plug-in device

Abstract

The application discloses a plug-in device, comprising an incoming line connecting part and an outgoing line connecting part, a first end of the incoming line connecting part and a first end of the outgoing line connecting part are used for connecting a fuse, a second end of the incoming line connecting part is used for connecting a power supply wire, and a second end of the outgoing line connecting part is used for connecting a load wire, wherein the second end of the outgoing line connecting part has at least one connecting branch, and each connecting branch is used as a load interface. The plug-in device can make the current enter the fuse through the incoming line connecting part, and then be branched off from the connecting branch of the outgoing line connecting part after passing through the fuse, so that the purpose of reducing the wire diameter of the branched wire is achieved, the wire can be protected, the capacity of the central distribution box and the wiring position can be used when the capacity and the wiring position cannot meet the requirements, and the design can be supplemented when the load configuration of the whole vehicle is increased, and the plug-in device has the advantages of simple structure, convenient use and high safety.

Description

Technical Field

[0001] This invention relates to the field of automotive electrical connection technology, and more particularly to a plug-in device. Background Technology

[0002] With the advancement of autonomous driving and vehicle intelligence, the number of electrical devices (loads) in vehicles is increasing. These loads are typically connected to the electrical system through a central distribution box, but the capacity and wiring locations of this box are limited. When the capacity and wiring locations of the central distribution box cannot meet the requirements, developers are often forced to use unprotected down-gauge wires—wires without matching fuses—due to the long development time and high costs involved in developing such boxes. This often results in wires burning out due to current exceeding their carrying capacity, posing a significant safety hazard. Therefore, improving the safety of vehicle power distribution, meeting the demands of increasing loads and vehicle development schedules, and reducing development costs have become urgent technical challenges. Summary of the Invention

[0003] This invention provides a plug-in device to address the safety hazards associated with existing unprotected wire diameter reduction methods.

[0004] This invention provides a plug-in device including an inlet connection and an outlet connection. A fuse is connected between the first end of the inlet connection and the first end of the outlet connection. A second end of the inlet connection is connected to a power supply conductor, and a second end of the outlet connection is connected to a load conductor. The second end of the outlet connection has at least one connecting branch, each serving as a load interface. The inlet connection is connected to the power supply conductor, and the outlet connection is connected to the load conductor. The inlet and outlet connections are connected by a fuse. Current flows through the inlet connection to the fuse and is then diverted from the connecting branch of the outlet connection. This achieves the purpose of reducing the wire diameter for current diversion, while also protecting the wire. It can be used to increase capacity when the capacity and wiring positions of the central distribution box are insufficient, and it can be used to supplement the design when the overall vehicle load configuration increases. The structure is simple, easy to use, and highly safe. Moreover, it is less expensive than expanding the distribution box and solves the safety hazards of existing unprotected wire diameter reduction methods. When there is only one connection branch, under the protection of the fuse, the diameter of the load conductor can be smaller than that of the power supply conductor, thus achieving the purpose of reducing the wire diameter.

[0005] According to one aspect of the present invention, it further includes at least one terminal block, wherein the second end of the incoming connection portion and / or at least one connecting branch are connected to the terminal block, and the terminal block is used to connect external wires. The connection between the power supply wire and the incoming connection portion, and the connection between the load wire and the connecting branch are achieved through the terminal block, resulting in convenient and neat connections, facilitating the planning of electrical circuits.

[0006] According to one aspect of the present invention, a plug-in portion is further included, the plug-in portion having at least one plug-in through hole extending from its first end to its second end. One end of the terminal block is connected to the second end of the incoming connection portion or a connecting branch, and the other end of the terminal block extends from one end of the plug-in through hole into the plug-in through hole. The other end of the plug-in through hole is used to connect an external wire. Since the terminal block extends into the plug-in through hole, the power supply wire can also extend into the plug-in through hole and connect to the terminal block, and then connect to the incoming connection portion. Similarly, the load wire can also extend into the plug-in through hole and connect to the terminal block, and then connect to the connecting branch. The plug-in portion with the plug-in through hole facilitates the connection of the load wire to the vehicle circuit, avoids excessive external solder joints, and achieves cost savings. Furthermore, the number of plug-in through holes can be multiple, each corresponding to a different terminal block, making the connection of each terminal block equally convenient and the wiring position more flexible.

[0007] According to one aspect of the present invention, a positioning plate is further included. At least one terminal block is disposed on the positioning plate, and the terminal block penetrates the positioning plate such that its two ends are located on opposite sides of the positioning plate. An inlet connection portion and an outlet connection portion are both located on a first side of the positioning plate, and one end of the terminal block on the first side of the positioning plate is connected to the inlet connection portion or the outlet connection portion. A plug-in portion is located on a second side of the positioning plate, and one end of the terminal block on the second side of the positioning plate extends into a plug-in through hole. The terminal block penetrates the positioning plate, with one end connected to the inlet connection portion and the outlet connection portion on one side of the positioning plate, and the other end connected to the plug-in portion on the other side of the positioning plate. The terminal block is positioned by the positioning plate, and multiple terminal blocks are arranged in a row through the positioning plate. The relative positions of the terminal blocks are stable, facilitating the connection of the circuit, making the connected circuit more stable, and also facilitating the overall assembly of multiple terminal blocks.

[0008] According to one aspect of the present invention, a positioning plate is further included, with at least one terminal block disposed on the positioning plate. The terminal block is laid flat on the side of the positioning plate from a first end to a second end. An inlet connection portion and an outlet connection portion are located near the first end of the positioning plate, and the end of the terminal block near the first end of the positioning plate is connected to the inlet connection portion or the outlet connection portion. A plug-in portion is located near the second end of the positioning plate, and the end of the terminal block near the second side of the positioning plate extends into a plug-in through hole. The terminal block is laid flat on the side of the positioning plate, and the terminal block can be manufactured in the form of a PCB (Printed Circuit Board), which has high integration, small space occupation, and facilitates circuit connection.

[0009] According to one aspect of the present invention, the device further includes a housing, a positioning plate, an inlet connection portion, and an outlet connection portion, all disposed within the housing. A plug-in portion is detachably connected to the housing from one side. The positioning plate, i.e., the wiring terminals, is disposed within the housing. The inlet connection portion, outlet connection portion, and wiring terminals are all disposed within the housing, facilitating connection to other devices via the housing. For example, when fixed to a vehicle body, the housing provides protection, ensuring structural and connection stability. The detachable connection between the plug-in portion and the housing facilitates the connection and fixation of power supply wires and load wires to the connection terminals.

[0010] According to one aspect of the present invention, a connector is provided on the top of the housing corresponding to the first end of the inlet connection and the first end of the outlet connection. The connector is used to fix a fuse. The fuse extends into the housing through the connector and connects to the inlet and outlet connections, facilitating the connection and replacement of the fuse. The connector can fix the fuse after it is connected, making the fuse position more stable. The connector is located on the top of the housing, making it easy to observe the fuse specifications and connection status, and also facilitating the connection and adjustment of the fuse specifications.

[0011] According to one aspect of the present invention, at least one positioning bracket is provided on the outer wall of the housing. The positioning bracket facilitates the installation of the housing. There may be two positioning brackets, respectively located on both sides of the housing, which makes the installation of the housing more convenient and the position more stable after installation.

[0012] According to one aspect of the present invention, a connector is provided at the first end of both the incoming line connection and the first end of the outgoing line connection, and the connector is used to connect a fuse. The end of the fuse is connected to the connector, thereby realizing the connection between the fuse and the incoming line connection and the outgoing line connection, which is quick and reliable.

[0013] According to one aspect of the present invention, the input connection portion and the output connection portion are arranged in pairs, with at least one pair. Each pair of input and output connection portions is used to connect a fuse. A pair of input and output connection portions can connect multiple loads with one fuse. Multiple pairs of input and output connection portions constitute multiple fuses, which can connect more loads. They can be grouped and connected according to the load type and specifications. Loads of the same type, such as multiple lamps, can be connected to the same pair of input and output connection portions. Loads with similar specifications, such as loads with similar rated currents, can also be connected to the same pair of input and output connection portions, making the load connection more reasonable and the current distribution more reasonable. It also facilitates the matching of fuse specifications and achieves more precise protection. For example, if loads with similar and small rated currents are grouped together and connected to the same pair of input and output connection portions, a fuse with the same small rated current can be matched to protect all loads in that group.

[0014] According to one aspect of the present invention, at least a portion of the surfaces of the inlet connection portion and the outlet connection portion are provided with a plating layer; the thickness of the plating layer in the area of ​​the inlet connection portion and the outlet connection portion for connecting the fuse is greater than or equal to the thickness of the plating layer outside the area.

[0015] According to one aspect of the present invention, the coating material is one or an alloy or combination of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, graphene and carbon-based compounds.

[0016] According to one aspect of the present invention, the thickness of the coating is in the range of 0.09 μm to 1500 μm.

[0017] According to one aspect of the present invention, the fuse is one or more of the following: a thermal fuse, a thermistor fuse, a positive temperature coefficient resistor fuse, a shape memory alloy fuse, a thermally triggered electronic fuse, and a current-triggered electronic fuse.

[0018] According to one aspect of the present invention, the current carrying capacity of the power supply conductor connected to the second end of the incoming connection is greater than or equal to the current carrying capacity of the load conductor connected to the second end of the outgoing connection.

[0019] According to one aspect of the present invention, the interface is connected to a cover, and at least one sealing element is sleeved on the cover, the sealing element being located between the cover and the housing. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the embodiments of the present invention will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a partial structural schematic diagram of the plug-in device according to an embodiment of the present invention from a certain perspective;

[0022] Figure 2 This is a partial structural schematic diagram of the plug-in device according to an embodiment of the present invention from another perspective;

[0023] Figure 3 This is a schematic diagram of the connection branch of the plug-in device according to an embodiment of the present invention;

[0024] Figure 4 This is an electrical schematic diagram of the plug-in device according to an embodiment of the present invention;

[0025] Figure 5 This is an exploded structural diagram of the plug-in device according to an embodiment of the present invention;

[0026] Figure 6 This is a schematic diagram of the assembly structure of the plug-in device according to an embodiment of the present invention;

[0027] Figure 7 This is a schematic diagram showing the assembly positions of the first and second sealing members of the plug-in device according to an embodiment of the present invention.

[0028] Figures 8 to 11 The diagram shows the fusing time characteristics of fuses with different rated currents under different fusing currents for the plug-in device of this invention.

[0029] In the attached image:

[0030] 100-Incoming cable connection, 200-Outgoing cable connection, 300-Fuse, 400-Power supply wire, 500-Load wire, 600-Terminal block, 700-Plug-in part, 800-Positioning plate, 900-Housing;

[0031] 101, 201 - Connectors;

[0032] 202 - Connect the branches;

[0033] 701 - Insertion through hole;

[0034] 901-Plug-in plate, 902-Positioning bracket, 903-First seal, 904-Second seal, 905-Cover. Detailed Implementation

[0035] The embodiments of the present invention will be further described in detail below with reference to the accompanying drawings and examples. The following detailed description of the embodiments and the accompanying drawings are used to illustrate the principles of the present invention by way of example, but should not be used to limit the scope of the present invention, that is, the present invention is not limited to the described embodiments.

[0036] In the description of this invention, it should be noted that, unless otherwise stated, the terms "first" and "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance; "a plurality of" means two or more; the terms "inner," "outer," "top," "bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0037] Please see Figure 1 , Figure 2 , Figure 3 and Figure 4 The plug-in device of this invention includes an inlet connection portion 100 and an outlet connection portion 200. A fuse 300 is connected between the first end of the inlet connection portion 100 and the first end of the outlet connection portion 200. The second end of the inlet connection portion 100 is connected to a power supply wire 400, and the second end of the outlet connection portion 200 is connected to a load wire 500. The second end of the outlet connection portion 200 has at least one connection branch 202. Each connection branch 202 serves as a load interface, and the load can be connected to the connection branch 202 through the load wire 500. In this embodiment, a fuse 300 is connected between the incoming connection part 100 and the outgoing connection part 200. The power supply wire 400 is connected to the incoming connection part 100. The load is connected to the connecting branch 202 of the outgoing connection part 200 through the load wire 500 to realize the power supply to the load. Multiple connecting branches 202 split the current and can supply power to multiple loads. It can reduce the wire diameter of the load wire 500. The fuse 300 protects the load wire 500 connected to the connecting branch 202, realizing the protection of reduced wire diameter and ensuring safety. Moreover, multiple loads share one fuse, saving the number of fuses 300 and increasing the convenience of wiring.

[0038] The wire diameter is usually directly proportional to the rated current; that is, the larger the wire diameter, the larger the rated current and the greater the current it can carry. In actual configuration, the required fuse 300 specification is calculated based on the load specifications. An appropriate fuse 300 is selected, and then a load conductor 500 with a suitable wire diameter is matched to the selected fuse 300. This ensures a proper match between the load, fuse 300, and load conductor 500, avoiding waste caused by using a large-diameter load conductor 500 for a small current, and also preventing the load conductor 500 from overheating and melting without the fuse 300 responding, thus eliminating safety hazards. The wire diameter of the outgoing connection 200 is also determined at the same time, while the wire diameter of the incoming connection 100 is designed based on the magnitude of the incoming current. The outgoing connection 200 can be made of one or more of the following materials: copper, aluminum, magnesium, and beryllium, or other common metals or alloys. It can be made into a sheet or column shape, and can extend in a straight line or at a right angle. At the second end, it branches into multiple parallel connecting branches 202. The incoming connection 100 can also be made of one or more of the following materials: copper, aluminum, magnesium, and beryllium, or other common metals or alloys. The shape of the incoming connection 100 is generally similar to that of the outgoing connection 200, except for the branching point at the second end. The design principle is to facilitate the connection of wires, including the power supply wire 400 and the load wire 500, and to facilitate the connection of the fuse 300.

[0039] When two or more connection branches 202 are connected to load conductors 500, the fuse 300 is matched with the load with the smallest rated current among the loads connected to the load conductors 500. The required specification of the fuse 300 is calculated based on the rated current of the loads to be connected to the load conductors 500. When there are multiple connection branches 202, that is, multiple loads to be connected, the fuse is matched according to the load with the smallest rated current. In other words, the calculated minimum specification of the fuse 300 is used as the actual selected specification of the fuse 300. Then, the load conductors 500 with appropriate wire diameter are matched according to the specification of the fuse 300. This can protect the load conductor 500 with the smallest wire diameter, thus protecting all load conductors 500. The calculation and matching methods are existing and will not be elaborated further.

[0040] When there is only one connecting branch 202, under the protection of the fuse 300, the wire diameter of the load conductor 500 can be made smaller than that of the power supply conductor 400, thus achieving the purpose of reducing the wire diameter.

[0041] As an optional embodiment, the plug-in device further includes at least one terminal block 600. The second end of the inlet connection portion 100 and at least one connecting branch 202 are both connected to terminal blocks 600. The terminal blocks 600 are used to connect external wires, specifically to the power supply wire 400 or the load wire 500. The terminal block 600 connected to the connecting branch 202, i.e., the terminal block 600 downstream of the fuse 300, has a wire diameter determined according to the specifications of the fuse 300, specifically referring to the aforementioned method for determining the wire diameter of the load wire 500. The terminal block 600 connected to the inlet connection portion 100, i.e., the terminal block 600 upstream of the fuse 300, has a wire diameter determined according to the incoming current. The terminal blocks 600 can be designed as universal types depending on upstream and downstream conditions, facilitating actual wiring and improving flexibility. The number of terminal blocks 600 can be the same as or more than the number of the inlet connection portion 100 plus all connecting branches 202, allowing them to be used as spares for other wiring. Terminal block 600 can be made of one or more of the following materials: copper, aluminum, and magnesium, or other common metals or alloys.

[0042] As an optional embodiment, the plug-in device further includes a plug-in portion 700, which has at least one plug-in through hole 701 extending from its first end to its second end. One end of the terminal 600 is connected to the second end of the incoming connection portion 100 or the connecting branch 202, and the other end of the terminal 600 extends from one end of the plug-in through hole 701 into the plug-in through hole 701. The other end of the plug-in through hole 701 is used to connect an external wire, specifically a fixed power supply wire 400 or a load wire 500, so that the power supply wire 400 is connected to the second end of the incoming connection portion 100 and the load wire 500 is connected to the connecting branch 202. The connection between the terminal block 600 and the second end of the inlet connection 100, and the connection between the terminal block 600 and the connecting branch 202, can both be soldered. The connection between the terminal crimp and the power supply wire 400 and the load wire 500 can also be a crimp connection. Taking the connection with the load wire 500 as an example, the load wire 500 extends into the insertion hole 701, and the terminal block 600 presses the load wire 500 in the insertion hole 701 to achieve the connection. Compared with soldering, this reduces external solder joints and increases the convenience of wiring. All the terminal blocks 600 can be arranged parallel to each other. Correspondingly, all the insertion holes 701 are also arranged parallel to each other and have the same distribution as the terminal blocks 600. The terminal blocks 600 and insertion holes 701 correspond one-to-one, and are inserted into the insertion holes 701.

[0043] Regarding the specific settings of terminal block 600, the following two examples illustrate the following:

[0044] Firstly, multiple terminals 600 are arranged in a row through a positioning plate 800. The terminals 600 penetrate the positioning plate 800, so that the two ends of the terminals 600 are located on both sides of the positioning plate 800. The inlet connection part 100 and the outlet connection part 200 are both located on the first side of the positioning plate 800. One end of the terminal 600 located on the first side of the positioning plate 800 is connected to the inlet connection part 100 or the outlet connection part 200. The plug-in part 700 is located on the second side of the positioning plate 800. One end of the terminal 600 located on the second side of the positioning plate 800 extends into the plug-in through hole 701. It can be understood that the terminals 600 are arranged perpendicularly to the positioning plate 800. The terminals 600 can be cylindrical. The positioning plate 800 serves as a positioning structure between the multiple terminals 600, so that the multiple terminals can be arranged in a row as needed. It also serves as a connection structure between the multiple terminals 600 as a whole and other components, such as the multiple terminals 600 being arranged in the housing 900 through the positioning plate 800.

[0045] Secondly, multiple terminals 600 are arranged in a row via a positioning plate 800. The terminals 600 are laid flat on the side of the positioning plate 800 from the first end to the second end. The inlet connection 100 and the outlet connection 200 are close to the first end of the positioning plate 800. One end of the terminal 600 near the first end of the positioning plate 800 is connected to the inlet connection 100 or the outlet connection 200. The plug-in part 700 is close to the second end of the positioning plate 800. One end of the terminal 600 near the second side of the positioning plate 800 extends into the plug-in through hole 701. The terminal blocks 600 are arranged parallel to each other on the sides of the positioning plate 800. They can be located on one or both sides of the positioning plate 800. In this case, the terminal blocks 600 and the positioning plate 800 can be fabricated as a PCB. The terminal blocks 600 are thin sheets. The positioning plate 800 serves to position the terminal blocks 600 and connect them to other components. Other components can be added to the positioning plate 800 to give it the functions typically found on a PCB, preferably for wiring, but this can be designed according to specific needs. Terminal blocks 600 in the same row can be evenly spaced, and the spacing between terminal blocks 600 in different rows can be the same, allowing for alignment and easy wiring. In specific implementations, different terminal blocks 600 can be marked with different colors to distinguish them as power connection terminals or load connection terminals during wiring.

[0046] Combination Figure 5As an optional embodiment, the positioning plate 800, the inlet connection part 100, and the outlet connection part 200 are all disposed within the housing 900. The plug-in part 700 is detachably connected to the housing 900 from one side, and the first end of the plug-in part 700 is located within the housing 900. The positioning plate 800 is disposed within the housing 900 so that all wiring terminals 600 are located within the housing 900. The positioning plate 800 can be configured to snap-fit ​​within the housing 900. The first end of the plug-in part 700 is inserted into the housing 900 from one side to achieve a detachable connection, specifically through a snap-fit ​​structure.

[0047] Furthermore, a connector is provided on the top of the housing 900 at the position corresponding to the first end of the inlet connection 100 and the first end of the outlet connection 200. The connector is used to fix the fuse 300. At the same time, a connector 101 (201) is provided at the first end of both the inlet connection 100 and the first end of the outlet connection 200. The connector 101 (201) is used to connect the fuse 300. The connector 101 (201) and the connecting branch 202 can be made of one or more of the following materials: copper, aluminum, magnesium, and beryllium, or other common metals or alloys.

[0048] The connector is located at the top of the housing 900. The fuse 300 is connected to the inlet connection 100 and outlet connection 200 located inside the housing 900 via the connector. Taking a commonly used MINI fuse (rated currents of 10A, 15A, 20A, 25A, 30A, etc.), i.e., the fuse 300 shown in the figure, as an example, the pins of the fuse 300 extend into the housing 900 through the connector and connect to the inlet connection 100 and outlet connection 200. Correspondingly, each end of the inlet connection 100 and outlet connection 200 connected to the fuse 300 is provided with a connector 101 (201). The connector 101 (201) can be ring-shaped and cooperates with the pins of the fuse 300 to realize the connection of the fuse 300 and facilitate the assembly of the fuse 300. The shape of the connector matches the shape of the fuse 300, and it can fix the fuse 300 after it is connected to the inlet connection 100 and the outlet connection 200. The connector can be formed by removing material from the top of the housing 900, or it can be integrally formed with the housing 900, or it can be formed on the connector plate 901 and then the connector plate 901 is connected to the top of the housing 900. Of course, the top of the housing 900 has an opening for installing the connector plate 901, and the connector plate 901 can be detachably connected to the opening.

[0049] Combination Figure 6As an optional embodiment, the outer wall of the housing 900 is provided with a positioning bracket 902, and there is at least one positioning bracket 902. Taking two positioning brackets 902 as an example, the two positioning brackets 902 are respectively located on both sides of the housing 900. The housing 900 is connected to other components through the positioning brackets 902, such as the assembly on the vehicle body. Its specific structure is determined according to the connection position and the specific components, and can be a slot-like structure or other structural forms. Considering the stability of the connection of the housing 900, positioning brackets 902 can be provided on both sides of the housing 900. Furthermore, the positioning brackets 902 on both sides of the housing 900 are symmetrically arranged. In combination with the above, the plug-in part 700 is connected to one end of the housing 900, which can be the front end of the housing 900. The fuse 300 is connected from the top of the housing 900. The positioning brackets 902 are located on the left and right sides of the housing 900, and the overall assembly of the device is convenient. The fuse 300 is assembled on the outside of the housing 900, which is beneficial to the heat dissipation of the fuse 300.

[0050] As an optional embodiment, the incoming connection portion 100 and the outgoing connection portion 200 are arranged in pairs, with at least one pair. Each pair of incoming connection portions 100 and outgoing connection portions 200 is used to connect a fuse 300. Each pair of incoming connection portions 100 and outgoing connection portions 200 can be referred to as a wiring module, and multiple wiring modules are located within the housing 900. Loads of the same type can be connected to one wiring module, such as multiple lamps or multiple horns. Loads of similar specifications can also be connected to one wiring module, such as lamps and horns with a rated current of 10A each, making the fuse 300 matched to each wiring module more suitable, providing protection without waste. The number of wiring modules and the number of shunt paths in each wiring module can be determined according to the specific load type, specifications, and number, combined with the requirements of the vehicle's electrical principles, to set a flexible load-bearing configuration, such as... Figure 4As shown, it can support four circuits, i.e., four circuits of fuses, which can greatly expand the capacity of the central distribution box. The spacing between adjacent wiring modules can be the same, so that the connectors 101 (201) of adjacent wiring modules are equally spaced, and the matching fuses 300 are also equally spaced. The plug interfaces on the plug board 901 are equally spaced, resulting in a neat structure and convenient use. The plug-in part 700, positioning plate 800, housing 900 and plug-in plate 901 are all made of insulating materials, such as amide, polycarbonate, polyvinyl chloride, polyurethane, polysulfone, polytetrafluoroethylene, polyethylene, polypropylene, polyphenylene ether, polyester, plastics (PPS, DAP, PBT, ABS), phenolic resin, urea formaldehyde, nylon, rubber (TPE, PFE, TPR, EVA), foam (XPE), cross-linked polyethylene (XLPE), ethylene-tetrafluoroethylene copolymer (ETFE), perfluoroalkoxyalkane, styrene-acrylonitrile copolymer, polymethyl methacrylate, polyphenylene sulfide, polystyrene, polyoxymethylene resin, etc., one or more of these.

[0051] As a further solution, at least a portion of the surfaces of the inlet and outlet connections are coated. Since the surfaces of the inlet and outlet connections are exposed to air and water, and in some places even to salt, they are susceptible to oxidation and salt spray corrosion, which can shorten the lifespan of the device. Therefore, coating both the inlet and outlet connections effectively prevents corrosion from air, water, and salt spray, extending the device's lifespan and reducing the occurrence of safety accidents.

[0052] The coating material is one or an alloy or combination of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, graphene, and carbon-based compounds. To demonstrate the impact of different coating materials on the service life of the connector, the service life of the connector under salt spray conditions was investigated. The results are shown in the table below:

[0053]

[0054]

[0055] As shown in the table above, under salt spray conditions, the service life of uncoated plug-in devices cannot meet the basic requirement of more than 3000 hours, while plug-in devices with other coatings can meet the requirement of a service life of more than 3000 hours.

[0056] Furthermore, the thickness of the plating on the areas of the incoming and outgoing connection parts used for connecting the fuse is greater than or equal to the thickness of the plating outside the areas, so as to provide focused protection for the areas where the fuse is connected.

[0057] The electrical conductivity of the plating on the areas of the inlet and outlet connectors used for connecting the fuse is superior to that of the plating outside these areas. For example, silver can be used in the fuse-connecting area, while tin can be used in other areas. Alternatively, gold can be used in the fuse-connecting area, while zinc can be used in other areas. This approach further reduces the contact resistance between the connectors and the fuse, increasing the lifespan of the connector. It also saves costs and expands the versatility of the connector.

[0058]

[0059] The conductivity of the plating on the areas of the inlet and outlet connections used for connecting the fuse is better than that of the plating outside these areas.

[0060] As a further step, the surface plating thickness of the inlet and outlet connectors is 0.09-1500 μm. To demonstrate the impact of plating thickness on the service life of the connector, a nickel plating was used, and the service life of the connector under salt spray conditions was investigated. The results are shown in the table below:

[0061]

[0062] As shown in the table above, when the coating thickness is less than 0.09 μm, the service life of the connector cannot meet the basic requirement of greater than 3000 hours. Similarly, when the coating thickness is greater than 1500 μm, the service life of the connector also cannot meet the basic requirement of greater than 3000 hours, and obtaining a coating thickness greater than 1500 μm significantly increases material usage and processing time. Therefore, the surface coating thickness for both the inlet and outlet connectors is selected to be 0.09-1500 μm. Within this coating thickness range, the contact voltage drop and the overall vehicle electrical failure rate meet the usage requirements.

[0063] As a further option, the fuse can be one or more of the following: a thermal fuse, a thermistor fuse, a positive temperature coefficient (PTC) resistor fuse, a shape memory alloy fuse, a thermally triggered electronic fuse (in the form of a sensor, controller, or power transistor), and a current-triggered electronic fuse (in the form of a sensor, controller, or power transistor). For the fusing time of fuses with different rated currents at different fusing currents, please refer to the following attached diagram:

[0064] Figure 8 This is a curve showing the fusing current (A) versus fusing time (S) when the fuse is a thermistor fuse. The curves in the figure represent the fusing time of the thermistor fuses with different rated currents under different fusing currents.

[0065] Figure 9 This is a curve showing the fusing current (A) versus fusing time (S) of a PTC fuse. The curves in the figure represent the fusing time of PTC fuses with different rated currents under different fusing currents.

[0066] Figure 10 This is a curve showing the fusing current (A) versus fusing time (S) when the fuse is a thermoelectric fuse. The curves in the figure represent the fusing time of thermoelectric fuses with different rated currents under different fusing currents.

[0067] Figure 11 This is a curve showing the fusing current (A) versus fusing time (S) of a shape memory alloy fuse. The curves in the figure represent the fusing time of shape memory alloy fuses with different rated currents under different fusing currents.

[0068] Furthermore, the current ratings of the fuses range from 0.5 to 3000A, and the cross-sectional area can be selected from 0.1 to 30mm². 2 .

[0069] The current-carrying capacity of the power supply conductor connected to the second end of the inlet connection is greater than or equal to the current-carrying capacity of the load conductor connected to the second end of the outlet connection, which facilitates the purpose of current diversion by reducing the conductor diameter. For example, the power supply conductor diameter can be selected from 0.35-50mm. 2 The diameter of the load conductor can be selected from 0.13-35mm. 2 .

[0070] Combination Figure 7 As a further embodiment, the connector is connected to a cover 905, and at least one first sealing element 903 is fitted onto the cover 905, located between the cover 905 and the housing 900. A second sealing element 904 is fitted onto the first end of the connector 700, located between the connector 700 and the housing 900. The first sealing element 903 and the second sealing element 904 improve the overall sealing performance of the device, enabling the connector to adapt to humid environments. The cover 905 can be detachably connected to the connector. Alternatively, the cover 905 can be integrally connected to the connector, for example, by fixing it to the connector via injection molding, making the cover 905 and the housing 900 a single unit.

[0071] Those skilled in the art will understand that the above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application. Therefore, if these modifications and variations of this application fall within the scope of the claims of this application and their equivalents, this application also intends to include these modifications and variations.

Claims

1. A plug-in device, characterized in that, The device includes an inlet connection and an outlet connection. A fuse is connected between a first end of the inlet connection and a first end of the outlet connection. A second end of the inlet connection is connected to a power supply conductor, and a second end of the outlet connection is connected to a load conductor. The second end of the outlet connection has at least one connecting branch, each of which serves as a load interface. The current carrying capacity of the power supply conductor connected to the second end of the inlet connection is greater than or equal to the current carrying capacity of the load conductor connected to the second end of the outlet connection. It also includes at least one terminal block, wherein the second end of the incoming connection portion and / or at least one of the connecting branches are connected to the terminal block, and the terminal block is used to connect an external wire; It also includes a positioning plate, on which at least one of the wiring terminals is disposed; It also includes a plug-in part having at least one plug-in through hole extending from its first end to its second end. One end of the terminal block is connected to the second end of the wire inlet connection part or the connection branch. The other end of the terminal block extends from one end of the plug-in through hole into the plug-in through hole. The other end of the plug-in through hole is used to connect an external wire. It also includes a housing, in which the positioning plate, the inlet connection and the outlet connection are all disposed, and the plug-in part is detachably connected to the housing from one side of the housing.

2. The plug-in device according to claim 1, characterized in that, The terminal block penetrates the positioning plate, such that both ends of the terminal block are located on both sides of the positioning plate. Both the inlet connection and the outlet connection are located on the first side of the positioning plate, and the terminal block is connected to the inlet connection or the outlet connection at one end of the first side of the positioning plate. The plug-in portion is located on the second side of the positioning plate, and one end of the wiring terminal located on the second side of the positioning plate extends into the plug-in through hole.

3. The plug-in device according to claim 1, characterized in that, The wiring terminals are laid flat on the side of the positioning plate from the first end to the second end; The inlet connection and the outlet connection are located at the first ends of the positioning plate, and the terminal block is connected to the inlet connection or the outlet connection at one end of the positioning plate. The second end of the plug-in portion is close to the positioning plate, and the end of the wiring terminal close to the second side of the positioning plate extends into the plug-in through hole.

4. The plug-in device according to claim 1, characterized in that, The top of the housing is provided with a connector corresponding to the first end of the inlet connection and the first end of the outlet connection. The connector is used to fix the fuse.

5. The plug-in device according to claim 1, characterized in that, The outer wall of the housing is provided with at least one positioning bracket.

6. The plug-in device according to claim 1, characterized in that, Both the first end of the inlet connection and the first end of the outlet connection are provided with connectors, which are used to connect fuses.

7. The plug-in device according to claim 1, characterized in that, The incoming line connection and the outgoing line connection are arranged in pairs, and there is at least one pair of incoming line connection and outgoing line connection. Each pair of incoming line connection and outgoing line connection is used to connect a fuse.

8. The plug-in device according to claim 1, characterized in that, At least a portion of the surfaces of the inlet connection and the outlet connection are provided with a plating layer; The thickness of the plating on the areas of the inlet and outlet connections used for connecting the fuse is greater than or equal to the thickness of the plating outside those areas.

9. The plug-in device according to claim 8, characterized in that, The coating material is one or an alloy or combination of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, graphene and carbon-based compounds.

10. The plug-in device according to claim 8 or 9, characterized in that, The thickness of the coating ranges from 0.09 μm to 1500 μm.

11. The plug-in device according to claim 1, characterized in that, The fuse is one or more of the following: a thermal fuse, a thermistor fuse, a positive temperature coefficient resistor fuse, a shape memory alloy fuse, a thermally triggered electronic fuse, and a current-triggered electronic fuse.

12. The plug-in device according to claim 4, characterized in that, The connector is connected to a cover, and at least one sealing element is fitted onto the cover, with the sealing element located between the cover and the housing.

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