Connecting wire harness for battery pack

Abstract

The invention relates to a connecting wire harness for a battery pack, which comprises a cable, one end of the cable is connected with an external joint for external equipment, and the other end of the cable is connected with a battery end connector; the battery end connector comprises a shell, a crimping type wiring terminal and an electrode column, the crimping type wiring terminal is arranged in the shell, a crimping cylinder of the crimping type wiring terminal is connected with the cable, the electrode column is arranged in the shell in a penetrating manner, and the tail end of the electrode column is vertically connected with the connecting end of the crimping type wiring terminal; a front end blind hole with a conical bottom face is formed in the front end face of the electrode column, the edge of the front end face of the electrode column extends forwards to form a sector-ring-shaped sector-ring column which is coaxial with the front end blind hole, the axial section of the sector-ring column is an inclined face inclining outwards in the axial direction, and the position, connected with the front end face of the electrode column, of the axial section of the sector-ring column is chamfered. According to the invention, the arc discharge problem can be well inhibited while the connection stability is ensured, and the safety is improved.

Description

Technical Field

[0001] This invention relates to the field of battery pack connection harness technology, and in particular to a connection harness for battery packs. Background Technology

[0002] Power battery packs are now widely used in electric motorcycles, electric vehicles, and other fields. They are connected to electrical devices via high-voltage power harnesses with connectors. Currently, the electrodes of these connectors are mainly cylindrical or prismatic in shape. Preventing loosening relies entirely on the friction between the outer shape of the electrode and the mounting hole, as well as the small contact area. Because electric motorcycles or electric vehicles experience bumps during operation, prolonged bumps can cause the connector electrodes to loosen from the battery pack. Loose battery pack connections lead to increased contact resistance, creating a risk of thermal runaway and potential arcing, which can cause a fire. Summary of the Invention

[0003] To address the shortcomings of existing methods, this invention provides a connecting harness for battery packs.

[0004] The technical solution adopted by this invention to solve its technical problem is as follows: a connecting harness for a battery pack, including a cable, one end of which is connected to an external connector for an external device, and the other end of which is connected to a battery connector; the battery connector includes a housing, a crimp terminal, and an electrode post, the crimp terminal being disposed inside the housing, the crimping sleeve of the crimp terminal being connected to the cable, the electrode post being disposed inside the housing and perpendicularly connected at its tail end to the connection end of the crimp terminal; a front blind hole with a tapered bottom surface is provided on the front end face of the electrode post, and a fan-shaped annular column with a fan-shaped cross-section coaxial with the front blind hole extends forward from the edge of the front end face of the electrode post, the axial cross-section of the fan-shaped annular column being an inclined plane inclined outward in the axial direction, and the axial cross-section of the fan-shaped annular column being rounded at the connection with the front end face of the electrode post.

[0005] Preferably, the outer wall of the electrode post is provided with a sidewall groove.

[0006] Preferably, the rear end face of the electrode post is provided with a rear blind hole with a tapered bottom surface.

[0007] Preferably, the two electrodes of the electrode post have a height difference of 0.5-2 mm.

[0008] Preferably, the angle of inclination of the axial section is in the range of 10-30 degrees.

[0009] Preferably, the inner wall of the crimping cylinder of the crimping terminal has a plurality of strip-shaped inner wall protrusions extending in the axial direction and spaced apart around the circumference of the crimping cylinder.

[0010] Preferably, the inner wall of the crimping cylinder of the crimping terminal has multiple discretely distributed conical protrusions extending around the circumference of the crimping cylinder at its rear end.

[0011] Preferably, a transparent mounting block is detachably provided on the housing at the position corresponding to the connection between the crimped terminal and the electrode post, and an irreversible thermochromic element is provided on the inner end face of the mounting block.

[0012] Preferably, the color-changing temperature of the thermochromic element is 120 degrees Celsius.

[0013] Preferably, the cable sheath is provided with an insulating corrugated tube.

[0014] The beneficial effects of this invention are as follows: This invention can stabilize the connection structure between the wiring harness and the battery pack. When the connection structure becomes loose, the inclined surface of the electrode post increases the air gap between the electrodes, thereby lengthening the arc and causing it to be extinguished due to insufficient voltage. At the same time, the inclined surface changes the local electric field distribution and forms an electric field concentration point, which can actively attract the arc to the front blind hole, making it a controlled miniature arc-extinguishing chamber, protecting the electrodes and improving safety. The perpendicular connection between the electrode post and the crimped terminal ensures that the electrode post and the wiring harness are perpendicular, which can avoid the force generated by the bending of the cable causing the electrode post connection structure to loosen. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the cross-sectional structure of an embodiment of the present invention; Figure 2 This is a schematic diagram of the bottom surface of an embodiment of the present invention; Figure 3 This is a schematic diagram of the top surface of an embodiment of the present invention; Figure 4 This is a schematic diagram of the structure of the electrode post according to an embodiment of the present invention; Figure 5 This is a schematic diagram of the structure of the crimped terminal block according to an embodiment of the present invention; Component names and serial numbers in the diagram: 1-Cable, 2-External connector, 3-Battery terminal connector, 30-Housing, 31-Crimp-type terminal block, 32-Electrode post, 300-Mounting block, 301-Thermochromic component, 310-Inner wall protrusion, 311-Conical protrusion, 320-Front end blind hole, 321-Fan ring post, 322-Side wall groove, 323-Rear end through hole, 3210-Axial section, 4-Bellpipe. Detailed Implementation

[0016] To more clearly illustrate the objectives, technical solutions, and advantages of the embodiments of the present invention, the present invention will be further described below in conjunction with the accompanying drawings and embodiments. It is clear and complete that the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the protection scope of the present invention.

[0017] Examples of embodiments of the present invention Figures 1 to 5As shown, a connection harness for a battery pack includes a cable 1. One end of the cable 1 is connected to an external connector 2 for connecting to an external device, and the other end is connected to a battery connector 3. The cable 1 uses a high-voltage power cable for battery packs as is commonly used in the prior art. The external connector 2 is used to connect to external components that the battery pack needs to connect to, such as an inverter. For example, the external connector 2 uses a three-phase pin-type power socket. A protective sleeve is provided at the connection point between the three-phase power socket and the cable 1, partially covering the tail of the three-phase power socket and partially covering the cable. The battery connector 3 is used to connect to the high-voltage output port of the battery pack. The battery connector 3 includes a housing 30, a pressure... The housing 30 includes a crimp terminal block 31 and an electrode post 32. The crimp terminal block 31 is housed within the housing 30, with its crimping sleeve connected to the cable 1. The electrode post 32 passes through the housing 1 and its tail end is perpendicularly connected to the connecting end of the crimp terminal block 31. The housing 30 consists of a top cover and a base. The housing 30 has a horizontal outlet for the cable 1, and the base has a through hole for the electrode post 32 to pass through in the vertical direction. The crimp terminal block 31 is housed within the housing 30, with one end being a crimping sleeve for crimping the cable 1, and the other end being a connecting end with a through hole for connecting to the tail end of the electrode post 32, which can be connected by welding or screws. The electrode post 32 is perpendicular to the direction of cable 1, which facilitates the installation of the wiring harness on the battery pack and prevents the connection of electrode post 32 from becoming loose due to the force generated by bending cable 1. Electrode post 32 is a copper post, including a positive electrode post and a negative electrode post, and correspondingly there are positive crimp terminals for connecting the positive electrode post and negative crimp terminals for connecting the negative electrode post. Cable 1 has corresponding positive and negative wires. A front blind hole 320 with a conical bottom surface is provided on the front end face of electrode post 32. The front blind hole 320 is located at the center of the front end face of electrode post 32. The front end face of electrode post 32 extends forward from the edge with a fan-shaped annular section that is connected to the front blind hole. The fan-shaped ring column 321 is coaxial with the hole 320. The outer diameter of the fan-shaped ring column 321 is the same as the outer diameter of the electrode column 32. The inner diameter of the fan-shaped ring column 321 is the same as the diameter of the front blind hole 320. The fan-shaped ring column 321 extends forward along the axis of the front blind hole 320. The axial section 3210 of the fan-shaped ring column 321 is an inclined plane that is inclined outward in the axial direction. The axial section 3210 of the fan-shaped ring column 321 has a rounded corner at the connection with the front end face of the electrode column 32. The axial section of the fan-shaped ring column is the side plane of the fan-shaped ring column in the axial direction. The axial section is inclined outward from the front end face of the electrode column and away from the axis. At the same time, the axial section of the fan-shaped ring column and the front end face of the electrode column have a rounded corner at the connection.In this way, when the electrode post 32 is installed onto the battery pack housing, the fan-shaped ring post 321 can act as a precise positioning pin, aligning and inserting it into the corresponding slot on the inner side of the battery pack housing. The tight fit between the axial section 3210 of the fan-shaped ring post 321 and the corresponding slot withstands the torque, forming an interlocking structure that prevents rotation. Furthermore, the inclined structure of the axial section 3210 causes the separation path between the electrode post 32 and the battery pack electrodes to change from parallel movement in the prior art to ramp sliding when loosening occurs, thus rapidly increasing the air gap between the electrodes. The large size of the arc causes a sharp decrease in the electric field strength within the gap, thus lengthening the arc and resulting in insufficient voltage to sustain it, leading to its extinction. Simultaneously, the fan-shaped ring column 321 alters the electric field distribution between the electrodes. When an arc is generated, it can be guided to the front blind hole 320 via the axial section 3210. The front blind hole 320 then becomes a controlled miniature arc-extinguishing chamber. At this point, an arc-resistant material can be applied to the inner wall of the front blind hole 320, confining the arc energy within it for absorption and cooling, significantly reducing the arc energy and duration. The rounded corner structure prevents the formation of sharp edges, avoiding premature arc generation caused by electric field concentration at that location when the electrodes become loose. Furthermore, this rounded corner structure also guides the arc from the axial section 3210 of the fan-shaped ring column 321 to the front blind hole 320, further improving safety.

[0018] Further improvements, such as Figure 1 and Figure 4 As shown, the outer wall of the electrode post 32 has a sidewall groove 322, which increases the surface area of ​​the electrode post 32 and enhances its radial heat dissipation capacity. The rear end face of the electrode post 32 has a rear blind hole 323 with a tapered bottom surface. Thus, the front blind hole 320 and the rear blind hole 323 form a low thermal resistance axial channel running directly from the front to the rear, significantly reducing the overall operating temperature rise of the electrode post 32. This is more efficient than relying solely on radial heat dissipation from the cylindrical sidewall. Simultaneously, the tapered bottom surfaces of the two blind holes form a stress transition structure, allowing stress generated inside the electrode post 32 due to temperature changes or external forces to concentrate on the tapered bottom surface, improving fatigue resistance.

[0019] Further improvements, such as Figure 2 As shown, there is a height difference of 0.5-2mm between the two electrodes of electrode post 32. That is to say, there is a height difference between the lengths of the positive electrode post and the negative electrode post. If a height difference of 0.8mm is selected, the two electrode posts 32 will not separate from the electrodes of the battery pack at the same time when the connection with the battery pack becomes loose. This prevents the two electrode circuits from generating an electric arc at the same moment, avoiding the simultaneous generation of two high-energy electric arcs, mutual interference, or even energy superposition, which is more conducive to the elimination of electric arcs.

[0020] Further improvements, such as Figure 1 , Figure 2and Figure 4 As shown, the inclination angle of the axial section 3210 is in the range of 10-30 degrees, which ensures the arc breaking effect of the axial section 3210 while also ensuring the structural strength of the electrode post 32.

[0021] Further improvements, such as Figure 1 and Figure 5 As shown, the inner wall of the crimping cylinder of the crimping terminal 31 has a plurality of strip-shaped inner wall protrusions 310 extending in the axial direction and arranged at intervals around the circumference of the crimping cylinder. The inner wall protrusions 310 are evenly spaced in the circumference of the inner wall of the crimping cylinder, and a groove is formed between two adjacent inner wall protrusions 310, which can effectively press the copper wire of the cable 1 in the crimping cylinder, ensuring the stability of the connection between the cable 1 and the crimping terminal 31. Meanwhile, the inner wall of the crimping cylinder of the crimping terminal 31 has multiple discretely distributed conical protrusions 311 extending around the circumference of the crimping cylinder. After crimping, the conical protrusions 311 will be locked into the insulation layer of the cable 1. When the cable 1 is subjected to an outward pulling force, the force will be transmitted to the insulation layer, and the discretely distributed conical protrusions 311 will prevent the insulation layer from moving outward, thereby transferring the pulling force directly to the crimping cylinder. This avoids the pulling force acting directly on the connection between the copper wire of the cable 1 and the crimping cylinder, ensuring the stable connection between the cable 1 and the crimping terminal 31.

[0022] Further improvements, such as Figure 1 and Figure 3As shown, a transparent mounting block 300 is detachably mounted on the housing 30 at the position corresponding to the connection between the crimped terminal 31 and the electrode post 32. An irreversible thermochromic element 301 is provided on the inner end face of the mounting block 300. This allows for monitoring of the temperature at the connection between the crimped terminal 31 and the electrode post 32. This structure can be applied to vehicles capable of battery swapping. When swapping batteries, the color change of the thermochromic element 301 can be observed through the mounting block 300 to determine whether the internal temperature of the battery connector 3 exceeds the specified temperature during use. This allows for timely detection of potential hazards hidden in the wiring harness, thus solving the problem of only monitoring the temperature of the battery pack in existing technologies. The defect of not monitoring the connecting wire harness; its detachable installation can be achieved by setting a countersunk through hole on the housing 30, and then setting the mounting block 300 into a T-shaped structure. The thermochromic element 301 is set at the bottom of the mounting block 300. Threaded holes are set on both sides of the countersunk part of the countersunk through hole. The mounting block through hole corresponding to the threaded hole is set at the corresponding position of the mounting block 300. Then, the mounting block 300 is installed on the housing 30 by using the screw passing through the mounting block through hole and the threaded connection of the threaded hole. The thermochromic element 301 is positioned at the connection position of the crimp terminal 31 and the electrode post 32. When a high temperature is generated at this position, the thermochromic element 301 will change color. The thermochromic component 301 has a color-changing temperature of 120 degrees Celsius. This means that if the temperature inside the battery connector 3 exceeds 120 degrees Celsius, the thermochromic component 301 will change color. If the thermochromic component 301 has changed color during battery replacement, it means that the battery connector 3 has undergone a dangerous high-temperature process, and its electrical performance and long-term reliability may have been damaged. It is necessary to inspect it immediately and analyze the cause of the high temperature to identify and eliminate hidden risks in a timely manner and improve the safety of use. At this time, the thermochromic component 301 can be an irreversible thermochromic ink layer coated on the inner end face of the mounting block 300.

[0023] Further improvements, such as Figures 1 to 3 As shown, the cable 1 is covered with an insulating corrugated tube 4, which protects the cable 1. One end of the corrugated tube 4 is installed inside the protective sleeve of the external connector 2, and the other end is installed inside the housing 30 of the battery connector 3.

[0024] Although the present invention has been described in detail above with general descriptions and specific embodiments, modifications or improvements can be made to it, which will be obvious to those skilled in the art. Therefore, all such modifications or improvements made without departing from the spirit of the present invention fall within the scope of protection claimed by the present invention.

Claims

1. A connecting harness for a battery pack, characterized in that, The device includes a cable, one end of which is connected to an external connector for connecting to an external device, and the other end is connected to a battery connector. The battery connector includes a housing, a crimp terminal, and an electrode post. The crimp terminal is disposed inside the housing, and its crimping sleeve is connected to the cable. The electrode post is disposed inside the housing and its tail end is perpendicularly connected to the connection end of the crimp terminal. The front end face of the electrode post has a front blind hole with a tapered bottom surface. The front end face of the electrode post extends forward along its edge with a fan-shaped annular column coaxial with the front blind hole. The axial section of the fan-shaped annular column is an inclined plane that slopes outward in the axial direction, and the axial section of the fan-shaped annular column is rounded at the connection point with the front end face of the electrode post.

2. The connecting harness for a battery pack according to claim 1, characterized in that, The outer wall of the electrode post is provided with a side wall groove.

3. The connecting harness for a battery pack according to claim 1, characterized in that, The electrode post has a blind hole with a tapered bottom surface on its rear end face.

4. The connecting harness for a battery pack according to claim 1, characterized in that, The two electrodes of the electrode post have a height difference of 0.5-2 mm.

5. The connecting harness for a battery pack according to claim 1, characterized in that, The angle of inclination of the axial section is in the range of 10-30 degrees.

6. The connecting harness for a battery pack according to claim 1, characterized in that, The crimping terminal has multiple strip-shaped inner wall protrusions extending axially and spaced around the circumference of the crimping cylinder.

7. The connecting harness for a battery pack according to claim 1, characterized in that, The crimping terminal has multiple discretely distributed conical protrusions extending around the circumference of the inner wall of the crimping cylinder at its rear end.

8. The connecting harness for a battery pack according to claim 1, characterized in that, A transparent mounting block is detachably mounted on the housing at the position corresponding to the connection between the crimped terminal and the electrode post. An irreversible thermochromic element is provided on the inner end face of the mounting block.

9. The connecting harness for a battery pack according to claim 8, characterized in that, The color-changing temperature of the thermochromic component is 120 degrees Celsius.

10. The connecting harness for a battery pack according to claim 1, characterized in that, The cable sheath is provided with an insulated corrugated tube.

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