Connector comprising a cooling fan

Abstract

A large current connector according to the present application can include a terminal member through which a large current can flow, a connector housing in which the terminal member is received, a temperature sensor attached to the terminal member, a fan unit placed in the connector housing and provided to operate when a temperature of the terminal member is higher than a predetermined threshold temperature, and an exhaust cover placed at a side of the connector housing and opened / closed by wind pressure when the fan unit operates.

Description

Technical Field

[0001] This disclosure relates to a connector, and more particularly, to a connector that includes a cooling fan and is capable of cooling the connector terminals when the temperature of the connector terminals rises by automatically controlling the cooling fan.

[0002] This application claims priority to Korean Patent Application No. 10-2020-0136066, filed in Korea on October 20, 2020, the disclosure of which is incorporated herein by reference. Background Technology

[0003] Recently, secondary batteries have been widely used not only for powering or storing energy in small devices (such as portable electronic devices), but also for powering or storing energy in large and medium-sized devices (such as electric vehicles). Secondary batteries are housed in battery packs and installed in large or medium-sized devices. In this case, to increase the capacity and output of the battery pack, a large number of secondary batteries are electrically connected within the pack. Multiple secondary batteries are housed in a module housing to form a battery module, and one or more battery modules are housed in a battery pack housing to form a battery pack.

[0004] The battery pack is connected to a load or charger via connectors. A load refers to a device that receives power from the battery pack, such as the motor or inverter of an electric vehicle. Electric vehicles require high voltages of 300V or higher and high currents ranging from tens to hundreds of amperes (A). Accordingly, connectors capable of withstanding high heat for power supply are used to connect the battery pack to the load.

[0005] However, with a continuous supply of high current, heat can intensify at the contact points of the connectors used for power supply, potentially leading to reduced power efficiency and fire risk. Accordingly, a suitable method for managing the temperature of connectors used for power supply is needed. Summary of the Invention

[0006] Technical issues

[0007] This disclosure is designed to address problems in the related art, and therefore aims to provide a connector including a cooling device that can cool the connector used for high current transmission when the temperature of the connector rises.

[0008] However, the technical problems to be solved by this disclosure are not limited to those described above, and other technical problems will be understood by those skilled in the art based on the following description.

[0009] Technical solution

[0010] A connector for high current according to an embodiment of this disclosure includes: a terminal member capable of high current transmission; a connector housing containing the terminal member; a temperature sensor attached to the terminal member; a fan unit disposed within the connector housing and configured to operate when the temperature of the terminal member is above a preset threshold temperature; and an exhaust cover disposed on one side of the connector housing and opened / closed by air pressure when the fan unit is operating.

[0011] The controller may be located in the connector housing, the controller is connected to the temperature sensor and the fan unit, and is configured to turn the fan unit on / off based on temperature data sensed by the temperature sensor.

[0012] The controller may be further configured such that when the temperature of the terminal component reaches a dangerous temperature that has been set as a dangerous level, the controller transmits a warning sound or danger signal to an external device.

[0013] The controller can be configured as a printed circuit board.

[0014] The connector housing may include: a bottom cover including a space therein for arranging the terminal member and the fan unit located below the terminal member; and a top cover coupled to the top of the bottom cover and having an inner surface on which the printed circuit board is fixedly mounted.

[0015] The connector for high current may further include an indicator light electrically connected to the printed circuit board, the indicator light being located in a hole formed in the top cover, and the indicator light indicating the temperature status of the terminal component.

[0016] The bottom cover may include ventilation holes in a portion corresponding to the lower part of the fan unit, and the exhaust cover may be configured to cover the ventilation holes.

[0017] The exhaust cover can be connected to the bottom cover via a damper hinge.

[0018] The damper hinge can be configured to apply torque in the direction of closing the exhaust cover and have a value less than the wind pressure at the lowest speed of the fan unit.

[0019] The connector for high current may further include a suction member disposed outside the vent, wherein the edge of the vent cap contacts the bottom cover outside the vent.

[0020] According to another aspect of this disclosure, a battery pack is provided, the battery pack including the connector for high current.

[0021] Beneficial effects

[0022] According to aspects of this disclosure, a connector for high current transmission can be provided, the connector including a cooling device capable of cooling the connector for high current transmission when the temperature of the connector rises.

[0023] The connector for high current according to this disclosure includes a temperature sensor, a cooling fan, and a printed circuit board (controller) capable of controlling the temperature sensor and the cooling fan. The cooling fan automatically operates to cool the terminals when a certain temperature is reached. Furthermore, when the temperature of the terminals is equal to or higher than a dangerous temperature, the printed circuit board can transmit a signal to an external device (e.g., a battery management system (BMS)) to cut off the power supply and ensure safety.

[0024] The effects of this disclosure are not limited to those mentioned above, and other effects not mentioned will be clearly understood by those skilled in the art based on the specification and accompanying drawings. Attached Figure Description

[0025] Figure 1 This is a perspective view showing a connector for high current according to an embodiment of the present disclosure.

[0026] Figure 2 It shows along Figure 1 A cross-sectional view of a connector used for high current, taken from the I-I' line.

[0027] Figure 3 It shows along Figure 1 A longitudinal cross-sectional view of a connector for high current, taken from line II-II'.

[0028] Figure 4 This is a view illustrating a cooling structure for a high-current connector according to an embodiment of the present disclosure.

[0029] Figure 5 It is shown Figure 4 A magnified view of part A.

[0030] Figure 6 This is a view showing the main components of a connector for high current according to an embodiment of the present disclosure. Detailed Implementation

[0031] Preferred embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings. Before the description, it should be understood that the terminology used in the specification and appended claims should not be construed as limited to its general and dictionary meaning, but rather interpreted based on the meaning and concept corresponding to the technical aspects of the present disclosure, on the basis of allowing the inventors to appropriately define the terminology for best interpretation. Therefore, the descriptions presented herein are merely preferred examples for illustrative purposes and are not intended to limit the scope of the present disclosure; thus, it should be understood that other equivalents and modifications can be made thereto without departing from the scope of the present disclosure.

[0032] These embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of this disclosure to those skilled in the art. Accordingly, for clarity, the thickness and dimensions of each element shown in the figures may be exaggerated, omitted, or drawn schematically. Accordingly, the dimensions of each element do not perfectly reflect the actual dimensions or ratios.

[0033] The high-current connector described in this disclosure is a component applied to a battery pack, which can be used to supply power from the battery pack to the inverter or motor of an electric vehicle. The following description is based on the assumption that the high-current connector is used to supply high voltage and high current from the battery pack to the load of the electric vehicle.

[0034] However, the connector for high current according to this disclosure should not be limited to one of the components used in a battery pack. That is, the connector for high current according to this disclosure can be used to electrically connect a power source and a device, electrically connect devices to devices, or electrically connect internal units of a device, rather than electrically connecting a battery pack.

[0035] Figure 1 This is a perspective view showing a connector for high current according to an embodiment of the present disclosure. Figure 2 It shows along Figure 1 A cross-sectional view of a connector used for high current, taken from the I-I' line. Figure 3 It shows along Figure 1 A longitudinal cross-sectional view of a connector for high current, taken from line II-II'.

[0036] refer to Figures 1 to 3 The connector for high current according to the embodiments of the present disclosure includes a terminal member 10, a connector housing 20, a temperature sensor 30, a fan unit 40, a controller 50, and an exhaust cover 23.

[0037] The terminal member 10 includes a positive electrode terminal 11 and a negative electrode terminal 12. The terminal member 10 is electrically connected to the terminals of other connectors in the battery pack, and serves as a channel for high current flow. Although the terminal member 10 described in this embodiment is a straight pin-shaped member that is connected to or disconnected from the terminals of the battery pack in an insert manner, this is merely an example, and the terminal member 10 can be changed to any different shape depending on the connection method of the mating male / female connectors.

[0038] The connector housing 20, which forms the exterior of the connector for high current, can accommodate the terminal member 10 and allows the high-voltage cable C connected to the terminal member 10 to be pulled back.

[0039] The connector housing 20 described in this embodiment includes a bottom cover 21, a top cover 27, and a flange 28.

[0040] The bottom cover 21 can be configured to house and secure the terminal member 10, and the top cover 27 can be attached to the top of the bottom cover 21. The bottom cover 21 and the top cover 27 can be fastened by a snap-fit ​​assembly, and an adhesive can be located at the interface between the bottom cover 21 and the top cover 27.

[0041] The fan unit 40 can be disposed in the space between the terminal member 10 and the bottom surface of the bottom cover 21, and the ventilation hole 22 can be formed in the bottom surface of the bottom cover 21. Under normal circumstances, the ventilation hole 22 is closed by the exhaust cover 23.

[0042] The top cover 27 can be configured such that the controller 50 is mounted on a portion of the inner surface corresponding to the vertical upper portion of the terminal member 10. For example, the controller 50 can be implemented as a printed circuit board, and the portion 27a of the top cover 27 corresponding to the vertical upper portion of the terminal member 10 can have a shape that matches the printed circuit board.

[0043] The flange 28 can be connected to the front of the bottom cover 21 and the top cover 27. The flange 28 may include: a blocking portion into which the positive electrode terminal 11 and the negative electrode terminal 12 are fixedly inserted; and a bracket portion surrounding the front of the bottom cover 22 and the top cover 27. Holes H into which bolts can be inserted may be formed in the corner region of the bracket portion. For example, a high-current connector can be connected to other connectors in the battery pack, and then, by means of bolts that can be inserted into the holes H of the flange 28, the high-current connector can be secured to the housing (not shown) of other connectors.

[0044] The temperature sensor 30 used to monitor temperature changes of the terminal component 10 may include a positive temperature coefficient (PTC) thermistor whose resistance increases with increasing temperature, or a negative temperature coefficient (NTC) thermistor whose resistance decreases with increasing temperature.

[0045] The thermistor is used as a sensor to convert thermal signals into electrical signals, which is well known in the art, and therefore its detailed description will be omitted.

[0046] The temperature sensor 30 is attached to the terminal member 10. In this embodiment, two temperature sensors 30 may be provided, each of which may be attached to at least a portion of the positive electrode terminal 11 and the negative electrode terminal 12, and may be connected to the controller 50 via wires. The temperature sensor 30 senses the temperature of the positive electrode terminal 11 and the negative electrode terminal 12 when a large current flows, and transmits the temperature information to the controller 50.

[0047] The controller 50 can be configured to perform the following control function: turn the fan unit 40 on / off based on temperature data sensed by the temperature sensor 30.

[0048] For example, the controller 50 can be connected to the fan unit 40 via a wire (not shown) to transmit power and signals, and can be configured to compare temperature data sensed by the temperature sensor 30 with a preset threshold temperature, and when the temperature data is higher than the threshold temperature, apply drive power and signals to the fan unit 40 to operate the fan unit 40.

[0049] The threshold temperature is the temperature at which power efficiency may decrease as the terminal temperature increases. The threshold temperature can be determined experimentally based on the material and size of the terminal component 10, the amplitude of the large current, etc.

[0050] Furthermore, the controller 50 can be configured to transmit a warning sound or danger signal to an external device when the temperature of the terminal component 10 reaches a dangerous temperature that has been set as a dangerous level.

[0051] The hazardous temperature set as a dangerous level is a high temperature at which the connector housing 20 may catch fire due to the heat of the terminal component 10. The hazardous temperature can be determined by testing based on the materials of the terminal component 10 and the connector housing 20.

[0052] For example, when the temperature of the positive electrode terminal 11 and the negative electrode terminal 12 continuously rises and reaches a dangerous temperature (e.g., 100°C), the controller 50 can transmit a danger signal to the battery management system (BMS), causing the BMS to open the contacts of the main relay device based on the danger signal to block the flow of a large current.

[0053] The controller 50 can be implemented as a printed circuit board, and processors, application-specific integrated circuits (ASICs), other chipsets, logic circuits, registers, communication modems, and data processing devices known in the art can be selectively disposed on the printed circuit board.

[0054] Indicator lights 51a and 51b can be disposed on the top cover 27. Indicator lights 51a and 51b, used to indicate the temperature status of the terminal component 10, can be electrically connected to the printed circuit board and can be located in holes formed in the top cover 27.

[0055] For example, the indicator lights 51a and 51b may include a red indicator light 51a and a green indicator light 51b. The green indicator light 51b can be controlled to illuminate when the temperature of the terminal component 10 is lower than a preset threshold temperature. The red indicator light 51a can be controlled to illuminate when the temperature of the terminal component 10 is equal to or higher than a preset threshold temperature. By checking whether the indicator lights 51a and 51b are illuminated, the user can determine whether the temperature of the terminal component 10 is currently within a normal or abnormal range. If the red indicator light 51a is illuminated but the fan unit 40 is not operating, there is a problem with the controller 50 or the fan unit 40, and therefore necessary measures should be taken quickly.

[0056] In the connector for high current according to this disclosure, the fan unit 40 is located in the connector housing 20 in order to cool the terminal member 10 more effectively and quickly when high voltage / high current flows.

[0057] Thus, when the fan unit 40 is located within the connector housing 20, a ventilation hole 22 is required to exhaust hot air to the outside when the fan unit 40 is running. Accordingly, in this embodiment, the ventilation hole 22 is provided in the portion of the bottom cover 21 corresponding to the lower part of the fan unit 40.

[0058] However, the vent 22 may serve as a channel through which fluid or dust may be introduced into the connector housing 20. Accordingly, the connector for high current described in this disclosure includes an exhaust cover 23 configured to normally close the vent 22 and to be selectively opened when the fan unit 40 is in operation.

[0059] For example, the exhaust cover 23 can be configured to be connected to the bottom cover 21 via a damper hinge 24, thereby remaining closed during normal operation, while the exhaust cover 23 is open when the fan unit 40 is running. Figure 4 The ground shown is opened by wind pressure.

[0060] The damper hinge 24 may include a damper and two metal members. The damper may include a body forming the exterior, blades disposed within the body, silicone oil, and a rotational shaft connected to the blades and extending into and out of the body, and may be configured to apply a torque of a certain magnitude to the rotational shaft. The two metal members may be connected to the rotational shaft of the damper and may be configured to rotate in the direction in which the torque is applied.

[0061] One of the two metal parts of the damper hinge 24 is fixedly connected to the outer surface of the bottom cover 21, and the other metal part is fixedly connected to the exhaust cover 23. In this configuration, when the torque direction of the damper hinge 24 is set to the direction in which the exhaust cover 23 is closed, the vent 22 can normally be kept closed by the exhaust cover 23 due to the torque of the damper hinge 24 during normal operation.

[0062] When the maximum torque of the damper hinge 24 is set to be less than the wind pressure at the minimum speed of the fan unit 40, the exhaust cover 23 can be opened by the wind pressure when the fan unit 40 is running, so that hot air in the connector housing 20 can be discharged to the outside through the ventilation hole 22. Then, when the temperature of the terminal component 10 returns to normal, the operation of the fan unit 40 can be stopped. In this case, the exhaust cover 23 can return to its initial position due to the torque of the damper hinge 254 to close the ventilation hole 22 again.

[0063] like Figure 4 and Figure 5 As shown, a suction member 60 may be further provided outside the vent 22, at which the edge of the exhaust cap 23 contacts the bottom cover 21. The suction member 60 can hold the exhaust cap 23 to prevent repeated opening / closing of the exhaust cap 23 during impact or vibration.

[0064] The suction member 60 can be formed of silicone resin material and can be configured as a suction cup shape capable of vacuum suction. In order to ensure space for the suction member 60 and improve the sealing properties of the corresponding part, the exterior of the vent 22 can have stepped surfaces T1, T2, and the edge of the exhaust cover 23 can be formed to correspond to the stepped surfaces T1, T2.

[0065] Thus, although the damper hinge 24 is used in this embodiment and the exhaust cover 23 is opened / closed by wind pressure when the fan unit 40 is running, a method using a coil spring instead of the damper hinge 24 could be considered.

[0066] Next, refer to Figure 6 The operating mechanism of the connector for high current according to embodiments of this disclosure is briefly described.

[0067] A connector for high current can be connected to other power connectors 100 located on one side of the battery pack. The power connector 100 forms a female / male pair with the high current connector described in this embodiment, and may include a positive electrode plug 101 and a negative electrode plug 102 that can be electrically connected to the positive electrode terminal 11 and the negative electrode terminal 12, respectively.

[0068] The positive / negative electrode plug and positive / negative electrode terminals 11 and 12 are connected, high voltage / high current flows through the positive / negative electrode terminals 11 and 12, and the temperature of the contact portion between the positive / negative electrode terminals 11 and 12 begins to rise.

[0069] Temperature changes at the positive / negative electrode terminals 11 and 12 are sensed by the temperature sensor 30 and transmitted to the controller 50. The controller 50 can monitor the temperature changes at the positive / negative electrode terminals 11 and 12 in real time and can transmit the temperature changes to an external device or BMS. In this case, the controller 50 and the external device or BMS can be configured to transmit and receive signals wired or wirelessly.

[0070] When the temperature of the positive / negative electrode terminals 11 and 12 is equal to or higher than a certain temperature, i.e., a preset threshold temperature, the controller 50 activates the fan unit 40. In this case, the rotational speed of the fan unit 40 can be set to increase or decrease based on temperature data by the controller 50.

[0071] Accordingly, the temperature of the positive / negative electrode terminals 11, 12 can be reduced again to below the threshold temperature, thereby reducing resistance loss and improving the efficiency of power supplied to loads such as electric vehicles.

[0072] Furthermore, if the temperature of the positive / negative electrode terminals 11 and 12 increases rapidly or continuously and reaches a dangerous temperature despite the fan unit 40 being operational, the controller 50 transmits a current blocking signal to the BMS for safety. In this situation, the BMS blocks current flow to the connector used for high current by controlling a relay device or the like.

[0073] According to the construction and operation of the connector for high current as described above in the embodiments of this disclosure, the terminal member 10 can be cooled to an appropriate temperature during high current transmission, thereby reducing resistance loss and improving power efficiency. Furthermore, in abnormal situations, the connector for high current can take necessary measures, such as blocking current, by applying a danger signal to an external device (e.g., BMS).

[0074] The battery pack according to this disclosure may include one or more connectors for high current described above. In addition to the connectors for high current, the battery pack may also include: battery modules comprising a plurality of battery cells electrically connected to each other; a battery pack housing in which one or more battery modules may be housed; and various means for controlling the charging / discharging of the battery modules, such as a BMS, relays, current sensors, and fuses.

[0075] The battery pack can be used in vehicles, such as electric vehicles or hybrid vehicles. It can also be used in energy storage devices or other IT products.

[0076] Although one or more embodiments of this disclosure have been described with reference to the accompanying drawings, this disclosure is not limited to the specific embodiments described above, and those skilled in the art will understand that various changes in form and detail may be made therein without departing from the scope defined by the appended claims.

[0077] Those skilled in the art will understand that when directional terms such as up, down, left, and right are used, these terms are merely for ease of interpretation and can be varied depending on the position of the target object, the observer's position, etc.

Claims

1. A connector for high current applications, comprising: Terminal components capable of transmitting large currents; A connector housing, in which the terminal components are housed; A temperature sensor, which is attached to the terminal component; A fan unit is disposed within the connector housing and configured to operate when the temperature of the terminal component is higher than a preset threshold temperature. and An exhaust cover is located on one side of the connector housing and is opened / closed by air pressure when the fan unit is running. The terminal component includes a positive electrode terminal and a negative electrode terminal, and the temperature sensor is respectively attached to at least some portions surrounding the positive electrode terminal and the negative electrode terminal.

2. The connector for high current according to claim 1, wherein, The controller is located in the connector housing, is connected to the temperature sensor and the fan unit, and is configured to turn the fan unit on / off based on temperature data sensed by the temperature sensor.

3. The connector for high current according to claim 2, wherein, The controller is further configured such that when the temperature of the terminal component reaches a dangerous temperature that has been set as a dangerous level, the controller transmits a warning sound or danger signal to an external device.

4. The connector for high current according to claim 2, wherein, The controller is configured as a printed circuit board.

5. The connector for high current according to claim 4, wherein, The connector housing includes: A bottom cover, the bottom cover including a space therein for housing the terminal member and the fan unit located below the terminal member; and A top cover is attached to the top of the bottom cover and has an inner surface on which the printed circuit board is fixedly mounted.

6. The connector for high current according to claim 5, further comprising an indicator light electrically connected to the printed circuit board, the indicator light being located in a hole formed in the top cover, and the indicator light indicating the temperature status of the terminal component.

7. The connector for high current according to claim 5, wherein, The bottom cover includes ventilation holes in a portion corresponding to the lower part of the fan unit, and the exhaust cover is configured to cover the ventilation holes.

8. The connector for high current according to claim 7, wherein, The exhaust cover is connected to the bottom cover via a damper hinge.

9. The connector for high current according to claim 8, wherein, The damper hinge is configured to apply torque in the direction of closing the exhaust cover and has a wind pressure value less than that at the lowest speed of the fan unit.

10. The connector for high current according to claim 7, further comprising a suction member disposed outside the vent, wherein the edge of the vent cap contacts the bottom cover outside the vent.

11. A battery pack comprising a connector for high current as described in any one of claims 1 to 10.

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