A portable high-current metal bar connector

Abstract

This invention relates to the field of automotive parts technology, and in particular to a convenient high-current metal busbar connector, comprising a plug housing, an aluminum busbar assembly, a socket assembly, and a plug assembly. The plug housing has a horizontal channel and a vertical channel connected to the horizontal channel. The aluminum busbar assembly inserted in the vertical channel connects to the plug assembly located in the horizontal channel. The plug assembly connects to the socket assembly located at the rear end of the plug housing. A plug cover for closing the horizontal channel is detachably mounted at the front end of the plug housing. The plug housing is connected to the socket assembly via mounting bolts. This invention enables short-term ultra-high current transmission of 600A and long-term stable current of 500A, and provides single-socket waterproof sealing, achieving dual protection for the battery pack, optimizing panel sealing, and meeting the requirements for durable and long-lasting device waterproofing.

Description

Technical Field

[0001] This invention relates to the field of automotive parts technology, and in particular to a convenient high-current metal busbar connector. Background Technology

[0002] Electric vehicles are a popular mode of transportation in today's society. They do not cause exhaust pollution, thus enjoying a unique market in cities. As a convenient daily mode of transportation, they are ideal for short- and medium-range use, possessing excellent development conditions and broad application prospects. With market development and improved living standards, electric vehicles are constantly adding new functions. Therefore, conventional charging connectors can no longer meet the technical requirements and safety guarantees of fast charging. Furthermore, conventional charging connectors face many limitations in fast charging design: 1. It is difficult to achieve a stable current of 400A or higher; 2. The cost of using copper wire bundles for high current is significant, as copper's high density and weight hinder energy conservation, emission reduction, and lightweighting in automobiles; 3. The instability of the overload capacity of conventional male and female terminals poses a significant challenge; 4. The sealing and waterproof performance of connectors is particularly important due to environmental factors such as rain, severe weather, and dust. Poor sealing and water infiltration can lead to short circuits, abnormal charging current transmission, and shortened product lifespan. Summary of the Invention

[0003] The present invention aims to overcome the above-mentioned defects and provide a convenient high-current metal busbar connector.

[0004] To overcome the deficiencies in the prior art, the technical solution adopted by the present invention to solve its technical problem is: a convenient high-current metal busbar connector, including a plug housing, an aluminum busbar assembly, a socket assembly, and a plug assembly. The plug housing is provided with a horizontal channel and a vertical channel connected to the horizontal channel. The aluminum busbar assembly inserted in the vertical channel is connected to the plug assembly provided in the horizontal channel. The plug assembly is connected to the socket assembly located at the rear end of the plug housing. The front end of the plug housing is detachably provided with a plug cover for covering the horizontal channel. The plug housing is connected to the socket assembly by mounting bolts.

[0005] The aluminum busbar assembly includes two symmetrically staggered aluminum busbars, a plug back cover, a plug metal busbar clip, a tail cover mating sealing ring, and a plug rear inner shell. The two aluminum busbars are sequentially inserted into the plug back cover, the plug metal busbar clip, the tail cover mating sealing ring, and the plug rear inner shell. The plug back cover is snapped into the plug outer shell.

[0006] The plug assembly includes an inner plug shell that snaps into a horizontal channel, an upper cover sealing ring embedded in the front end of the plug shell, a plug mating sealing ring embedded in the rear end of the plug shell, and a plug front cover embedded in the horizontal channel. The plug front cover presses against the plug mating sealing ring, and the upper cover sealing ring fits against the plug upper cover.

[0007] The socket assembly includes a socket long terminal connected to two aluminum busbars, a socket outer shell inserted into the plug housing, a socket inner shell inserted into the socket outer shell, a panel waterproof sealing ring, and an installation interface. The socket inner shell is snapped into the plug front cover. The socket long terminal passes through the plug front cover, the socket inner shell, and the installation interface in sequence. The panel waterproof sealing ring is embedded in the socket outer shell. The end surfaces of the aluminum busbars connected to the socket long terminal are sequentially coated with a nickel plating layer and a silver plating layer.

[0008] Further improvements include connecting the two aluminum busbars to the long terminal of the socket via mounting bolts, and welding a silver-plated copper ring to the side where the aluminum busbars are connected to the long terminal of the socket via laser welding.

[0009] Further improvements include connecting the two aluminum busbars to the long terminal of the socket via assembly bolts, and welding a silver-plated copper sheet to the side of the aluminum busbars connected to the long terminal of the socket via molecular diffusion welding.

[0010] Further improvements include the plug cover being rotatably mounted around a pivot center on the plug housing, with a plug cover spring fitted on the pivot for pressing the plug cover, and the plug cover being connected to the plug housing via mounting bolts.

[0011] Further improvements include a long key located inside the socket housing and embedded in a keyway on the long terminal of the socket.

[0012] Further improvements include the socket housing comprising a mounting plate and an annular cylinder connected to the side of the mounting plate, the mounting plate having an interface for engaging with the inner shell of the socket, the annular cylinder being inserted into an annular groove at the rear end of the plug housing, and the inner wall of the annular cylinder being fitted with a plug mating sealing ring.

[0013] Further improvements include the alignment of the notch on the annular cylinder with the window on the inner shell of the plug.

[0014] Further improvements include the socket inner shell comprising two terminal tubes for embedding long terminals of the socket and a connecting plate connecting the two terminal tubes, the connecting plate being embedded in the socket outer shell and fitting the panel waterproof sealing ring.

[0015] Further improvements include embedding a terminal O-ring seal on the long terminal of the socket.

[0016] Further improvements include inserting a metal bar lock key between the two aluminum bars to restrict the vertical movement of the aluminum bars.

[0017] The beneficial effects of this invention are: it has high current stable transmission capability; 1) it requires a temperature resistance higher than the assembly's temperature limit and can still work effectively in an environment of 85 degrees Celsius.

[0018] 2) The product can achieve a short-term ultra-high current transmission of 600A and a long-term stable current of 500A.

[0019] 3) The single socket is sealed and waterproof, providing dual protection for the battery pack.

[0020] 4) Optimize panel sealing to ensure durable and long-lasting waterproofing of equipment.

[0021] 5) Use bolt connections to ensure reliable and stable plug and socket connections.

[0022] 6) The aluminum busbar stamping and welding process is adopted, which saves costs and reduces the switching resistance.

[0023] 7) Using aluminum busbars as conductors meets the current demand for lightweight vehicles and reduced fuel consumption.

[0024] 8) Aluminum busbars can be bent, replacing traditional wiring.

[0025] 9) Optimize the waterproof performance inside the connector, that is, the sealing between the internal terminals and the connector, to ensure that the function of stable current transmission and signal operation is safe.

[0026] 10) The screw-in structure improves the reliability of the connector and ensures that there is no risk of loosening under severe vibration or misoperation. Attached Figure Description

[0027] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0028] Figure 1 This is an exploded view of the present invention;

[0029] Figure 2 This is an assembly diagram of the aluminum busbar and the long terminal of the socket in this invention;

[0030] Figure 3 This is a side view of the aluminum busbar shaft in this invention. Figure 1 ;

[0031] Figure 4 This is a side view of the aluminum busbar shaft in this invention. Figure 2 ;

[0032] Figure 5 This is an exploded view of the socket assembly in this invention;

[0033] Figure 6This is an assembly diagram of the socket assembly in this invention;

[0034] Figure 7 This is a cross-sectional view of the assembly shaft of the present invention. Figure 1 ;

[0035] Figure 8 This is an isometric view of the plug housing and plug assembly assembly in this invention;

[0036] Figure 9 This is an exploded view of the plug in this invention;

[0037] Figure 10 This is an assembly view of the plug in this invention;

[0038] Figure 11 This is a side sectional view of the plug and aluminum busbar assembly of the present invention.

[0039] Figure 12 This is a cross-sectional view of the socket assembly in this invention;

[0040] Figure 13 This is an assembly side view of the present invention;

[0041] In the diagram: 1-Aluminum strip, 2-Plug rear cover, 3-Plug metal strip clip, 4-Tail cover mating seal ring, 5-Plug rear inner shell, 6-Plug outer shell, 7-Plug top cover, 8-Plug top cover spring, 9-Shaft, 10-Plug upper inner shell, 11-Assembly bolt, 12-Metal strip locking key, 13-Top cover seal ring, 14-Plug mating seal ring, 15-Plug front cover, 16-Terminal O-ring seal, 17-Socket long terminal, 18-Socket outer shell, 19-Socket inner shell, 20-Panel waterproof seal ring, 21-Installation interface, 22-Keyway, 23-Silver-plated copper ring, 24-Silver-plated copper sheet, 25-Mating interface, 26-Annular cylinder, 27-Notch, 28-Mounting plate, 29-Terminal cylinder, 30-Connecting plate, 31-Annular groove, 32-Long key, 33-Horizontal channel, 34-Vertical channel. Detailed Implementation

[0042] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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, 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.

[0043] according to Figure 1 , Figure 2 , Figure 5 , Figure 6 , Figure 7 , Figure 8, Figure 9 , Figure 10 , Figure 11 , Figure 12 and Figure 13 As shown, a convenient high-current metal busbar connector includes a plug housing 6, an aluminum busbar assembly, a socket assembly, and a plug assembly. The plug housing 6 has a horizontal channel 33 and a vertical channel 34 connected to the horizontal channel 33. The aluminum busbar assembly inserted in the vertical channel 34 is connected to the plug assembly in the horizontal channel 33. The plug assembly is connected to the socket assembly located at the rear end of the plug housing 6. The front end of the plug housing 6 is detachably provided with a plug cover 7 for covering the horizontal channel 33. The plug housing 6 is connected to the socket assembly by mounting bolts 11.

[0044] The aluminum busbar assembly includes two symmetrically staggered aluminum busbars 1, a plug rear cover 2, a plug metal busbar clip 3, a tail cover mating sealing ring 4, and a plug rear inner shell 5. The two aluminum busbars 1 are sequentially inserted into the plug rear cover 2, the plug metal busbar clip 3, the tail cover mating sealing ring 4, and the plug rear inner shell 5. The plug rear cover 2 is snapped into the plug outer shell 6.

[0045] The socket assembly includes an inner shell 10 of the plug that snaps into the horizontal channel 33, an upper cover sealing ring 13 embedded in the front end of the plug outer shell 6, a plug mating sealing ring 14 embedded in the rear end of the plug outer shell 6, and a front cover 15 of the plug embedded in the horizontal channel 33. The front cover 15 of the plug presses against the plug mating sealing ring 14, and the upper cover sealing ring 13 fits against the upper cover 7 of the plug.

[0046] according to Figure 9 As shown, the socket assembly includes a socket long terminal 17 connected to two aluminum busbars 1 respectively, a socket housing 18 inserted into the plug housing 6, a socket inner housing 19 inserted into the socket housing 18, a panel waterproof sealing ring 20, and a mounting interface 21. The socket inner housing 19 is snapped into the plug front cover 15. The socket long terminal 17 passes through the plug front cover 15, the socket inner housing 19, and the mounting interface 21 in sequence. The panel waterproof sealing ring 20 is embedded in the socket housing 18. The end surface of the aluminum busbar 1 connected to the socket long terminal 17 is sequentially provided with a nickel plating layer and a silver plating layer. The nickel-based silver plating method is used to reduce the overall contact resistance.

[0047] By employing the above-described implementation method, multiple sealing rings are provided in the plug assembly, socket assembly, and aluminum busbar assembly, thereby optimizing the waterproof performance of the connector's interior, i.e., the sealing performance of the internal terminals and the connector. This ensures that the function of stable current and signal transmission operates under safe conditions. Furthermore, the bolted connection between the plug and socket enhances the reliability of the connector, ensuring that there is no risk of loosening under severe vibration or misoperation.

[0048] This device can achieve short-term ultra-high current transmission of 600A and long-term stable current of 500A. It also features a single-socket sealed waterproof design, providing dual protection for the battery pack. The panel sealing is optimized to meet the requirements for durable and long-lasting waterproofing, exceeding the temperature resistance limit of the entire assembly. It can still work effectively in an environment of 85 degrees Celsius.

[0049] according to Figure 1 , Figure 3 and Figure 4 As shown, the two aluminum busbars 1 are connected to the socket long terminal 17 by mounting bolts 11. On the side where the aluminum busbar 1 is connected to the socket long terminal 17, a silver-plated copper ring 23 is welded by laser welding. Laser welding can destroy the contact part between the silver-plated copper ring 23 and the aluminum busbar 1, so that the contact part between the silver-plated copper ring 23 and the socket long terminal 17 is well preserved.

[0050] The two aluminum busbars 1 are connected to the socket long terminal 17 via mounting bolts 11. On the side where the aluminum busbar 1 connects to the socket long terminal 17, a silver-plated copper sheet 24 is welded using molecular diffusion welding. This welding method ensures that the plating layer is relatively well preserved, thus reducing contact resistance. The connection between the aluminum busbar 1 and the socket long terminal 17 enhances the stability and reliability of the connector, facilitates the replacement of the socket long terminal 17, and improves the sustainability of the connector's use.

[0051] according to Figure 9 and Figure 10 As shown, the plug cover 7 is rotatably mounted around the center of the rotating shaft 9 provided on the plug housing 6. A plug cover spring 8 for pressing the plug cover 7 is sleeved on the rotating shaft 9. The plug cover 7 is connected to the plug housing 6 by mounting bolts 11. With the above embodiment, the plug cover 7 and the plug housing 6 are integrated into one piece, which makes it convenient and quick to open and close the cover, and realizes rapid assembly and separation.

[0052] according to Figure 2 and Figure 7 As shown, the long key 32 provided inside the socket inner shell 19 is embedded in the keyway 22 opened on the socket long terminal 17, so as to realize the function of the long key 32 stopping the socket long terminal 17.

[0053] according to Figure 5 As shown, the socket housing 18 includes a mounting plate 28 and an annular cylinder 26 connected to the side of the mounting plate 28. The mounting plate 28 has a mating interface 25 that engages with the socket inner housing 19. The annular cylinder 26 is inserted into an annular groove 31 at the rear end of the plug housing 6. The inner wall of the annular cylinder 26 is fitted with a plug mating sealing ring 14. The mating sealing ring 14 prevents water from entering through the gap between the annular cylinder 26 and the plug housing 6, ensuring the sealing of the plug and socket connection.

[0054] according to Figure 9As shown, the notch 27 on the annular cylinder 26 aligns with the window 35 on the inner shell 10 of the plug, facilitating the connection between the aluminum busbar 1 and the long terminal 17 of the socket.

[0055] The socket inner shell 19 includes two terminal tubes 29 for embedding the socket long terminals 17 and a connecting plate 30 connecting the two terminal tubes 29. The connecting plate 30 is embedded in the socket outer shell 18 and fits the panel waterproof sealing ring 20.

[0056] according to Figure 12 As shown, a terminal O-ring 16 is embedded on the long terminal 17 of the socket. The terminal O-ring 16 can prevent water from entering the plug assembly along the direction of the long terminal 17 of the socket.

[0057] according to Figure 1 As shown, a metal bar lock key 12 is inserted between the two aluminum bars 1 to restrict the up and down movement of the aluminum bars 1.

[0058] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A convenient high-current metal busbar connector, characterized in that, The device includes a plug housing (6), an aluminum busbar assembly, a socket assembly, and a plug assembly. The plug housing (6) has a horizontal channel (33) and a vertical channel (34) connected to the horizontal channel (33). The aluminum busbar assembly inserted in the vertical channel (34) is connected to the plug assembly in the horizontal channel (33). The plug assembly is connected to the socket assembly located at the rear end of the plug housing (6). The front end of the plug housing (6) is detachably provided with a plug cover (7) for covering the horizontal channel (33). The plug housing (6) is connected to the socket assembly by mounting bolts (11). The aluminum busbar assembly includes two symmetrically staggered aluminum busbars (1), a plug back cover (2), a plug metal busbar clip (3), a tail cover mating sealing ring (4), and a plug rear inner shell (5). The two aluminum busbars (1) are sequentially inserted into the plug back cover (2), the plug metal busbar clip (3), the tail cover mating sealing ring (4), and the plug rear inner shell (5). The plug back cover (2) is snapped into the plug outer shell (6). The plug assembly includes an inner shell (10) of the plug that snaps into the horizontal channel (33), a top cover sealing ring (13) embedded in the front end of the plug outer shell (6), a plug mating sealing ring (14) embedded in the rear end of the plug outer shell (6), and a front cover (15) of the plug embedded in the horizontal channel (33). The front cover (15) of the plug presses against the plug mating sealing ring (14), and the top cover sealing ring (13) fits against the top cover (7) of the plug. The socket assembly includes a socket long terminal (17) connected to two aluminum busbars (1), a socket housing (18) inserted into the plug housing (6), a socket inner housing (19) inserted into the socket housing (18), a panel waterproof sealing ring (20), and an installation interface (21). The socket inner housing (19) is snapped into the plug front cover (15). The socket long terminal (17) passes through the plug front cover (15), the socket inner housing (19), and the installation interface (21) in sequence. The panel waterproof sealing ring (20) is embedded in the socket housing (18). The end surface of the aluminum busbar (1) connected to the socket long terminal (17) is sequentially provided with a nickel plating layer and a silver plating layer.

2. The convenient high-current metal busbar connector as described in claim 1, characterized in that: The two aluminum bars (1) are connected to the socket long terminal (17) by assembly bolts (11), and a silver-plated copper ring (23) is welded to the side where the aluminum bars (1) are connected to the socket long terminal (17) by laser welding.

3. A convenient high-current metal busbar connector as described in claim 1, characterized in that: The two aluminum busbars (1) are connected to the socket long terminal (17) by assembly bolts (11), and the side of the aluminum busbar (1) connected to the socket long terminal (17) is welded with a silver-plated copper sheet (24) by molecular diffusion welding.

4. A convenient high-current metal busbar connector as described in claim 1, characterized in that: The plug cover (7) is rotatably mounted around the center of the pivot (9) on the plug housing (6). A plug cover spring (8) for pressing the plug cover (7) is mounted on the pivot (9). The plug cover (7) is connected to the plug housing (6) by mounting bolts (11).

5. A convenient high-current metal busbar connector as described in claim 1, characterized in that: The long key (32) provided inside the socket inner shell (19) is embedded in the keyway (22) opened on the socket long terminal (17).

6. A convenient high-current metal busbar connector as described in claim 1, characterized in that: The socket housing (18) includes a mounting plate (28) and an annular cylinder (26) connected to the side of the mounting plate (28). The mounting plate (28) has a mating interface (25) that engages with the socket inner housing (19). The annular cylinder (26) is inserted into an annular groove (31) at the rear end of the plug housing (6). The inner wall of the annular cylinder (26) is fitted with a plug mating sealing ring (14).

7. A convenient high-current metal busbar connector as described in claim 6, characterized in that: The notch (27) on the annular cylinder (26) aligns with the window (35) on the inner shell (10) of the plug.

8. A convenient high-current metal busbar connector as described in claim 1, characterized in that: The socket inner shell (19) includes two terminal tubes (29) for embedding the socket long terminals (17) and a connecting plate (30) connecting the two terminal tubes (29). The connecting plate (30) is embedded in the socket outer shell (18) and fits the panel waterproof sealing ring (20).

9. A convenient high-current metal busbar connector as described in claim 1, characterized in that: The socket long terminal (17) is fitted with a terminal O-ring (16).

10. A convenient high-current metal busbar connector as described in claim 1, characterized in that: A metal bar lock key (12) is inserted between the two aluminum bars (1) to restrict the up and down movement of the aluminum bars (1).

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