DC battery special plug and socket assembly and forming method thereof

Abstract

The present invention relates to a plug and socket assembly specifically designed for DC batteries and a molding method thereof, comprising a male plug body and a female plug body that cooperate with each other. The male plug body is provided with a cylindrical male pin and a male communication pin; the female plug body is provided with a cylindrical female pin and a female communication pin, and the side wall of the female pin is provided with a through slot. The male pin and the female pin cooperate, and the female pin has an initial inner diameter smaller than the outer diameter of the male pin. A safety distance is reserved between the male communication pin and the male pin, and between the female communication pin and the female pin. The male and female pins each include a pin body, which is divided into a contact end and a fixed end. The fixed end is provided with a rubber-coated shoulder, an injection-molded shoulder, and a contact shoulder coaxially arranged with the pin body. The rubber-coated shoulder, injection-molded shoulder, and contact shoulder are arranged in sequence from the fixed end to the contact end. The cylindrical male pin can, firstly, prevent the mixing of conventional plugs and DC plugs, and secondly, the cylindrical metal pin has a lower resistance than the flat-pin metal pin, allowing for a greater overcurrent.

Description

Technical Field

[0001] The present invention relates to the technical field of electrical coupling components, in particular to a plug and socket assembly dedicated to a DC battery and a molding method thereof. Background Art

[0002] At present, the battery of an electric vehicle is usually charged using a separately configured charging cable, with plugs at both ends of the charging cable connected to the external power grid and the battery respectively.

[0003] In the prior art, the appearance of a conventional battery-specific plug is very similar to an ordinary pinion plug, which makes it easy to confuse the battery-specific DC plug with a conventional AC plug. Once the wrong charging cable is connected, it is easy to cause a safety hazard. Summary of the Invention

[0004] In response to the shortcomings of the above-mentioned existing production technology, the applicant provides a special plug for DC batteries and a molding method thereof, which can avoid mixing with conventional AC plugs while also increasing the advantages of overcurrent and communication capabilities.

[0005] The technical solutions adopted in the present invention are as follows:

[0006] A plug and socket assembly for a DC battery, comprising a male plug body and a female plug body that cooperate with each other, wherein a cylindrical male pin and a male communication pin are provided in the male plug body;

[0007] The female plug body is provided with a cylindrical female pin and a female communication pin, and a through slot is provided on the side wall of the female pin;

[0008] The male pin and the female pin are matched, and the inner diameter of the female pin is initially smaller than the outer diameter of the male pin. A safety distance is reserved between the male pins and between the female pins.

[0009] As a further improvement of the above technical solution:

[0010] The male pin and the female pin both include a pin body, which is divided into a contact end and a fixed end. The fixed end is provided with a rubber-coated shoulder, an injection-molded shoulder, and a contact shoulder coaxially arranged with the pin body. The rubber-coated shoulder, injection-molded shoulder, and contact shoulder are arranged in sequence from the fixed end to the contact end.

[0011] The outer diameters of the rubber-coated shoulder, the injection-molded shoulder, and the contact shoulder are equal.

[0012] The axial length of the injection-molded shoulder is greater than that of the rubber-coated shoulder, and the axial length of the rubber-coated shoulder is greater than that of the contact shoulder.

[0013] A deformation distance is reserved between an end of the through slot on the female pin close to the contact shoulder and the contact shoulder.

[0014] The fixed end surfaces of the male pin and the female pin are provided with tapered holes for accommodating metal wires.

[0015] The male plug body and the female plug body both include a connector for fixing the pins. The connector is provided with a protective shell extending around the end face of the pins. The male pins, female pins, male communication pins and female communication pins all fall into the protective shell.

[0016] The connectors of the male plug body and the female plug body are both formed with a shell, and the end of the shell facing away from the protective shell is connected with a net tail.

[0017] A method for forming a special plug for a DC battery comprises the following steps:

[0018] The molding method of the male plug body is as follows:

[0019] First coating: Connect the male pins and the male communication pins to the wires, and coat the male pins and the male communication pins with plastic so that the male pins, the male communication pins and the connection with the wires are limited by plastic;

[0020] Second encapsulation: Encapsulate the semi-finished product formed by the first encapsulation to form a cubic outer contour of the male plug body;

[0021] The third overmolding: On the side of the semi-finished product formed by the second overmolding away from the male pins and the male communication pins, a net tail is formed by injection molding, and the wires extend from the net tail;

[0022] The molding method of the female plug body is as follows:

[0023] The plastic shell of the female plug body is molded in one step, and holes for accommodating the female pin and the female communication pin are reserved on the plastic shell; the female pin and the female communication pin are inserted into the reserved holes; the plastic shell with the female pin and the female communication pin installed is filled with glue, and the plastic shell, the female pin and the female communication pin are bonded together.

[0024] The beneficial effects of the present invention are as follows:

[0025] The present invention features a compact, rational, and easy-to-use structure. The male pins are designed to be cylindrical, unlike conventional 'P' plugs. This prevents mixing conventional AC plugs with the battery DC plugs suitable for the present invention. Furthermore, the cylindrical metal pins have lower resistance than flat pins, allowing for greater overcurrent tolerances and reducing safety hazards caused by misconnection of AC power. The mounting holes of the present invention's plugs are contoured to match those of existing 'P' plugs on the market, allowing for interoperability with existing product molds, thus reducing complexity during production.

[0026] The present invention also provides a communication pin, which is used to transmit relevant information about battery charging, such as charging status, battery status and other parameters, for easy reading.

[0027] The female pin in the present invention is provided with a through slot, which enables the female pin to accommodate a male pin with a larger inner diameter than its own initial state, and the male pin with a larger diameter is connected more tightly to the female pin when the male pin is connected.

[0028] The pin of the present invention is gold-plated, and the pin itself is made of copper. The pin diameter is made as thick as possible within the allowable range, and the performance of the material and the characteristic that the larger the diameter, the smaller the resistance are are used to assist in improving the current carrying capacity of the pin.

[0029] The molding method of the plug and socket assembly adopted in the present invention is based on reliability considerations. It changes the conventional scheme of first making the plug and socket and then inserting the pin by interference fit. The pin is first used as the core, and the plastic is injection-molded to form a connecting block that firmly grasps the pin. The plastic is then overmolded a second time on the connecting block to form an outer shell. Finally, the outer shell is overmolded to form a mesh tail. The advantage of this molding method is that the outer layer of plastic can firmly grasp the pin and wire. During multiple plugging and unplugging processes, the pin is not easy to loosen between it and the plug or socket it is in. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 This is a structural diagram of the male plug body and the female plug body of the present invention used in combination.

[0031] Figure 2 This is a schematic structural diagram of the male plug body of the present invention.

[0032] Figure 3 It is a side view of the male plug body of the present invention.

[0033] Figure 4 Schematic diagram of the male pin structure of the present invention.

[0034] Figure 5 It is a side view of the male pin of the present invention.

[0035] Figure 6 This is a front view of the female plug body of the present invention.

[0036] Figure 7 This is a schematic diagram of the female pin structure of the present invention.

[0037] Wherein: 1. Male plug body; 2. Female plug body; 3. Contact pin body; 4. Rubber-coated shoulder; 5. Injection-molded shoulder; 6. Contact shoulder; 7. Tapered hole; 8. Inner core; 9. Protective shell; 10. Outer shell; 11. Net tail; 12. Wire;

[0038] 101, male pin; 102, male communication pin;

[0039] 201, female pin; 202, female communication pin; 203, through slot. DETAILED DESCRIPTION

[0040] The specific embodiments of the present invention will be described below with reference to the accompanying drawings.

[0041] like Figures 1-6 As shown, the DC battery dedicated plug and socket assembly of this embodiment includes a male plug body 1 and a female plug body 2 that cooperate with each other. The male plug body 1 is provided with a cylindrical male pin 101 and a male communication pin 102;

[0042] The female plug body 2 is provided with a cylindrical female pin 201 and a female communication pin 202, and a through slot 203 is provided on the side wall of the female pin 201;

[0043] The male pin 101 cooperates with the female pin 201. The inner diameter of the female pin 201 is initially smaller than the outer diameter of the male pin 101. A safety distance is reserved between the male communication pin 102 and the male pin 101, and between the female communication pin and the female pin 201.

[0044] Both the male pin 101 and the female pin 201 include a pin body 3, which is divided into a contact end and a fixed end. The fixed end is provided with a rubber-coated shoulder 4, an injection-molded shoulder 5, and a contact shoulder 6 coaxially arranged with the pin body 3. The rubber-coated shoulder 4, the injection-molded shoulder 5, and the contact shoulder 6 are arranged in sequence from the fixed end to the contact end.

[0045] The outer diameters of the rubber-coated shoulder 4, the injection-molded shoulder 5, and the contact shoulder 6 are equal.

[0046] The axial length of the injection-molded shoulder 5 is greater than the axial length of the rubber-coated shoulder 4 , and the axial length of the rubber-coated shoulder 4 is greater than the axial length of the contact shoulder 6 .

[0047] A deformation distance b is reserved between the end of the through slot 203 on the female pin 201 close to the contact shoulder 6 and the contact shoulder 6 .

[0048] The fixed end surfaces of the male pin 101 and the female pin 201 are provided with tapered holes 7 for accommodating metal wires.

[0049] Both the male plug body 1 and the female plug body 2 include a connector for fixing the pins. The connector is provided with a protective shell 9 around the end face of the pins. The male pin 101, the female pin 201, the male communication pin and the female communication pin 202 all fall into the protective shell 9.

[0050] A shell 10 is formed on the outside of the connector of the male plug body 1 and the female plug body 2 , and a mesh tail 11 is connected to one end of the shell 10 facing away from the protective shell 9 .

[0051] The method for forming the dedicated plug for DC battery of this embodiment includes the following steps:

[0052] The molding method of the male plug body 1 is as follows:

[0053] First coating: Connect the male pin 101 and the male communication pin 102 to the wire, and coat the tail of the male pin 101 and the male communication pin 102 with plastic so that the male pin 101, the male communication pin 102 and the connection with the wire are limited by plastic;

[0054] Second encapsulation: encapsulating the semi-finished product formed by the first encapsulation to form a cubic outer contour of the male plug body 1;

[0055] The third overmolding: a mesh tail is formed by injection molding on the side of the semi-finished product formed by the second overmolding away from the male pin 101 and the male communication pin 102, and the wire extends from the mesh tail;

[0056] The molding method of the female plug body 2 is as follows:

[0057] The plastic shell of the female plug body 2 is molded in one step, and holes are reserved on the plastic shell for accommodating the female pin 201 and the female communication pin 202; the female pin 201 and the female communication pin 202 are inserted into the reserved holes; the plastic shell with the female pin 201 and the female communication pin 202 installed is filled with glue, and the plastic shell, the female pin 201 and the female communication pin 202 are bonded together.

[0058] The specific structure of this embodiment is as follows:

[0059] like Figure 1 and Figure 2 As shown, a male plug body 1 is equipped with two male pins 101, which are arranged side by side. A male communication pin is set in the space between the two male pins 101. There are four male communication pins, each two in a group. The connection line of the two male communication pins in a group is parallel to the connection line of the two male pins 101, and the distance between the two groups of male communication pins is greater than the diameter of the male pin 101.

[0060] A safety distance a is reserved between the male communication pin and the male pin 101 to prevent the male pin 101 and the male communication pin from being too close to each other and causing a short circuit.

[0061] like Figure 3 and Figure 4 As shown, one end of the plastic shoulder 4 is flush with the fixed end of the pin body 3, and the tapered hole 7 is provided on the end surface of the fixed end, and the depth of the tapered hole 7 is greater than the axial length of the plastic shoulder 4. During the plastic coating, the tapered hole 7 and the wire 12 therein are fixed by the plastic coating.

[0062] like Figure 5As shown, a female plug body 2 is equipped with two female pins 201, which are arranged side by side. A female communication pin 202 is set in the space between the female and male pins 101. There are four female communication pins 202, each two forming a group. The line connecting the two female communication pins 202 in a group is parallel to the line connecting the two female pins 201, and the distance between the two groups of female communication pins 202 is greater than the diameter of the male pin 101.

[0063] A safety distance a is reserved between the female communication pin 202 and the female plug pin 201 to prevent the female plug pin 201 and the female communication pin 202 from being too close to each other and causing a short circuit.

[0064] like Figure 5 and Figure 6 As shown, the female pin 201 in this embodiment has a ring array of through slots 203 , with a total of four through slots 203 .

[0065] The present invention is particularly suitable for charging batteries of two-wheeled high-speed motorcycles. The male plug body 1 and the female plug body 2 are respectively connected to the charging line 12 and the battery. The male pin 101 and the female pin 201 are adapted in shape, and conventional plugs cannot be mixed. While ensuring DC exclusive use, the overcurrent can also be increased. Compared with the overcurrent of 10A of the conventional pin, the overcurrent in the present invention can be increased to 40A, and the charging status and battery status can be timely output through the communication pin.

[0066] The above description is an explanation of the present invention, not a limitation of the present invention. The scope of the present invention is defined in the claims. Any modifications may be made within the scope of protection of the present invention.

Claims

1. A method for forming a plug and socket assembly for a DC battery, wherein the formed assembly comprises a male plug body (1) and a female plug body (2) that cooperate with each other, and is characterized in that: The male plug body (1) is provided with a cylindrical male plug pin (101) and a male communication pin (102); The female plug body (2) is provided with a cylindrical female plug pin (201) and a female communication pin (202), and an array of through slots (203) are provided on the outer wall of the female plug pin (201); The male pin (101) cooperates with the female pin (201), the inner diameter of the female pin (201) in the initial state is smaller than the outer diameter of the male pin (101), and a safety distance is reserved between the male communication pin (102) and the male pin (101), and between the female communication pin and the female pin (201); A deformation distance is reserved between the through slot (203) on the female pin (201) and the contact shoulder (6), at one end thereof close to the contact shoulder (6); The molding method includes the following steps: using the pin as the core, injection molding and overmolding, forming a connecting block on the pin to hold the pin firmly, then overmolding the connecting block a second time to form a shell, and finally overmolding the shell to form a net tail. The molding method of the male plug body (1) is as follows: First rubber coating: connect the male pin (101) and the male communication pin (102) to the wire, and coat the tail of the male pin (101) and the male communication pin (102) with rubber so that the male pin (101) and the male communication pin (102) and the connection with the wire are limited by plastic; Second encapsulation: encapsulating the semi-finished product formed by the first encapsulation to form a cubic outer contour of the male plug body (1); The third encapsulation: a mesh tail is formed by injection molding on the side of the semi-finished product formed by the second encapsulation away from the male pin (101) and the male communication pin (102), and the wire extends from the mesh tail; The molding method of the female plug body (2) is as follows: A plastic shell of a female plug body (2) is formed in one step, and a hole for accommodating a female plug pin (201) and a female communication pin (202) is reserved on the plastic shell; the female plug pin (201) and the female communication pin (202) are inserted into the reserved hole; and the plastic shell with the female plug pin (201) and the female communication pin (202) installed is filled with glue, and the plastic shell, the female plug pin (201) and the female communication pin (202) are bonded together to form the plastic shell.

2. The DC battery dedicated plug and socket assembly according to claim 1, characterized in that: The male pin (101) and the female pin (201) both include a pin body (3), the pin body (3) being divided into a contact end and a fixed end, the fixed end being provided with a rubber-coated shoulder (4), an injection-molded shoulder (5), and a contact shoulder (6) coaxially arranged with the pin body (3), the rubber-coated shoulder (4), the injection-molded shoulder (5), and the contact shoulder (6) being arranged in sequence from the fixed end to the contact end.

3. The DC battery dedicated plug and socket assembly according to claim 2, characterized in that: The outer diameters of the rubber-coated shoulder (4), the injection-molded shoulder (5), and the contact shoulder (6) are equal.

4. The DC battery dedicated plug and socket assembly according to claim 2, characterized in that: The axial length of the injection-molded shoulder (5) is greater than the axial length of the rubber-coated shoulder (4), and the axial length of the rubber-coated shoulder (4) is greater than the axial length of the contact shoulder (6).

5. The DC battery dedicated plug and socket assembly according to claim 1, characterized in that: The fixed end surfaces of the male pin (101) and the female pin (201) are provided with tapered holes (7) for accommodating metal wires.

6. The DC battery dedicated plug and socket assembly according to claim 1, characterized in that: The male plug body (1) and the female plug body (2) both include a connector for fixing the pins, the connector being provided with a protective shell (9) extending around the end faces of the pins, the male pin (101), the female pin (201), the male communication pin and the female communication pin (202) all falling within the protective shell (9).

7. The DC battery dedicated plug and socket assembly according to claim 6, characterized in that: The connectors of the male plug body (1) and the female plug body (2) are both formed with a shell (10), and one end of the shell (10) facing away from the protective shell (9) is connected to a net tail (11).

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