DC charging dock low voltage module and DC charging dock

Abstract

This invention discloses a low-voltage module for a DC charging dock and a DC charging dock. The low-voltage module includes an insulator and an electrical connector. The electrical connector includes a first contact portion for electrical contact with the PE terminal of the DC charging dock; a second contact portion for electrical contact with the A- terminal of the DC charging dock; and a connecting portion electrically connecting the first and second contacts and fixed to the insulator. The low-voltage module is adapted to be externally and pluggably installed into a slot on the charging dock housing. When the low-voltage module is installed in the slot, the first and second contacts make electrical contact with the PE terminal and the A- terminal respectively, to electrically connect the A- terminal to the PE terminal. In this invention, the PE terminal and the A- terminal of the DC charging dock are electrically interconnected by the electrical connector of the low-voltage module, achieving a common ground for the PE terminal and the A- terminal, effectively preventing the low-voltage auxiliary circuit of the DC charging dock from burning out.

Description

Technical Field

[0001] This invention relates to the field of electric vehicle charging technology, and more particularly to a low-voltage module for a DC charging socket and a DC charging socket including the low-voltage module. Background Technology

[0002] In existing technology, the PE terminal (or grounding protection terminal) and A- terminal (or low-voltage auxiliary power negative terminal) of the DC charging socket are each wired separately. This results in the PE terminal and A- terminal not being grounded together; that is, the PE terminal and A- terminal are not electrically interconnected and grounded together. Therefore, in practical applications, sometimes a large voltage difference exists when the DC charging socket and DC charging gun are mated because the PE terminal and A- terminal are not grounded together. This can cause a large current to flow in the low-voltage auxiliary circuit of the DC charging socket connected to either the A+ terminal or the A- terminal, easily leading to the burnout of the low-voltage auxiliary circuit.

[0003] Furthermore, in existing technologies, to improve the charging speed of new energy electric vehicles, it is necessary to increase the charging current, which is currently as high as 600A and may even increase to 1000A in the future. When a large current flows through the power terminals of the DC charger, a large amount of heat is generated, which causes the temperature of the power terminals of the DC charger to rise sharply. If the temperature rise cannot be controlled in time, it may lead to safety accidents, such as burning out the DC charger or other electrical equipment.

[0004] In existing technologies, to control the temperature rise of the power terminals, a lead frame is typically installed in the DC charging socket, and a low-voltage module of the DC charging socket is integrated on the lead frame. This low-voltage module includes a temperature sensor and a thermally conductive pad surrounding the temperature sensor. The thermally conductive pad is in thermal contact with the power terminals, and the temperature sensor is electrically connected to the lead frame. However, in existing technologies, the lead frame is bulky and needs to be pre-installed in the charging socket housing, making it very inconvenient to use. Furthermore, in existing technologies, to facilitate the installation of the lead frame, the charging socket housing needs to adopt a split design, which leads to a complex charging socket housing structure. In addition, existing lead frames need to be able to rotate between the locked position and the unlocked position of the power terminals, which makes the lead frame and charging socket housing more complex, assembly more difficult, and costs higher. Summary of the Invention

[0005] The purpose of this invention is to solve at least one aspect of the aforementioned problems and defects existing in the prior art.

[0006] According to one aspect of the present invention, a low-voltage module for a DC charging dock is provided. The low-voltage module includes an insulator and an electrical connector. The electrical connector includes: a first contact portion for electrical contact with the PE terminal of the DC charging dock; a second contact portion for electrical contact with the A- terminal of the DC charging dock; and a connecting portion electrically connecting the first contact portion and the second contact portion and being fixed to the insulator. The low-voltage module is adapted to be externally and pluggably mounted into a slot on a charging dock housing, wherein the first contact portion and the second contact portion, when the low-voltage module is mounted into the slot, respectively make electrical contact with the PE terminal and the A- terminal to electrically connect the A- terminal to the PE terminal.

[0007] According to an exemplary embodiment of the present invention, the insulator is injection molded onto the electrical connector, such that the insulator and the electrical connector become a single unit.

[0008] According to another exemplary embodiment of the present invention, the electrical connector is an integral stamped part.

[0009] According to another exemplary embodiment of the present invention, the first contact portion includes a pair of first springs for clamping and electrically contacting the PE terminal; and / or the second contact portion includes a pair of second springs for clamping and electrically contacting the A- terminal.

[0010] According to another exemplary embodiment of the present invention, the insulator has a first locking portion that abuts against the PE terminal when the DC charging socket low-voltage module is installed in the slot to lock the PE terminal in the charging socket housing; and / or the insulator has a second locking portion that abuts against the A- terminal when the DC charging socket low-voltage module is installed in the slot to lock the A- terminal in the charging socket housing.

[0011] According to another exemplary embodiment of the present invention, the low-voltage module of the DC charging dock further includes: a thermally conductive pad assembled onto the insulator for thermal contact with the power terminals of the DC charging dock; a temperature sensor disposed in the thermally conductive pad for detecting the temperature of the power terminals; and a conductive lead disposed in the insulator and electrically connected to the temperature sensor, wherein the thermally conductive pad makes thermal contact with the power terminals when the low-voltage module of the DC charging dock is installed in the slot to transfer the heat of the power terminals to the temperature sensor.

[0012] According to another exemplary embodiment of the present invention, the insulator is an injection molded part that is directly injection molded onto the conductive lead and the electrical connector, such that the conductive lead, the electrical connector and the insulator are integrated into one piece.

[0013] According to another exemplary embodiment of the invention, the conductive lead has a connection end electrically connected to the temperature sensor and an external pin for electrically connecting to a connector located outside the charging housing.

[0014] According to another exemplary embodiment of the present invention, the insulator includes: a support portion adapted to be inserted into a slot in the charging housing; and a mating portion adapted to be positioned outside the charging housing, wherein the thermal pad and the temperature sensor are mounted on the support portion, the mating portion having an insertion cavity that allows the connector to be inserted, and an external pin of the conductive lead extending into the insertion cavity for electrical connection with the inserted connector.

[0015] According to another exemplary embodiment of the present invention, a sealing ring mounting groove is formed on the outer peripheral surface of the bracket portion, and the DC charging base low-voltage module further includes a sealing ring installed in the sealing ring mounting groove. The sealing ring is adapted to be pressed between the inner wall surfaces of the slots of the bracket portion and the charging base housing to achieve a seal between the two.

[0016] According to another exemplary embodiment of the present invention, the bracket portion has a cover portion for sealing the inlet of the slot of the charging dock housing, and the insulator further includes a plurality of snap fasteners connected to the periphery of the cover portion, the plurality of snap fasteners being spaced apart around the outer periphery of the cover portion for engaging with a plurality of protrusions on the charging dock housing to lock the DC charging dock low-voltage module to the charging dock housing.

[0017] According to another exemplary embodiment of the present invention, the conductive lead includes a positive lead and a negative lead that are electrically connected to the positive pin and the negative pin of the temperature sensor, respectively; and the external pins of the positive lead and the negative lead extend into the insertion cavity of the mating part for electrical connection with the inserted connector.

[0018] According to another exemplary embodiment of the present invention, the connection end of the positive lead is adapted to be pluggably electrically connected to the positive pin of the temperature sensor; and / or the connection end of the negative lead is adapted to be pluggably electrically connected to the negative pin of the temperature sensor.

[0019] According to another exemplary embodiment of the present invention, the connection end of the positive lead is in the form of an elastic clip, adapted to clamp the positive pin of the temperature sensor; and / or the connection end of the negative lead is in the form of an elastic clip, adapted to clamp the negative pin of the temperature sensor.

[0020] According to another exemplary embodiment of the present invention, the low-voltage module of the DC charging dock includes a plurality of thermal pads and a plurality of temperature sensors respectively disposed in the plurality of thermal pads, the plurality of thermal pads being used to make thermal contact with a plurality of power terminals respectively, and the plurality of temperature sensors being used to detect the temperature of the plurality of power terminals respectively.

[0021] According to another exemplary embodiment of the present invention, the conductive lead includes a plurality of positive leads and a single negative lead; the connection ends of the plurality of positive leads are respectively electrically connected to the positive pins of the plurality of temperature sensors, and the single negative lead has a plurality of connection ends respectively electrically connected to the negative pins of the plurality of temperature sensors; the external pins of the plurality of positive leads and the external pins of the single negative lead extend into the insertion cavity of the mating part for electrical connection with the inserted connector.

[0022] According to another exemplary embodiment of the present invention, the thermal pad is block-shaped, and a recessed receiving portion is formed on the insulator, the thermal pad being positioned and installed in the receiving portion; a mounting groove is formed in the thermal pad, the main body of the temperature sensor is inserted into the mounting groove of the thermal pad, and the positive and negative leads of the temperature sensor protrude from the thermal pad.

[0023] According to another exemplary embodiment of the present invention, the thermal pad has an arcuate contact surface adapted to abut against the outer peripheral surface of the power terminal to increase the thermal contact area between the thermal pad and the power terminal.

[0024] According to another exemplary embodiment of the present invention, the low-voltage module of the DC charging dock further includes a circuit board, which is mounted and fixed to the insulator. The first contact portion and the second contact portion of the electrical connector are fixed to contact springs on the circuit board, and the connection portion of the electrical connector is a conductive trace formed on the circuit board.

[0025] According to another exemplary embodiment of the present invention, the low-voltage module of the DC charging dock further includes: a thermal pad assembled on the circuit board for thermal contact with the power terminals of the DC charging dock; a temperature sensor disposed in the thermal pad for detecting the temperature of the power terminals; and an external pin fixed to the circuit board for electrical connection with a connector located outside the charging dock housing, the temperature sensor being electrically connected to the external pin via conductive traces on the circuit board, the thermal pad being in thermal contact with the power terminals when the low-voltage module of the DC charging dock is installed in the slot to transfer heat from the power terminals to the temperature sensor.

[0026] According to another aspect of the present invention, a DC charging dock is provided. The DC charging dock includes: a charging dock housing having a first socket, a second socket, and a slot communicating with the first socket and the second socket; a PE terminal assembly including a PE terminal and inserted into the first socket; an A-terminal assembly including an A-terminal and inserted into the second socket; and the aforementioned DC charging dock low-voltage module, inserted from outside the charging dock housing into the slot. A first contact portion and a second contact portion of the electrical connector respectively make electrical contact with the PE terminal and the A-terminal to electrically connect the A-terminal to the PE terminal.

[0027] According to an exemplary embodiment of the present invention, the PE terminal assembly further includes: a grounding wire electrically connected to the PE terminal and led out from a first socket in the charging housing; and a first seal, injection molded onto the PE terminal, the first seal being pressed between the inner wall surfaces of the PE terminal and the first socket to achieve a seal between the two.

[0028] According to another exemplary embodiment of the present invention, the A-terminal assembly further includes: a second seal, which is injection molded onto the A-terminal and is pressed between the inner wall surfaces of the A-terminal and the second socket to achieve a seal between the two.

[0029] According to another exemplary embodiment of the present invention, a plurality of protrusions are formed on the outer side of the peripheral wall of the slot of the charging dock housing. The plurality of protrusions are distributed at intervals around the slot and are used to engage with a plurality of snaps on the insulator of the DC charging dock low-voltage module to lock the DC charging dock low-voltage module to the charging dock housing.

[0030] According to another exemplary embodiment of the present invention, the axial direction of the slot is perpendicular to the axial direction of the first socket and the second socket, and the DC charging socket low-voltage module is inserted into the slot radially along the first socket and the second socket.

[0031] According to another exemplary embodiment of the present invention, a third socket is further formed in the charging dock housing, and the slot communicates with the third socket; the DC charging dock further includes a power terminal assembly inserted into the third socket, the power terminal assembly including a power terminal, and the thermal pad of the low-voltage module of the DC charging dock is in thermal contact with the power terminal to transfer the heat of the power terminal to the temperature sensor of the low-voltage module of the DC charging dock.

[0032] According to another exemplary embodiment of the present invention, the power terminal assembly further includes: a high-voltage cable electrically connected to the power terminal and led out from the charging socket housing; and a sealing plug fitted onto the high-voltage cable and inserted into the third socket, the sealing plug being pressed between the inner wall surfaces of the high-voltage cable and the third socket to achieve a seal between the two.

[0033] According to another exemplary embodiment of the present invention, the power terminal includes: a cylindrical portion for mating with a mating power terminal; and a welding portion connected to the rear end of the cylindrical portion for welding to a high-voltage cable, wherein the thermal pad is in thermal contact with the outer peripheral surface of the cylindrical portion of the power terminal and is adjacent to the welding portion of the power terminal.

[0034] According to another exemplary embodiment of the present invention, a sealing ring mounting groove is formed on the rear end of the cylindrical portion of the power terminal, and the power terminal assembly further includes a sealing ring mounted in the sealing ring mounting groove. The sealing ring is pressed between the cylindrical portion of the power terminal and the inner wall surface of the third socket of the charging housing to achieve a seal between the two.

[0035] According to another exemplary embodiment of the present invention, the charging dock housing has a plurality of third sockets, and the DC charging dock has a plurality of power terminal assemblies respectively inserted into the plurality of third sockets; the slot communicates with the plurality of third sockets, and the low-voltage module of the DC charging dock includes a plurality of thermally conductive pads that are in thermal contact with the power terminals of the plurality of power terminal assemblies respectively, and a plurality of temperature sensors for detecting the temperature of the plurality of power terminals respectively.

[0036] According to another exemplary embodiment of the present invention, the charging base housing is a one-piece injection molded part.

[0037] In the aforementioned exemplary embodiments of the present invention, the electrical connector in the low-voltage module of the DC charging dock can electrically interconnect the PE terminal and the A- terminal of the DC charging dock together, thereby enabling the PE terminal and the A- terminal to share a common ground, thereby effectively preventing the low-voltage auxiliary circuit of the DC charging dock from being burned out.

[0038] Furthermore, in some of the exemplary embodiments of the present invention, the DC charging dock low-voltage module is not only small in size, but can also be directly inserted into the slot on the charging dock housing from the outside of the charging dock housing, making its installation and use very convenient.

[0039] Furthermore, in some of the exemplary embodiments of the present invention described above, the low-voltage module of the DC charging dock integrates a temperature sensor for detecting the temperature of the power terminals of the DC charging dock, thereby preventing the DC charging dock from being burned out due to overheating.

[0040] Other objects and advantages of the invention will become apparent from the following description of the invention with reference to the accompanying drawings, and will help to provide a comprehensive understanding of the invention. Attached Figure Description

[0041] Figure 1 A perspective view of a DC charging dock according to an exemplary embodiment of the present invention is shown;

[0042] Figure 2 An exploded view of a DC charging dock according to an exemplary embodiment of the present invention is shown;

[0043] Figure 3 A perspective view showing a DC charging dock low-voltage module, PE terminal, A- terminal and power terminal according to an exemplary embodiment of the present invention;

[0044] Figure 4 An exploded view of the low-voltage module and power terminals of a DC charging dock according to an exemplary embodiment of the present invention is shown.

[0045] Figure 5 A perspective view showing the low-voltage module, PE terminal, and A- terminal of a DC charging dock according to an exemplary embodiment of the present invention, viewed from the front.

[0046] Figure 6 A perspective view of the DC charging dock low-voltage module, PE terminal, and A- terminal as shown in an exemplary embodiment of the present invention, viewed from the rear.

[0047] Figure 7 An exploded view of the low-voltage module, PE terminal, and A- terminal of a DC charging dock according to an exemplary embodiment of the present invention is shown.

[0048] Figure 8 A perspective view of a low-voltage DC charging dock module according to an exemplary embodiment of the present invention is shown.

[0049] Figure 9 An exploded schematic diagram of a low-voltage DC charging dock module according to an exemplary embodiment of the present invention is shown.

[0050] Figure 10 Another exploded schematic diagram of a low-voltage DC charging dock module according to an exemplary embodiment of the present invention is shown;

[0051] Figure 11 A perspective view showing the conductive leads and temperature sensor of a low-voltage module of a DC charging dock according to an exemplary embodiment of the present invention.

[0052] Figure 12 A perspective view of a low-voltage DC charging dock module according to an exemplary embodiment of the present invention is shown.

[0053] Figure 13 A perspective view of the electrical connectors of a low-voltage module of a DC charging dock according to an exemplary embodiment of the present invention is shown.

[0054] Figure 14 This diagram shows the electrical connections of the low-voltage module of the DC charging dock according to an exemplary embodiment of the present invention, in electrical contact with the PE terminal and the A- terminal;

[0055] Figure 15 A perspective view of the power terminals of a DC charging dock according to an exemplary embodiment of the present invention is shown.

[0056] Figure 16 A side view of the power terminal assembly of a DC charging dock according to an exemplary embodiment of the present invention is shown. Detailed Implementation

[0057] The technical solution of the present invention will be further described in detail below through embodiments and in conjunction with the accompanying drawings. In this specification, the same or similar reference numerals indicate the same or similar components. The following description of the embodiments of the present invention with reference to the accompanying drawings is intended to explain the overall inventive concept of the present invention and should not be construed as a limitation thereof.

[0058] Furthermore, in the following detailed description, numerous specific details are set forth for ease of explanation to provide a thorough understanding of the embodiments disclosed herein. However, it will be apparent that one or more embodiments may be practiced without these specific details. In other instances, well-known structures and apparatuses are illustrated to simplify the figures.

[0059] According to a general technical concept of the present invention, a low-voltage module for a DC charging dock is provided. The low-voltage module includes an insulator and an electrical connector. The electrical connector includes: a first contact portion for electrical contact with the PE terminal of the DC charging dock; a second contact portion for electrical contact with the A- terminal of the DC charging dock; and a connecting portion electrically connecting the first contact portion and the second contact portion and being fixed to the insulator. The low-voltage module is adapted to be externally and pluggably installed into a slot on a charging dock housing. When the low-voltage module is installed into the slot, the first contact portion and the second contact portion make electrical contact with the PE terminal and the A- terminal respectively, to electrically connect the A- terminal to the PE terminal.

[0060] According to another general technical concept of the present invention, a DC charging dock is provided. The DC charging dock includes: a charging dock housing having a first socket, a second socket, and a slot communicating with the first socket and the second socket; a PE terminal assembly including a PE terminal and inserted into the first socket; an A-terminal assembly including an A-terminal and inserted into the second socket; and the aforementioned DC charging dock low-voltage module, inserted from outside the charging dock housing into the slot. A first contact portion and a second contact portion of the electrical connector respectively make electrical contact with the PE terminal and the A-terminal to electrically connect the A-terminal to the PE terminal.

[0061] Figure 1 A perspective view of a DC charging dock according to an exemplary embodiment of the present invention is shown; Figure 2 An exploded view of a DC charging dock according to an exemplary embodiment of the present invention is shown; Figure 3 A perspective view showing a DC charging dock low-voltage module 100, PE terminal 111, A- terminal 121 and power terminal 131 according to an exemplary embodiment of the present invention; Figure 4 An exploded view of the DC charging dock low-voltage module 100 and power terminal 131 according to an exemplary embodiment of the present invention is shown. Figure 5 A perspective view showing a DC charging dock low-voltage module 100, PE terminal 111 and A- terminal 121 as described in an exemplary embodiment of the present invention; Figure 6 A perspective view of the DC charging dock low-voltage module 100, PE terminal 111 and A- terminal 121 as shown in an exemplary embodiment of the present invention, viewed from the rear. Figure 7 An exploded view of the DC charging dock low-voltage module 100, PE terminal 111, and A- terminal 121 according to an exemplary embodiment of the present invention is shown. Figure 8A perspective view of a DC charging dock low-voltage module 100 according to an exemplary embodiment of the present invention is shown. Figure 9 An exploded schematic diagram of a DC charging dock low-voltage module 100 according to an exemplary embodiment of the present invention is shown. Figure 10 Another exploded schematic diagram of a DC charging dock low-voltage module 100 according to an exemplary embodiment of the present invention is shown; Figure 11 A perspective view showing the conductive lead 6 and temperature sensor 4 of a DC charging dock low-voltage module 100 according to an exemplary embodiment of the present invention. Figure 12 A perspective view of a DC charging dock low-voltage module 100 according to an exemplary embodiment of the present invention is shown. Figure 13 A perspective view showing the electrical connector 3 of a DC charging dock low-voltage module 100 according to an exemplary embodiment of the present invention; Figure 14 A schematic diagram showing the electrical connection 3 of a DC charging dock low-voltage module 100 according to an exemplary embodiment of the present invention is electrically connected to the PE terminal 111 and the A- terminal 121.

[0062] like Figures 1 to 14 As shown, in an exemplary embodiment of the present invention, a low-voltage module 100 for a DC charging dock is disclosed. The low-voltage module 100 includes an insulator 2 and an electrical connector 3. The electrical connector 3 includes a first contact portion 31, a second contact portion 32, and a connecting portion 30. The first contact portion 31 is used for electrical contact with the PE terminal 111 of the DC charging dock. The second contact portion 32 is used for electrical contact with the A- terminal 121 of the DC charging dock. The connecting portion 30 electrically connects the first contact portion 31 and the second contact portion 32 and is fixed to the insulator 2. The low-voltage module 100 is adapted to be externally and pluggably installed into a slot 14 on the charging dock housing 1. When the low-voltage module 100 is installed into the slot 14, the first contact portion 31 and the second contact portion 32 make electrical contact with the PE terminal 111 and the A- terminal 121 respectively, so as to electrically connect the A- terminal 121 to the PE terminal 111.

[0063] like Figures 1 to 14 As shown in the illustrated embodiment, the insulator 2 is directly injection molded onto the electrical connector 3, making the insulator 2 and the electrical connector 3 a single unit. This reduces manufacturing costs and improves production efficiency.

[0064] like Figures 1 to 14 As shown in the illustrated embodiment, the electrical connector 3 can be a one-piece stamped part. However, the present invention is not limited to the illustrated embodiment; for example, the electrical connector 3 can also be made of multiple parts welded together.

[0065] like Figures 1 to 14As shown in the illustrated embodiment, the first contact portion 31 includes a pair of first spring tabs. The pair of first spring tabs are used to hold the PE terminal 111. The second contact portion 32 includes a pair of second spring tabs. The pair of second spring tabs are used to hold the A- terminal 121. However, the present invention is not limited to the illustrated embodiment, and the first contact portion 31 and the second contact portion 32 may also employ other suitable elastic contact structures.

[0066] like Figures 1 to 14 As shown in the illustrated embodiment, the insulator 2 has a first locking portion 210 that abuts against the PE terminal 111 when the DC charging socket low-voltage module 100 is installed into the slot 14, thereby locking the PE terminal 111 into the charging socket housing 1. The insulator 2 also has a second locking portion 220 that abuts against the A- terminal 121 when the DC charging socket low-voltage module 100 is installed into the slot 14, thereby locking the A- terminal 121 into the charging socket housing 1.

[0067] like Figures 1 to 14 As shown in the illustrated embodiment, the DC charging dock low-voltage module 100 further includes a thermal pad 5, a temperature sensor 4, and a conductive lead 6. The thermal pad 5 is assembled onto the insulator 2 for thermal contact with the power terminal 131 of the DC charging dock. The temperature sensor 4 is disposed in the thermal pad 5 for detecting the temperature of the power terminal 131. The conductive lead 6 is disposed in the insulator 2 and electrically connected to the temperature sensor 4. The thermal pad 5 makes thermal contact with the power terminal 131 when the DC charging dock low-voltage module 100 is installed in the slot 14 to transfer heat from the power terminal 131 to the temperature sensor 4.

[0068] like Figures 1 to 14 As shown in the illustrated embodiment, the insulator 2 is directly injection molded onto the conductive lead 6 and the electrical connector 3, making the conductive lead 6, the electrical connector 3, and the insulator 2 a single unit.

[0069] like Figures 1 to 14 As shown, in the illustrated embodiment, the conductive lead 6 has a connection end 6a electrically connected to the temperature sensor 4 and an external pin 6b for electrically connecting to a connector located outside the charging housing 1.

[0070] like Figures 1 to 14 As shown in the illustrated embodiment, the insulator 2 includes a support portion 21 and a mating portion 22. The support portion 21 is adapted to be inserted into a slot 14 of the charging housing 1. The mating portion 22 is adapted to be positioned outside the charging housing 1. A thermal pad 5 and a temperature sensor 4 are mounted on the support portion 21. The mating portion 22 has an insertion cavity 20 that allows a connector to be inserted, and an external pin 6b of a conductive lead 6 extends into the insertion cavity 20 for electrical connection with the inserted connector.

[0071] like Figures 1 to 14 As shown in the illustrated embodiment, a sealing ring mounting groove 24 is formed on the outer peripheral surface of the bracket portion 21. The DC charging base low-voltage module 100 also includes a sealing ring 26 installed in the sealing ring mounting groove 24. The sealing ring 26 is adapted to be pressed between the bracket portion 21 and the inner wall surface of the slot 14 of the charging base housing 1 to achieve a seal between the two.

[0072] like Figures 1 to 14 As shown, in the illustrated embodiment, the bracket portion 21 has a cover portion 23 for sealing the entrance of the slot 14 of the charging base housing 1. The insulator 2 also includes a plurality of snap fasteners 25 connected to the periphery of the cover portion 23. The plurality of snap fasteners 25 are spaced apart around the outer periphery of the cover portion 23 and are used to engage with a plurality of protrusions 15 on the charging base housing 1 respectively to lock the DC charging base low voltage module 100 to the charging base housing 1.

[0073] like Figures 1 to 14 As shown, in the illustrated embodiment, the conductive lead 6 includes a positive lead 61 and a negative lead 62 that are electrically connected to the positive pin 41 and the negative pin 42 of the temperature sensor 4, respectively. The external pins 6b of the positive lead 61 and the negative lead 62 extend into the insertion cavity 20 of the mating part 22 for electrical connection with the inserted connector.

[0074] like Figures 1 to 14 As shown, in the illustrated embodiment, the connection end 6a of the positive lead 61 is adapted to be pluggably electrically connected to the positive pin 41 of the temperature sensor 4. The connection end 6a of the negative lead 62 is adapted to be pluggably electrically connected to the negative pin 42 of the temperature sensor 4.

[0075] like Figures 1 to 14 As shown in the illustrated embodiment, the connection end 6a of the positive lead 61 is in the shape of an elastic clip, suitable for clamping the positive pin 41 of the temperature sensor 4. The connection end 6a of the negative lead 62 is in the shape of an elastic clip, suitable for clamping the negative pin 42 of the temperature sensor 4.

[0076] like Figures 1 to 14 As shown in the illustrated embodiment, the DC charging dock low-voltage module 100 includes a plurality of thermal pads 5 and a plurality of temperature sensors 4 respectively disposed in the plurality of thermal pads 5. The plurality of thermal pads 5 are used to make thermal contact with a plurality of power terminals 131 respectively, and the plurality of temperature sensors 4 are used to detect the temperature of the plurality of power terminals 131 respectively.

[0077] like Figures 1 to 14As shown in the illustrated embodiment, the conductive lead 6 includes a plurality of positive leads 61 and a single negative lead 62. The connection ends 6a of the plurality of positive leads 61 are electrically connected to the positive pins 41 of the plurality of temperature sensors 4, respectively. The single negative lead 62 has a plurality of connection ends 6a that are electrically connected to the negative pins 42 of the plurality of temperature sensors 4, respectively. The external pins 6b of the plurality of positive leads 61 and the external pins 6b of the single negative lead 62 extend into the insertion cavity 20 of the mating portion 22 for electrical connection with the inserted connector.

[0078] like Figures 1 to 14 As shown in the illustrated embodiment, the thermal pad 5 is block-shaped, with a recessed receiving portion 205 formed on the insulator 2. The thermal pad 5 is positioned and installed into the receiving portion 205. A mounting groove 51 is formed in the thermal pad 5, and the main body of the temperature sensor 4 is inserted into the mounting groove 51 of the thermal pad 5. The positive electrode pin 41 and the negative electrode pin 42 of the temperature sensor 4 extend out from the thermal pad 5.

[0079] like Figures 1 to 14 As shown in the illustrated embodiment, the thermal pad 5 has an arcuate contact surface 5a adapted to abut against the outer peripheral surface of the power terminal 131 to increase the thermal contact area between the thermal pad 5 and the power terminal 131.

[0080] Please note that the DC charging dock low-voltage module 100 of the present invention is not limited to the illustrated embodiment. For example, in another exemplary embodiment of the present invention, the DC charging dock low-voltage module further includes a circuit board (not shown), which is mounted and fixed to an insulator 2. For ease of installation, the insulator 2 may be in the form of a housing. The first contact portion 31 and the second contact portion 32 of the aforementioned electrical connector 3 are fixed to contact springs on the circuit board, and the connection portion 30 of the aforementioned electrical connector 3 may be a conductive trace formed on the circuit board. Furthermore, in this embodiment, the DC charging dock low-voltage module also includes a thermal pad 5, a temperature sensor 4, and an external pin 6b. The thermal pad 5 is assembled onto the circuit board for thermal contact with the power terminal 131 of the DC charging dock. The temperature sensor 4 is disposed in the thermal pad 5 for detecting the temperature of the power terminal 131. The external pin 6b is fixed to the circuit board 2 for electrical connection to a connector (not shown) located outside the charging dock housing 1. The temperature sensor 4 is electrically connected to the external pin 6b via conductive traces on the circuit board. The thermal pad 5 makes thermal contact with the power terminal 131 when the DC charging dock low-voltage module 100 is installed into the slot 14, so as to transfer the heat of the power terminal 131 to the temperature sensor 4.

[0081] like Figures 1 to 14As shown, in another exemplary embodiment of the present invention, a DC charging dock is also disclosed. The DC charging dock includes: a charging dock housing 1, a PE terminal assembly 110, an A-terminal assembly 120, and a DC charging dock low-voltage module 100. The charging dock housing 1 has a first socket 11, a second socket 12, and a slot 14 communicating with the first socket 11 and the second socket 12. The PE terminal assembly 110 includes a PE terminal 111 and is inserted into the first socket 11. The A-terminal assembly 120 includes an A-terminal 121 and is inserted into the second socket 12. The DC charging dock low-voltage module 100 is inserted from outside the charging dock housing 1 into the slot 14. The first contact portion 31 and the second contact portion 32 of the electrical connector 3 make electrical contact with the PE terminal 111 and the A-terminal 121, respectively, to electrically connect the A-terminal 121 to the PE terminal 111.

[0082] like Figures 1 to 14 As shown, in the illustrated embodiment, the PE terminal assembly 110 further includes a grounding wire (not shown) and a first seal 112. The grounding wire is electrically connected to the PE terminal 111 and extends from the first socket 11 of the charging housing 1. The first seal 112 is injection molded onto the PE terminal 111. The first seal 112 is pressed between the inner wall surfaces of the PE terminal 111 and the first socket 11 to achieve a seal between them.

[0083] like Figures 1 to 14 As shown, in the illustrated embodiment, the A-terminal assembly 120 further includes a second seal 122. The second seal 122 is injection molded onto the A-terminal 121. The second seal 122 is pressed between the inner wall surfaces of the A-terminal 121 and the second socket 12 to achieve a seal between them.

[0084] like Figures 1 to 14 As shown in the illustrated embodiment, a plurality of protrusions 15 are formed on the outer side of the peripheral wall of the slot 14 of the charging dock housing 1. The plurality of protrusions 15 are spaced apart around the slot 14 and are used to engage with a plurality of snaps 25 on the insulator 2 of the DC charging dock low voltage module 100 to lock the DC charging dock low voltage module 100 to the charging dock housing 1.

[0085] like Figures 1 to 14 As shown in the illustrated embodiment, the axial direction of the slot 14 is perpendicular to the axial direction of the first socket 11 and the second socket 12, and the DC charging socket low-voltage module 100 is inserted into the slot 14 radially along the first socket 11 and the second socket 12.

[0086] like Figures 1 to 14As shown in the illustrated embodiment, a third socket 13 is also formed in the charging dock housing 1, and the slot 14 communicates with the third socket 13. The DC charging dock also includes a power terminal assembly 130 inserted into the third socket 13. The power terminal assembly 130 includes a power terminal 131. The thermal pad 5 of the DC charging dock low-voltage module 100 is in thermal contact with the power terminal 131 to transfer the heat of the power terminal 131 to the temperature sensor 4 of the DC charging dock low-voltage module 100.

[0087] Figure 15 A perspective view showing the power terminal 131 of a DC charging dock according to an exemplary embodiment of the present invention; Figure 16 A side view of the power terminal assembly 130 of a DC charging dock according to an exemplary embodiment of the present invention is shown.

[0088] like Figure 15 and Figure 16 As shown, in the illustrated embodiment, the power terminal assembly 130 further includes a high-voltage cable 134 and a sealing plug (not shown). The high-voltage cable 134 is electrically connected to the power terminal 131 and extends from the charging housing 1. The sealing plug is fitted onto the high-voltage cable 134 and inserted into the third socket 13. The sealing plug is pressed between the inner wall surfaces of the high-voltage cable 134 and the third socket 13 to achieve a seal between them.

[0089] like Figure 15 and Figure 16 As shown in the illustrated embodiment, the power terminal 131 includes a cylindrical portion 132 and a soldering portion 133. The cylindrical portion 132 is used to mate with a mating power terminal (not shown). The soldering portion 133 is connected to the rear end of the cylindrical portion 132 and is used to solder to a high-voltage cable 134. A thermally conductive pad 5 is in thermal contact with the outer peripheral surface of the cylindrical portion 132 of the power terminal 131 and is adjacent to the soldering portion 133 of the power terminal 131.

[0090] like Figure 15 and Figure 16 As shown, in the illustrated embodiment, a sealing ring mounting groove 135 is formed on the rear end of the cylindrical portion 132 of the power terminal 131. The power terminal assembly 130 also includes a sealing ring (not shown) mounted in the sealing ring mounting groove 135, which is pressed between the cylindrical portion 132 of the power terminal 131 and the inner wall surface of the third insertion hole 13 of the charging housing 1 to achieve a seal between the two.

[0091] like Figures 1 to 14As shown in the illustrated embodiment, the charging dock housing 1 has a plurality of third sockets 13, and the DC charging dock has a plurality of power terminal assemblies 130 respectively inserted into the plurality of third sockets 13. Slots 14 communicate with the plurality of third sockets 13, and the DC charging dock low-voltage module 100 includes a plurality of thermally conductive pads 5 that are in thermal contact with the power terminals 131 of the plurality of power terminal assemblies 130, and a plurality of temperature sensors 4 for respectively detecting the temperature of the plurality of power terminals 131. In the illustrated embodiment, the charging dock housing 1 has two third sockets 13, the DC charging dock has two power terminal assemblies 130, and the DC charging dock low-voltage module 100 includes two thermally conductive pads 5 and two temperature sensors 4.

[0092] like Figures 1 to 14 As shown in the illustrated embodiment, the charging base housing 1 is a one-piece injection molded part.

[0093] Those skilled in the art will understand that the embodiments described above are exemplary and can be improved upon. The structures described in the various embodiments can be freely combined without causing structural or principle conflicts, and these changes should fall within the protection scope of this invention.

[0094] Although the invention has been described in conjunction with the accompanying drawings, the embodiments disclosed in the drawings are intended to illustrate preferred embodiments of the invention and should not be construed as limiting the invention.

[0095] While some embodiments of the general concept of the invention have been shown and described, those skilled in the art will understand that changes may be made to these embodiments without departing from the principles and spirit of the general concept of the invention, the scope of which is defined by the claims and their equivalents.

[0096] It should be noted that the word "comprising" does not exclude other elements or steps, and the words "a" or "an" do not exclude multiple elements. Furthermore, any reference numerals in the claims should not be construed as limiting the scope of the invention.

Claims

1. A low voltage module for a direct current charging station, characterized in that, include: Insulator (2); and Electrical connector (3), comprising: The first contact portion (31) is used for electrical contact with the PE terminal (111) of the DC charging socket; The second contact portion (32) is used for electrical contact with the A-terminal (121) of the DC charging socket; and The connecting part (30) electrically connects the first contact part (31) and the second contact part (32) and is fixed to the insulator (2). The DC charging dock low-voltage module (100) is adapted to be externally and pluggably installed into a slot (14) on the charging dock housing (1). The first contact portion (31) and the second contact portion (32) make electrical contact with the PE terminal (111) and the A- terminal (121) respectively when the DC charging dock low-voltage module (100) is installed into the slot (14) to electrically connect the A- terminal (121) to the PE terminal (111).

2. The low-voltage module for a DC charging dock according to claim 1, characterized in that: The insulator (2) is directly injection molded onto the electrical connector (3), making the insulator (2) and the electrical connector (3) a single unit.

3. The low-voltage module for a DC charging dock according to claim 1, characterized in that: The electrical connector (3) is an integral stamped part.

4. The low-voltage module for a DC charging dock according to claim 1, characterized in that: The first contact portion (31) includes a pair of first spring contacts for holding the PE terminal (111); and / or The second contact portion (32) includes a pair of second springs for holding the A-terminal (121).

5. The low-voltage module for a DC charging dock according to claim 1, characterized in that: The insulator (2) has a first locking part (210) that abuts against the PE terminal (111) when the DC charging dock low voltage module (100) is installed into the slot (14) to lock the PE terminal (111) in the charging dock housing (1). and / or The insulator (2) has a second locking part (220) that abuts against the A-terminal (121) when the DC charging dock low-voltage module (100) is installed into the slot (14) to lock the A-terminal (121) in the charging dock housing (1).

6. The low-voltage module for a DC charging dock according to claim 1, characterized in that, Also includes: A thermal pad (5) is assembled onto the insulator (2) for thermal contact with the power terminal (131) of the DC charging dock; A temperature sensor (4) is disposed in the thermal pad (5) for detecting the temperature of the power terminal (131); and A conductive lead (6) is disposed in the insulator (2) and electrically connected to the temperature sensor (4). The thermal pad (5) makes thermal contact with the power terminal (131) when the DC charging dock low-voltage module (100) is installed into the slot (14) to transfer the heat of the power terminal (131) to the temperature sensor (4).

7. The low-voltage module for a DC charging dock according to claim 6, characterized in that: The insulator (2) is directly injection molded onto the conductive lead (6) and the electrical connector (3), so that the conductive lead (6), the electrical connector (3) and the insulator (2) become a single unit.

8. The low-voltage module for a DC charging dock according to claim 6, characterized in that: The conductive lead (6) has a connection end (6a) electrically connected to the temperature sensor (4) and an external pin (6b) for electrically connecting to a connector located outside the charging housing (1).

9. The low-voltage module for a DC charging dock according to claim 8, characterized in that: The insulator (2) comprises: The bracket portion (21) is adapted to be inserted into the slot (14) of the charging base housing (1); and A mating part (22) is adapted to be positioned outside the charging housing (1), the thermal pad (5) and the temperature sensor (4) are mounted on the bracket part (21), the mating part (22) has an insertion cavity (20) that allows the connector to be inserted, and the external pin (6b) of the conductive lead (6) extends into the insertion cavity (20) to be electrically connected to the inserted connector.

10. The low-voltage module for a DC charging dock according to claim 9, characterized in that: A sealing ring mounting groove (24) is formed on the outer peripheral surface of the bracket portion (21). The DC charging base low voltage module (100) also includes a sealing ring (26) installed in the sealing ring mounting groove (24). The sealing ring (26) is adapted to be pressed between the inner wall surface of the slot (14) of the bracket portion (21) and the charging base housing (1) to achieve a seal between the two.

11. The low-voltage module for a DC charging dock according to claim 9, characterized in that: The bracket portion (21) has a cover portion (23) for sealing the entrance of the slot (14) of the charging base housing (1). The insulator (2) also includes a plurality of snap fasteners (25) connected to the periphery of the cover portion (23). The plurality of snap fasteners (25) are spaced apart around the outer periphery of the cover portion (23) and are used to engage with a plurality of protrusions (15) on the charging base housing (1) to lock the DC charging base low voltage module (100) to the charging base housing (1).

12. The low-voltage module for a DC charging dock according to claim 9, characterized in that: The conductive lead (6) includes a positive lead (61) and a negative lead (62) that are electrically connected to the positive pin (41) and the negative pin (42) of the temperature sensor (4), respectively; and The external pins (6b) of the positive lead (61) and the negative lead (62) extend into the insertion cavity (20) of the mating part (22) for electrical connection with the inserted connector.

13. The low-voltage module for a DC charging dock according to claim 12, characterized in that: The connection terminal (6a) of the positive lead (61) is adapted to be pluggably electrically connected to the positive pin (41) of the temperature sensor (4); and / or The connection end (6a) of the negative lead (62) is adapted to be pluggably electrically connected to the negative pin (42) of the temperature sensor (4).

14. The low-voltage module for a DC charging dock according to claim 13, characterized in that: The connection end (6a) of the positive lead (61) is in the shape of an elastic clip, suitable for clamping the positive pin (41) of the temperature sensor (4); and / or The connection end (6a) of the negative lead (62) is in the shape of an elastic clip, which is suitable for clamping the negative pin (42) of the temperature sensor (4).

15. The low-voltage module for a DC charging dock according to claim 9, characterized in that: The DC charging dock low-voltage module (100) includes multiple thermal pads (5) and multiple temperature sensors (4) respectively disposed in the multiple thermal pads (5). The multiple thermal pads (5) are used to make thermal contact with multiple power terminals (131) respectively, and the multiple temperature sensors (4) are used to detect the temperature of the multiple power terminals (131) respectively.

16. The low-voltage module for a DC charging dock according to claim 15, characterized in that: The conductive lead (6) includes a plurality of positive leads (61) and a single negative lead (62); The connection terminals (6a) of the plurality of positive leads (61) are electrically connected to the positive pins (41) of the plurality of temperature sensors (4), and the single negative lead (62) has a plurality of connection terminals (6a) that are electrically connected to the negative pins (42) of the plurality of temperature sensors (4). The external pins (6b) of the plurality of positive leads (61) and the external pins (6b) of the single negative lead (62) extend into the insertion cavity (20) of the mating part (22) for electrical connection with the inserted connector.

17. The low-voltage module for a DC charging dock according to claim 6, characterized in that: The thermal pad (5) is block-shaped and has a recessed receiving portion (205) formed on the insulator (2). The thermal pad (5) is positioned and installed in the receiving portion (205). A mounting groove (51) is formed in the thermal pad (5), and the main body of the temperature sensor (4) is inserted into the mounting groove (51) of the thermal pad (5). The positive electrode pin (41) and the negative electrode pin (42) of the temperature sensor (4) extend out from the thermal pad (5).

18. The low-voltage module for a DC charging dock according to claim 17, characterized in that: The thermal pad (5) has an arc-shaped contact surface (5a) suitable for abutting against the outer peripheral surface of the power terminal (131) to increase the thermal contact area between the thermal pad (5) and the power terminal (131).

19. The low-voltage module for a DC charging dock according to claim 1, characterized in that, Also includes: The circuit board is mounted and secured to the insulator (2). The first contact portion (31) and the second contact portion (32) of the electrical connector (3) are contact springs fixed to the circuit board, and the connecting portion (30) of the electrical connector (3) is a conductive trace formed on the circuit board.

20. The low-voltage module for a DC charging dock according to claim 19, characterized in that, Also includes: A thermal pad (5) is assembled onto the circuit board for thermal contact with the power terminal (131) of the DC charging dock; A temperature sensor (4) is disposed in the thermal pad (5) for detecting the temperature of the power terminal (131); and An external pin (6b) is fixed to the circuit board (2) for electrical connection with a connector located outside the charging housing (1). The temperature sensor (4) is electrically connected to the external pin (6b) via conductive traces on the circuit board. The thermal pad (5) makes thermal contact with the power terminal (131) when the DC charging dock low-voltage module (100) is installed into the slot (14) to transfer the heat of the power terminal (131) to the temperature sensor (4).

21. A DC charging dock, characterized in that, include: The charging dock housing (1) has a first socket (11), a second socket (12) and a slot (14) communicating with the first socket (11) and the second socket (12); A PE terminal assembly (110) includes a PE terminal (111) and is inserted into the first socket (11); An A-terminal assembly (120) includes an A-terminal (121) and is inserted into the second socket (12); and The low-voltage module (100) of the DC charging dock according to any one of claims 1-20 is inserted into the slot (14) from the outside of the charging dock housing (1). The first contact portion (31) and the second contact portion (32) of the electrical connector (3) make electrical contact with the PE terminal (111) and the A-terminal (121) respectively, so as to electrically connect the A-terminal (121) to the PE terminal (111).

22. The DC charging dock according to claim 21, characterized in that: The PE terminal assembly (110) also includes: A grounding wire is electrically connected to the PE terminal (111) and leads out from the first socket (11) of the charging housing (1); and A first seal (112) is injection molded onto the PE terminal (111), and the first seal (112) is pressed between the inner wall surfaces of the PE terminal (111) and the first socket (11) to achieve a seal between the two.

23. The DC charging dock according to claim 21, characterized in that: The A-terminal assembly (120) also includes: The second seal (122) is injection molded onto the A-terminal (121). The second seal (122) is pressed between the inner wall surfaces of the A-terminal (121) and the second socket (12) to achieve a seal between the two.

24. The DC charging dock according to claim 21, characterized in that: A plurality of protrusions (15) are formed on the outer side of the peripheral wall of the slot (14) of the charging dock housing (1). The plurality of protrusions (15) are distributed at intervals around the slot (14) and are used to engage with a plurality of snaps (25) on the insulator (2) of the DC charging dock low voltage module (100) to lock the DC charging dock low voltage module (100) to the charging dock housing (1).

25. The DC charging dock according to claim 21, characterized in that: The axial direction of the slot (14) is perpendicular to the axial direction of the first socket (11) and the second socket (12), and the DC charging socket low voltage module (100) is inserted into the slot (14) radially along the first socket (11) and the second socket (12).

26. The DC charging dock according to claim 21, characterized in that: A third socket (13) is also formed in the charging base housing (1), and the slot (14) communicates with the third socket (13); The DC charging dock also includes a power terminal assembly (130) inserted into the third socket (13). The power terminal assembly (130) includes a power terminal (131). The thermal pad (5) of the DC charging dock low-voltage module (100) is in thermal contact with the power terminal (131) to transfer the heat of the power terminal (131) to the temperature sensor (4) of the DC charging dock low-voltage module (100).

27. The DC charging dock according to claim 26, characterized in that: The power terminal assembly (130) also includes: A high-voltage cable (134) is electrically connected to the power terminal (131) and extends from the charging housing (1); and A sealing plug is fitted onto the high-voltage cable (134) and inserted into the third socket. The sealing plug is pressed between the inner wall of the high-voltage cable (134) and the third socket (13) to achieve a seal between the two.

28. The DC charging dock according to claim 26, characterized in that: The power terminal (131) includes: The cylindrical portion (132) is used for mating with the mating power terminals; and The welding section (133), connected to the rear end of the cylindrical section (132), is used for welding to the high-voltage cable (134). The thermal pad (5) is in thermal contact with the outer peripheral surface of the cylindrical portion (132) of the power terminal (131) and is adjacent to the welding portion (133) of the power terminal (131).

29. The DC charging dock according to claim 28, characterized in that: A sealing ring mounting groove (135) is formed on the rear end of the cylindrical portion (132) of the power terminal (131). The power terminal assembly (130) also includes a sealing ring installed in the sealing ring mounting groove (135). The sealing ring is pressed between the cylindrical portion (132) of the power terminal (131) and the inner wall surface of the third insertion hole (13) of the charging housing (1) to achieve a seal between the two.

30. The DC charging dock according to claim 26, characterized in that: The charging dock housing (1) has a plurality of third sockets (13), and the DC charging dock has a plurality of power terminal assemblies (130) respectively inserted into the plurality of third sockets (13); The slot (14) is connected to the plurality of third sockets (13), and the DC charging dock low voltage module (100) includes a plurality of thermal pads (5) that are in thermal contact with the power terminals (131) of the plurality of power terminal assemblies (130) respectively, and a plurality of temperature sensors (4) for detecting the temperature of the plurality of power terminals (131) respectively.

31. The DC charging dock according to any one of claims 21-30, characterized in that: The charging base housing (1) is an integral injection molded part.

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