A connection mechanism, an electrical power transmission device, and a motor vehicle

Abstract

The application provides a connecting mechanism, which comprises a male connecting mechanism and a female connecting mechanism, the male connecting mechanism comprises a flat band, a flat terminal and a male shell connected with the flat band and the flat terminal, the female connecting mechanism comprises a mating terminal and a female shell connected with the mating terminal, the male connecting mechanism and the female connecting mechanism are electrically connected through the flat terminal and the mating terminal, and the male shell and the female shell are assembled to form the connecting mechanism. The flat bands are arranged in layers and have appropriate intervals, so that the electromagnetic interference caused by the flat bands after being electrified on other components can be effectively reduced, the shielding layer structure of the high-voltage charging wire harness is cancelled, and the cost is reduced and the weight is reduced.

Description

Technical Field

[0001] This invention relates to the field of charging technology, and in particular to a connection mechanism, an electrical energy transmission device, and a motor vehicle. Background Technology

[0002] New energy vehicles use charging systems to replenish their batteries. Besides the charging socket, the charging system also includes a high-voltage connection mechanism that connects to the battery system. The charging harness is the most important unit in the electric vehicle's high-voltage system. Traditional charging harnesses use copper wires as charging cables, with the ends of the copper wires connected to plug terminals for electrical connection to the battery system. Current high-voltage connection mechanisms are all assembly-structure connectors, which suffer from complex structures, difficult assembly, and high connector costs. Furthermore, the high copper usage in the cables and terminals, along with the complex connection processing, also contributes to the high cost of high-voltage connection mechanisms.

[0003] When a large current passes through a high-voltage charging harness, it can cause electromagnetic interference to other components. To avoid this electromagnetic interference, a shielding layer needs to be added to the outside of the high-voltage charging harness. This shielding of the high-voltage charging harness significantly increases its cost and weight.

[0004] In addition, most charging systems have a temperature sensing structure installed on the charging base, but not on the connection mechanism. However, the conduction current is the same. When the temperature of the connection mechanism rises, it is also necessary to monitor it and stop the charging operation in time to protect the safety of the charging harness and battery system.

[0005] With the expansion of the electric vehicle market, there is an urgent need for a simple, cost-effective connection mechanism and power transmission device for charging systems. Summary of the Invention

[0006] The purpose of this invention is to provide a connection mechanism in which flat strips are stacked and spaced appropriately, which can effectively reduce electromagnetic interference to other components after the flat strips are energized, thereby eliminating the need for a high-voltage charging harness shielding layer structure and achieving the goal of reducing costs and weight.

[0007] The above-mentioned objectives of the present invention can be achieved by the following technical solutions:

[0008] The present invention provides a connection mechanism, including a male connection mechanism and a female connection mechanism. The male connection mechanism includes a flat strip, a flat terminal, and a male housing connected to the flat strip and the flat terminal. The female connection mechanism includes a mating terminal and a female housing connected to the mating terminal. The male connection mechanism and the female connection mechanism are electrically connected to the mating terminal through the flat terminal. The male housing is connected to the female housing to form the connection mechanism.

[0009] In a preferred embodiment, the aspect ratio of the cross-section of the flat strip is 1:1 to 120:1.

[0010] In a preferred embodiment, there are at least two flat strips stacked one on top of the other, and the male end housing is integrally injection molded to form an insulating structure on at least a portion of the flat strips and the outer periphery of the flat terminal.

[0011] In a preferred embodiment, the flat strip includes a flat wire core and an outer insulation layer, wherein the outer insulation layer is partially stripped to expose the flat wire core, and the end of the outer insulation layer is inside the male end housing or abuts against the male end housing.

[0012] In a preferred embodiment, the flat strip comprises a flat wire core with a hardness of 8HV-105HV.

[0013] In a preferred embodiment, there are at least two flat strips, which are stacked one on top of the other. Each flat strip contains a flat wire core, and the vertical distance between the two flat wire cores is less than or equal to 27 cm.

[0014] In a preferred embodiment, the flat strip is at least two strips, each strip comprising a flat wire core, and the vertical distance between the two flat wire cores is less than or equal to 7 cm.

[0015] In a preferred embodiment, there are at least two flat strips, which are stacked one on top of the other. Each flat strip contains a flat wire core, and the overlap of the two flat wire cores along the stacking direction is 40%-100%.

[0016] In a preferred embodiment, the flat strip includes a flat wire core, the front end of which is connected to the flat terminal, and the male end housing covers at least a portion of the flat terminal.

[0017] In a preferred embodiment, the flat strip includes a flat wire core, and the flat wire core and the flat terminal are integrally formed.

[0018] In a preferred embodiment, the flat terminal protrudes at least partially from the male housing, or the male housing has a receiving cavity, and the flat terminal protrudes at least partially from the bottom surface of the receiving cavity, but does not extend beyond the male housing.

[0019] In a preferred embodiment, the flat strip includes a flat wire core, and a bend is included between the flat wire core and the flat terminal, the bend having an angle of 0°-180°.

[0020] In a preferred embodiment, the flat terminal is at least partially provided with a conductive and corrosion-resistant layer.

[0021] In a preferred embodiment, the thickness of the conductive anti-corrosion layer is from 0.3 μm to 3000 μm.

[0022] In a preferred embodiment, the thickness of the conductive anti-corrosion layer is from 2.5 μm to 1000 μm.

[0023] In a preferred embodiment, the end of the flat terminal is provided with a chamfer.

[0024] In a preferred embodiment, the male terminal connection mechanism includes an interlocking connector, which is at least partially integrally injection molded into the male terminal housing.

[0025] In a preferred embodiment, the plug-in terminal includes a fixing part and a wire clamping part, the female end connection mechanism further includes a cable, the fixing part is electrically connected to the conductive part at the front end of the cable, and the wire clamping part is electrically connected to the flat terminal.

[0026] In a preferred embodiment, a clamp is fitted onto the clamping part, and the clamp is made of shape memory alloy.

[0027] In a preferred embodiment, the shape memory alloy is set within the range of 40°C to 70°C. When the temperature of the clamp is below the shape memory temperature, the clamp is in an expanded state; when the temperature of the clamp is above the shape memory temperature, the clamp is in a clamped state.

[0028] In a preferred embodiment, a clamp is fitted onto the clamping part, the clamp including a side wall and an elastic unit fixed on the side wall, the elastic unit being in contact with the outer side of the clamping part.

[0029] In a preferred embodiment, the force applied by the elastic element to the clamping portion ranges from 3N to 200N.

[0030] In a preferred embodiment, the elastic unit is an elastic rubber body, a spring, or a metal sheet.

[0031] In a preferred embodiment, the clamping portion of the interlocking terminal is formed by stacking multiple layers of sheet terminals, and a groove is formed in the sheet terminal to match and interlock with the flat strip.

[0032] In a preferred embodiment, the gap between two adjacent sheet terminals is less than 0.2 mm.

[0033] In a preferred embodiment, at least a portion of the sheet terminal is made of shape memory alloy.

[0034] In a preferred embodiment, the deformation temperature of the shape memory alloy is set within the range of 40°C to 70°C. When the temperature of the sheet terminal is lower than the deformation temperature, the plurality of grooves are in an expanded state; when the temperature of the sheet terminal is higher than the deformation temperature, the plurality of grooves are in a clamped state.

[0035] In a preferred embodiment, the female end housing is integrally injection molded to form an insulating structure on at least a portion of the outer periphery of the mating terminals.

[0036] In a preferred embodiment, the female terminal connection mechanism further includes a cable electrically connected to the mating terminal, the mating terminal and at least a portion of the cable being disposed within the female terminal housing, and the mating terminal being at least partially exposed outside the female terminal housing.

[0037] In a preferred embodiment, the clamping portion at least partially protrudes from the outer wall of the female end housing, or the female end housing is provided with an open boss, and the clamping portion is at least partially disposed within the open boss.

[0038] In a preferred embodiment, the female end connection mechanism has a high-voltage interlock structure, and the high-voltage interlock structure is electrically connected to the interlock connector to form a circuit.

[0039] In a preferred embodiment, the female end connection mechanism and / or the male end connection mechanism have a sealing structure.

[0040] In a preferred embodiment, the sealing structure is formed by secondary injection molding on the female end shell and / or the male end shell.

[0041] In a preferred embodiment, the female terminal connection mechanism and / or the male terminal connection mechanism have at least one temperature sensing structure for measuring the temperature of the mating terminal and / or the flat strip and / or the flat terminal.

[0042] In a preferred embodiment, the temperature measuring structure is attached to the mating terminal and / or the flat strip and / or the flat terminal to measure the temperature of the mating terminal and / or the flat strip and / or the flat terminal.

[0043] In a preferred embodiment, the male end connection mechanism has at least one temperature measuring structure, the flat strips are at least two, and the temperature measuring structure is located between the flat strips to measure the temperature of the flat strips.

[0044] In a preferred embodiment, the male end connection mechanism and the female end connection mechanism are connected by one or more of the following methods: adhesive connection, magnetic connection, bayonet connection, plug connection, locking connection, bundling connection, threaded connection, rivet connection, and welding connection.

[0045] In a preferred embodiment, the mating terminal includes a wire clamping portion, and the flat terminal is mated with the wire clamping portion to form an electrical connection. The mating force between the flat terminal and the wire clamping portion is between 3N and 150N.

[0046] In a preferred embodiment, the insertion force between the flat terminal and the clamping portion is between 10N and 130N.

[0047] In a preferred embodiment, the contact resistance between the flat terminal and the mating terminal is less than 9mΩ.

[0048] In a preferred embodiment, the contact resistance between the flat terminal and the mating terminal is less than 1mΩ.

[0049] In a preferred embodiment, the number of insertions and removals between the male end connection mechanism and the female end connection mechanism is greater than or equal to 9.

[0050] In a preferred embodiment, the weight of the male end connection mechanism is less than or equal to 305g.

[0051] In a preferred embodiment, the height of the male end connection mechanism along the insertion / removal direction is less than or equal to 108 mm.

[0052] The present invention provides an electrical power transmission device comprising the connection mechanism described in any one of the above claims.

[0053] The present invention provides a motor vehicle comprising the connection mechanism described in any of the preceding claims.

[0054] The features and advantages of this invention are:

[0055] 1. The connecting mechanism of the present invention features an injection-molded male end shell, which is simple to process and has a low cost. It can be directly injection-molded into the flat strip and used for insulation, which can reduce the installation of the flat strip. Furthermore, the front end of the flat strip can be molded into various shapes as required without considering assembly issues, thus saving processing steps and reducing processing costs.

[0056] 2. The connection mechanism of the present invention, with the flat strips stacked and set with appropriate spacing, can effectively reduce the electromagnetic interference caused to other components after the flat strips are energized, thereby eliminating the need for the high-voltage charging harness shielding layer structure and achieving the requirements of reducing costs and weight.

[0057] 3. In the connection between flat terminals and mating terminals, the conductive and anti-corrosion layer can reduce the electrochemical reaction between the flat terminals and mating terminals of the flat strip, solving the technical problem that the flat strip needs to be connected to other terminals or electrical devices through copper terminals.

[0058] 4. The mating terminals consist of multiple stacked sheet terminals. The sheet terminals are easily deformable and can be plugged into the flat terminals of the flat strip. The flat terminals of the flat strip contact the strip grooves of the sheet terminals to achieve electrical connection, which can ensure the stability of the connection between the mating terminals and the flat strip.

[0059] 5. By integrating the flat wire core of the flat strip with the flat terminal into an integrated structure, it can be directly connected to the mating terminal, solving the problems of high cost and low efficiency of connecting copper terminals to the flat strip, and enabling safe and fast plugging and unplugging.

[0060] 6. The mating terminals have a memory function. Below the extreme temperature, the grooved strip of the mating terminal is usually in an expanded state. At this time, the flat terminal of the flat strip can achieve a forceless connection, making it easy for operators to plug and unplug electrical appliances. During operation, the mating terminals conduct current. Due to the resistance, the temperature of the mating terminals gradually increases. When the temperature rises above the extreme temperature, the grooved strip of the mating terminal will radially contract. The increase in temperature increases the contact area and contact force between the grooved strip of the mating terminal and the flat terminal of the flat strip, improving the reliability of the contact. Since the requirement of insertion force is eliminated, the work is easier and the work efficiency is improved.

[0061] 7. The embedded high-voltage interlock structure replaces the previous assembled high-voltage interlock. It is fixed in the connection mechanism by one-piece injection molding, eliminating the need for assembly, reducing costs, and fully meeting the high-voltage interlock effect.

[0062] 8. The sealing structure of the connecting mechanism no longer uses a separate sealing ring, but adopts a secondary injection molding sealing structure to replace the traditional sealing ring. It can be directly molded onto the connecting mechanism, resulting in better injection molding bonding and reduced costs.

[0063] 9. The temperature measuring mechanism can monitor the temperature of the terminals inside the connection mechanism independently, avoiding the inability to monitor the temperature of the connection mechanism due to the failure of temperature sensors in other locations. Attached Figure Description

[0064] To more clearly illustrate the technical solutions in this invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0065] Figure 1 This is a schematic diagram of the connecting mechanism in this invention.

[0066] Figure 2 This is a schematic diagram of the male end connection mechanism in this invention.

[0067] Figure 3This is a schematic diagram of the flat wire core structure in this invention.

[0068] Figure 4 This is a schematic diagram of the female end connection mechanism in this invention.

[0069] Figure 5 This is a schematic diagram of the plug-in terminal structure in this invention.

[0070] Figure 6 This is a schematic diagram of the connection structure between the flat wire core and the plug-in terminal in this invention.

[0071] Figure 7 This is a schematic diagram of the interlocking connector structure in this invention.

[0072] Figure 8 This is a schematic diagram of the high-voltage interlock structure in this invention.

[0073] Figure 9 This is a schematic diagram of the magnetic field structure of the flat wire core in this invention.

[0074] Figure 10 This is a schematic diagram of the vertical distance structure of the flat wire core in this invention.

[0075] Figure 11 This is a schematic diagram of the flat wire core structure in this invention.

[0076] Figure 12 This is a schematic diagram of the clamp structure in this invention.

[0077] Figure 13 In this invention Figure 1 A cross-sectional view of the connecting mechanism structure along direction A.

[0078] in:

[0079] 10. Male terminal connection mechanism; 11. Flat strip; 111. Flat wire core; 112. Outer insulation layer; 113. Flat terminal; 1131. Bending part; 12. Male terminal housing; 14. Interlocking connector;

[0080] 20. Female terminal connection mechanism; 21. Cable; 22. Female terminal housing; 23. Plug-in terminal; 231. Fixing part; 232. Wire clamping part; 234. Sheet terminal; 24. High voltage interlocking structure;

[0081] 30. Clamp; 31. Sidewall; 32. Elastic unit;

[0082] 40. Sealed structure. Detailed Implementation

[0083] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0084] A connection mechanism includes a male connection mechanism 10 and a female connection mechanism 20. The male connection mechanism 10 includes a flat strip 11, a flat terminal 113, and a male housing 12 connected to the flat strip 11 and the flat terminal 113. The female connection mechanism 20 includes a mating terminal 23 and a female housing 22 connected to the mating terminal 23. The male connection mechanism 10 and the female connection mechanism 20 are electrically connected to the mating terminal 23 via the flat terminal 113. The male housing 12 is connected to the female housing 22, forming a connection mechanism. Figure 1-4 As shown.

[0085] By stacking the flat strips and setting appropriate spacing, electromagnetic interference caused to other components after the flat strips are energized can be effectively reduced, thereby eliminating the need for the high-voltage charging harness shielding layer structure and achieving the requirements of reducing costs and weight.

[0086] Furthermore, the flat ribbon 11 offers significant advantages in heat dissipation and assembly. Due to the large width-to-height ratio of its conductive portion, it has a larger surface area in contact with the external environment, enabling effective heat dissipation and rapidly reducing cable temperature rise caused by current, thus extending cable lifespan. Additionally, when the installation environment lacks sufficient height, the flat ribbon 11 can be used to reduce the cable laying height, allowing for close assembly against the installation environment, reducing installation space requirements, and improving space utilization.

[0087] In some embodiments, the flat strip 11, the flat terminal 113 and the plug terminal 23 are made of one or more metallic conductive materials containing nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium, beryllium and lead. These materials are stable and have good conductivity. Preferred materials are those containing copper or copper alloys or aluminum or aluminum alloys.

[0088] In some embodiments, the flat strip 11 is made of one or more of aluminum, phosphorus, tin, copper, iron, manganese, chromium, titanium, and lithium. The use of aluminum or aluminum alloys as the material for the flat strip 11 is one of the main methods for energy conservation and cost reduction in recent years. In the field of electrical connections, copper wires are used for current conduction due to their high conductivity and good ductility. However, with the rising price of copper, the material cost of using copper as wire is increasing. Therefore, people are beginning to look for alternatives to copper to reduce costs. Aluminum accounts for approximately 7.73% of the Earth's crust. After optimization of refining technology, its price is relatively low, and compared to copper, aluminum is lighter and its conductivity is second only to copper. Aluminum can replace some copper in the field of electrical connections. Therefore, replacing copper with aluminum is a development trend in the field of automotive electrical connections.

[0089] In one embodiment, the aspect ratio of the cross-sectional area of ​​the flat strip 11 is 1:1 to 120:1.

[0090] To verify the effect of the cross-sectional aspect ratio of the flat strip 11 on the temperature rise and tensile strength of the flat strip 11, the inventors selected flat strip 11 samples with the same cross-sectional area but different aspect ratios and tested the temperature rise and tensile strength of the flat strip 11. The test results are shown in Table 1.

[0091] The method for testing the temperature rise of the flat strip 11 is as follows: The same current is passed through the flat strip 11, and the temperature at the same location on the flat strip 11 before and after temperature stabilization is measured in a closed environment. The absolute value of the difference is then taken. In this embodiment, a temperature rise greater than 50K is considered unacceptable.

[0092] The tensile strength test method for the flat strip 11 is as follows: Using a universal tensile testing machine, the two ends of the flat strip 11 sample are fixed on the tensile fixtures of the universal tensile testing machine and stretched at a speed of 50 mm / min. The tensile force value at the final breakage is recorded. In this embodiment, a tensile force value greater than 1600 N is considered a qualified value.

[0093] Table 1: Effect of the cross-sectional aspect ratio of flat strip 11 on the temperature rise and tensile strength of flat strip 11

[0094]

[0095] As shown in Table 1 above, when the aspect ratio of the flat strip 11 is less than 1:1, a temperature rise greater than 50K is considered unqualified. When the aspect ratio of the flat strip 11 is greater than or equal to 1:1, a temperature rise less than 50K is considered qualified, and the condition improves with each passing year. This is because the larger the aspect ratio of the flat strip 11, the larger its heat dissipation area. For the same temperature increase, a flat strip 11 with better heat dissipation will have a lower temperature rise. When the aspect ratio of the flat strip 11 is greater than 120:1, the flat strip 11 is too thin. When subjected to tensile force, the thin flat strip 11 cannot withstand the large tensile force and will break. In this case, the tensile strength of the flat strip 11 does not meet the qualification requirements. Therefore, the inventors set the aspect ratio of the flat strip 11 to be between 1:1 and 120:1.

[0096] In one implementation, such as Figure 2 As shown, there are at least two flat strips 11, which are stacked one on top of the other. The male end housing 12 is integrally injection molded to form an insulating structure on the outer periphery of at least part of the flat strips 11 and the flat terminal 113.

[0097] A typical conductive circuit consists of two wires. For example, a DC charging socket has a DC positive charging cable and a DC negative charging cable, while an AC charging socket has an AC live wire charging cable and an AC neutral wire charging cable. The flat strips 11 are stacked vertically, which effectively utilizes assembly space and also helps to cancel electromagnetic interference. After the two flat strips 11 are stacked vertically, the raw material of the male end shell 12 is injected into the space between and around the flat strips 11 using an injection mold to form the male end shell 12.

[0098] In some embodiments, when there are many loops to connect, the flat strip 11 can also be 3, 4 or more, connecting different loops.

[0099] In this embodiment, the connecting mechanism is provided with an injection-molded male end shell 12, which is simple to process and has a low cost. It can be directly injection-molded into the flat strip 11 and insulated, which can reduce the installation of the flat strip 11. Furthermore, the front end of the flat strip 11 can be molded into various shapes as required without considering assembly issues, thus saving processing steps and reducing processing costs.

[0100] Furthermore, the flat ribbon 11 offers significant advantages in heat dissipation and assembly. Due to the large width-to-height ratio of its conductive portion, it has a larger surface area in contact with the external environment, enabling effective heat dissipation and rapidly reducing cable temperature rise caused by current, thus extending cable lifespan. Additionally, when the installation environment lacks sufficient height, the flat ribbon 11 can be used to reduce the cable laying height, allowing for close assembly against the installation environment, reducing installation space requirements, and improving space utilization.

[0101] In one embodiment, the flat strip 11 includes a flat wire core 111 and an outer insulation layer 112, wherein the outer insulation layer 112 is partially stripped to expose the flat wire core 111, and the end of the outer insulation layer 112 is inside the male end housing 12 or abuts against the male end housing 12.

[0102] The flat wire core 111 is the conductive part of the flat strip 11, and the outer insulation layer 112 is the insulating part of the flat strip 11. Before injection molding the male end shell 12, a portion of the outer insulation layer 112 of the flat strip 11 needs to be peeled off to expose the internal flat wire core 111, and then the male end shell 12 is integrally injection molded.

[0103] Preferably, the flat strip 11 includes a flat wire core 111, the flat wire core 111 having a hardness of 8HV-105HV.

[0104] To verify the effect of the hardness of the flat wire core 111 on the force of the flat terminal 113 peeling off from the flat wire core 111 and the bending torque of the flat wire core 111 in the XY direction, the inventors selected flat wire core 111 samples of the same size and specifications but with different hardnesses, and tested the force of the flat terminal 113 peeling off from the flat wire core 111 and the bending torque of the flat wire core 111. The test results are shown in Table 2.

[0105] Test method for peeling force of flat terminal 113: Using a universal tensile testing machine, the flat terminal 113 and flat wire core 111 are vertically fixed on the tensile fixture of the universal tensile testing machine, and stretched at a speed of 50 mm / min. The tensile force value when the flat terminal 113 is finally peeled from the flat wire core 111 is recorded. In this embodiment, a tensile force value greater than 900N is a qualified value.

[0106] Torque test method for bending flat wire core 111: Using a torque tester, when the flat wire core 111 is bent at the same radius and speed by 90°, the torque value of the deformation of the flat wire core 111 during the bending process is tested. In this embodiment, a torque value of less than 30 N·m is considered a qualified value.

[0107] Table 2: Effect of the hardness of flat wire core 111 on the peeling force of flat terminal 113 and the bending torque of flat wire core 111

[0108]

[0109] As can be seen from Table 2 above, when the hardness of the flat wire core 111 is less than 8HV, the tensile force when the flat terminal 113 is peeled off from the flat wire core 111 is less than the acceptable value. In this case, the flat terminal 113 connected to the flat wire core 111 is easily peeled off under external force, thus preventing circuit conduction to the wire core 111 and causing the flat wire core 111 to malfunction, failing to achieve the purpose of power transmission. In severe cases, this can lead to short circuits and combustion accidents. When the hardness of the flat wire core 111 is greater than 105HV, due to its high hardness, a greater torque is required to deform the flat wire core 111 when it needs to be bent. In this case, the torque value does not meet the acceptable value requirement. Therefore, the inventors set the hardness of the flat wire core 111 to be 8HV-105HV.

[0110] As can be seen from the data in Table 2, when the hardness of the flat wire core 111 is 10HV-55HV, the tensile force when the flat terminal 113 is peeled from the flat wire core 111 and the bending torque of the flat wire core 111 in the XY direction are both within a good range. Therefore, the inventors prefer the hardness of the flat wire core 111 to be 10HV-55HV.

[0111] Furthermore, there are at least two flat strips 11, which are stacked one on top of the other. Each flat strip 11 contains a flat wire core 111, and the vertical distance between the two flat wire cores 111 is less than or equal to 27cm.

[0112] Furthermore, the flat strip 11 consists of at least two strips, each containing a flat wire core 111, and the vertical distance between the two flat wire cores 111 is less than or equal to 7 cm.

[0113] like Figure 9 As shown, the flat strip 11 generates an induced magnetic field when energized, which can cause electromagnetic interference to the outside world. The conventional solution in the prior art is to place an electromagnetic shielding layer outside the flat strip 11. To eliminate the shielding structure, reduce cost, and lighten weight, the present invention employs the following design: the power transmission system for vehicles includes two stacked flat strips 11.

[0114] When the two flat strips 11 are stacked one on top of the other, the resulting magnetic field is as follows: Figure 9-11 As shown. Since the flat wire core 111 has a flat structure, its magnetic field is strongest at its largest area. By stacking the flat wire cores 111, the magnetic fields of the two flat wire cores 111 can be canceled out (since the current in the two flat wire cores 111 is the same in magnitude but opposite in direction A, the induced magnetic field strength is the same but opposite in direction), thereby eliminating the electromagnetic interference to other electrical devices caused by the flat wire core 111 being energized.

[0115] Preferably, the width directions of the two flat strips 11 are parallel to each other. The flat strips 11 are mirror images of each other. The distance between the two flat strip cores 111 is H. The stacking direction of the two flat strips 11 is... Figure 10 The up and down directions in the middle.

[0116] When the overlap of the two flat strips 11 along the stacking direction is 100%, the effect of the distance H between the flat strip cores 111 on the magnetic field cancellation is shown in Table 3. A magnetic field cancellation percentage greater than 30% is considered a qualified value.

[0117] Table 3: Influence of the distance H between the flat wire cores 111 on the magnetic field cancellation when the overlap of the two flat strips 11 is 100%.

[0118]

[0119] The overlap degree refers to the percentage of the overlapping area of ​​the two flat strips 11 along the stacking direction to the area of ​​one flat strip 11.

[0120] As shown in Table 3, when the overlap of the two flat strips 11 along the stacking direction is 100%, and the distance H between the two flat strip cores 111 is less than or equal to 27cm, the magnetic field cancellation percentage is qualified and has a certain effect on preventing electromagnetic interference. Preferably, when the vertical distance between the two flat strip cores 111 is less than or equal to 7cm, the magnetic field can be effectively cancelled and the effect is obvious. Therefore, the distance H between the two flat strip cores 111 is further set to less than or equal to 7cm.

[0121] In this embodiment, the connecting mechanism uses a layered arrangement of flat strips 11 with appropriate spacing to effectively reduce electromagnetic interference to other components after the flat strips 11 are powered on. This eliminates the need for a shielding device in the connecting structure, thereby reducing costs and weight.

[0122] In one embodiment, there are at least two flat strips 11, which are stacked one on top of the other. The flat strip 11 includes flat wire cores 111, and the overlap of the two flat wire cores 111 along the stacking direction is 40%-100%.

[0123] When the flat strips 11 are stacked one on top of the other, since the flat strips 11 have a flat structure, their magnetic field is strongest at the part with the largest area. By stacking the flat strips 11, the magnetic fields of the positive and negative flat strip cores 111 can be canceled, thereby eliminating electromagnetic interference to other electrical devices caused by the flat strips 11 being energized.

[0124] The distance between the flat strips 11 and the degree of overlap of the flat strips 11 have a great influence on the degree of magnetic field cancellation. This invention effectively cancels the magnetic field of the flat strips 11 by designing the stacking of the two flat strips 11 and controlling the stacking distance and overlap of the two flat strips.

[0125] When the distance between the flat cores 111 of the two flat strips 11 is 7cm, the effect of the overlap of the two flat strips 11 along the stacking direction on the magnetic field cancellation is shown in Table 4. The magnetic field cancellation percentage is greater than 30% and is considered a qualified value.

[0126] Table 4: Influence of the overlapping area of ​​the two flat strip cores 111 on the magnetic field cancellation when the distance between them is 7 cm.

[0127]

[0128] As shown in Table 4, when the distance between the two flat strip cores 111 is 7cm, the overlap of the flat strips 11 along the stacking direction is 40%-100%, the magnetic field cancellation percentage is qualified, and it has a certain effect on preventing electromagnetic interference. The effect is obvious when the overlap of the two flat strips 11 along the stacking direction is above 90%, and the effect is optimal when the overlap of the two flat strips 11 along the stacking direction is 100%.

[0129] In one implementation, such as Figure 2-3 As shown, the flat strip 11 includes a flat wire core 111, the front end of which is connected to a flat terminal 113. The male end housing 12 covers at least a portion of the flat terminal 113. The flat strip 11, after stripping away the outer insulation layer 112, exposes the flat wire core 111, and the portion that electrically connects to the mating terminal 23 is the flat terminal 113. The flat terminal 113 allows for effective mating connection with the mating terminal 23, achieving effective electrical connection of the connection mechanism.

[0130] like Figure 6 As shown, in order to enable the flat terminal 113 to be effectively connected to the mating terminal 23, during the integral molding process of the flat strip 11 and the male end housing 12, the flat terminal 113 needs to be exposed outside the male end housing 12 to prevent the flat terminal 113 and the mating terminal 23 from being unable to be connected due to the coverage of the male end housing 12.

[0131] Preferably, the front end of the flat wire core 111 is connected to the flat terminal 113 by one or more of the following methods: resistance welding, friction welding, ultrasonic welding, arc welding, laser welding, electron beam welding, pressure diffusion welding, magnetic induction welding, screwing, snap-fitting, splicing, and crimping.

[0132] Resistance welding is a method that uses a strong current to pass through the contact point between the electrode and the workpiece, and heat is generated by the contact resistance to achieve welding. The front end of the flat wire core 111 is welded to the conductive part of the flat terminal 113 by resistance welding.

[0133] Friction welding is a method that uses the heat generated by friction between the contact surfaces of workpieces as a heat source to cause plastic deformation of the workpieces under pressure for welding. The front end of the flat wire core 111 is welded to the conductive part of the flat terminal 113 by friction welding.

[0134] Ultrasonic welding utilizes high-frequency vibration waves transmitted to the surfaces of two objects to be welded. Under pressure, the surfaces of the two objects rub against each other to form a fusion between molecular layers. The front end of the flat wire core 111 and the conductive part of the flat terminal 113 are ultrasonically welded.

[0135] Arc welding refers to the use of an electric arc as a heat source, utilizing the physical phenomenon of air discharge to convert electrical energy into the heat and mechanical energy required for welding, thereby achieving the purpose of joining metals. The main methods include shielded metal arc welding, submerged arc welding, and gas shielded welding.

[0136] Laser welding is a highly efficient and precise welding method that uses a high-energy-density laser beam as a heat source.

[0137] Electron beam welding refers to the welding process that uses an accelerated and focused electron beam to bombard a welding surface placed in a vacuum or non-vacuum environment, causing the workpiece to melt and thus achieving welding.

[0138] Pressure welding is a method of welding that applies pressure to the workpieces, causing the joint surfaces to come into close contact and produce a certain amount of plastic deformation.

[0139] Diffusion welding refers to a solid-state welding method in which the workpiece is subjected to high temperature and pressure, but no visible deformation or relative movement is produced.

[0140] Magnetic induction welding involves two workpieces being welded undergoing a high-speed, instantaneous collision under the influence of a strong pulsed magnetic field. The surface of the materials is subjected to a high pressure wave, causing the atoms of the two materials to meet within the interatomic distance, thus forming a stable metallurgical bond at the interface.

[0141] A threaded connection is a detachable connection made by using threaded parts (or the threaded portion of the connected parts) to join the connected parts together. Commonly used threaded fasteners include bolts, studs, screws, and set screws, most of which are standard parts.

[0142] The snap-fit ​​method refers to the use of corresponding claws or slots on the connecting ends or surfaces, allowing for assembly and connection. The advantages of the snap-fit ​​method are quick connection and detachability.

[0143] The splicing method refers to setting corresponding grooves and protrusions on the connecting ends or surfaces, and assembling them together by tenoning or splicing the grooves and protrusions. The advantages of the splicing method are stable connection and disassembly capability.

[0144] Crimping is a manufacturing process in which the connecting ends and connecting surfaces are assembled and then pressed together using a crimping machine. The advantage of crimping is its mass production capability; by using automated crimping machines, products of consistent quality can be manufactured rapidly and in large quantities.

[0145] Through the above connection method, an appropriate connection method or combination of connection methods can be selected according to the actual usage environment and the actual usage state of the front end of the flat wire core 111 and the conductive part of the flat terminal 113 to achieve an effective electrical connection.

[0146] In some embodiments, the flat strip 11 includes a flat wire core 111, which is integral with the flat terminal 113. The flat wire core 111 and the flat terminal 113 can be made of the same material, which can save the use of the flat terminal 113, reduce material costs, save processing time, and allow the front end of the flat wire core 111 to be shaped into various shapes as needed without considering assembly issues.

[0147] Furthermore, the flat terminal 113 at least partially protrudes from the male housing 12, or the male housing 12 has a receiving cavity, and the flat terminal 113 at least partially protrudes from the bottom surface of the receiving cavity, but does not exceed the male housing 12. The flat terminal 113 protrudes from the male housing 12 and can be directly connected to the mating terminal 23 in the female housing 22, or it can be disposed inside the receiving cavity of the male housing 12, with the mating terminal 23 in the female housing 22 extending into the receiving cavity and connecting to the flat terminal 113.

[0148] By connecting the flat terminal 113 to the mating terminal 23, the flat terminal 113 of the flat strip 11 performs the function of a terminal itself and connects directly to the mating terminal 23, which solves the problem of high cost and low efficiency of connecting copper terminals to the flat strip 11, and enables safe and fast plugging and unplugging.

[0149] In one implementation, such as Figure 3 As shown, the flat tape 11 includes a flat wire core 111, and a bending portion 1131 is included between the flat wire core 111 and the flat terminal 113. The angle of the bending portion 1131 is 0°-180°. The bending portion 1131 is set with different bending angles to be suitable for connection mechanisms with different shapes and different directions of the mating terminals 23. According to the needs of the installation environment, as well as the need to simplify the structure of the connection mechanism and reduce the connection space, the designer can set different angles of the bending portion 1131 for connection with mating terminals 23 with different angles, thereby changing the cable routing on both sides of the connection mechanism. In addition, the body of the flat tape 11 is connected to the flat terminal 113 through the bending portion 1131, and the extension direction of the flat tape 11 is adjusted by the bending portion 1131 to facilitate the adaptation of the flat tape 11 to the installation environment.

[0150] In this embodiment, the flat strip 11 also has the advantage of being easy to bend and shape. That is, the flat strip 11 can maintain its shape after bending, so it can be arranged with the body sheet metal. It can be bent and shaped as needed at different positions to save space and also make it easy to fix.

[0151] In one embodiment, the flat terminal 113 is at least partially provided with a conductive anti-corrosion layer. When the materials of the flat terminal 113 and the mating terminal 23 are inconsistent, electrochemical corrosion will occur between them due to the potential difference, thereby reducing the service life of the flat terminal 113 and the mating terminal 23. In order to reduce this electrochemical corrosion, a conductive anti-corrosion layer can be provided on the flat terminal 113. The conductive anti-corrosion material can be a metallic material whose potential is between that of the materials of the flat terminal 113 and the mating terminal 23, thereby isolating the flat terminal 113 and the mating terminal 23, slowing down electrochemical corrosion, and extending the service life of the flat terminal 113 and the mating terminal 23.

[0152] In the connection between the flat terminal 113 and the mating terminal 23, the conductive anti-corrosion layer can reduce the electrochemical reaction between the flat terminal 113 and the mating terminal 23 of the flat strip 11, thus solving the technical problem that the flat strip 11 needs to be connected to other terminals or electrical devices through terminals of other materials.

[0153] Furthermore, the conductive anti-corrosion layer is attached to at least a portion of the surface of the flat terminal 113 by one or more of the following methods: electroplating, chemical plating, magnetron sputtering, vacuum plating, pressure welding, diffusion welding, friction welding, resistance welding, ultrasonic welding, or laser welding.

[0154] Electroplating is a process that uses the principle of electrolysis to plate a thin layer of another metal or alloy onto the surface of certain metals.

[0155] Chemical plating is a process in which metal is deposited through a controlled redox reaction catalyzed by a metal.

[0156] Magnetron sputtering utilizes the interaction of magnetic and electric fields to cause electrons to spiral near the target surface, thereby increasing the probability of electrons colliding with argon gas to generate ions. The generated ions then collide with the target surface under the influence of the electric field, thus sputtering the target material.

[0157] Vacuum plating is a method of depositing various metal and non-metal thin films on the surface of plastic parts under vacuum conditions through methods such as distillation or sputtering.

[0158] Pressure welding is a method of welding that applies pressure to the workpieces to make the joint surfaces come into close contact and produce a certain amount of plastic deformation.

[0159] Friction welding is a method that uses the heat generated by friction between the contact surfaces of workpieces as a heat source to cause plastic deformation of the workpieces under pressure, thereby performing welding.

[0160] Resistance welding is a method of welding that uses a strong current to pass through the contact point between the electrode and the workpiece, generating heat through contact resistance.

[0161] Ultrasonic welding uses high-frequency vibration waves to be transmitted to the surfaces of two objects to be welded. Under pressure, the surfaces of the two objects rub against each other, forming a fusion between molecular layers.

[0162] Laser welding is a highly efficient and precise welding method that uses a high-energy-density laser beam as a heat source.

[0163] Diffusion welding refers to a solid-state welding method that applies pressure to the workpiece at high temperature without causing visible deformation or relative movement. By employing multiple methods or combinations thereof, a conductive and corrosion-resistant layer can be stably deposited on the surface of the flat terminal 113.

[0164] In one embodiment, the thickness of the conductive anti-corrosion layer is from 0.3 μm to 3000 μm.

[0165] In one embodiment, the thickness of the conductive anti-corrosion layer is from 2.5 μm to 1000 μm.

[0166] To test the effect of different conductive anti-corrosion layer thicknesses on voltage drop, the inventors used connectors 113 of the same material and structure, and applied conductive anti-corrosion layers of different thicknesses to the flat terminals 113. Then, they tested the voltage drop after the flat terminals 113 and the mating terminals 23 were connected. The results are shown in Table 5.

[0167] In this embodiment, a voltage drop greater than 4mV after the flat terminal 113 is plugged into the plug terminal 23 is considered unqualified.

[0168] Table 5. Effect of different conductive anti-corrosion layer thicknesses on voltage drop (mV):

[0169]

[0170]

[0171] The data above shows that when the thickness of the conductive anti-corrosion layer is greater than 3000 μm and less than 0.3 μm, the voltage drop of the connection structure between the flat terminal 113 and the mating terminal 23 is greater than 4 mV, which does not meet the requirements. Therefore, the inventors selected a conductive anti-corrosion layer thickness of 0.3 μm to 3000 μm. Specifically, when the thickness of the conductive anti-corrosion layer is in the range of 2.5 μm to 1000 μm, the voltage drop of the connection structure between the flat terminal 113 and the mating terminal 23 is optimal. Therefore, preferably, the inventors selected a conductive anti-corrosion layer thickness of 2.5 μm to 1000 μm.

[0172] In one embodiment, the conductive anti-corrosion layer is made of one or more of the following materials: nickel, cadmium, manganese, zirconium, cobalt, tin, titanium, chromium, gold, silver, zinc, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, hard silver, and silver-gold-zirconium alloy.

[0173] Preferably, the conductive and corrosion-resistant layer is made of the same material as the battery electrode to which the flat terminal 113 is connected. This design enhances the surface strength of the flat terminal 113 and prevents corrosion caused by the flat terminal 113 contacting dissimilar metals.

[0174] The following also uses the flat strip 11 as an example. A conductive and anti-corrosion layer is provided on the flat terminal 113. In order to demonstrate the influence of different conductive and anti-corrosion materials on the performance of the flat terminal 113, the inventors used flat terminals 113 of the same specifications and materials but with different conductive and anti-corrosion materials to conduct a series of corrosion resistance time tests. The experimental results are shown in Table 6.

[0175] The corrosion resistance time test in Table 6 involves placing the flat terminal 113 sample into a salt spray test chamber and spraying salt spray on all locations of the flat terminal 113. Every 20 hours, the sample is removed, cleaned, and the surface corrosion is observed; this constitutes one cycle. The test is stopped when the corroded area on the surface of the flat terminal 113 sample exceeds 10% of the total area, and the cycle number at that time is recorded. In this embodiment, a cycle count less than 80 is considered unqualified.

[0176] Table 6: Influence of different conductive and anti-corrosion layer materials on the corrosion resistance of flat terminal sample 113

[0177]

[0178] As shown in Table 6, when the conductive anti-corrosion layer material contains commonly used metals such as tin, nickel, and zinc, the experimental results are not as good as those using other selected metals. The experimental results using other metals show significantly higher than the standard values ​​and more stable performance. Therefore, the inventors selected a conductive anti-corrosion layer material containing (or being) one or more of the following: nickel, cadmium, manganese, zirconium, cobalt, tin-titanium, chromium, gold, silver, zinc-tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, hard silver, and silver-gold-zirconium alloy. A more preferred approach is to select a conductive anti-corrosion layer material containing (or being) one or more of the following: cadmium, manganese, zirconium, cobalt, titanium, chromium, gold, silver, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, hard silver, and silver-gold-zirconium alloy.

[0179] In one embodiment, the end of the flat terminal 113 is chamfered. During the processing and installation of the flat strip 11, and the installation of the mating terminal 23, there will be assembly errors. Similarly, the assembly of the flat terminal 113 and the mating terminal 23 will also have significant assembly errors. To facilitate convenient and accurate mating connection between the flat terminal 113 and the mating terminal 23, a chamfer is provided at the end of the flat terminal 113, which serves as a guide when inserted into the mating terminal 23.

[0180] In one implementation, such as Figure 7 and Figure 13 As shown, the male terminal connection mechanism 10 includes an interlock connector 14, which is at least partially integrally injection molded into the male terminal housing 12. High-voltage interlocking is a safety design method that uses low-voltage signals to monitor the integrity of the high-voltage circuit. The specific implementation of high-voltage interlocking varies depending on the project. High-voltage interlocking monitors the unexpected disconnection of the high-voltage circuit to prevent damage to the vehicle due to sudden loss of power. The high-voltage interlocking in this embodiment, as shown... Figure 13 As shown, one end is an interlock connector 14, which is a U-shaped or V-shaped low-voltage circuit with two pins that are electrically connected. It does not require installation and can be directly molded in the male end housing 12 by integral injection molding. It is matched and connected with the high-voltage interlock structure 24 in the female end connection mechanism 20 to form a low-voltage monitoring circuit. When the connection mechanism in this embodiment is accidentally disconnected, the interlock connector 14 and the high-voltage interlock structure 24 will also be disconnected at the same time. The low-voltage monitoring circuit will alarm the central control system to prevent the car from being damaged due to sudden loss of power.

[0181] In one implementation, such as Figure 5As shown, the plug-in terminal 23 includes a fixing part 231 and a wire clamping part 232. The female terminal connection mechanism 20 also includes a cable 21. The fixing part 231 is electrically connected to the conductive part at the front end of the cable 21, and the wire clamping part 232 is electrically connected to the flat terminal 113. The plug-in connection between the wire clamping part 232 of the plug-in terminal 23 and the flat terminal 113 enables the flat tape 11 and the cable 21 to achieve circuit conduction.

[0182] Furthermore, the fixed part 231 and the conductive part at the front end of the cable 21 are connected by one or more of the following methods: resistance welding, friction welding, ultrasonic welding, arc welding, laser welding, electron beam welding, pressure diffusion welding, magnetic induction welding, screwing, snap-fitting, splicing, and crimping.

[0183] Resistance welding is a method that uses a strong current to pass through the contact point between the electrode and the workpiece, and generates heat through the contact resistance to achieve welding. The conductive parts of the fixing part 231 and the cable 21 are welded by resistance welding.

[0184] Friction welding is a method that uses the heat generated by friction between the contact surfaces of workpieces as a heat source to cause plastic deformation of the workpieces under pressure for welding. The fixed part 231 and the conductive part of the cable 21 are welded by friction welding.

[0185] Ultrasonic welding is a method that uses high-frequency vibration waves to be transmitted to the surfaces of two objects to be welded. Under pressure, the surfaces of the two objects rub against each other to form a fusion between molecular layers. The conductive parts of the fixing part 231 and the cable 21 are ultrasonically welded.

[0186] Arc welding refers to the use of an electric arc as a heat source, utilizing the physical phenomenon of air discharge to convert electrical energy into the heat and mechanical energy required for welding, thereby achieving the purpose of joining metals. The main methods include shielded metal arc welding, submerged arc welding, and gas shielded welding.

[0187] Laser welding is a highly efficient and precise welding method that uses a high-energy-density laser beam as a heat source.

[0188] Electron beam welding refers to the welding process that uses an accelerated and focused electron beam to bombard a welding surface placed in a vacuum or non-vacuum environment, causing the workpiece to melt and thus achieving welding.

[0189] Pressure welding is a method of welding that applies pressure to the workpieces, causing the joint surfaces to come into close contact and produce a certain amount of plastic deformation.

[0190] Diffusion welding refers to a solid-state welding method in which the workpiece is subjected to high temperature and pressure, but no visible deformation or relative movement is produced.

[0191] Magnetic induction welding involves two workpieces colliding at high speed under a strong pulsed magnetic field. The high pressure wave causes atoms of the two materials to meet within their interatomic distance, forming a stable metallurgical bond at the interface. It is a type of solid-state cold welding that can weld together the fixed part 231 (which may have similar or dissimilar properties) and the conductive part of the cable 21.

[0192] A threaded connection is a detachable connection made by using threaded parts (or the threaded portion of the connected parts) to join the connected parts together. Commonly used threaded fasteners include bolts, studs, screws, and set screws, most of which are standard parts.

[0193] The snap-fit ​​method refers to the use of corresponding claws or slots on the connecting ends or surfaces, allowing for assembly and connection. The advantages of the snap-fit ​​method are quick connection and detachability.

[0194] The splicing method refers to setting corresponding grooves and protrusions on the connecting ends or surfaces, and assembling them together by tenoning or splicing the grooves and protrusions. The advantages of the splicing method are stable connection and disassembly capability.

[0195] Crimping is a manufacturing process in which the connecting ends and connecting surfaces are assembled and then pressed together using a crimping machine. The advantage of crimping is its mass production capability; by using automated crimping machines, products of consistent quality can be manufactured rapidly and in large quantities.

[0196] Through the above connection method, an appropriate connection method or combination of connection methods can be selected according to the actual usage environment and the actual usage state of the conductive parts of the fixing part 231 and the cable 21 to achieve an effective electrical connection.

[0197] In some embodiments, a clamping band 30 is fitted onto the clamping portion 232, such as... Figure 12 As shown, the clamp 30 is made of shape memory alloy. The clamp 30 can clamp the wire clamping part 232. Shape memory alloy is a smart metal with memory; its microstructure has two relatively stable states. At high temperatures, this alloy can be molded into any desired shape, and at lower temperatures, it can be stretched. However, if reheated, it remembers its original shape and reverts to its original form. The crystal structure of the shape memory alloy is different above and below its transformation temperature. When the temperature changes around the transformation temperature, the shape memory alloy will contract or expand, causing its shape to change. In some embodiments, the shape memory alloy is a nickel-titanium alloy.

[0198] Furthermore, the transformation temperature of the shape memory alloy is set within the range of 40℃-70℃. When the temperature of the clamp 30 is lower than the transformation temperature, the clamp 30 is in an expanded state; when the temperature of the clamp 30 is higher than the transformation temperature, the clamp 30 is in a clamped state.

[0199] Generally, the abnormal temperature is selected between 40℃ and 70℃. If the abnormal temperature is below 40℃, the ambient temperature of the clamping part 232 and the clamp 30 will reach close to 40℃ when no current is conducted. At this time, the clamp 30 will be in a clamped state, the gap of the clamping part 232 will become smaller, and the flat terminal 113 will not be able to be inserted into the clamping part 232. This will cause the flat terminal 113 to fail to connect with the clamping part 232, and thus it will not be able to work.

[0200] In some embodiments, a clamp 30 is fitted onto the clamping portion 232. The clamp 30 includes a side wall 31 and an elastic unit 32 fixed on the side wall 31. The elastic unit 32 is in contact with the outer side of the clamping portion 232.

[0201] The clamp 30 applies pressure to the clamping part 232 through the elastic unit 32 provided on the side wall, so that the strip groove of the clamping part 232 can clamp the flat terminal 113 of the flat strip 11 more tightly, ensuring the contact area between the clamping part 232 and the flat terminal 113, reducing the contact resistance and improving the conductivity.

[0202] The clamp 30 ensures a tight connection between the wire clamp 232 and the flat terminal 113.

[0203] Furthermore, the force applied by the elastic unit 32 to the clamping portion 232 ranges from 3N to 200N.

[0204] To verify the effect of the pressure applied by the elastic unit 32 to the clamping part 232 on the contact resistance and insertion / removal of the flat terminal 113 with a large eccentricity after insertion, the inventors selected flat wire cores 111 and clamping parts 232 of the same size and specifications, applied different pressures by the elastic unit 32 to the clamping part 232, and then selected flat terminals 113 with the same eccentricity to be inserted into the clamping part 232. The contact resistance between the terminals after insertion and the proportion of successful insertion of the flat terminal 113 in multiple insertion / removal experiments were tested. The test results are shown in Table 7.

[0205] Contact resistance testing method: Using a microresistance meter, place one end of the measuring terminal on the flat terminal 113 and the other end on the clamp terminal 213. The placement positions are the same for each measurement. Then, read the contact resistance reading on the microresistance meter. In this embodiment, a contact resistance greater than 1mΩ is considered unacceptable.

[0206] The method for testing the insertion success rate is as follows: The pressure value applied by each elastic unit 32 to the clamping part 232 is used to insert it with 100 flat terminals 113 with the same eccentricity. The number of successful insertions in one attempt is recorded, and the result is multiplied by 100% by the total number of insertions. In this embodiment, an insertion success rate of less than 95% is considered unqualified.

[0207] Table 7: Effects of different pressures on contact resistance and mating success rate

[0208]

[0209] As shown in Table 7, when the pressure applied by the elastic unit 32 to the wire clamping part 232 is less than 3N, although the mating success rate is acceptable, the contact resistance between the mating terminal 23 and the wire clamping part 232 is greater than 1mΩ, which is too high. When the pressure applied by the elastic unit 32 to the wire clamping part 232 is greater than 200N, the mating success rate is less than 95%, which cannot meet the application requirements. Therefore, the inventors set the pressure applied by the elastic unit 32 to the wire clamping part 232 to be 3N-200N.

[0210] Furthermore, the elastic unit 32 can be an elastic rubber body, a spring, or a metal spring. The elastic unit 32 can be an elastic rubber body, relying on the elastic force of the compressed elastic rubber body to ensure the pressure applied to the clamping part 232; the elastic unit 32 can be a compression spring, relying on the elastic force of the compressed spring to ensure the pressure applied to the clamping part 232; the elastic unit 32 can also be a metal spring, which is integrally formed with the clamp 30. It can be a single-ended spring with one end fixed and the other end free, or a double-ended spring with both ends fixed and a protrusion in the middle. The pressure applied to the clamping part 232 is ensured by the elastic force of the metal spring itself.

[0211] In one embodiment, the clamping portion 232 of the mating terminal 23 is formed by stacking multiple layers of sheet terminals 234, with grooves formed in the sheet terminals 234 for mating and mating with the flat strip 11. The flat terminal 113 can be inserted into the groove and electrically connected to the clamping portion 232. The groove clamps the flat terminal 113 of the flat strip 11, fixing the flat strip 11 and the mating terminal 23 together and providing a large contact area between them, ensuring the reliability of the electrical connection. By adjusting the width of the groove or the number of sheet terminals 234, the clamping force can be controlled to facilitate adaptation to the flat terminal 113 and meet various mating requirements.

[0212] like Figure 5As shown, the mating terminal 23 is composed of multiple sheet terminals 234 stacked together. The sheet terminals 234 are easy to deform and can be plugged into the flat terminals 113 of the flat strip 11. The flat terminals 113 of the flat strip 11 contact the grooves of the sheet terminals 234 to achieve electrical connection, which can ensure the stability of the connection between the mating terminal 23 and the flat strip 11.

[0213] Specifically, the clamping part 232 is formed by stacking multiple layers of sheet terminals 234, and a groove is formed in the sheet terminal 234. The groove is inserted into the flat terminal 113 of the flat strip 11 to achieve electrical connection.

[0214] In some embodiments, the gap between two adjacent sheet terminals 234 is less than 0.2 mm. The purpose of this gap is to allow airflow between the sheet terminals 234, which reduces the temperature rise between the flat terminal 113 and the mating terminal 23, protects the conductive anti-corrosion layer of the flat terminal 113, extends the service life of the flat terminal 113, and ensures the mating force between the flat terminal 113 and the mating terminal 23. When the gap is greater than 0.2 mm, it does not increase heat dissipation; instead, it causes the mating terminal 23 with the same contact area to occupy a larger width, wasting space.

[0215] In some embodiments, the sheet terminal 234 is at least partially made of a shape memory alloy. As previously described, a shape memory alloy is a smart metal with memory properties; its microstructure has two relatively stable states. At high temperatures, this alloy can be molded into any desired shape, and at lower temperatures, it can be stretched. However, if reheated, it remembers its original shape and reverts to its original form. The crystal structure of a shape memory alloy differs above and below its transformation temperature. When the temperature changes around the transformation temperature, the shape memory alloy contracts or expands, causing its shape to change. In some embodiments, the shape memory alloy is a nickel-titanium alloy.

[0216] Furthermore, the deformation temperature of the shape memory alloy is set within the range of 40℃-70℃. When the temperature of the sheet terminal 234 is lower than this deformation temperature, the multiple grooves are in an expanded state; when the temperature of the sheet terminal 234 is higher than this deformation temperature, the multiple grooves are in a clamped state.

[0217] Under normal circumstances, the abnormal temperature is set within the range of 40℃-70℃. This is because if the abnormal temperature is below 40℃, the ambient temperature of the plug terminal 23 will also reach close to 40℃ without conducting current. At this time, the multiple sheet terminals 234 will be clamped, the groove of the plug terminal 23 will become smaller, and the flat terminal 113 will not be able to be inserted into the plug terminal 23. This will cause the flat terminal 113 and the plug terminal 23 to fail to connect, and thus the plug terminal 23 will not be able to work.

[0218] At room temperature, the flat terminal 113 begins to conduct electricity after being plugged into the plug terminal 23. Since the multiple sheet terminals 234 are in an expanded state at the beginning of the plugging, the contact area between the flat terminal 113 and the plug terminal 23 is small, and the current is large. This causes the sheet terminals 234 to start to heat up after plugging. If the abnormal temperature is higher than 70°C, the plug terminal 23 will heat up for a long time. The plugging structure of the flat terminal 113 and the plug terminal 23 will be in a high current state for a long time, which can easily cause electrical aging. In severe cases, it can overload and damage the plugging structure of the flat terminal 113 and the plug terminal 23, causing unnecessary losses.

[0219] Therefore, the transformation temperature of shape memory alloys is generally set between 40℃ and 70℃.

[0220] The mating terminal 23 has a memory function. Below the abnormal temperature, the groove of the mating terminal 23 is usually in an expanded state. At this time, the flat terminal 113 of the flat strip 11 can achieve insertion force-free connection, making it easy for operators to plug and unplug electrical appliances. During operation, the mating terminal 23 conducts current. Due to the resistance, the temperature of the mating terminal 23 gradually increases. When the temperature rises above the abnormal temperature, the groove of the mating terminal 23 will radially shrink. The increase in temperature increases the contact area and contact force between the groove of the mating terminal 23 and the flat terminal 113 of the flat strip 11, improving the reliability of the contact. Since the insertion force requirement is eliminated, the work is easier and the work efficiency is improved.

[0221] In one embodiment, the female end housing 22 is integrally injection molded to form an insulating structure on at least a portion of the outer periphery of the mating terminal 23. The connection mechanism in this embodiment uses an injection-molded female end housing 22, which is simple to process, has low cost, and can be directly injection molded onto the outside of the mating terminal 23 for insulation.

[0222] In one embodiment, the female terminal connection mechanism 20 further includes a cable 21 electrically connected to the mating terminal 23. The mating terminal 23 and at least a portion of the cable 21 are disposed within the female terminal housing 22, with at least a portion of the mating terminal 23 exposed outside the female terminal housing 22. Through the cable 21 connected to the mating terminal 23, and the electrical connection between the mating terminal 23 and the flat terminal 113, the flat strip 11 and the cable 21 can be electrically connected, thereby achieving circuit conduction and enabling current conduction.

[0223] In one embodiment, the clamping portion 232 at least partially protrudes from the outer wall of the female end housing 22, or the female end housing 22 is provided with an open boss, and the clamping portion 232 is at least partially disposed within the open boss. In the above embodiment, the flat terminal 113 protrudes from the male end housing 12 and can be mated to the clamping portion 232 disposed within the open boss. Alternatively, the male end housing 12 has a groove, and the flat terminal 113 protrudes from the bottom surface of the groove but does not extend beyond the male end housing 12, and can be mated to the clamping portion 232 protruding from the outer wall of the female end housing 22.

[0224] In one implementation, such as Figure 8 As shown, the female connection mechanism 20 has a high-voltage interlock structure 24, which is electrically connected to the interlock connector 14 to form a circuit. High-voltage interlock is a safety design method that uses a low-voltage signal to monitor the integrity of the high-voltage circuit. It monitors the unexpected disconnection of the high-voltage circuit to prevent damage to the vehicle due to sudden loss of power. The high-voltage interlock in this embodiment is as follows... Figure 13 As shown, one end is an interlock connector 14, which is a U-shaped or V-shaped low-voltage circuit with two pins that are electrically connected. The other end is a female connection mechanism 20, which connects two terminals of the low-voltage circuit and the terminals of the high-voltage interlock structure 24. The terminals of the high-voltage interlock structure 24 are matched and connected with the pins of the interlock connector 14 to form a low-voltage monitoring circuit. When the connection mechanism in this embodiment is accidentally disconnected, the interlock connector 14 and the high-voltage interlock structure 24 will also be disconnected at the same time. The low-voltage monitoring circuit will alarm the central control system to prevent the car from being damaged due to sudden loss of power.

[0225] The embedded high-voltage interlock structure 24 replaces the previous assembled high-voltage interlock. It is fixed in the connector by one-piece injection molding, eliminating the need for assembly, reducing costs, and fully meeting the high-voltage interlock effect.

[0226] In one embodiment, the female terminal connection mechanism 20 and / or the male terminal connection mechanism 10 have a sealing structure 40. The sealing structure 40 can seal the flat terminal 113, the mating terminal 23, and part of the flat strip 11 and the cable 21 into the connection mechanism, preventing external dust and water from damaging and corroding the internal conductive mechanism, and greatly extending the service life of the connection mechanism.

[0227] Furthermore, the sealing structure 40 is formed by secondary injection molding on the female end housing 22 and / or the male end housing 12. The sealing structure 40 of the connecting mechanism no longer uses a separate sealing ring, but instead adopts a secondary injection molded sealing structure 40 to replace the traditional sealing ring. It can be directly molded on the connecting mechanism, resulting in better injection molding adhesion and reduced costs.

[0228] Furthermore, the sealing structure 40 is made of rubber, soft rubber, or silicone. These materials allow for easy processing and bonding by heating and melting them in an injection molding machine, thus significantly extending the service life of the sealing structure 40. Additionally, these materials possess good elasticity, allowing them to deform under pressure during assembly and fill gaps, achieving excellent sealing performance. Moreover, the materials are water and oil resistant, ensuring a long service life and safe sealing performance for the sealing structure 40.

[0229] Furthermore, the maximum gap between the sealing structure 40 and the male end connection mechanism 10 and / or the female end connection mechanism 20 is less than 520 nm.

[0230] To verify the influence of the gap size between each sealing structure 40 and adjacent devices on the sealing level, the inventors used the dry air method to test the sealing device. By evacuating or pressurizing the air, the pressure difference between the inside and outside of the test sample was controlled. If leakage exists, the pressure difference between the inside and outside will decrease. The sealing performance can be detected by detecting changes in air pressure. The test medium is dry air, which is non-toxic and harmless and does not damage the test sample. At the same time, the test environment is clean and tidy. Taking the test of the sealing structure 40 set on the male end connection mechanism as an example, the inventors completely sealed other connection points after the male end connection mechanism 10 and the female end connection mechanism 20 were connected. Sealing structures 40 with different sealing degrees were selected, and some dry air in the sealing structure 40 was extracted so that the air pressure inside the sealing structure 40 was lower than the external air pressure. The internal air pressure of the sealing structure 40 was continuously monitored. If the air pressure increased, it was considered unqualified. The test results are shown in Table 8.

[0231] Table 8. The effect of the maximum clearance between the sealing structure 40 and the male end connection mechanism 10 and / or the female end connection mechanism 20 on air pressure changes.

[0232] Maximum gap (nm) 530 520 500 450 400 350 300 280 260 Has the air pressure changed? yes no no no no no no no no

[0233] As shown in Table 8, when the maximum gap between the sealing structure 40 and the male end connection mechanism 10 and / or the female end connection mechanism 20 exceeds 520 nm, the gas pressure changes, indicating that gas has entered the sealing structure 40, and the test fails. Therefore, the inventors selected a maximum gap of not less than 520 nm between the sealing structure 40 and the male end connection mechanism 10 and / or the female end connection mechanism 20.

[0234] In one embodiment, the female terminal connection mechanism 20 and / or the male terminal connection mechanism 10 have at least one temperature sensing structure for measuring the temperature of the mating terminal 23 and / or the flat strip 11 and / or the flat terminal 113. The temperature sensing structure can be at a certain distance from the mating terminal 23 and / or the flat strip 11. Heat radiation from the mating terminal 23 and / or the flat strip 11 is transferred to the temperature sensing structure, which then measures the temperature of the mating terminal 23 and / or the flat strip 11. Alternatively, the temperature sensing structure may include a conductive element that is in contact with the mating terminal 23 and / or the flat strip 11. The temperature of the mating terminal 23 and / or the flat strip 11 is measured by the temperature transferred through the conductive element. This data is then transmitted to the control system to adjust the current flowing through the mating terminal 23 and / or the flat strip 11, thereby adjusting the temperature of the female terminal connection mechanism 20 or the male terminal connection mechanism 10.

[0235] Furthermore, the temperature sensing structure is attached to the mating terminal 23 and / or the flat strip 11 and / or the flat terminal 113 to measure the temperature of the mating terminal 23 and / or the flat strip 11 and / or the flat terminal 113. The temperature sensing structure is a temperature sensor that directly attaches to the mating terminal 23 and / or the flat strip 11 and / or the flat terminal 113, allowing direct acquisition of the actual temperature of the mating terminal 23 and / or the flat strip 11 and / or the flat terminal 113. This eliminates the need for calculations to obtain the actual temperature of the mating terminal 23 and / or the flat strip 11 and / or the flat terminal 113, resulting in a simpler structure and more accurate temperature measurement.

[0236] In one embodiment, the male-end connection mechanism 10 has at least one temperature-sensing structure, and there are at least two flat strips 11. The temperature-sensing structure is located between the flat strips 11 and is used to measure the temperature of the flat strips 11. By placing the temperature-sensing structure between the flat strips 11, the heat conducted by multiple flat strips 11 can be obtained simultaneously, which can balance the heat generation of multiple flat strips 11. This not only saves the number of temperature-sensing structures, but also allows direct acquisition of the highest temperature of multiple flat strips 11, thus playing a good role in temperature control of the flat strips 11.

[0237] The temperature measuring structure can be a temperature sensor, which can be an NTC temperature sensor or a PTC temperature sensor, to monitor the temperature of the male terminal connection mechanism 10 or the female terminal connection mechanism 20 in a timely and accurate manner.

[0238] The temperature sensor is either an NTC or PTC temperature sensor. The advantages of using these two types of temperature sensors are: small size, ability to measure gaps that other thermometers cannot; ease of use, with resistance values ​​selectable between 0.1 and 100 kΩ; easy to process into complex shapes, allowing for mass production; good stability and strong overload capacity, making them suitable for products like adapters that require small size and stable performance.

[0239] The use of a temperature measuring mechanism allows for independent monitoring of the terminal temperature inside the connection mechanism, preventing the inability to monitor the temperature of the connection mechanism due to damage to temperature sensors in other locations.

[0240] Furthermore, the male end connection mechanism 10 and the female end connection mechanism 20 are connected by one or more of the following methods: adhesive connection, magnetic connection, bayonet connection, plug connection, locking connection, bundling connection, threaded connection, rivet connection and welding connection.

[0241] In the first feasible technical solution, an adhesive structure can be adopted, such as providing adhesive layers on the surfaces to be spliced ​​of the male end connection mechanism 10 and the female end connection mechanism 20, and fixing the two together by adhesive bonding.

[0242] In the second feasible technical solution, a magnetic attraction structure can be adopted. For example, magnetic attraction components are also provided on the surfaces to be spliced ​​of the male end connection mechanism 10 and the female end connection mechanism 20, making the connection convenient and quick.

[0243] In the third feasible technical solution, a plug-in structure can be adopted. The outer shell of the male end connection mechanism 10 is provided with a pin, and the outer surface of the outer shell of the female end connection mechanism 20 is provided with a slot. After the pin is inserted into the slot, it is fixedly connected, thereby fixing the male end connection mechanism 10 and the female end connection mechanism 20 together, and realizing the connection between the male end connection mechanism 10 and the female end connection mechanism 20.

[0244] In the fourth feasible technical solution, a snap-fit ​​structure can be adopted. For example, a snap-fit ​​is provided on the male end shielding shell 14 of the male end connection mechanism 10, and a slot is provided on the female end of the female end connection mechanism 20. After the snap-fit ​​and the slot are assembled, they are fixedly connected, thereby fixing the male end connection mechanism 10 and the female end connection mechanism 20.

[0245] In the fifth feasible technical solution, a bolted connection structure can be adopted. This structure includes a bolt and a nut. The bolt is fixed to the surface to be joined on the male end connecting mechanism 10, and the nut is set on the surface to be joined on the female end connecting mechanism 20 and is rotatable. After the bolt and nut are screwed together and tightened, the surfaces to be joined on the male end connecting mechanism 10 and the female end connecting mechanism 20 are fixedly connected. The bolted connection structure uses bolts and nuts with a minimum size of M3, and the minimum tightening torque is 0.2 N·m.

[0246] In the sixth feasible technical solution, a riveting structure can be adopted. The riveting structure includes a rivet and a fixing hole. The fixing hole is set on the surface of the male end connecting mechanism 10 and the female end connecting mechanism 20 to be spliced. The rivet passes through the fixing hole and deforms the end through which the rivet passes, so that the fixing hole is tightened, thereby fixing the surface of the male end connecting mechanism 10 and the female end connecting mechanism 20 to be spliced ​​to be fixedly connected.

[0247] In the seventh feasible technical solution, a welding structure can be adopted. For example, the welded parts are placed on the surfaces to be joined between the male end connecting mechanism 10 and the female end connecting mechanism 20. A welding machine is used to melt and connect the welded parts together, thereby fixing the surfaces to be joined between the male end connecting mechanism 10 and the female end connecting mechanism 20. The welding machine includes a hot melt welding machine and an ultrasonic welding machine.

[0248] In the eighth feasible technical solution, a bundling structure can be adopted. The bundling structure includes bundling components. Grooves are provided on the surfaces of the male end connecting mechanism 10 and the female end connecting mechanism 20. The bundling components are used to bundle the surfaces of the male end connecting mechanism 10 and the female end connecting mechanism 20 to be spliced ​​together at the groove positions, thereby fixing the splicing surfaces of the male end connecting mechanism 10 and the female end connecting mechanism 20 together. The bundling components include cable ties, pipe clamps, hooks, etc.

[0249] In the ninth feasible technical solution, a locking structure can be adopted. The locking structure includes a locking element, which is located on the adjacent surface of the male end connecting mechanism 10 and the female end connecting mechanism 20 to be spliced, or on the surface to be spliced. The splicing surfaces of the male end connecting mechanism 10 and the female end connecting mechanism 20 are fixedly connected by the locking element.

[0250] In one embodiment, the mating terminal 23 includes a wire clamping portion 232, and the flat terminal 113 is mated with the wire clamping portion 232 to form an electrical connection. The mating force between the flat terminal 113 and the wire clamping portion 232 is between 3N and 150N.

[0251] To verify the effect of the insertion force between the flat terminal 113 and the clamping part 232 on the contact resistance and insertion condition of the flat strip 11 and the mating terminal 23, the inventors selected flat strip 11 and mating terminal 23 of the same shape and size, and designed the insertion force between the flat strip 11 and the mating terminal 23 to be different, in order to observe the contact resistance between the flat strip 11 and the mating terminal 23, as well as the condition after multiple insertions.

[0252] The contact resistance is detected by using a micro resistance meter to measure the resistance at the contact position between the flat terminal 113 and the clamping part 232, and the value on the micro resistance meter is read as the contact resistance between the flat terminal 113 and the clamping part 232. In this embodiment, a contact resistance of less than 50μΩ is an ideal value.

[0253] The test method for the mating of the flat terminal 113 and the clamping part 232 is to perform 50 matings between the flat terminal 113 and the clamping part 232, and observe the number of times the terminal falls off after being inserted and removed and the number of times it cannot be inserted or removed. The number of times the terminal falls off after being inserted and removed should be less than 3 times, and the number of times it cannot be inserted or removed should be less than 5 times.

[0254] Table 9 shows the effect of different flat terminal 113 and wire clamp 232 on contact resistance and mating condition:

[0255]

[0256] As can be seen from Table 9 above, when the insertion force between the flat terminal 113 and the wire clamp 232 is less than 3N, the contact resistance between them is higher than the ideal value due to the insufficient bonding force. Furthermore, the terminal falls off more than three times after insertion and removal, indicating a substandard condition. When the insertion force between the flat terminal 113 and the wire clamp 232 is greater than 150N, the terminal cannot be inserted or removed more than five times, also indicating a substandard condition. Therefore, the inventors set the insertion force between the flat terminal 113 and the wire clamp 232 to be between 3N and 150N.

[0257] As can be seen from Table 9 above, when the insertion force between the flat terminal 113 and the wire clamp 232 is between 10N and 130N, there is neither a case of falling off after insertion and removal nor a case of being unable to insert or remove, and the contact resistance value is also within the ideal range. Therefore, the inventors have set the preferred insertion force between the flat terminal 113 and the wire clamp 232 to be between 10N and 135N.

[0258] In one embodiment, the contact resistance between the flat terminal 113 and the mating terminal 23 is less than 9 mΩ. Preferably, the contact resistance between the flat terminal 113 and the mating terminal 23 is less than 1 mΩ. Generally, a large current needs to be conducted between the flat terminal 113 and the mating terminal 23. If the contact resistance between the flat terminal 113 and the mating terminal 23 is greater than 9 mΩ, a large temperature rise will occur at the contact point, and the temperature will increase over time. Excessive temperature between the flat terminal 113 and the mating terminal 23 will cause asynchronous mechanical deformation between the conductive anti-corrosion layer and the flat terminal 113, and between the mating terminal 23 and the terminal plating, due to differences in materials and thermal expansion rates. This results in internal stress between the conductive anti-corrosion layer and the flat terminal 113, and between the mating terminal 23 and the terminal plating. In severe cases, this can cause the conductive anti-corrosion layer and the terminal plating to peel off, failing to provide protection. Secondly, excessively high temperatures between the flat terminal 113 and the mating terminal 23 can conduct heat to the insulation layer of the flat strip 11 and the insulation layer of the wires connected to the mating terminal 23, causing the corresponding insulation layers to melt and fail to provide insulation protection. In severe cases, this can lead to short circuits, damage to the connection structure, or even fires and other safety accidents. Therefore, the inventors have set the contact resistance between the flat terminal 113 and the mating terminal 23 to be less than 9mΩ.

[0259] To verify the effect of the contact resistance between the flat terminal 113 and the mating terminal 23 on the temperature rise and conductivity of the connection mechanism, the inventors selected the same flat strip 11, mating terminals 23 with different contact resistances, and tested the conductivity and temperature rise of the mating structure.

[0260] The conductivity test involves inserting the flat terminal 113 into the mating terminal 23, energizing the connection structure, and then measuring the conductivity at the mating point. In this embodiment, a conductivity greater than 99% is considered ideal.

[0261] The temperature rise test involves passing the same current through the connector structure in a closed environment and measuring the temperature at the same location on the flat terminal 113 and the mating terminal 23 before power-on and after the temperature has stabilized, and then taking the absolute value of the difference. In this embodiment, a temperature rise greater than 50K is considered unacceptable.

[0262] Table 10 shows the effect of contact resistance between different flat terminals 113 and mating terminals 23 on conductivity and temperature rise.

[0263]

[0264] As can be seen from Table 10 above, when the contact resistance between the flat terminal 113 and the mating terminal 23 is greater than 9mΩ, the temperature rise of the mating structure exceeds 50K, and the conductivity of the mating structure is also less than 99%, which does not meet the standard requirements. Therefore, the inventors set the contact resistance between the flat terminal 113 and the mating terminal 23 to be less than 9mΩ. Furthermore, the inventors found that when the contact resistance is less than 1mΩ, the temperature rise is significantly reduced, and the conductivity is also higher. Therefore, the invention preferably sets the contact resistance between the flat terminal 113 and the mating terminal 23 to be less than 1mΩ.

[0265] In one embodiment, the number of insertions and removals between the male terminal connection mechanism 10 and the female terminal connection mechanism 20 is greater than or equal to 9 times. When assembling the connection mechanism with the electrical device, the male terminal connection mechanism 10 and the female terminal connection mechanism 20 need to be assembled together. Subsequent maintenance or component disassembly may require separating the male terminal connection mechanism 10 and the female terminal connection mechanism 20 before insertion and removal. Therefore, the number of insertions and removals between the male terminal connection mechanism 10 and the female terminal connection mechanism 20 cannot be less than 9 times. If it is less than 9 times, the male terminal connection mechanism 10 or the female terminal connection mechanism 20 may be damaged during a disassembly or maintenance process and may not be able to carry the current. In this case, the entire connection mechanism, including the wiring harness, would need to be replaced, which would not only consume maintenance time but also increase maintenance costs. Therefore, regardless of the material selection of the male terminal connection mechanism 10 and the female terminal connection mechanism 20, or the design of the insertion and removal mechanism, locking mechanism, and sealing mechanism between the male terminal connection mechanism 10 and the female terminal connection mechanism 20, they need to undergo at least 9 disassembly and assembly cycles to meet the usage requirements of the connection mechanism.

[0266] In one embodiment, the weight of the male-end connection mechanism 10 is less than or equal to 305g. For example... Figure 1 As shown, the male connector is located above the connection mechanism and is plugged into and fixed to the female connection mechanism 20. When the weight of the male connection mechanism 10 is too large, the female connection mechanism 20 will also receive a large force. When the electrical device vibrates, the entire connection mechanism will vibrate. Due to inertia, the male connection mechanism 10 will be subjected to a large vibration and will make abnormal noise. Abnormal noise is not allowed during the use of the electrical device.

[0267] To verify the effect of the weight of the male end connection mechanism 10 on the abnormal noise of the connection mechanism, the inventors used the same female end connection mechanism 20 and male end connection mechanism 10 samples with different weights, assembled them, installed them on the vibration test bench, and conducted vibration tests. They observed whether the male end connection mechanism 10 produced abnormal noise during the vibration test. The test results are shown in Table 11.

[0268] Table 11 shows the effect of the weight of the male-end connection mechanism 10 on the abnormal noise generated by the connection mechanism.

[0269] Weight (g) 265 275 285 295 305 315 325 335 345 Is there any unusual noise? no no no no no yes yes yes yes

[0270] As shown in Table 11, when the weight of the male end connection mechanism 10 exceeds 305g, abnormal noise occurs during the vibration test, and the test fails. Therefore, the inventor selected a weight of less than or equal to 305g for the male end connection mechanism 10.

[0271] In one embodiment, the height of the male terminal connection mechanism 10 along the insertion / removal direction is less than or equal to 108 mm. After the male terminal connection mechanism 10 and the female terminal connection mechanism 20 are assembled together, they need to be installed in the electrical appliance. However, in general, the space reserved in the electrical appliance is relatively small. If the male terminal connection mechanism 10 is too high, it will be impossible to install it in the electrical appliance, and it will also be a waste of raw materials. Therefore, the male terminal connection mechanism 10 needs to be designed to be lower than a certain height.

[0272] To verify the effect of the height of the male terminal connection mechanism 10 along the insertion / removal direction on the installation of the connection mechanism, the inventors used the same female terminal connection mechanism 20 and samples of male terminal connection mechanisms 10 with different heights along the insertion / removal direction. After assembly, they installed them on the electrical device and observed whether the male terminal connection mechanism 10 interfered with other components of the electrical device during the installation process. The test results are shown in Table 12.

[0273] Table 12. Influence of the height of the male connection mechanism 10 along the insertion / removal direction on the installation of the connection mechanism.

[0274] Height (mm) 68 78 88 98 108 118 128 138 148 Interference no no no no no yes yes yes yes

[0275] As shown in Table 12, when the height of the male terminal connection mechanism 10 along the insertion / removal direction is greater than 108mm, it cannot be installed in the designated position of the electrical device, and the test fails. The height of the male terminal connection mechanism 10 along the insertion / removal direction is less than or equal to 108mm.

[0276] The present invention also provides an electrical power transmission device, which includes the above-described connecting mechanism.

[0277] The present invention also provides a motor vehicle, which includes the above-described connecting mechanism and power transmission device.

[0278] The connecting mechanism of the present invention features an injection-molded male end shell 12, which is simple to process and has a low cost. It can be directly injection-molded into the flat strip 11 for insulation, which can reduce the installation of the flat strip 11. Furthermore, the front end of the flat strip 11 can be molded into various shapes as required without considering assembly issues, thus saving processing steps and reducing processing costs.

[0279] The connection mechanism of the present invention, with the flat strips 11 stacked and spaced appropriately, can effectively reduce the electromagnetic interference caused to other components after the flat strips 11 are energized, thereby eliminating the need for the high-voltage charging harness shielding layer structure and achieving the requirements of reducing cost and weight.

[0280] The flat strip 11 can be made of materials containing aluminum or aluminum alloys, which are lighter and cheaper, and can better meet the requirements of energy conservation, emission reduction and cost reduction of motor vehicles.

[0281] The flat strip 11 does not need to be made into a flat terminal 113 separately. It can be used as a flat terminal 113 simply by bending and chamfering the front end of the flat wire core 111. This saves the processing cost of the flat terminal 113, reduces the connection between the flat wire core 111 and the flat terminal 113, reduces the voltage drop of the flat strip 11, and improves the mechanical and electrical performance of the connection mechanism.

[0282] In the connection between the flat terminal 113 and the mating terminal 23, the conductive anti-corrosion layer can reduce the electrochemical reaction between the flat terminal 113 and the mating terminal 23 of the flat strip 11, thus solving the technical problem that the flat strip 11 needs to be connected to other terminals or electrical devices through copper terminals.

[0283] The mating terminal 23 is composed of multiple sheet terminals 234 stacked together. The sheet terminals 234 are easy to deform and can be plugged into the flat terminals 113 of the flat strip 11. The flat terminals 113 of the flat strip 11 contact the strip grooves of the sheet terminals 234 to achieve electrical connection, which can ensure the stability of the connection between the mating terminal 23 and the flat strip 11.

[0284] By connecting the flat terminal 113 to the mating terminal 23, the flat terminal 113 of the flat strip 11 performs the function of a terminal itself and connects directly to the mating terminal 23, which solves the problem of high cost and low efficiency of connecting copper terminals to the flat strip 11, and enables safe and fast plugging and unplugging.

[0285] The mating terminal 23 has a memory function. Below the abnormal temperature, the strip groove of the mating terminal 23 is usually in an expanded state. At this time, the flat terminal 113 of the flat strip 11 can achieve insertion force-free connection, making it easy for operators to plug and unplug electrical appliances. During operation, the mating terminal 23 conducts current. Due to the resistance, the temperature of the mating terminal 23 gradually increases. When the temperature rises above the abnormal temperature, the strip groove of the mating terminal 23 will radially shrink. The increase in temperature increases the contact area and contact force between the strip groove of the mating terminal 23 and the flat terminal 113 of the flat strip, improving the reliability of the contact. Since the insertion force requirement is eliminated, the work is easier and the work efficiency is improved.

[0286] The embedded high-voltage interlock structure 24 replaces the previous assembled high-voltage interlock. It is fixed in the connection mechanism by one-piece injection molding, eliminating the need for assembly, reducing costs, and fully meeting the high-voltage interlock effect.

[0287] The sealing structure of the connecting mechanism no longer uses a separate sealing ring, but adopts a secondary injection molding sealing structure to replace the traditional sealing ring. It can be directly molded onto the connecting mechanism, resulting in better injection molding bonding and reduced costs.

[0288] The use of a temperature measuring mechanism allows for independent monitoring of the terminal temperature inside the connection mechanism, preventing the inability to monitor the temperature of the connection mechanism due to damage to temperature sensors in other locations.

[0289] The above descriptions are merely a few embodiments of the present invention. Those skilled in the art can make various modifications or variations to the embodiments of the present invention based on the content disclosed in the application documents without departing from the spirit and scope of the present invention.

Claims

1. A connection mechanism comprising a male connection mechanism and a female connection mechanism, characterized in that, The male connecting mechanism comprises a flat ribbon, a flat terminal and a male shell connected with the flat ribbon and the flat terminal, the female connecting mechanism comprises a mating terminal and a female shell connected with the mating terminal, the male connecting mechanism and the female connecting mechanism are electrically connected through the flat terminal and the mating terminal, and the male shell is connected with the female shell to form the connecting mechanism, The flat ribbon comprises at least two independent flat ribbons, and the flat ribbons are stacked in an up-down manner, The flat ribbon comprises a flat ribbon core as a conductive part of the flat ribbon, and a front end of the flat ribbon core is bent to form the flat terminal, The male shell is integrally injection molded on at least part of the flat ribbon and the flat terminal to form an insulation structure.

2. The connection mechanism of claim 1, wherein The length-width ratio of the cross section of the flat ribbon is 1:1-120:

1.

3. The connection mechanism of claim 1, wherein The flat ribbon further comprises an outer insulation layer, and the outer insulation layer is partially stripped to expose the flat ribbon core, and an end of the outer insulation layer is in or abuts against the male shell.

4. The connection mechanism of claim 1, wherein The hardness of the flat ribbon core is 8HV-105HV.

5. The connection mechanism of claim 1, wherein The vertical distance between the two flat ribbon cores is less than or equal to 27cm.

6. The connection mechanism of claim 5, wherein, The vertical distance between the two flat ribbon cores is less than or equal to 7cm.

7. The connection mechanism of claim 1, wherein The overlapping degree of the two flat ribbon cores in the stacking direction is 40%-100%.

8. The attachment mechanism of claim 1, wherein, The flat terminal at least partially protrudes from the male shell, or the male shell has a receiving cavity, and the flat terminal at least partially protrudes from the bottom surface of the receiving cavity but does not exceed the male shell.

9. The attachment mechanism of claim 1, wherein, The flat ribbon core and the flat terminal comprise a bending part therebetween, and the angle of the bending part is 0°-180°.

10. The attachment mechanism of claim 1, wherein, The flat terminal is at least partially provided with a conductive anti-corrosion layer.

11. The connection mechanism of claim 10, wherein, The thickness of the conductive anti-corrosion layer is 0.3μm to 3000μm.

12. The connection mechanism of claim 11, wherein, The thickness of the conductive anti-corrosion layer is 2.5μm to 1000μm.

13. The attachment mechanism of claim 1, wherein, An end of the flat terminal is provided with a chamfer.

14. The attachment mechanism of claim 1, wherein, The male connecting mechanism comprises an interlocking connector which is at least partially integrally injection molded in the male shell.

15. The attachment mechanism of claim 1, wherein, The mating terminal comprises a fixed part and a wire clamping part, and the female connecting mechanism further comprises a cable, the fixed part is electrically connected with a conductive part at the front end of the cable, and the wire clamping part is electrically connected with the flat terminal.

16. The connection mechanism of claim 15, wherein, The wire clamping part is sleeved with a clamp, and the material of the clamp is a memory alloy.

17. The connection mechanism of claim 16, wherein, The metamorphic temperature of the memory alloy is set in the range of 40℃-70℃, the clamp is in an expanded state when the temperature of the clamp is lower than the metamorphic temperature, and the clamp is in a clamped state when the temperature of the clamp is higher than the metamorphic temperature.

18. The attachment mechanism of claim 15, wherein, The wire clamping part is sleeved with a clamp, and the clamp comprises a side wall and an elastic unit fixed on the side wall, and the elastic unit is in contact with the outside of the wire clamping part.

19. The connection mechanism of claim 18, wherein, The force range of the elastic unit applied to the wire clamping part is 3N-200N.

20. The attachment mechanism of claim 18, wherein, The elastic unit is an elastic rubber body, a spring or a metal spring.

21. The attachment mechanism of claim 15, wherein, The wire clamping part of the mating terminal is formed by stacking a plurality of sheet-shaped terminals, and a groove is formed in the sheet-shaped terminal to match the flat ribbon for mating connection.

22. The attachment mechanism of claim 21, wherein, The gap between two adjacent sheet-shaped terminals is less than 0.2mm.

23. The attachment mechanism of claim 21, wherein, The material of the sheet terminal is at least partially memory alloy.

24. The attachment mechanism of claim 23, wherein, The transformation temperature of the memory alloy is set in the range of 40-70℃, and the plurality of grooves are in the expanded state when the temperature of the sheet terminal is lower than the transformation temperature, and the plurality of grooves are in the clamped state when the temperature of the sheet terminal is higher than the transformation temperature.

25. The attachment mechanism of claim 1, wherein, The female end shell is integrally injection molded to form an insulation structure on at least part of the periphery of the plug-in terminal.

26. The attachment mechanism of claim 1, wherein, The female end connecting mechanism further comprises a cable electrically connected to the plug-in terminal, and the plug-in terminal and at least part of the cable are arranged in the female end shell, and the plug-in terminal is at least partially exposed outside the female end shell.

27. The attachment mechanism of claim 15, wherein, The wire clamping part at least partially protrudes from the outer wall of the female end shell, or the female end shell is provided with an open boss, and the wire clamping part is at least partially arranged in the open boss.

28. The attachment mechanism of claim 14, wherein, The female end connecting mechanism has a high-voltage interlock structure, which is electrically connected to the interlock connector to form a loop.

29. The attachment mechanism of claim 1, wherein, The female end connecting mechanism and / or the male end connecting mechanism have a sealing structure.

30. The attachment mechanism of claim 29, wherein, The sealing structure is a secondary injection molding on the female end shell and / or the male end shell.

31. The attachment mechanism of claim 1, wherein, The female end connecting mechanism and / or the male end connecting mechanism have at least one temperature measuring structure for measuring the temperature of the plug-in terminal and / or the flat ribbon and / or the flat terminal.

32. The attachment mechanism of claim 31, wherein, The temperature measuring structure is in contact with the plug-in terminal and / or the flat ribbon and / or the flat terminal to measure the temperature of the plug-in terminal and / or the flat ribbon and / or the flat terminal.

33. The attachment mechanism of claim 1, wherein, The male end connecting mechanism has at least one temperature measuring structure between different flat ribbons to measure the temperature of the flat ribbons.

34. The attachment mechanism of claim 1, wherein, The male end connecting mechanism and the female end connecting mechanism are connected by one or more of the following methods: adhesive connection, magnetic attraction connection, bayonet connection, plug-in connection, lock connection, bundling connection, threaded connection, rivet connection and welding connection.

35. The attachment mechanism of claim 1, wherein, The plug-in terminal comprises a wire clamping part, and the flat terminal is electrically connected to the wire clamping part by plug-in connection, and the plug-in force between the flat terminal and the wire clamping part is between 3N and 150N.

36. The attachment mechanism of claim 35, wherein, The plug-in force between the flat terminal and the wire clamping part is between 10N and 130N.

37. The attachment mechanism of claim 1, wherein, The contact resistance between the flat terminal and the plug-in terminal is less than 9mΩ.

38. The attachment mechanism of claim 37, wherein, The contact resistance between the flat terminal and the plug-in terminal is less than 1mΩ.

39. The attachment mechanism of claim 1, wherein, The number of plug-in times between the male end connecting mechanism and the female end connecting mechanism is greater than or equal to 9 times.

40. The attachment mechanism of claim 1, wherein, The weight of the male end connecting mechanism is less than or equal to 305g.

41. The attachment mechanism of claim 1, wherein, The height of the male end connecting mechanism in the plug-in direction is less than or equal to 108mm.

42. An electrical power transfer device, comprising: The connecting mechanism according to any one of claims 1-41.

43. A motor vehicle characterized by The connecting mechanism according to any one of claims 1-41.

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