A liquid-cooled terminal structure for high-power charging

Abstract

The present invention proposes a liquid-cooled terminal assembly for high-power charging, including a liquid-cooled cable and a quick connector. The center of the liquid-cooled cable is provided with a cable internal pipe, and the cable internal pipe is covered with a cable conductor; one end of the quick connector is connected to the internal pipe, and the other end is provided with a tubular copper core; the other end of the tubular copper core corresponding to the end connected to the quick connector is provided with a adapter; the cable conductor, the tubular copper core and the adapter are crimped to form a crimping area. The present invention has a fast charging speed, good waterproof effect, easy installation and low production cost.

Description

Technical Field

[0001] The present invention belongs to the technical field related to electric vehicles, and particularly relates to the field of liquid-cooled terminal structures for high-power charging of electric vehicles.

Background Art

[0002] It has been a common consensus around the world that new energy vehicles replace fuel vehicles. With the continuous progress of science and technology, new energy vehicles are also developing rapidly towards lightweight, integrated, and intelligent directions. The requirements for charging power and charging speed are getting higher and higher. Simply increasing the cross-sectional area of the conductor to increase the current-carrying capacity cannot meet the actual usage requirements. Currently, the prior art has also proposed high-power liquid-cooled charging guns. Generally, in a liquid-cooled cable, the cooling pipe is led out from the conductor, and the conductor is crimped with the terminal. The cooling only acts on the cable part, and the temperature in the terminal crimping area and the area in contact with the socket is still high. Similarly, some technologies use potting for heat dissipation in the crimping area, which takes up a large amount of space, has an unclear heat dissipation effect, is actually complex to process, and is difficult to achieve mass production; the crimping area and the contact area become weak points in the overall circulation loop.

[0003] Therefore, it is necessary to propose a new technical method to change the current situation. The design scheme of the liquid-cooled terminal assembly for high-power charging can well solve the above problems.

Summary of the Invention

[0004] To solve the above problems, the present invention proposes a liquid-cooled terminal assembly for high-power charging, and its technical solution is as follows:

[0005] It includes a liquid-cooled cable and a quick connector. A cable internal pipeline is provided in the center of the liquid-cooled cable. One end of the quick connector is connected to the internal pipeline, and the other end is connected to a tubular copper core; a transition piece is provided at the other end corresponding to the end of the tubular copper core connected to the quick connector; one end of the transition piece is threadedly connected to a power terminal; the power terminal has a hollow structure inside, and a through cooling pipeline is formed inside the assembly where the cable is connected to the terminal; the cable internal pipeline is coated with a cable conductor; the cable conductor is coated on the outer wall of the tubular copper core and is further assembled into the rear-end hole of the transition piece for crimping to form a crimping area.

[0006] Optionally, a power terminal is provided at the other end corresponding to the end of the transition piece connected to the tubular copper core. A right-angle adapter is provided on the upper side of the transition piece, and one end of the right-angle adapter is connected to an external cooling pipeline.

[0007] Optionally, the crimping area has a hollow structure and a cooling channel is provided inside. The crimping area has an inner circular and outer hexagonal shape.

[0008] Optionally, the cable internal pipeline is made of a material with high strength and high thermal conductivity.

[0009] Optionally, the cable conductor is in a grouped spiral structure, and an outer cable insulating sheath is provided outside the cable conductor.

[0010] Optionally, the outer diameter of the crimping area of the tubular copper core is equal to the outer diameter of the built-in pipe of the cable.

[0011] Optionally, the tubular copper core and the adapter are connected by crimping, and a double-layer seal is provided between the outer wall of the tubular copper core at the front end of the crimping area and the inner wall of the adapter; the adapter and the power terminal are connected by threads, a groove is provided on the side of the adapter, a boss is provided on the power terminal at the connection point, and a seal is provided in the groove.

[0012] Optionally, an insulating heat shrinkable sheath is provided outside the crimping area and the cable conductor.

[0013] Optionally, the adapter and the power terminal are connected by pipe threads, and the quick connector and the tubular copper core are connected by pipe threads.

[0014] Optionally, the crimping area is a hollow inner circle and outer hexagonal structure, and a supporting tooling consisting of a slotted sleeve and a ejector pin is provided on one side. After crimping in the crimping area, the supporting tooling is withdrawn in two stages, with the ejector pin withdrawing first, and then the slotted sleeve radially shrinks and withdraws. After the supporting tooling is withdrawn, the tail of the power terminal is connected to the adapter by a pipe thread connection, and the head of the power terminal is connected to the insulating cap by an interference fit with a snap-on structure. The insulating cap can prevent fingers from accidentally touching the conductor and play a role in insulation and anti-electric shock protection.

[0015]

Beneficial Effects

[0016] The present invention has fast charging speed, good waterproof effect, easy installation and low production cost; the cable adopts a 25 square small-sized copper conductor, and a cooling pipe is built in the center of the cable. The coolant can adopt a conductive coolant. The flow rate of the coolant is not affected by the temperature and can quickly take away the heat, replacing the 120 square copper wire specification, and truly realizing the requirement of small-sized cable for large current transmission. The two groups of inlet and outlet cooling pipes are in a parallel state, which saves assembly space and avoids the safety hazards caused by the bending and aging of large cables; the detachable structure design reduces the difficulty of assembly, improves production efficiency, saves labor costs, and improves maintenance efficiency.

Brief Description of the Drawings

[0017] Figure 1 It is a schematic diagram of the structure of the present invention;

[0018] Figure 2 is a cross-sectional view of the present invention;

[0019] Figure 3 The invention discloses a split groove type sleeve and ejector pin supporting tooling for crimping;

[0020] Figure 4 This is a schematic diagram of the use of the tooling during crimping of the present invention;

[0021] In the figure: 1 - liquid-cooled cable, 101 - outer insulation layer of the cable, 102 - built-in pipe of the cable, 103 - cable conductor, 2 - quick connector, 3 - tubular copper core, 4 - first sealing ring, 5 - adapter, 6 - power terminal, 7 - insulating cap, 8 - right-angle adapter, 9 - outer cooling pipe, 10 - second sealing ring, 11 - insulating heat-shrinkable sheath, 12 - crimping area, 13 - split grooved thimble, 14 - ejector pin.

Specific Embodiments

[0022] Here, exemplary embodiments will be described in detail, and examples thereof are shown in the drawings. When the following description refers to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the present application. On the contrary, they are merely examples of devices consistent with some aspects of the present application as detailed in the appended claims.

[0023] The terms used in the present application are for the purpose of describing specific embodiments only and are not intended to limit the present application. Unless otherwise defined, the technical terms or scientific terms used in the present application should have the ordinary meanings understood by those of ordinary skill in the field to which the present invention pertains. The terms "a" or "an" and the like used in the specification and claims of the present application do not denote a limitation of quantity either, but rather mean that there is at least one. "Plural" includes two, which is equivalent to at least two. The terms "comprising" or "including" and the like mean that the elements or items appearing before "comprising" or "including" cover the elements or items listed after "comprising" or "including" and their equivalents, and do not exclude other elements or items. The terms "connected" or "coupled" and the like are not limited to physical or mechanical connections, and may include electrical connections, whether direct or indirect. The singular forms "a", "the" and "said" used in the specification and appended claims of the present application are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein refers to and includes any or all possible combinations of one or more of the associated listed items.

[0024] The following combines the attached Figures 1-4 and specific embodiments to further illustrate the technology to help understand the content of the present application.

[0025] Such as Figure 1As shown in the figure, the present invention provides a liquid-cooled terminal assembly for high-power charging, which includes a liquid-cooled cable (1), a quick connector (2), a tubular copper core (3), an adapter (5), a first sealing ring (4) and a second sealing ring (10), a power terminal (6), an insulating cap (7), a right-angle adapter (8), and an external cooling pipe (9); As Figure 3 As shown, a cable internal pipe (102) is provided in the center of the liquid-cooled cable (1). A cable conductor (103) is provided outside the cable internal pipe (102). The cable conductor (103) is uniformly coated on the surface of the cable internal pipe (102) in a grouped spiral structure; A cable outer insulation layer (101) is provided outside the cable conductor (103); This arrangement structure can ensure that after the cable outer insulation sheath (101) is peeled off, the cable conductor (103) can maintain its original shape and is not easy to scatter.

[0026] As Figure 2 As shown, the cable internal pipe (102) is connected to the quick connector (2), and the quick connector (2) is connected to the tubular copper core (3). A certain length of the cable conductor (103) is reserved to wrap the quick connector (2), and further wrapped on the outer diameter of the tubular copper core (3); The outer diameter of the tubular copper core (3) is the same as the outer diameter of the cable internal pipe (102). Therefore, the cable conductor (103) is still uniformly coated on the outer diameter of the tubular copper core (3); Further, the cable conductor (103) and the tubular copper core (3) are inserted into the adapter (5) together for crimping. The specific crimping is as Figure 3 、 Figure 4 shown, Figure 3 is a support tooling composed of a grooved guide sleeve (13) and a thimble (14). The head of the grooved guide sleeve (13) is provided with a grooved structure and can undergo radial deformation. The thimble (14) is assembled inside the grooved guide sleeve (13) and plays a role of rigid support. After the thimble (14) is inserted, the grooved guide sleeve (13) is supported at this time and cannot undergo radial deformation. Before crimping, the support tooling composed of the grooved guide sleeve (13) and the thimble (14) is installed from the front end of the tubular copper core (3). After crimping, the thimble (14) of the support tooling first withdraws. After the thimble (14) withdraws, the grooved guide sleeve (13) radially contracts and withdraws smoothly; A structure with a hollow inner circle and an outer hexagon is crimped at the position of the corresponding crimping area (12) of the adapter (5). The advantage of this crimping method is that the cable conductors are uniformly arranged between the copper core and the adapter, the crimping is reliable, the crimping resistance is low, and the pipe in the center of the crimping area will not deform, ensuring the smooth flow of the coolant, and solving the problem of excessive temperature rise in the terminal crimping area in the prior art.

[0027] As Figure 2As shown, the front end of the adapter (5) is threadedly connected to the power terminal (6). The upper side of the adapter (5) is connected to the right-angle adapter (8). An insulating cap (7) is provided at the front end of the power terminal (6) to provide protection against electric shock. Further, the right-angle adapter (8) is connected to the external cooling channel (9). By using a right-angle adapter connection, the inlet and outlet cooling pipes are in a parallel state, which is convenient for installation and operation and saves space. Further, the power terminal (6) has a hollow structure, and there is a gap between the outer wall of the tubular copper core (3) and the inner wall of the power terminal (6), and the cooling medium can flow in the gap. Further, a first sealing ring (4) is provided between the front end of the adapter (5) and the power terminal (6), and a second sealing ring (10) is provided between the tubular copper core (3) and the adapter (5) to ensure that the cooling medium does not leak. During operation, the cooling medium enters from the internal pipe (102) of the liquid-cooled cable, flows through the gap inside the component, and flows out from the external cooling pipe, forming a complete circulation loop. All the live components have cooling channels inside, which can comprehensively cool the entire cable and the component, and there are no over-temperature weak points.

[0028] The above embodiments are illustrative of the present invention and not restrictive thereof. Any solution obtained by simply transforming the present invention falls within the protection scope of the present invention.

Claims

1. A liquid-cooled terminal structure for high-power charging, characterized in that: It includes a liquid-cooled cable (1) and a quick connector (2). A cable built-in pipe (102) is provided in the center of the liquid-cooled cable (1). One end of the quick connector (2) is connected to the built-in pipe (102), and the other end is connected to a tubular copper core (3). A transfer piece (5) is provided at the other end corresponding to the end of the tubular copper core (3) connected to the quick connector (2). One end of the transfer piece (5) is threadedly connected to a power terminal (6). The inside of the power terminal (6) is a hollow structure, and a through cooling pipe is formed inside the assembly where the cable is connected to the terminal. The cable built-in pipe (102) is externally coated with a cable conductor (103). The cable conductor (103) is coated on the outer wall of the tubular copper core (3) and is further assembled into the rear hole of the transfer piece (5) for crimping to form a crimping area (12). The crimping area (12) has a hollow inner circle and outer hexagon structure, and a support tooling composed of a split groove sleeve (13) and a thimble (14) is provided on one side. After crimping in the crimping area (12), the support tooling withdraws in two stages. First, the thimble (14) withdraws, and after the thimble withdraws, the split groove sleeve (13) radially contracts and withdraws. After the support tooling withdraws, the tail of the power terminal (6) is connected to the transfer piece (5) by a pipe thread connection method, and the head of the power terminal (6) is connected to an insulating cap (7) by an interference fit of a snap structure.

2. The liquid cooling terminal structure for high-power charging according to claim 1, wherein: A power terminal (6) is provided at the other end corresponding to the end of the transfer piece (5) connected to the tubular copper core (3). A right-angle adapter (8) is provided on the upper side of the transfer piece (5), and an external cooling pipe (9) is connected to one end of the right-angle adapter (8).

3. The liquid-cooled terminal structure for high-power charging according to claim 1, wherein: The crimping area (12) is a hollow structure with a cooling channel provided inside, and the crimping area (12) has an inner circle and outer hexagon shape.

4. A liquid-cooled terminal structure for high-power charging according to claim 1, characterized in that: The cable built-in pipe (102) is made of a material with high strength and high thermal conductivity.

5. The liquid cooling terminal structure for high-power charging according to claim 1, wherein: The cable conductor (103) has a grouped spiral structure, and a cable outer insulation sheath (101) is provided outside the cable conductor (103).

6. The liquid-cooled terminal structure for high-power charging according to claim 1, characterized in that: The outer diameter of the crimping area of the tubular copper core (3) is equal to the outer diameter of the cable built-in pipe (102).

7. A liquid-cooled terminal structure for high-power charging according to claim 2, characterized in that: The tubular copper core (3) and the transfer piece (5) are connected by a crimping method. A double-layer seal (4) is provided between the outer wall of the tubular copper core (3) at the front end of the crimping area (12) and the inner wall of the transfer piece (5). The transfer piece (5) and the power terminal (6) are threadedly connected. A groove is provided on the side of the transfer piece (5), a boss is provided at the connection part of the power terminal (6), and a seal (10) is provided in the groove.

8. The liquid cooling terminal structure for high-power charging according to claim 1, wherein: An insulating heat-shrinkable sheath (11) is provided outside the crimping area (12) and the cable conductor (103).

9. The liquid cooling terminal structure for high-power charging according to claim 1, wherein: The transfer piece (5) and the power terminal (6) are connected by a pipe thread connection method, and the quick connector (2) and the tubular copper core (3) are connected by a pipe thread connection method.

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