A charging plug for new energy vehicles and its manufacturing method

Abstract

The present invention discloses a charging plug for a new energy vehicle and a manufacturing method thereof. It includes an inner core, a plug connector, a plug body, and a cable. The inner core is located within the plug connector and is detachably connected to the plug connector. One end of the plug body is connected to the plug connector, and the other end of the plug body is connected to the cable. The end of the cable is located within the plug body and is fixedly connected to the plug body by injection molding. The inner core is electrically connected to the cable. A protective sleeve matching the plug body is provided on the plug body, and the plug body is located within the protective sleeve. One end of the plug connector is provided with a waterproof cover matching it, and the other end of the plug connector is located within the protective sleeve and is connected to the plug body. The protective sleeve is fixedly connected to the plug connector and the plug body respectively by injection molding. The beneficial effects of the present invention are: adopting injection molding and secondary overmolding processes, without any fasteners, greatly improving the compressive strength of the product, having high insulation, being safe and reliable, and having good sealing and waterproof properties.

Description

Technical Field

[0001] The present invention relates to the technical field of new energy vehicles, and in particular to a charging plug for a new energy vehicle and a manufacturing method thereof. Background Art

[0002] With the continuous development of society and the continuous improvement of the domestic economic level in China, the awareness of environmental protection among Chinese residents has gradually increased, and the demand for low-carbon life and low-carbon economy has become even stronger. At the same time, it is an indisputable fact that the oil prices at home and abroad have been rising continuously. Therefore, in the automotive industry, people are urgently seeking new engine technologies to replace the traditional internal combustion engine technology. In such a general environment, new energy vehicles such as electric vehicles or hybrid vehicles that meet people's expectations for energy conservation and environmental protection are becoming increasingly popular. The popularization and promotion of new energy vehicles have become an inevitable trend, and the charging equipment related to new energy vehicles has also received more and more attention from manufacturers.

[0003] The charging plug of a new energy vehicle plays an important role during the charging process. Therefore, the charging plug needs to be durable and safe. However, the existing charging plugs are often composed of various components connected by fasteners and do not have good sealing and waterproof properties. Summary of the Invention

[0004] The present invention aims to overcome the deficiency that the existing charging plugs do not have good sealing and waterproof properties, and provides a charging plug for a new energy vehicle with good sealing and waterproof properties and a manufacturing method thereof.

[0005] To achieve the above object, the present invention adopts the following technical solutions:

[0006] A charging plug for a new energy vehicle, which comprises an inner core, a plug connector, a plug body and a cable. The inner core is located inside the plug connector and is detachably connected to the plug connector. One end of the plug body is connected to the plug connector, and the other end of the plug body is connected to the cable. The end of the cable is located inside the plug body and is fixedly connected to the plug body by injection molding. The inner core is electrically connected to the cable. A protective sleeve matching the plug body is provided on the plug body, and the plug body is located inside the protective sleeve. One end of the plug connector is provided with a waterproof cover matching the plug connector. The other end of the plug connector is located inside the protective sleeve and is connected to the plug body. The protective sleeve is fixedly connected to the plug connector and the plug body by injection molding respectively.

[0007] The inner core is located inside the plug connector and is detachably connected to the plug connector. One end of the plug body is connected to the plug connector, and the other end of the plug body is connected to the cable. The end of the cable is located inside the plug body and is fixedly connected to the plug body by injection molding. The inner core is electrically connected to the cable. A protective sleeve matching the plug body is provided on the plug body, and the plug body is located inside the protective sleeve. One end of the plug connector is provided with a waterproof cover matching it, and the other end of the plug connector is located inside the protective sleeve and is connected to the plug body. The protective sleeve is fixedly connected to the plug connector and the plug body by injection molding respectively. In the present invention, the protective sleeve is integrally formed with the plug connector and the plug body by injection molding, using a secondary overmolding process, without any fasteners, greatly improving the compressive strength of the product, having high insulation, being safe and reliable, and achieving the purpose of having good sealing and waterproof properties.

[0008] Preferably, the shapes of the plug body and the protective sleeve are both arc-shaped. The material used for the plug body is PC, and the material used for the protective sleeve is TPR. Such a design is beneficial to enhancing the use feel of the charging plug.

[0009] Preferably, the plug connector is a male head. One end of the male head is located inside the waterproof cover matching it and is detachably connected to the waterproof cover. The other end of the male head is located inside the protective sleeve and is connected to the plug body. The protective sleeve is fixedly connected to the male head and the plug body by injection molding respectively. The end of the male head located inside the waterproof cover is provided with a plurality of slots one. The inner core includes a mounting seat one, and the mounting seat one is detachably connected to the end of the male head located inside the protective sleeve. A plurality of pins matching the slots one are mounted on the mounting seat one. One end of the pin is located on one side of the mounting seat one and penetrates through the corresponding slot one and is located inside the slot one, and the other end of the pin is located on the other side corresponding to the mounting seat one and is located inside the plug body. The end of the pin located inside the plug body is electrically connected to the cable. The pins inside the slot one are inserted into the socket, and the circuit can be connected to achieve charging of the vehicle. The design is reasonable; the protective sleeve is integrally formed with the male head and the plug body by injection molding, using a secondary overmolding process, without any fasteners, greatly improving the compressive strength of the plug, having high insulation, being safe and reliable, and having good sealing and waterproof properties; the waterproof cover protects the plugging part of the male head from water ingress and dust accumulation, ensuring the normal use of the plug.

[0010] Preferably, there are a total of seven slots. The pins include three live pins, one neutral pin, one ground pin, and two guide pins. The structures of the live pins, the neutral pin, and the ground pin are the same. Each live pin includes a nut and a hollow column. The hollow column is installed on the first mounting seat. One end of the hollow column is located on one side of the first mounting seat and penetrates through the corresponding first slot to be threadedly connected to the nut. The nut is located within the first slot. The other end of the hollow column is located on the other side corresponding to the first mounting seat and is within the plug body. A through hole is provided within the hollow column. An internal thread is provided at one end of the through hole. The nut is frustum-shaped. One end of the nut is provided with a stud that matches the internal thread and has a diameter the same as the outer diameter of the hollow column. The nut is installed at the end of the hollow column by matching the stud with the internal thread. The diameter of the other end of the nut is smaller than the diameter of the end of the nut where the stud is provided. One end of the stud is fixedly connected to the nut. The other end of the stud is provided with a T-shaped rotating groove. A T-shaped column that matches the T-shaped rotating groove is provided within the T-shaped rotating groove. One end of the T-shaped column is rotatably connected to the T-shaped rotating groove. The other end of the T-shaped column is provided with a connection block that matches the through hole. The connection block is slidably connected to the through hole. A first limiting plate is provided at the other end of the through hole. A first limiting hole is provided on the first limiting plate. A limiting rubber ring is provided within the first limiting hole. The live wire within the cable is electrically connected to the connection block by press-fitting through the limiting rubber ring within the corresponding live pin. The portion of the live wire within the cable that is within the through hole is greater than the length of the through hole. The neutral wire within the cable is electrically connected to the connection block by press-fitting through the limiting rubber ring within the corresponding neutral pin. The portion of the neutral wire within the cable that is within the through hole is greater than the length of the through hole. The ground wire within the cable is electrically connected to the connection block by press-fitting through the limiting rubber ring within the corresponding ground pin. The portion of the ground wire within the cable that is within the through hole is greater than the length of the through hole. The material used for one of the guide pins is PP, and the material used for the other guide pin is CP.The friction coefficient of the contact surface between the T-shaped rotating groove and the T-shaped column is designed to be minimized. The corresponding wiring inside the cable is connected from the rear end of the pin. When a fault such as poor contact or power failure occurs in one of the wirings on the cable, the maintenance personnel only need to unscrew the nut at the front end of the pin by threading. While the nut drives the stud to rotate, the stud is rotationally connected to the T-shaped column through the T-shaped rotating groove, and the T-shaped column remains at a small rotation angle or even does not rotate, thus preventing the wiring from being damaged due to excessive torsion. Since when a fault such as poor contact or power failure occurs in one of the wirings on the cable, the wiring is likely to become loose, especially when pulled by the nut, the wiring is electrically connected to the connecting block through the interference fit through the limiting rubber ring inside the corresponding pin. And the part of the wiring located inside the through hole is longer than the length of the through hole. There is a certain frictional force between the limiting rubber ring and the wiring, which is beneficial to preventing the wiring inside the through hole from detaching from the through hole and causing difficulties for the maintenance personnel to perform maintenance. Such a design is beneficial when the nut pulls the wiring, and the wiring is not easily detached from the connecting block. Even when the wiring detaches from the connecting block, after the maintenance personnel unscrew the nut, they only need to invert the plug, and the part of the wiring located inside the through hole hangs vertically downward, and the wiring is exposed outside the through hole, which is convenient for the maintenance personnel to perform maintenance. The present invention has good sealing and waterproof properties, and is also beneficial to maintenance, with strong practicability. The guiding pin is convenient for guiding when the inner core and the male head are installed.

[0011] Preferably, one end of the T-shaped rotating groove is located inside the stud and its diameter is larger than that of the other end. The other end of the T-shaped rotating groove is located at the end of the stud. One end of the T-shaped column is located inside the T-shaped rotating groove and its diameter is larger than that of the other end. The other end of the T-shaped column is connected to the connecting block. The depth of the end of the T-shaped rotating groove located inside the stud is greater than the height of the end of the T-shaped column located inside the T-shaped rotating groove.

[0012] Preferably, a support plate is provided in the through hole, and the support plate is in the shape of a circular ring. The edge of the support plate is fixedly connected to the inner wall of the through hole. A plurality of springs are provided on the support plate, and the plurality of springs are evenly distributed along the edge of the support plate. One end of the spring is fixedly connected to the support plate, and the other end of the spring is in contact with the connecting block. The top of the connecting block is fixedly connected to the T-shaped column, and the bottom of the connecting block is in contact with the spring. The live wire in the cable line passes through the limiting rubber ring in the corresponding live wire pin and the support plate and the connecting block in sequence, and is electrically connected. The neutral wire in the cable line passes through the limiting rubber ring in the corresponding neutral wire pin and the support plate and the connecting block in sequence, and is electrically connected. The ground wire in the cable line passes through the limiting rubber ring in the corresponding ground wire pin and the support plate and the connecting block in sequence, and is electrically connected. The material used for the nut is insulating material, and the materials used for the stud, hollow column, T-shaped column and connecting block are all conductive metals. The insulating material is generally plastic, and the conductive metal can be brass, red copper, galvanized copper, etc. according to the needs. Under the action of the spring, it is fully guaranteed that the T-column and the bottom of the T-slot can be in contact, which is conducive to connecting the circuit and the design is reasonable; the spring is in contact with the connecting block, which makes it easy for the connecting block to separate from the spring, thereby facilitating maintenance.

[0013] Preferably, one end of the plug body is fixedly connected to the cable by injection molding, and the other end of the plug body is provided with an installation groove, and a wire collection plate is provided in the installation groove, and the wire collection plate is fixedly connected to the side wall of the installation groove, and five rectangular holes are provided on the wire collection plate, which correspond to the live wire pin, the neutral wire pin and the grounding pin respectively, and a rotating shaft is provided in the rectangular hole, and a winding reel is provided on the rotating shaft, and the winding reel is rotatably connected to the side wall of the rectangular hole through the rotating shaft, the live wire in the cable is wound on the corresponding winding reel, and is electrically connected to the connecting block through the corresponding limiting rubber ring passed through the winding reel, the neutral wire in the cable is wound on the corresponding winding reel, and is electrically connected to the connecting block through the corresponding limiting rubber ring passed through the winding reel, and the ground wire on the cable is wound on the corresponding winding reel, and is electrically connected to the connecting block through the corresponding limiting rubber ring passed through the winding reel. During maintenance, maintenance personnel will process the connection between the corresponding wiring and the connection block on the cable line, and may even need to cut off the damaged part of the wiring to shorten the wiring. At this time, the maintenance personnel only need to pull the corresponding wiring to a certain length to partially release it from the reel to facilitate the next maintenance.

[0014] As another preference, the socket is a female head. One end of the female head is located inside a waterproof cover that matches it and is detachably connected to the waterproof cover. The other end of the female head is located inside a protective sleeve and is connected to the plug body. The protective sleeve is fixedly connected to the female head and the plug body respectively by injection molding. One end of the female head located inside the protective sleeve is provided with a number of mounting posts, and a protective groove is provided inside the mounting posts. One end of the female head located inside the waterproof cover is provided with a second slot. A number of limiting posts corresponding to the mounting posts are provided inside the second slot. A second limiting hole is provided inside the limiting posts. One end of the second limiting hole is provided with a second limiting plate. The second limiting plate is located inside the second slot and at one end of the limiting post. The other end of the limiting post is fixedly connected to the bottom of the second slot. A round hole is provided at the center position of the second limiting plate. One end of the second limiting hole is communicated with the round hole. The other end of the second limiting hole sequentially penetrates through the bottom of the second slot and the bottom of the protective groove and is communicated with the inside of the protective groove. The inner core includes a second mounting seat. The second mounting seat is detachably connected to one end of the female head located inside the protective sleeve. A number of plugging posts matching the second limiting holes are mounted on the second mounting seat. One end of the plugging post is located on one side of the second mounting seat and inside the second limiting hole. One end of the plugging post located inside the second limiting hole is provided with a plugging groove. The inner diameter of the plugging groove is the same as the diameter of the round hole. The other end of the plugging post is located on the corresponding other side of the second mounting seat and inside the protective groove. One end of the plugging post located inside the protective groove is electrically connected to the cable. The plugging post is inserted into the socket, and the circuit can be connected to charge the vehicle. The design is reasonable. The protective sleeve is respectively injection molded with the female head and the plug body by a secondary overmolding process without any fasteners, greatly improving the compressive strength of the product, having high insulation, being safe and reliable, and having good sealing and waterproof properties. The waterproof cover protects the plugging part of the female head from water ingress and dust accumulation, ensuring the normal use of the plug.

[0015] Preferably, there are seven limiting posts in total. The plugging posts include three live wire plugging posts, one neutral wire plugging post, one ground wire plugging post and two guiding plugging posts. The live wire inside the cable is electrically connected to the end of the corresponding live wire plugging post located inside the protective groove. The neutral wire inside the cable is electrically connected to the end of the corresponding neutral wire plugging post located inside the protective groove. The ground wire inside the cable is electrically connected to the end of the corresponding ground wire plugging post located inside the protective groove. The guiding plugging posts facilitate the guiding function when the inner core is installed with the female head.

[0016] The present invention also provides a manufacturing method for a charging plug of a new energy vehicle, including the following steps:

[0017] Step 1, injection molding machines are used to injection mold the waterproof cover, the socket, the inner core and the plug body respectively;

[0018] Step 2, the inner core is installed inside the socket by fixing screws. The waterproof cover is installed at one end of the socket. The other end of the socket is connected to one end of the plug body. The cable penetrates through the other end of the plug body and is located inside the plug body;

[0019] Step 3: Finally, the protective sleeve is integrally formed with the plug connector and the plug body through the secondary overmolding process.

[0020] The waterproof cover, plug connector, inner core, and plug body are first injection molded. After assembly, the protective sleeve is integrally formed with the plug connector and the plug body by injection molding, using the secondary overmolding process. Without any fasteners, it greatly improves the compressive strength of the product, has high insulation, is safe and reliable, and achieves the purpose of having good sealing and waterproof performance.

[0021] Preferably, in Step 2, the plug body and the cable are integrally formed by filling injection molding. This improves the sealing performance at the connection between the plug body and the cable, and at the same time, filling injection molding is beneficial to enhancing the use feel.

[0022] Preferably, in Step 2, the plug connector is a male head. The pins and Mounting Base 1 are injection molded by an injection molding machine to form the inner core. Then, under the guiding action of the guiding pins, the corresponding pins are inserted into the matching Slot 1. Finally, Mounting Base 1 is installed at one end where the plug connector is connected to the plug body through fixing screws. The pins and Mounting Base 1 are injection molded by an injection molding machine to form the inner core. The inner core in an integral manner is more conducive to the assembly of the production line and improves work efficiency.

[0023] As another preference, in Step 2, the plug connector is a female head. The plug pins and Mounting Base 2 are injection molded by an injection molding machine to form the inner core. Then, under the guiding action of the guiding plug pins, the corresponding plug pins are inserted into the matching Limit Hole 2. Finally, Mounting Base 2 is installed at one end where the plug connector is connected to the plug body through fixing screws. The plug pins and Mounting Base 2 are injection molded by an injection molding machine to form the inner core. The inner core in an integral manner is more conducive to the assembly of the production line and improves work efficiency.

[0024] The beneficial effects of the present invention are as follows: The present invention adopts injection molding and the secondary overmolding process, without any fasteners, greatly improving the compressive strength of the product, having high insulation, being safe and reliable, having good sealing and waterproof performance; being convenient for maintenance and having strong practicability. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 is the structural schematic diagram of the present invention;

[0026] Figure 2 is Figure 1 the right view of

[0027] Figure 3 is the exploded view when the plug connector is a male head;

[0028] Figure 4 is Figure 2 the sectional view taken along line A - A when the plug connector in

[0029] Figure 5It is a schematic structural diagram when the plug connector is a male head;

[0030] Figure 6 It is Figure 5 The sectional view taken along B - B in

[0031] Figure 7 It is a schematic structural diagram of the internal structure of pins other than the guiding pins;

[0032] Figure 8 It is a schematic structural diagram of the internal connection structure between pins other than the guiding pins and the cable;

[0033] Figure 9 It is Figure 7 The enlarged view at position A in

[0034] Figure 10 It is Figure 7 The enlarged view at position B in

[0035] Figure 11 It is a schematic structural diagram of the wire collecting board;

[0036] Figure 12 It is an exploded view when the plug connector is a female head;

[0037] Figure 13 It is Figure 2 The sectional view taken along A - A when the plug connector is a female head in

[0038] Figure 14 It is a schematic structural diagram when the plug connector is a female head;

[0039] Figure 15 It is Figure 14 The sectional view taken along B - B in

[0040] In the figure: 1. Inner core, 2. Plug connector, 3. Plug body, 4. Cable, 5. Protective sleeve, 6. Waterproof cover, 7. Slot 1, 8. Mounting seat 1, 9. Pin, 10. Nut, 11. Hollow column, 12. Through hole, 13. Stud, 14. T - shaped rotating groove, 15. T - shaped column, 16. Connecting block, 17. Limiting plate 1, 18. Limiting hole 1, 19. Limiting rubber ring, 20. Support plate, 21. Spring, 22. Installation groove, 23. Wire collecting board, 24. Rectangular hole, 25. Rotating shaft, 26. Reel, 27. Mounting post, 28. Protection groove, 29. Slot 2, 30. Limiting post, 31. Limiting hole 2, 32. Limiting plate 2, 33. Round hole, 34. Mounting seat 2, 35. Inserting column, 36. Inserting slot. Detailed implementation manners

[0041] The present invention will be further described below in conjunction with the accompanying drawings and specific implementation manners.

[0042] As Figure 1 、Figure 2 Figure 3 and Figure 4 In the described embodiment, a charging plug for a new energy vehicle includes an inner core 1, a plug connector 2, a plug body 3, and a cable 4. The inner core 1 is located within the plug connector 2 and is detachably connected to the plug connector 2. One end of the plug body 3 is connected to the plug connector 2, and the other end of the plug body 3 is connected to the cable 4. The end of the cable 4 is located within the plug body 3 and is fixedly connected to the plug body 3 by injection molding. The inner core 1 is electrically connected to the cable 4. A protective sleeve 5 that matches the plug body 3 is provided on the plug body 3. The plug body 3 is located within the protective sleeve 5. One end of the plug connector 2 is provided with a waterproof cover 6 that matches it. The other end of the plug connector 2 is located within the protective sleeve 5 and is connected to the plug body 3. The protective sleeve 5 is fixedly connected to the plug connector 2 and the plug body 3 respectively by injection molding. The shapes of the plug body 3 and the protective sleeve 5 are both arc-shaped. The material used for the plug body 3 is PC, and the material used for the protective sleeve 5 is TPR.

[0043] As Figure 4 shown, the plug connector 2 is a male head. One end of the male head is located within the waterproof cover 6 that matches it and is detachably connected to the waterproof cover 6. The other end of the male head is located within the protective sleeve 5 and is connected to the plug body 3. The protective sleeve 5 is fixedly connected to the male head and the plug body 3 respectively by injection molding. As Figure 5 and Figure 6 shown, several slots one 7 are provided at one end of the male head located within the waterproof cover 6. As Figure 4 and as Figure 6 shown, the inner core 1 includes a mounting base one 8. The mounting base one 8 is detachably connected to one end of the male head located within the protective sleeve 5. Several pins 9 that match the slots one 7 are mounted on the mounting base one 8. One end of the pin 9 is located on one side of the mounting base one 8 and passes through the corresponding slot one 7 and is located within the slot one 7. The other end of the pin 9 is located on the other side corresponding to the mounting base one 8 and is located within the plug body 3. One end of the pin 9 located within the plug body 3 is electrically connected to the cable 4.

[0044] As Figure 5 shown, there are a total of seven slots one 7. The pins 9 include three live pins, one neutral pin, one ground pin, and two guiding pins. The structures of the live pins, the neutral pin, and the ground pin are all the same. As Figure 7 shown, the live pin includes a nut 10 and a hollow column 11. The hollow column 11 is mounted on the mounting base one 8. One end of the hollow column 11 is located on one side of the mounting base one 8 and passes through the corresponding slot one 7 and is threadedly connected to the nut 10. The nut 10 is located within the slot one 7. As Figure 8 shown, the other end of the hollow column 11 is located on the other side corresponding to the mounting base one 8 and is located within the plug body 3. As Figure 7 and Figure 8As shown, a through hole 12 is provided inside the hollow column 11. One end of the through hole 12 is provided with internal threads. The shape of the nut 10 is frustum-shaped. One end of the nut 10 is provided with a stud 13 that matches the internal threads and its diameter is the same as the outer diameter of the hollow column 11. The nut 10 is installed at the end of the hollow column 11 through the matching of the stud 13 and the internal threads. The diameter of the other end of the nut 10 is smaller than the diameter of the end of the nut 10 where the stud 13 is provided. One end of the stud 13 is fixedly connected to the nut 10, as Figure 9 shown. The other end of the stud 13 is provided with a T-shaped rotating groove 14. A T-shaped column 15 that matches it is provided inside the T-shaped rotating groove 14. One end of the T-shaped column 15 is rotatably connected to the T-shaped rotating groove 14. The other end of the T-shaped column 15 is provided with a connection block 16 that matches the through hole 12. The connection block 16 is slidably connected to the through hole 12, as Figure 10 shown. The other end of the through hole 12 is provided with a first limiting plate 17. A first limiting hole 18 is provided on the first limiting plate 17. A limiting rubber ring 19 is provided inside the first limiting hole 18, as Figure 8 shown. The live wire inside the cable 4 passes through the limiting rubber ring 19 inside the corresponding live wire pin by interference fit and is electrically connected to the connection block 16. The part of the live wire inside the cable 4 located inside the through hole 12 is longer than the length of the through hole 12. The neutral wire inside the cable 4 passes through the limiting rubber ring 19 inside the corresponding neutral wire pin by interference fit and is electrically connected to the connection block 16. The part of the neutral wire inside the cable 4 located inside the through hole 12 is longer than the length of the through hole 12. The ground wire inside the cable 4 passes through the limiting rubber ring 19 inside the corresponding ground wire pin by interference fit and is electrically connected to the connection block 16. The part of the ground wire inside the cable 4 located inside the through hole 12 is longer than the length of the through hole 12. The material of one of the guiding pins is PP, and the material of the other guiding pin is CP.

[0045] As Figure 9 shown, one end of the T-shaped rotating groove 14 is located inside the stud 13 and its diameter is larger than the diameter of the other end. The other end of the T-shaped rotating groove 14 is located at the end of the stud 13. One end of the T-shaped column 15 is located inside the T-shaped rotating groove 14 and its diameter is larger than the diameter of the other end. The other end of the T-shaped column 15 is connected to the connection block 16. The depth of the end of the T-shaped rotating groove 14 located inside the stud 13 is greater than the height of the end of the T-shaped column 15 located inside the T-shaped rotating groove 14.

[0046] As Figure 9 shown, a support plate 20 is provided inside the through hole 12. The shape of the support plate 20 is annular. The edge of the support plate 20 is fixedly connected to the inner side wall of the through hole 12. A number of springs 21 are provided on the support plate 20. The number of springs 21 is evenly distributed along the edge of the support plate 20. One end of the spring 21 is fixedly connected to the support plate 20. The other end of the spring 21 is in contact with the connection block 16. The top end of the connection block 16 is fixedly connected to the T-shaped column 15. The bottom end of the connection block 16 is in contact with the spring 21, as Figure 7and Figure 8 As shown in Figure 8 , the live wire in the cable 4 sequentially passes through the limiting rubber ring 19 and the support plate 20 in the corresponding live wire pin and is electrically connected to the connecting block 16. The neutral wire in the cable 4 sequentially passes through the limiting rubber ring 19 and the support plate 20 in the corresponding neutral wire pin and is electrically connected to the connecting block 16. The ground wire in the cable 4 sequentially passes through the limiting rubber ring 19 and the support plate 20 in the corresponding ground wire pin and is electrically connected to the connecting block 16. The material of the nut 10 is an insulating material, and the materials of the stud 13, the hollow column 11, the T-shaped column 15, and the connecting block 16 are all conductive metals.

[0047] As Figure 8 shown, one end of the plug body 3 is fixedly connected to the cable 4 by injection molding. The other end of the plug body 3 is provided with an installation groove 22. A wire collecting board 23 is arranged in the installation groove 22, and the wire collecting board 23 is fixedly connected to the side wall of the installation groove 22. As Figure 11 shown, the wire collecting board 23 is provided with five rectangular holes 24 respectively corresponding to the live wire pin, the neutral wire pin, and the grounding pin one by one. A rotating shaft 25 is arranged in the rectangular hole 24, and a wire reel 26 is arranged on the rotating shaft 25. The wire reel 26 is rotatably connected to the side wall of the rectangular hole 24 through the rotating shaft 25. As Figure 8 shown, the live wire in the cable 4 is wound around the corresponding wire reel 26, and is electrically connected to the connecting block 16 through the wire reel 26 passing through the corresponding limiting rubber ring 19. The neutral wire in the cable 4 is wound around the corresponding wire reel 26, and is electrically connected to the connecting block 16 through the wire reel 26 passing through the corresponding limiting rubber ring 19. The ground wire on the cable 4 is wound around the corresponding wire reel 26, and is electrically connected to the connecting block 16 through the wire reel 26 passing through the corresponding limiting rubber ring 19.

[0048] As Figure 12 and Figure 13 shown, the socket 2 is a female head. One end of the female head is located in the waterproof cover 6 matching with it and is detachably connected to the waterproof cover 6. The other end of the female head is located in the protective sleeve 5 and is connected to the plug body 3. The protective sleeve 5 is fixedly connected to the female head and the plug body 3 respectively by injection molding. One end of the female head located in the protective sleeve 5 is provided with a plurality of mounting posts 27, and a protective groove 28 is arranged in the mounting posts 27. One end of the female head located in the waterproof cover 6 is provided with a second slot 29, and a plurality of limiting posts 30 corresponding to the mounting posts 27 are arranged in the second slot 29. As Figure 13As shown, a limiting hole two 31 is provided inside the limiting column 30. One end of the limiting hole two 31 is provided with a limiting plate two 32. The limiting plate two 32 is located inside the slot two 29 and at one end of the limiting column 30. The other end of the limiting column 30 is fixedly connected to the bottom of the slot two 29. A round hole 33 is provided at the central position of the limiting plate two 32. One end of the limiting hole two 31 is connected to the round hole 33. The other end of the limiting hole two 31 sequentially penetrates the bottom of the slot two 29 and the bottom of the protection groove 28 and is connected to the inside of the protection groove 28, as Figure 12 , Figure 14 and Figure 15 shown, the inner core 1 includes a mounting base two 34. The mounting base two 34 is detachably connected to one end of the female head located inside the protective sleeve 5. A plurality of insertion columns 35 matching the limiting hole two 31 are mounted on the mounting base two 34. One end of the insertion column 35 is located on one side of the mounting base two 34 and inside the limiting hole two 31. An insertion slot 36 is provided at one end of the insertion column 35 located inside the limiting hole two 31. The inner diameter of the insertion slot 36 is the same as the diameter of the round hole 33. The other end of the insertion column 35 is located on the corresponding other side of the mounting base two 34 and inside the protection groove 28. One end of the insertion column 35 located inside the protection groove 28 is electrically connected to the cable 4.

[0049] As Figure 14 shown, there are seven limiting columns 30 in total. The insertion columns 35 include three live wire insertion columns 35, one neutral wire insertion column 35, one ground wire insertion column 35 and two guiding insertion columns 35, as Figure 15 shown, the live wire inside the cable 4 is electrically connected to the end of the corresponding live wire insertion column 35 located inside the protection groove 28. The neutral wire inside the cable 4 is electrically connected to the end of the corresponding neutral wire insertion column 35 located inside the protection groove 28. The ground wire inside the cable 4 is electrically connected to the end of the corresponding ground wire insertion column 35 located inside the protection groove 28.

[0050] The present invention also provides a manufacturing method for a charging plug of a new energy vehicle, including the following steps:

[0051] As Figure 3 and Figure 12 shown, step one, the waterproof cover 6, the plug connector 2, the inner core 1 and the plug body 3 are respectively injection-molded by an injection molding machine;

[0052] As Figure 4 and Figure 13 shown, step two, the inner core 1 is installed inside the plug connector 2 through fixing screws. The waterproof cover 6 is installed at one end of the plug connector 2. The other end of the plug connector 2 is connected to one end of the plug body 3. The cable 4 penetrates the other end of the plug body 3 and is located inside the plug body 3;

[0053] Step three, finally, the protective sleeve 5 is injection-molded with the plug connector 2 and the plug body 3 into one body through a two-shot overmolding process.

[0054] In Step 2, the plug body 3 and the cable 4 are integrally formed by filling injection molding.

[0055] As Figure 3 shown, in Step 2, the plug connector 2 is a male head. The pin 9 and the mounting base 8 are injection molded by an injection molding machine to form the inner core 1. Then, under the guiding action of the guiding pin 9, the corresponding pin 9 is inserted into the mating slot 7. Finally, the mounting base 8 is mounted at one end where the plug connector 2 is connected to the plug body 3 by fixing screws.

[0056] As Figure 12 shown, in Step 2, the plug connector 2 is a female head. The plug post 35 and the mounting base 2 are injection molded by an injection molding machine to form the inner core 1. Then, under the guiding action of the guiding plug post 35, the corresponding plug post 35 is inserted into the mating limiting hole 31. Finally, the mounting base 34 is mounted at one end where the plug connector 2 is connected to the plug body 3 by fixing screws.

[0057] The waterproof cover 6, the plug connector 2, the inner core 1, and the plug body 3 are first injection molded. After assembly, the protective sleeve 5 is integrally formed with the plug connector 2 and the plug body 3 by injection molding, adopting a two-shot overmolding process without any fasteners, greatly improving the compressive strength of the product, having high insulation, and being safe and reliable. The waterproof cover 6 protects the male or female head plugging part from water ingress and dust accumulation, ensuring the normal use of the plug, thus achieving the purpose of having good sealing performance and waterproofness.

[0058] Through injection molding, if the connection between the wiring inside the cable 4 and the pin 9 fails and cannot be repaired, it often has to be discarded. Therefore, in the present invention, the friction coefficient of the contact surface between the T-shaped rotating groove 14 and the T-shaped column 15 is designed to be minimized. When a certain wiring on the cable 4 has a fault such as poor contact or no power supply, the maintenance personnel only need to unscrew the nut 10. While the nut 10 drives the stud 13 to rotate, the stud 13 is rotationally connected to the T-shaped column 15 through the T-shaped rotating groove 14, and the T-shaped column 15 remains at a small rotation angle or even does not rotate, so as to prevent the wiring from being damaged due to excessive torsion; Since when a certain wiring on the cable 4 has a fault such as poor contact or no power supply, the wiring is likely to become loose, especially when pulled by the nut 10, the wiring is very easy to fall off. Therefore, the design is adopted that the wiring is electrically connected to the connecting block 16 through the interference fit through the limiting rubber ring 19 inside the corresponding pin 9, and the part of the wiring located inside the through hole 12 is longer than the length of the through hole 12. Since there is a certain frictional force between the limiting rubber ring 19 and the wiring, it is beneficial to prevent the wiring inside the through hole 12 from detaching from the through hole 12 and causing difficulties for the maintenance personnel to repair; At the same time, when the maintenance personnel pull the wiring through the nut 10, the wiring is not easy to detach from the connecting block 16. Even when the wiring detaches from the connecting block 16, after the maintenance personnel unscrew the nut 10, they only need to invert the plug, and the part of the wiring located inside the through hole 12 hangs vertically downward, and the wiring exposes outside the through hole 12, which is convenient for the maintenance personnel to repair; The present invention has good sealing and waterproof properties, and at the same time is beneficial to maintenance, with strong practicability; The guiding pin 9 is convenient for guiding when the inner core 1 is installed with the male head. During maintenance, the maintenance personnel will process the connection between the corresponding wiring on the cable 4 and the connecting block 16, and even need to cut off a damaged part of the wiring, making the wiring shorter. At this time, the maintenance personnel only need to pull the corresponding wiring to a certain length to release part of it from the wire reel 26, which is convenient for the next maintenance.

[0059] The materials used for the nut 10, the hollow column 11, the T-shaped column 15 and the connecting block 16 are all conductive metals. The conductive metal can be selected from brass, red copper, copper galvanized, etc. according to requirements. Under the action of the spring 21, it fully ensures that the bottom of the T-shaped column 15 can be in contact with the T-shaped groove, so as to facilitate the connection of the circuit, and the design is reasonable; The spring 21 is in contact with the connecting block 16, which is convenient for the connecting block 16 to disengage from the spring 21, thus facilitating maintenance.

Claims

1. A charging plug for a new energy vehicle, characterized in that It includes an inner core (1), a plug connector (2), a plug body (3) and a cable (4). The inner core (1) is located inside the plug connector (2) and is detachably connected to the plug connector (2). One end of the plug body (3) is connected to the plug connector (2), and the other end of the plug body (3) is connected to the cable (4). The end of the cable (4) is located inside the plug body (3) and is fixedly connected to the plug body (3) by injection molding. The inner core (1) is electrically connected to the cable (4). A protective sleeve (5) matching the plug body (3) is provided on the plug body (3). The plug body (3) is located inside the protective sleeve (5). One end of the plug connector (2) is provided with a waterproof cover (6) matching it. The other end of the plug connector (2) is located inside the protective sleeve (5) and is connected to the plug body (3). The protective sleeve (5) is fixedly connected to the plug connector (2) and the plug body (3) respectively by injection molding; the plug connector (2) is a male head. One end of the male head is located inside the waterproof cover (6) matching it and is detachably connected to the waterproof cover (6). Several first slots (7) are provided at one end of the male head located inside the waterproof cover (6). The inner core (1) includes a first mounting seat (8). The first mounting seat (8) is detachably connected to one end of the male head located inside the protective sleeve (5). Several pins (9) matching the first slots (7) are mounted on the first mounting seat (8). There are seven first slots (7) in total. The pins (9) include three live pins, one neutral pin, one ground pin and two guiding pins. The structures of the live pins, the neutral pin and the ground pin are the same. The live pin includes a nut (10) and a hollow column (11). The hollow column (11) is mounted on the first mounting seat (8). One end of the hollow column (11) is located on one side of the first mounting seat (8) and penetrates through the corresponding first slot (7) to be threadedly connected to the nut (10). The nut (10) is located inside the first slot (7). The other end of the hollow column (11) is located on the other side corresponding to the first mounting seat (8) and is located inside the plug body (3). A through hole (12) is provided inside the hollow column (11). An internal thread is provided at one end of the through hole (12). The nut (10) is in the shape of a frustum of a cone. One end of the nut (10) is provided with a stud (13) matching the internal thread and its diameter is the same as the outer diameter of the hollow column (11). The nut (10) is mounted at the end of the hollow column (11) by matching the stud (13) with the internal thread. The diameter of the other end of the nut (10) is smaller than the diameter of the end of the nut (10) provided with the stud (13). One end of the stud (13) is fixedly connected to the nut (10). A T-shaped rotating groove (14) is provided at the other end of the stud (13). A T-shaped column (15) matching the T-shaped rotating groove (14) is provided inside the T-shaped rotating groove (14). One end of the T-shaped column (15) is rotatably connected to the T-shaped rotating groove (14). The other end of the T-shaped column (15) is provided with a connecting block (16) matching the through hole (12).The connecting block (16) is slidably connected to the through hole (12). A first limiting plate (17) is provided at the other end of the through hole (12). A first limiting hole (18) is provided on the first limiting plate (17). A limiting rubber ring (19) is provided in the first limiting hole (18). The live wire in the cable (4) is in interference fit through the limiting rubber ring (19) in the corresponding live wire pin and is electrically connected to the connecting block (16). The part of the live wire in the cable (4) located in the through hole (12) is longer than the length of the through hole (12). The neutral wire in the cable (4) is in interference fit through the limiting rubber ring (19) in the corresponding neutral wire pin and is electrically connected to the connecting block (16). The part of the neutral wire in the cable (4) located in the through hole (12) is longer than the length of the through hole (12). The ground wire in the cable (4) is in interference fit through the limiting rubber ring (19) in the corresponding ground wire pin and is electrically connected to the connecting block (16). The part of the ground wire in the cable (4) located in the through hole (12) is longer than the length of the through hole (12). The material of one of the guiding pins is PP, and the material of the other guiding pin is CP., 2. The charging plug for a new energy vehicle according to claim 1, characterized in that, The shapes of the plug body (3) and the protective sleeve (5) are both arc-shaped. The material of the plug body (3) is PC, and the material of the protective sleeve (5) is TPR.

3. The charging plug for a new energy vehicle according to claim 1, characterized in that, One end of the T-shaped rotating groove (14) is located inside the stud (13) and its diameter is larger than that of the other end. The other end of the T-shaped rotating groove (14) is located at the end of the stud (13). One end of the T-shaped column (15) is located inside the T-shaped rotating groove (14) and its diameter is larger than that of the other end. The other end of the T-shaped column (15) is connected to the connecting block (16). The depth of the T-shaped rotating groove (14) at the end located inside the stud (13) is greater than the height of the T-shaped column (15) at the end located inside the T-shaped rotating groove (14).

4. The charging plug for a new energy vehicle according to claim 3, characterized in that, A support plate (20) is provided inside the through hole (12). The shape of the support plate (20) is circular ring-shaped. The edge of the support plate (20) is fixedly connected to the inner side wall of the through hole (12). A plurality of springs (21) are provided on the support plate (20). The plurality of springs (21) are evenly distributed along the edge of the support plate (20). One end of the spring (21) is fixedly connected to the support plate (20), and the other end of the spring (21) is in contact with the connecting block (16). The top end of the connecting block (16) is fixedly connected to the T-shaped column (15), and the bottom end of the connecting block (16) is in contact with the spring (21). The live wire in the cable wire (4) sequentially passes through the limiting rubber ring (19) inside the corresponding live wire pin and the support plate (20) and is electrically connected to the connecting block (16). The neutral wire in the cable wire (4) sequentially passes through the limiting rubber ring (19) inside the corresponding neutral wire pin and the support plate (20) and is electrically connected to the connecting block (16). The ground wire in the cable wire (4) sequentially passes through the limiting rubber ring (19) inside the corresponding ground wire pin and the support plate (20) and is electrically connected to the connecting block (16). The material of the nut (10) is an insulating material, and the materials of the stud (13), the hollow column (11), the T-shaped column (15), and the connecting block (16) are all conductive metals.

5. A charging plug for a new energy vehicle according to claim 1, characterized in that, One end of the plug body (3) is fixedly connected to the cable (4) by injection molding. The other end of the plug body (3) is provided with an installation groove (22). A wire collecting board (23) is arranged in the installation groove (22). The wire collecting board (23) is fixedly connected to the side wall of the installation groove (22). Five rectangular holes (24) corresponding to the live pin, neutral pin and ground pin respectively are arranged on the wire collecting board (23). A rotating shaft (25) is arranged in the rectangular hole (24). A wire reel (26) is arranged on the rotating shaft (25). The wire reel (26) is rotatably connected to the side wall of the rectangular hole (24) through the rotating shaft (25). The live wire in the cable (4) is wound around the corresponding wire reel (26), and is electrically connected to the connection block (16) through the wire reel (26) passing through the corresponding limiting rubber ring (19). The neutral wire in the cable (4) is wound around the corresponding wire reel (26), and is electrically connected to the connection block (16) through the wire reel (26) passing through the corresponding limiting rubber ring (19). The ground wire on the cable (4) is wound around the corresponding wire reel (26), and is electrically connected to the connection block (16) through the wire reel (26) passing through the corresponding limiting rubber ring (19).

6. The manufacturing method of a charging plug for a new energy vehicle according to claim 1, characterized in that, Including the following steps: Step 1, the waterproof cover (6), the plug connector (2), the inner core (1) and the plug body (3) are respectively made by injection molding of an injection molding machine; Step 2, the inner core (1) is installed in the plug connector (2) by fixing screws. The waterproof cover (6) is installed at one end of the plug connector (2). The other end of the plug connector (2) is connected to one end of the plug body (3). The cable (4) passes through the other end of the plug body (3) and is located inside the plug body (3); Step 3, finally, the protective sleeve (5) is integrally formed with the plug connector (2) and the plug body (3) by secondary overmolding process.

7. The manufacturing method of a charging plug for a new energy vehicle according to claim 6, characterized in that, In Step 2, the plug body (3) and the cable (4) are integrally formed by filling injection molding.

8. The manufacturing method of a charging plug for a new energy vehicle according to claim 6, characterized in that, in In Step 2, the plug connector (2) is a male head. The pin (9) and the mounting seat one (8) are injection molded by an injection molding machine to form the inner core (1). Then, through the guiding action of the guiding pin (9), the corresponding pin (9) is inserted into the corresponding slot one (7). Finally, the mounting seat one (8) is installed at the connection end of the plug connector (2) and the plug body (3) by fixing screws.

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