端连接的第一连接器11和第二连接器12，第一连接器11内部设置回转腔体94，第二连接器12内部设置转接腔体95，回转腔体94、转接腔体95分别与电连接骨架2的一个中空内腔3联通。
并且具体地，第一连接器11和第二连接器12中的一者上设置有导入管91，与回转腔体94和转接腔体95中的一者联通；第一连接器11和第二连接器12中的另一者上设置有导出管92，与回转腔体94和转接腔体95中的另一者联通。也就是说，在本实施例中，如图7所示，导入管91设置在第二连接器12上，与转接腔体95联通；导出管92设置在第一连接器11上，与回转腔体94联通。当然也可以理解，在其他实施例中，导入管91设置在第一连接器11上，与回转腔体94联通；而导出管92设置在第二连接器12上，与转接腔体95联通。
由此，冷却液可以在循环泵的驱动下，经由导入管91从电连接骨架2的一端，例如第二连接器12内进入电连接骨架2的中空内腔3，流经中空内腔3后，再经由导出管92流出，并经过冷却系统的冷却后，再由循环泵再次进入中空内腔3，形成一个完整的冷却循环。
在一些实施例中，电连接骨架2在回转腔体94的部分以及在转接腔体95的部分，均设置有径向方向的通孔93，冷却液通过通孔93流经回转腔体94、中空内腔3和转接腔体95。
具体地，如图7所示，电连接骨架2在回转腔体94内部的部分，径向方向设置通孔93，冷却液通过该通孔93流经中空内腔3和回转腔体94。
具体地，如图7所示，电连接骨架2在转接腔体95内部的部分，径向方向设置通孔93，冷却液通过该通孔93流经中空内腔3和转接腔体95。
因此，冷却液可以通过通孔93流经回转腔体94、中空内腔3和转接腔体95。
更具体地，如图7所示，导入管91插入第二连接器12的转接腔体95中并与中空内腔3联通；导出管92插入第一连接器11的回转腔体94中并与中空内腔3联通。
然而，在一些其他未示出的实施例中，导入管与导出管一端可以与电连接骨架的通孔匹配连接，另一端穿过第一连接器和第二连接器外壁并伸出到第一连接器和第二连接器外侧。由此，冷却液不必充满回转腔体和转接腔体95即可实现与中空内腔的联通。
进一步地，在一些其他未图示的实施例中，本发明的具有液冷功能的电连接器总成可以具有两根(或者，更多根)电连接骨架，以及与电连接骨架两端连接的第一连接器和第二连接器。第一连接器和第二连接器中均设置有分别与每一电连接骨架两端连接的 连接端子。具体地，电连接骨架中可以只具有如图2所示的一个中空内腔3。当然可以理解，电连接骨架中也可以具有如图5所示的多个中空内腔3。因此，在电连接骨架具有多个中空内腔的情况下，为了保证冷却液在一根电连接骨架中的各个中空内腔中流通，如图6所示，可以在各个中空内腔3之间设置相互联通的通孔93。
进一步地，在一些实施例中，例如，在导入管91和导出管92与电连接骨架2上的通孔93连接，而不是直接与回转腔体94或转接腔体95连接的情况下，为了实现两根甚至多根电连接骨架2之间的中空内腔3的联通，可以在各电连接骨架2之间设置连接孔，因此，冷却液经由连接孔以及通孔93流通各中空内腔3。
在一些实施例中，导入管91与第一连接器11、第二连接器12两者中的一者之间设置第一密封结构；
导出管92与第一连接器11、第二连接器12两者中的另一者之间设置第二密封结构。
具体地，在一些实施例中，导入管91可以与第二连接器12之间设置第一密封结构。第一密封结构可以是密封环。类似地，导出管92可以与第一连接器11之间设置第二密封结构。第二密封结构可以与第一密封结构相同。当然也可以理解，在其他实施例中，第二密封结构与第一密封结构不同。
在一些实施例中，连接器与屏蔽层5之间设置第三密封结构。具体地，在一些实施例中，如图7所示，第一连接器11或第二连接器12与屏蔽层5之间设置密封环8(可以理解为第三密封结构)。密封环8将回转腔体94和转接腔体95密封。密封环8能够防止冷却液从第一连接器11或第二连接器12与屏蔽层5的连接处泄露。
在一些实施例中，冷却介质为冷却气体或冷却液体。冷却气体可以为制冷后的空气。冷却液体可以为水、乙二醇、硅油、氟化物、蓖麻油、椰子油、玉米油、棉籽油、亚麻子油、橄榄油、棕榈油、花生油、葡萄籽油、菜籽油、红花油、向日葵油、大豆油、各种植物油的高油酸变体、癸烯-4-酸、癸烯酸、月桂烯酸、天台乌药酸、十四碳烯酸、抹香鲸酸、粗租酸、棕榈油酸、芹岩酸、油酸、十八碳烯酸、鳕烯酸、巨头鲸鱼酸、鲸蜡烯酸、芥酸、和神经酸、甘油、变压器油、车轴油、内燃机油或压缩机油的一种或几种；也可在冷却液中加入添加剂，所述添加剂选自抗氧化剂、倾点抑制剂、缓蚀剂、抗菌剂、粘度改性剂中一种或几种。冷却液的沸点可以设置成大于等于100℃。冷却油具有灵敏的热平衡能力，超强的热传导能力，超宽的工作温度区间，杜绝沸腾开锅，冷却系统微压力，低温环境不用添加防冻剂，避免了气蚀、液垢、电解等腐蚀伤害等优点。
在一些实施例中，冷却液对电连接骨架2的冷却速率为0.05K/s-5K/s。发明人为了 验证冷却液的冷却速率对电连接骨架2温升的影响，选用10根相同截面积、相同材质、相同长度的电连接骨架2，并通相同的电流，采用不同冷却速率的冷却液，对电连接骨架2进行冷却，并读取各个电连接骨架2的温升值，记录在表4中。
实验方法是在封闭的环境中，将采用不同冷却速率的冷却液的电连接骨架2导通相同的电流，记录通电前的温度和通电后温度稳定时的温度，并作差取绝对值。在本实施例中，温升小于50K为合格值。
表4：不同冷却速率的冷却液对连接端子7温升的影响
从上表4中可以看出，当冷却速率小于0.05K/s时，电连接骨架2的温升值不合格，冷却速率越大，电连接骨架2的温升值越小。但是当冷却液的冷却速率大于5K/s后，电连接骨架2的温升没有明显降低，而更高的冷却速率意味着更高的价格和更复杂的工艺，因此，发明人将冷却液的冷却速率设定为0.05K/s-5K/s。
在一些实施例中，其中一个连接器为充电座。电连接骨架2的两端分别连接一个连接器，在一些情况下，其中一个连接器(例如第一连接器11)可以为充电座，通过利用电连接骨架2为另一端的连接器(例如第二连接器12)进行充电。
在一些实施例中，电连接骨架2的部分区域为柔性。柔性体能够保证电连接骨架2上能够做出较大的折弯角度，以方便设置在拐角比较大的车体内。同时，柔性体能够吸收电连接骨架2的振动，使电连接骨架2的振动不会影响到连接器以及对应的车身上的其他用电装置。
在一些实施例中，电连接骨架2包括至少一个弯折部，以满足电连接骨架2安装在车体的需要。
本发明还提供了一种车辆，包括如上所述的具有液冷功能的连接器总成、循环泵和冷却装置，中空内腔3与循环泵和冷却装置联通。
具体地，在一些实施例中，导入管91与循环泵的进液口联通，循环泵的出液口与冷却装置的进液口联通，冷却装置的出液口与导出管92联通，导出管92与中空内腔3联通。
虽然已经通过例子对本发明的一些特定实施例进行了详细说明，但是本领域的技术 人员应该理解，以上例子仅是为了进行说明，而不是为了限制本发明的范围。本领域的技术人员应该理解，可在不脱离本发明的范围和精神的情况下，对以上实施例进行修改。本发明的范围由所附权利要求来限定。

Claims (29)

  1. 一种具有液冷功能的连接器总成，包括至少一根电连接骨架和连接器，其特征在于，所述连接器中包含连接端子，所述电连接骨架两端分别与连接端子电连接，所述电连接骨架具有至少一个中空内腔，所述中空内腔流通冷却液。
  2. 根据权利要求1所述的具有液冷功能的连接器总成，其特征在于，所述冷却液的材质为绝缘材料。
  3. 根据权利要求1所述的具有液冷功能的连接器总成，其特征在于，所述电连接骨架的材质含有刚性的空心导体材料。
  4. 根据权利要求1所述的具有液冷功能的连接器总成，其特征在于，所述电连接骨架通过焊接或压接的方式与所述连接端子电连接。
  5. 根据权利要求1所述的具有液冷功能的连接器总成，其特征在于，所述电连接骨架外轮廓的横截面形状为圆形、椭圆形、矩形、多边形、A形、B形、D形、M形、N形、O形、S形、E形、F形、H形、K形、L形、T形、U形、V形、W形、X形、Y形、Z形、P形、半弧形、弧形、波浪形中的一种或几种。
  6. 根据权利要求3所述的具有液冷功能的连接器总成，其特征在于，当所述电连接骨架具有一个中空内腔时，所述空心导体材料的壁厚一致。
  7. 根据权利要求3所述的具有液冷功能的连接器总成，其特征在于，所述空心导体材料的横截面积为1.5mm2-240mm2。
  8. 根据权利要求1所述的具有液冷功能的连接器总成，其特征在于，所述中空内腔的截面积之和占所述电连接骨架外切圆的截面积的3.7％-75％。
  9. 根据权利要求1所述的具有液冷功能的连接器总成，其特征在于，所述连接器内部还包含屏蔽内壳，所述屏蔽内壳的材质含有导电材料。
  10. 根据权利要求9所述的具有液冷功能的连接器总成，其特征在于，所述屏蔽内壳的材质含有导电金属或导电塑胶。
  11. 根据权利要求10所述的具有液冷功能的连接器总成，其特征在于，所述导电塑胶为包含导电颗粒的高分子材料，所述导电颗粒材质含有金属、导电陶瓷、含碳导体、固体电解质、混合导体的一种或几种；所述高分子材料的材质含有四苯乙烯、聚氯乙烯、聚乙烯、聚酰胺、聚四氟乙烯、四氟乙烯/六氟丙烯共聚物、乙烯/四氟乙烯共聚物、聚丙烯、聚偏氟乙烯、聚氨酯、聚对苯二甲酸、聚氨酯弹性体、苯乙烯嵌段共聚物、全氟烷氧基烷烃、氯化聚乙烯、聚亚苯基硫醚、聚苯乙烯、交联聚烯烃、乙丙橡胶、乙烯/ 醋酸乙烯共聚物、氯丁橡胶、天然橡胶、丁苯橡胶、丁腈橡胶、硅橡胶、顺丁橡胶、异戊橡胶、乙丙橡胶、氯丁橡胶、丁基橡胶、氟橡胶、聚氨酯橡胶、聚丙烯酸酯橡胶、氯磺化聚乙烯橡胶、氯醚橡胶、氯化聚乙烯橡胶、氯硫橡胶、苯乙烯丁二烯橡胶、丁二烯橡胶、氢化丁腈橡胶、聚硫橡胶、交联聚乙烯、聚碳酸酯、聚砜、聚苯醚、聚酯、酚醛树脂、脲甲醛、苯乙烯-丙烯腈共聚物、聚甲基丙烯酸酯、聚甲醛树酯中的一种或几种。
  12. 根据权利要求11所述的具有液冷功能的连接器总成，其特征在于，所述金属的材质含有镍、镉、锆、铬、钴、锰、铝、锡、钛、锌、铜、银、金、磷、碲、铍中的一种或几种。
  13. 根据权利要求11所述的具有液冷功能的连接器总成，其特征在于，所述含碳导体含有石墨银、石墨烯银、石墨粉、碳纳米管材料、石墨烯材料中的一种或多种。
  14. 根据权利要求9所述的具有液冷功能的连接器总成，其特征在于，所述屏蔽内壳的转移阻抗为小于100mΩ。
  15. 根据权利要求1所述的具有液冷功能的连接器总成，其特征在于，所述电连接骨架的外周套设绝缘层。
  16. 根据权利要求9所述的具有液冷功能的连接器总成，其特征在于，所述电连接骨架的外周套设绝缘层，所述绝缘层外周还套设屏蔽层和外绝缘层。
  17. 根据权利要求16所述的具有液冷功能的连接器总成，其特征在于，所述屏蔽层与所述屏蔽内壳电连接。
  18. 根据权利要求1所述的具有液冷功能的连接器总成，其特征在于，所述连接器包括连接所述电连接骨架两端的第一连接器和第二连接器，所述第一连接器内部设置回转腔体，所述第二连接器内部设置转接腔体，所述回转腔体、所述转接腔体分别与所述中空内腔联通，所述第一连接器和所述第二连接器中的一者上设置有导入管，与所述回转腔体和所述转接腔体中的一者联通；所述第一连接器和所述第二连接器中的另一者上设置有导出管，与所述回转腔体和所述转接腔体中的另一者联通。
  19. 根据权利要求18所述的具有液冷功能的连接器总成，其特征在于，所述电连接骨架在所述回转腔体的部分以及在所述转接腔体的部分，均设置有径向方向的通孔，所述冷却液通过所述通孔流经所述回转腔体、所述中空内腔和所述转接腔体。
  20. 根据权利要求19所述的具有液冷功能的连接器总成，其特征在于，所述导入管与所述导出管一端与所述通孔匹配连接，另一端穿过所述第一连接器和所述第二连接器外壁并伸出到所述第一连接器和所述第二连接器外侧。
  21. 根据权利要求18所述的具有液冷功能的连接器总成，其特征在于，所述导入管与所述第一连接器、所述第二连接器两者中的一者之间设置第一密封结构；
    所述导出管与所述第一连接器、所述第二连接器两者中的另一者之间设置第二密封结构。
  22. 根据权利要求1所述的具有液冷功能的连接器总成，其特征在于，所述冷却液的沸点大于等于100℃。
  23. 根据权利要求1所述的具有液冷功能的连接器总成，其特征在于，所述冷却液为水、乙二醇、硅油、氟化物、蓖麻油、椰子油、玉米油、棉籽油、亚麻子油、橄榄油、棕榈油、花生油、葡萄籽油、菜籽油、红花油、向日葵油、大豆油、各种植物油的高油酸变体、癸烯-4-酸、癸烯酸、月桂烯酸、天台乌药酸、十四碳烯酸、抹香鲸酸、粗租酸、棕榈油酸、芹岩酸、油酸、十八碳烯酸、鳕烯酸、巨头鲸鱼酸、鲸蜡烯酸、芥酸、和神经酸、甘油、变压器油、车轴油、内燃机油或压缩机油的一种或几种。
  24. 根据权利要求1所述的具有液冷功能的连接器总成，其特征在于，所述冷却液对所述电连接骨架的冷却速率为0.05K/s-5K/s。
  25. 根据权利要求1所述的具有液冷功能的连接器总成，其特征在于，其中一个所述连接器为充电座。
  26. 根据权利要求1所述的具有液冷功能的连接器总成，其特征在于，所述电连接骨架的部分区域为柔性。
  27. 根据权利要求1所述的具有液冷功能的连接器总成，其特征在于，所述电连接骨架包括至少一个弯折部。
  28. 一种车辆，其特征在于，包括如权利要求1-27任一项所述的具有液冷功能的连接器总成、循环泵和冷却装置，所述中空内腔与所述循环泵和所述冷却装置联通。
  29. 根据权利要求28所述的车辆，其特征在于，与所述中空内腔联通的导入管与所述循环泵的进液口联通，所述循环泵的出液口与所述冷却装置的进液口联通，所述冷却装置的出液口与导出管联通，所述导出管与所述中空内腔联通。
PCT/CN2023/081258 2022-03-14 2023-03-14 一种具有液冷功能的连接器总成及一种车辆 WO2023174245A1 (zh)

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