An electric vehicle onboard battery charging device, material and use method

Abstract

The present invention belongs to the field of power supply, power distribution and energy storage, and discloses an electric vehicle on-board battery charging device, material and use method. The material includes C / C composite material and non-metallic and metal outer surface materials and buffer insulation pads of mixed molten salt or boron nitride. The metal outer surface material is applied to the metal surface of each connection, connector and charging gun head connector in the charging device by plasma spraying or radio frequency magnetron sputtering; the mixed molten salt is prepared by ZnCl2, AlCl3 or NaCl; radio frequency magnetron sputtering is used to densely form boron nitride on the metal surface of the power connection line and the charging connection line at both ends, and then heated by high-temperature gas to form a thin film. The use method connects the power connection line, charging module, charging connection line and charging gun in sequence through the connector to form a charging circuit, and also charges and stores energy for the on-board battery of the new energy electric vehicle through the charging gun head connector. The present invention is flexible in application and has low repair costs for damaged components.

Description

Technical Field

[0001] The present invention belongs to the technical field of power supply, power distribution and electric energy storage, and in particular relates to an electric vehicle onboard battery charging device, material and use method. Background Art

[0002] With the advancement of technology and social development, new energy electric vehicles are becoming increasingly popular, especially new energy electric vehicles have become the means of transportation for many families. New energy electric vehicles include electric two-wheelers, electric three-wheelers, electric four-wheelers, multi-wheel electric trucks, and multi-wheel electric buses. At present, the charging methods of new energy electric vehicles mainly include DC charging and AC charging. The DC charging method usually uses a DC charging pile to provide a large current for charging in a short time, commonly known as fast charging. The AC charging method mainly uses an AC charging pile and a household AC power supply for a long time with a small current, commonly known as slow charging. These two methods have their own advantages and disadvantages and are suitable for different usage scenarios.

[0003] As new energy electric vehicles enter households, the charging method of charging piles is far from meeting the demand, and home charging is undoubtedly more cost-effective. In home charging, the integrated charging equipment configured by the manufacturer is usually used for charging. The existing charging equipment usually includes a charger and a charging gun. The charger is connected to the power supply through a power cord, and the charger and the charging gun are connected with a charging cable. Slow charging usually uses a small current constant voltage or constant current charging method, and the charging time is usually 5 to 8 hours, or even up to 10 to 20 hours. Due to the small current, slow charging has little effect on the life of the battery. At the same time, since it mainly uses household power, it is relatively convenient to install and use, but the charging time is long and is not very suitable for scenarios that require fast charging.

[0004] The existing AC charging principle of electric vehicles is: the plug is connected to AC power, and the DC charging current is output through the power supply control device of the control box. The DC power is connected to the charging gun through the cable, and the charging gun is inserted into the vehicle interface and connected to the vehicle battery, thereby realizing the charging of the vehicle battery of the new energy electric vehicle. Due to the frequent use of charging equipment, in the case of unstable voltage or long-term use causing the wire to bend, it will cause damage to the cable, charger or charging gun, and the entire charging device cannot be used because of the damage of a certain component. Summary of the invention

[0005] The purpose of the present invention is to address the problem that existing new energy electric vehicle charging devices are easy to damage and inconvenient to maintain, and propose a charging device, material and use method for a new energy electric vehicle on-board battery. A split charging device is provided by configuring an easy-to-connect plug-in interface. After the components of the charging device are damaged, the corresponding components can be replaced as needed, which solves the problem of component damage of the charging device conveniently, efficiently and at low cost. In order to enhance the safety and durability of the plug-in connector, the non-metallic surface of each connector in the charging device is coated with a non-metallic outer surface material layer; the metal surface of each connector in the charging device is coated with a metal outer surface material layer. The charger, charging gun, connecting wire and other components are all detachable components, which are easy to update and replace. The length of the connecting wire can also be customized as needed according to actual needs, making home charging more convenient.

[0006] In order to achieve the above object, the present invention provides the following technical solutions:

[0007] On the one hand, the present invention proposes a material for an on-board battery charging device of an electric vehicle, comprising a non-metallic outer surface material, a metal outer surface material and a buffer heat insulation pad, wherein the non-metallic outer surface material and the metal outer surface material are respectively coated on the non-metallic and metal outer surfaces of the charging device; the charging device comprises a power connection line, a charging module, a charging connection line and a charging gun which are sequentially connected through a connector; the charging gun comprises at least a gun head connector;

[0008] The non-metallic outer surface material is coated on the non-metallic surface of each connector in the charging device; the metal outer surface material is coated on the metal surface of each component, connector and gun head connector in the charging device; the non-metallic outer surface material is a C / C composite material; the metal outer surface material includes a first layer, a second layer and a third layer starting from the metal outer surface, the first layer is a mixed molten salt or boron nitride; the second layer is a synthetic resin, which is a polyester, polycarbonate, silicone polycarbonate or silicone polyurethane coating; the third layer is a magnesium oxide film; the mixed molten salt is prepared by ZnCl2, AlCl3, NaCl or a combination thereof; the boron nitride is a dense boron nitride; the first layer, the second layer and the third layer are sequentially coated on the metal outer surface; the buffer and thermal insulation pad is used for compressing the connector and the gun head connector; the material of the buffer and thermal insulation pad is plastic, rubber or microporous foam material; the rubber is prepared by mixing nitrile rubber into a natural latex / polylactic acid composite material; the natural latex / polylactic acid composite material.

[0009] The preparation of the rubber is specifically as follows: a composite material containing latex and polylactide is surface treated with a silane coupling agent, and then mixed with a silicone rubber matrix to obtain a mixture; the mixture is then vulcanized with hot air to obtain a cross-linked network rubber material, and finally the rubber material is molded using a mold.

[0010] The temperature range of the hot air vulcanization is 70 to 90° C.; the vulcanization time is 2 to 4 hours; the vulcanization pressure is 10 MPa to 20 MPa; the latex is natural latex, polyisoprene latex, emulsified latex of isoprene rubber, and natural latex modified with graphene oxide.

[0011] The preparation process of the microporous foam material is specifically as follows: high-temperature and high-pressure carbon dioxide gas is introduced into a polypropylene material matrix to prepare micron-sized micron pores which are then molded; the microporous foam material has excellent shock absorption, cushioning and heat insulation properties.

[0012] The first layer is formed by plasma spraying or radio frequency magnetron sputtering onto the metal outer surfaces of the power connection line, both ends of the charging connection line and each connector of the charging device, and then heated by high-temperature gas.

[0013] The second layer is a metal outer surface coated with a mixed molten salt or boron nitride by evaporation to spraying or sputtering; the third layer of oxide film is coated on the second layer of the metal outer surface at room temperature.

[0014] On the other hand, the present invention provides a method for using an on-board battery charging device of an electric vehicle, including electrical connection and charging; the electrical connection includes: connecting one end of a power connection line to a power plug of an AC power source, and connecting the other end of the power connection line to a first connector; electrically connecting the first connector to a second connector, and the second connector is then connected to a charger in a charging module, and the charger is electrically connected to a third connector; electrically connecting the third connector to a fourth connector; electrically connecting one end of the charging connection line to the fourth connector, and the other end to the fifth connector; electrically connecting the fifth connector to the sixth connector; electrically connecting the sixth connector to a gun head connector;

[0015] The charging specifically includes: the power plug is connected to the power supply, the first and second connectors are electrically connected by plugging, the third and fourth connectors are electrically connected by plugging, the fifth and sixth connectors are electrically connected by plugging, the gun head connector of the charging gun is connected to the charging port of the battery on the electric vehicle, and the charging device as a whole forms a charging path to charge the battery on the electric vehicle.

[0016] The method for using the on-board battery charging device of an electric vehicle also includes a charging mode and a power supply mode; the charging mode is specifically: checking whether the sixth connector is electrically connected to the charging connection line to be in full contact, and after confirmation, connecting the gun head connector to the charging port of the on-board battery; the charging gun in the power supply mode also includes an electric energy conversion unit and one or more output sockets; and the power supply mode is specifically: electrically connecting the gun head connector to the charging port of the on-board battery, and electrically connecting the output end of the electric energy conversion unit to one or more output sockets, so as to convert the electric energy of the on-board battery into direct current or alternating current, and provide battery power output to the outside through one or more output sockets.

[0017] The method for using the on-board battery charging device of an electric vehicle is to separate and disconnect the sixth connector electrically connected to the charging gun and the fifth connector electrically connected to the charging connection line, connect the input end of the power conversion unit to the charging port of the on-board battery through the gun head connector of the charging gun, and electrically connect the output end of the output power conversion unit to one or more output sockets to convert the electric energy of the on-board battery into direct current or alternating current, and provide and output the battery power to the outside through one or more output sockets.

[0018] The electric energy conversion unit includes a DC-DC converter and / or a DC-AC converter; the output socket is a DC socket and / or an AC socket, which is used to provide DC output or AC output to the outside, or to provide AC and DC output at the same time; the charging connection line is a cable including 2, 3 or 5 power conductors, and the power conductor is a rare earth alloy conductor containing copper or aluminum; the charging connection line is a cable including one or more signal lines; the charging module also includes a charging monitoring unit for detecting and displaying the charging information of the charger during the charging process and for monitoring the actual state of charge SOC of the battery to obtain relevant charging information; the charging module also includes a leakage protection unit for cutting off the charging line and stopping the charging operation when the cable is powered off, or has a leakage fault, or a surge fault; a one-button power-off switch is arranged on the housing of the charging module, and the one-button power-off switch is connected to the leakage protection unit, and when pressed, the leakage protection unit is triggered to cut off the charging line.

[0019] On the other hand, the present invention also proposes an electric vehicle onboard battery charging device, the charging device comprising a power connection line, a charging module, a charging connection line and a charging gun connected in sequence through a connector, the charging gun at least comprising a gun head connector;

[0020] The metal outer surfaces of the connector and the connecting parts in the charging device are covered with metal outer surface material;

[0021] The non-metallic outer surfaces of the connectors and connectors in the charging device are covered with non-metallic outer surface materials;

[0022] The connector in the charging device is provided with a buffer and heat-insulating pad for fastening the connector.

[0023] Beneficial effects:

[0024] Compared with the prior art, the electric vehicle battery charging device, material and use method provided by the present invention have the following beneficial effects:

[0025] 1. The non-metallic surface and metal outer surface materials are coated on the connectors in the charging device, which not only enhances the safety and durability of the entire charging device, but also increases the corrosion resistance and high temperature resistance; the heat-insulating cushion enables the connectors and / or connectors to be well connected and more firmly;

[0026] 2. The method of use realizes the split setting of the components of the charging device by electrically connecting the components through the plug-in and flexibly setting the composition and connection relationship in the charging and power supply modes. The charger, charging gun and charging cable are all connected by plug-in, which realizes the effect of split storage and plug-in use, and is easy to carry and saves space;

[0027] 3. When the components of the charging device are damaged, the method of use only requires replacement of the damaged components without replacing the charging device, which saves costs for the user. Replacing or repairing components can save the user's time and improve the efficiency of restoring charging.

[0028] 4. The method of use sets a power supply socket on the charging gun of the device to output the power of the vehicle battery as DC or AC, which is used as a DC or AC power supply to supply power to the outside, providing users with a more convenient experience in scenarios including outdoor camping, emergency rescue lighting, washing clothes and cooking; the method relies on the charging module of the device to set a charging information display, which can promptly inform or prompt the user of the current charging status and information. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention:

[0030] Figure 1 A schematic diagram of a method for using an electric vehicle charging device according to the present invention;

[0031] illustrate:

[0032] 1-power connection line, 11-power plug, 1002-control box, 1003-cable, 4-charging gun, 1005-power supply control device, 5-new energy electric vehicle, 51-vehicle interface, 52-vehicle battery, 20-charger. DETAILED DESCRIPTION

[0033] In order to clearly describe the technical solutions of the embodiments of the present invention, in the embodiments of the present invention, words such as "first" and "second" are used to distinguish the same items or similar items with basically the same functions and effects. For example, the first threshold and the second threshold are only used to distinguish different thresholds, and their order is not limited. Those skilled in the art can understand that words such as "first" and "second" do not limit the quantity and execution order, and words such as "first" and "second" do not necessarily limit them to be different.

[0034] It should be noted that, in the present invention, words such as "exemplary" or "for example" are used to indicate examples, illustrations or descriptions. Any embodiment or design described as "exemplary" or "for example" in the present invention should not be interpreted as being more preferred or more advantageous than other embodiments or designs. Specifically, the use of words such as "exemplary" or "for example" is intended to present related concepts in a specific way.

[0035] In the present invention, "at least one" means one or more, and "plurality" means two or more. "And / or" describes the association relationship of associated objects, indicating that three relationships may exist. For example, A and / or B can mean: A exists alone, A and B exist at the same time, and B exists alone, where A and B can be singular or plural. The character " / " generally indicates that the associated objects before and after are in an "or" relationship. "At least one of the following" or similar expressions refers to any combination of these items, including any combination of single or plural items. For example, at least one of a, b or c can mean: a, b, c, the combination of a and b, the combination of a and c, the combination of b and c, or the combination of a, b and c, where a, b, c can be single or multiple.

[0036] Example 1

[0037] The present invention proposes a material for an on-board battery charging device of an electric vehicle. When implemented specifically, the material comprises a non-metallic outer surface material, a metal outer surface material and a buffer heat-insulating pad. The non-metallic outer surface material and the metal outer surface material are coated on the non-metallic and metal outer surfaces of the charging device respectively; the charging device comprises a power connection line, a charging module, a charging connection line and a charging gun which are sequentially connected via a connector; the charging gun comprises at least a gun head connector; the non-metallic outer surface material is coated on the non-metallic surface of each connector in the charging device; the metal outer surface The material is coated on the metal surface of each component, connector and gun head connector in the charging device; the non-metallic outer surface material is a C / C composite material; the metal outer surface material includes a first layer, a second layer and a third layer starting from the metal outer surface, the first layer is a mixed molten salt or boron nitride; the present embodiment is dense boron nitride; the mixed molten salt is prepared by ZnCl2, AlCl3 and NaCl in a ratio of 4:4:2; the second layer is silicone polycarbonate; the third layer is a magnesium oxide film; the first layer, the second layer and the third layer are sequentially coated on the metal outer surface;

[0038] The non-metallic gold surface and metal outer surface materials coat the connectors in the charging device with non-metallic surfaces and metal outer surface materials, which not only enhances the safety and durability of the entire charging device, but also increases the corrosion resistance and high temperature resistance;

[0039] The heat-insulating cushion is used to compress the connector and the gun head connector; the material of the heat-insulating cushion is plastic, rubber or microporous foam material; the rubber is prepared by mixing nitrile rubber into a natural latex / polylactic acid composite material; the natural latex / polylactic acid composite material. The heat-insulating cushion enables the connector to be well connected and more firmly.

[0040] The rubber is prepared by the following steps: firstly, a composite material containing latex and polylactide is surface treated with a silane coupling agent, and then mixed with a silicone rubber matrix to obtain a mixture; and then the mixture is vulcanized by hot air;

[0041] Specifically for the first embodiment: the hot air vulcanization temperature is 80°C; the vulcanization time is 2 hours; the vulcanization pressure is 15 MPa;

[0042] Preferably, in the second embodiment, the hot air vulcanization temperature is 70° C., the vulcanization time is 4 hours, and the vulcanization pressure is 10 MPa.

[0043] Preferably, in the third embodiment, the hot air vulcanization temperature is 90° C., the vulcanization time is 2.5 hours, and the vulcanization pressure is 20 MPa.

[0044] The rubber material with a cross-linked network is prepared by hot air vulcanization in the first, second and third embodiments, and finally the rubber material is molded using a mold to obtain the rubber required for the aforementioned buffer and thermal insulation pad of the present invention.

[0045] The latex is natural latex, polyisoprene latex, emulsified latex of isoprene rubber and natural latex modified by graphene oxide; specifically in this embodiment: the latex is natural latex modified by graphene oxide;

[0046] The preparation process of the microporous foam material is specifically as follows: high-temperature and high-pressure carbon dioxide gas is introduced into a polypropylene material matrix to prepare micron-sized micron pores which are then molded; the microporous foam material has excellent shock absorption, cushioning and heat insulation properties.

[0047] The first layer is plasma sprayed onto the metal outer surfaces of the power connection line, both ends of the charging connection line and each connector of the charging device to form a thin film which is then heated by high-temperature gas.

[0048] The second layer is deposited on the metal outer surface of boron nitride by evaporation; and the third oxide film is coated on the second layer on the metal outer surface at room temperature.

[0049] On the other hand, the present invention provides a method for using an on-board battery charging device of an electric vehicle, including electrical connection and charging; the electrical connection includes: connecting one end of a power connection line to a power plug of an AC power source, and connecting the other end of the power connection line to a first connector; electrically connecting the first connector to a second connector, and the second connector is then connected to a charger in a charging module, and the charger is electrically connected to a third connector; electrically connecting the third connector to a fourth connector; electrically connecting one end of the charging connection line to the fourth connector, and the other end to the fifth connector; electrically connecting the fifth connector to the sixth connector; electrically connecting the sixth connector to a gun head connector;

[0050] The charging specifically includes: the power plug is connected to the power supply, the first and second connectors are electrically connected by plugging, the third and fourth connectors are electrically connected by plugging, the fifth and sixth connectors are electrically connected by plugging, the gun head connector of the charging gun is connected to the charging port of the battery on the electric vehicle, and the charging device as a whole forms a charging path to charge the battery on the electric vehicle.

[0051] The method for using the on-board battery charging device of an electric vehicle also includes a charging mode and a power supply mode; the charging mode is specifically: checking whether the sixth connector is electrically connected to the charging connection line to be in full contact, and after confirmation, connecting the gun head connector to the charging port of the on-board battery; the charging gun in the power supply mode also includes an electric energy conversion unit and one or more output sockets; and the power supply mode is specifically: electrically connecting the gun head connector to the charging port of the on-board battery, and electrically connecting the output end of the electric energy conversion unit to one or more output sockets, so as to convert the electric energy of the on-board battery into direct current or alternating current, and provide battery power output to the outside through one or more output sockets.

[0052] The method for using the on-board battery charging device of an electric vehicle is to separate and disconnect the sixth connector electrically connected to the charging gun and the fifth connector electrically connected to the charging connection line, connect the input end of the power conversion unit to the charging port of the on-board battery through the gun head connector of the charging gun, and electrically connect the output end of the output power conversion unit to an output socket (or expand it to more than two through the socket, and the actual device is connected to no more than 20 sockets), convert the electric energy of the on-board battery into direct current or alternating current, and provide and output the battery power to the outside through an output socket (or expand it to more than two through the socket, and no more than 20 sockets).

[0053] The method of use realizes the split setting of the components of the charging device by electrically connecting the components through plug-in connectors and flexibly setting the composition and connection relationship in the charging and power supply modes. The charger, charging gun and charging connection line are all connected in a plug-in manner, achieving the effect of split storage and plug-in use, which is easy to carry and saves space.

[0054] The electric energy conversion unit includes a DC-DC converter and / or a DC-AC converter; the output socket is a DC socket and / or an AC socket, which is used to provide DC output or AC output to the outside, or to provide AC and DC output at the same time; preferably, the charging connection line is a cable including two power conductors and two signal lines, and the power conductors are rare earth alloy conductors containing copper; the charging module also includes a charging monitoring unit for detecting and displaying the charging information of the charger during the charging process and for monitoring the actual state of charge SOC of the battery to obtain relevant charging information; the charging module also includes a leakage protection unit for cutting off the charging line and stopping the charging operation when the cable is powered off, or has a leakage fault, or a surge fault; a one-button power-off switch is arranged on the housing of the charging module, and the one-button power-off switch is connected to the leakage protection unit, and when pressed, the leakage protection unit is triggered to cut off the charging line.

[0055] When a component of the charging device is damaged, the method of use only requires replacing the damaged component without replacing the charging device, which saves costs for the user. Replacing or repairing components can save the user's time and improve the efficiency of restoring charging.

[0056] Furthermore, the usage method sets a power supply socket on the charging gun of the device to output the power of the vehicle battery as DC or AC, which is used as a DC or AC power supply to supply power to the outside, thereby providing users with a more convenient experience in scenarios including outdoor camping, emergency rescue lighting, washing clothes and cooking. The method relies on the charging module of the device to set a charging information display, which can promptly inform or prompt the user of the current charging status and information.

[0057] like Figure 1 As shown, the on-board battery 52 of the new energy electric vehicle 5 is charged by AC, the power plug 11 is connected to AC, and the three pins of ground E, live wire L, and neutral wire N are respectively connected to the three wires of the power connection line 1. The control box 1002 is connected through the power connection line 1. The control box 1002 includes a power supply control device 1005, which controls the output DC charging current. The DC charging current is connected to the charging gun 4 through the cable 1003, and the charging gun 4 is inserted into the vehicle interface 51 to connect and charge the on-board battery 52 of the new energy electric vehicle 5. The aforementioned charging equipment (corresponding to the part between the power plug 11 and the charging gun 4) is frequently used. When the voltage is unstable or the wire is bent due to long-term use, the cable, charger or charging gun will be damaged, causing the entire charging device to be unusable due to damage to a certain component. The length of the cable 1003 between the control box 1002 and the charging gun 4 cannot be adjusted, and the power supply cannot be connected when the vehicle is far away. Although leakage protection is also configured, the protection function is still defective, for example, the circuit cannot be cut off from the outside.

[0058] The on-board battery charging device of a new energy electric vehicle based on the present invention comprises a power connection line, a charging module charging connection line and a charging gun, wherein: the first end of the power connection line is provided with a power plug for connecting to a power source, and the second end of the power connection line is provided with a first connector; the charging module comprises a second connector, a charger and a third connector connected in sequence; the first end of the charging connection line is provided with a fourth connector, and the second end is provided with a fifth connector; the charging gun comprises a sixth connector and a gun head connector.

[0059] The metal outer surfaces of the connector and the connecting parts in the charging device are covered with metal outer surface material;

[0060] The non-metallic outer surfaces of the connectors and connectors in the charging device are covered with non-metallic outer surface materials;

[0061] The connector in the charging device is provided with a buffer and heat-insulating pad for fastening the connector.

[0062] During specific implementation, a schematic diagram of the connection status of a charging device for charging a vehicle-mounted battery of a two-wheeled or three-wheeled new energy electric vehicle is shown, in which a power plug is connected to an AC power source, a first connector and a second connector are electrically connected together by plugging, a third connector and a fourth connector are electrically connected together by plugging, and a fifth connector is directly connected to a charging port of the vehicle-mounted battery of a two-wheeled or three-wheeled new energy electric vehicle, forming a charging path for charging the vehicle-mounted battery of a two-wheeled or three-wheeled new energy electric vehicle.

[0063] Schematic diagram of the connection status of the charging device for the on-board battery of the new energy electric vehicle during charging, the power plug is connected to the AC power supply, the first connector and the second connector are electrically connected together by plugging, the third connector and the fourth connector are electrically connected together by plugging, the fifth connector and the sixth connector are electrically connected together by plugging, the gun head connector of the charging gun 4 is connected to the charging port of the on-board battery of the new energy electric vehicle, and the new energy electric vehicle charging device forms a charging path as a whole to charge the on-board battery of the new energy electric vehicle.

[0064] The non-metallic outer surfaces of the first connector, the second connector, the third connector, the fourth connector and the fifth connector are coated with a C / C composite material layer; preferably, the coating is performed by plasma spraying.

[0065] The metal surfaces of the first connector, the second connector, the third connector, the fourth connector and the fifth connector are coated with a surface coating by plasma spraying or radio frequency magnetron sputtering. Preferably, the surface coating is a mixed molten salt or dense boron nitride; the thickness of the surface coating is less than or equal to 100 μm. The mixed molten salt is prepared by AlCl3. When the surface coating is dense boron nitride, the preferred preparation method is: using radio frequency magnetron sputtering to dense boron nitride to the metal surfaces at both ends of the power connection line and the charging connection line, forming a thin film and then heating it with high-temperature gas.

[0066] The surface coatings on the non-metallic surface and the metal surface enable the connector to have good oxidation resistance and corrosion resistance, as well as good high-temperature mechanical and chemical stability.

[0067] The metal surface of the power connection line and the charging connection line is coated with a surface coating by plasma spraying or radio frequency magnetron sputtering. Preferably, the surface coating is a mixed molten salt or dense boron nitride; the thickness of the surface coating is less than or equal to 100μm. The mixed molten salt is prepared by ZnCl2 and NaCl. When the surface coating is dense boron nitride, the preferred preparation method is: using radio frequency magnetron sputtering to dense boron nitride to the metal surface at both ends of the power connection line and the charging connection line, forming a thin film and then heating it with high-temperature gas. The surface coating makes the power connection line and the charging connection line have good anti-oxidation and anti-corrosion properties; as well as good high-temperature mechanical and chemical stability.

[0068] The outer surfaces of the charging module 2, the charging gun 4 and the vehicle interface 51 can achieve good anti-oxidation and anti-corrosion properties by coating the C / C composite material layer; preferably, the coating is plasma spraying.

[0069] By using household power to charge the onboard batteries of two-wheeled electric vehicles, three-wheeled electric vehicles, and electric vehicles, the energy storage function can be realized. On the one hand, it can supply the electric energy consumption of new energy electric vehicles themselves, and on the other hand, it can also output electric energy to the outside as a power source when necessary, realize the power supply function, convert battery power into DC or AC output, and distribute power to the outside through DC sockets and / or AC sockets.

[0070] The charging gun also includes an electric energy conversion unit and one or three output sockets; the input end of the electric energy conversion unit is electrically connected to the battery of the new energy vehicle through the gun head connector of the charging gun; the output end of the electric energy conversion unit is electrically connected to one or three output sockets; the electric energy conversion unit converts the electric energy of the battery into direct current or alternating current, and provides battery power output to the outside through the one or three output sockets. The electric energy conversion unit includes a DC-DC converter and / or a DC-AC converter. The output socket is a DC socket and / or an AC socket, which is used to provide DC output or AC output to the outside, or to provide AC and DC output at the same time.

[0071] The charging module further includes:

[0072] A charging monitoring unit is used to detect and display the charging information of the charger during the charging process;

[0073] The leakage protection unit is used to cut off the charging line and stop the charging operation when the cable is powered off, has a leakage fault, or has a surge fault;

[0074] The one-button power-off switch is configured on the charging module housing and connected to the leakage protection unit. When pressed, it will trigger the leakage protection unit to cut off the charging line in an emergency.

[0075] The charging monitoring unit displays the charging information on a liquid crystal screen, including the current charging voltage and current, the remaining charging time, the battery level or the estimated remaining time. The charging monitoring unit monitors the actual state of charge (SOC) of the battery to obtain relevant charging information.

[0076] The plug connectors shown in this embodiment include plugs and sockets, which refer to devices that connect electrical appliances and other devices to a power source. Generally speaking, a plug refers to a movable connector that is connected to a device that uses electricity through wires; while a socket is fixed to a device or building structure. Plugs usually have protruding rod-shaped, blade-shaped, or other electronic contacts (called male connectors), while sockets have correspondingly shaped electronic contact slots (called female connectors); the plug connectors that appear in pairs and are plugged in and connected to each other are plugs or sockets, and when one is a socket, the other is a corresponding plug. The above-mentioned plug connectors are designed with plugs or sockets that comply with national standards. After plugging and connecting, ensure that relevant safety standards for waterproofing and leakage prevention are met.

[0077] The connector is a snap-on connector, or a screw-on socket connector, or a connector with screw and nut fasteners respectively arranged on the outside. For example, a snap-on connector with a square, circular or trapezoidal interface, or a socket connector with threads arranged on the outside of the socket and internal threads arranged on the plug end, or a connector with nuts arranged on the side of the socket and screw fasteners arranged on the side of the plug. The above fastening design can avoid the possible virtual connection problem between the plug and the socket, and improve safety.

[0078] The screw-on sleeve connector or the connector with screw and nut fasteners respectively arranged on the outside is equipped with a buffer and heat-insulating pad in a specific application for compressing the connector with screw and nut fasteners to ensure that the screw and nut fasteners are separated by heat and buffer to ensure compression;

[0079] The buffer and heat-insulating pad is made of plastic, rubber or microporous foam material;

[0080] The rubber is surface treated with a latex / polylactide composite material using a silane coupling agent, and then mixed into a silicone rubber matrix to obtain a mixture; the mixture is then vulcanized by hot air to obtain a rubber material containing a cross-linked network, and finally the rubber material is molded using a mold;

[0081] The buffer thermal insulation pad is obtained by using a silane coupling agent to treat the surface of the thermal conductive filler, then adding the surface treated thermal conductive filler into the buffer and mixing them evenly;

[0082] The preparation process of the microporous foam material is specifically as follows: high-temperature and high-pressure carbon dioxide gas is introduced into a polypropylene material matrix, and the prepared micron-sized micron pores are then molded;

[0083] The microporous foam material has excellent shock absorption, cushioning and heat insulation properties;

[0084] The height of the buffer insulation pad, i.e., the cushion thickness, is greater than or equal to 2 mm and less than or equal to 10 mm. Specifically in this embodiment, the cushion thickness of the buffer insulation pad is 5 mm. Preferably, the plastic is a rigid polyurethane foam plastic. The buffer insulation pad has high toughness, strong sealing and anti-aging properties. The buffer insulation pad is provided with an accelerator and an antioxidant; the accelerator is an organic additive; preferably, the organic additive includes sulfonamides and diphenylguanidine accelerators and benzothiazoles.

[0085] The socket and the plug housing connection further include a sealing gasket, for example, a sealing gasket is provided on the socket side, and an angular edge is used on the plug side. When the plug and the socket are connected by snapping, sleeve connection, or screw nut fastening, the angular edge presses the sealing gasket tightly, which can achieve the effect of waterproofing and anti-oxidation after connection, which can extend the service life and enhance the safety of electricity use. By providing a sealing mechanism, the electrical plug-in sealing connection is achieved, which can be waterproof, anti-corrosion, and anti-leakage, and at the same time reduce the loss caused by oxidation of the joint.

[0086] The length of the charging cable is set to 5 to 100 meters, preferably 10 to 50 meters, and the preferred length is 10 meters, 20 meters, 25 meters, 30 meters, and 40 meters; the charging cable is a rare earth alloy cable containing copper or aluminum, and the charging cable is a cable including 2, 3 or 5 power conductors. The charging cable is a cable including a signal line. For example, rare earth aluminum alloy cable technology uses special processes to use aluminum alloy materials as cable conductors, and improves the conductivity, hardness, and heat resistance of aluminum by adding trace amounts of iron, silicon, magnesium, rare earth and other elements to aluminum, thereby avoiding the problems of connection stability and low mechanical properties of pure aluminum cables.

[0087] When charging with AC, the cable used includes a charging cable with 3 power conductors; or a charging cable with 5 power conductors. When charging with DC, the cable used is a charging cable with 2 power conductors.

[0088] The power conductor cable not only includes a conductor, but also includes a shielding layer, a filling layer, an inner sheath, an outer sheath and an insulating layer. The physical protection performance, electromagnetic performance and electrical safety performance can be enhanced through the above cable structure. At the same time, the above cable also includes one or more signal lines for transmitting charging information and / or battery status information. The cables in the prior art are mainly aluminum alloy core extruded insulated power cables. On the one hand, the inner conductor of the cable is easily oxidized, and on the other hand, the outer sheath is also prone to aging, causing damage to the cable. In particular, the pressure on the filler can easily cause deformation and damage to the cable.

[0089] The present invention adopts a rare earth alloy wire as the wire of the charging connection line, which improves the anti-oxidation performance and wire strength under the premise of ensuring the conductivity. At the same time, the filling layer is a compressive filling layer, and the filling material of the filling layer is modified nano magnesium oxide cross-linked polyethylene, cross-linked modified polyethylene or silane cross-linked polyethylene. While ensuring the compressive mechanical properties, it also has the effect of easy heat dissipation.

[0090] The charging device for the on-board battery of a new energy electric vehicle of the present invention includes a power connection line, a charging module, a charging connection line, and a charging gun. By arranging corresponding groups of connectors between the above components, a split connection relationship is realized. When charging, the corresponding groups of connectors are connected in pairs to form a connected charging circuit, and the on-board battery of the new energy electric vehicle is charged through the gun head connector of the charging gun; in the non-charging state, the electric energy of the on-board battery can also be converted and output through an independent charging gun; when the charging gun is not connected, the on-board battery of the electric two-wheeled or three-wheeled vehicle is directly charged through the connector of the charging connection line. By applying the present invention, a split plug-in charging connection can be realized, and the charging connection method can be selected according to the type of charging object, which increases the application flexibility, reduces the repair cost of damaged components and improves the repair efficiency.

[0091] New energy electric vehicles include electric two-wheelers, electric three-wheelers, electric four-wheelers, multi-wheel electric trucks, and multi-wheel electric buses. Usually, electric two-wheelers or three-wheelers usually use low-capacity batteries as on-board batteries, while electric four-wheelers, multi-wheel electric trucks, and multi-wheel electric buses are usually electric vehicles, which usually use high-capacity lithium-ion or sodium-ion power batteries as on-board batteries.

[0092] The charging form of new energy electric vehicles is constantly improving, and the commercial link of the manufacturer's on-board distribution of charging devices will gradually withdraw. Consumers will choose charging devices on their own after purchasing a car, or update the charging devices on their own after the original charging devices are damaged or exceed the service life. The charging device of the present invention can use the power converter (socket) of the municipal power supply as the charging power source, and connect to the vehicle's power socket through the charging device. Because the charging gun, charging connection line, charger and other components of the existing charging device are easily damaged during long-term use. For example, the charger as an energy conversion device is easily affected by voltage and damages its life, and the connection line is stretched or crushed and damaged and broken. Using the split plug-in charging device of the present invention, after any component is damaged, only the damaged component can be repaired or replaced. On the one hand, the cost is reduced, and the user does not need to pay the high cost of replacing the entire charging device; on the other hand, it can speed up the progress of restoring the normal operation of the charging device and reduce the loss of users due to the inability to charge. For users, the cost-effectiveness of home charging is improved.

[0093] Although the present invention has been described in conjunction with specific features and embodiments thereof, it is apparent that various modifications and combinations may be made thereto without departing from the spirit and scope of the present invention. Accordingly, this specification and the accompanying drawings are merely exemplary illustrations of the present invention as defined by the appended claims and are deemed to cover any and all modifications, variations, combinations or equivalents within the scope of the present invention. Obviously, those skilled in the art may make various modifications and variations to the present invention without departing from the spirit and scope of the present invention. Thus, the present invention is intended to include such modifications and variations if they fall within the scope of the claims of the present invention and their equivalents.

Claims

1. An electric vehicle battery charging device, comprising a power connection line, a charging module, a charging connection line and a charging gun connected in sequence through a connector, wherein the charging gun at least comprises a gun head connector, characterized in that: The split connection relationship is realized by arranging corresponding groups of connectors between the power connection line, the charging module, the charging connection line and the charging gun; the first end of the power connection line is provided with a power plug for connecting the power supply, and the second end of the power connection line is provided with a first connector; the charging module includes a second connector, a charger and a third connector connected in sequence; the first end of the charging connection line is provided with a fourth connector, and the second end is provided with a fifth connector; the charging gun includes a sixth connector and a gun head connector; the power plug is connected to the AC power supply, the first connector and the second connector are electrically connected together by plugging, the third connector and the fourth connector are electrically connected together by plugging, and the fifth connector is directly connected to the charging port of the two-wheeled or three-wheeled new energy vehicle battery; when the device is charging, the corresponding groups of connectors are connected in pairs to form a connected charging circuit, and the vehicle-mounted battery of the new energy electric vehicle is charged through the gun head connector of the charging gun; in the non-charging state, the electric energy of the vehicle-mounted battery can also be converted and output through an independent charging gun; when the charging gun is not connected, the vehicle-mounted battery of the electric two-wheeled or three-wheeled vehicle is directly charged through the connector of the charging connection line; The metal outer surface of the connector and the connecting piece in the on-board battery charging device of the electric vehicle is coated with a metal outer surface material, and the non-metal outer surface of the connector and the connecting piece in the on-board battery charging device of the electric vehicle is coated with a non-metal outer surface material, and a buffer heat insulation pad for tightening the connecting piece is provided for pressing the plug connector and the gun head connecting piece; the buffer heat insulation pad is used for pressing the plug connector and the gun head connecting piece, and its material is plastic, rubber or microporous foam material; The metal outer surface material is coated on the metal surface of each component in the charging device, the metal surface of the connector and the metal surface of the gun head connecting piece, including a first layer, a second layer and a third layer starting from the metal outer surface; The first layer is a mixed molten salt or boron nitride; the second layer is a synthetic resin, which is a polyester, polycarbonate, silicone polycarbonate or silicone polyurethane coating; the third layer is a magnesium oxide film; the mixed molten salt is prepared by ZnCl2, AlCl3, NaCl or a combination thereof; the boron nitride is dense boron nitride; the first layer, the second layer and the third layer are sequentially coated on the outer surface of the metal; The rubber is prepared by mixing nitrile rubber into a natural latex / polylactic acid composite material; the preparation of the rubber of the natural latex / polylactic acid composite material is specifically as follows: a composite material containing latex and polylactide is surface treated with a silane coupling agent, and then mixed into a silicone rubber matrix to obtain a mixture; the mixture is then vulcanized with hot air to obtain a rubber material with a cross-linked network, and finally the rubber material is molded using a mold; The temperature range of the hot air vulcanization is 70 to 90° C.; the vulcanization time is 2 to 4 hours; the vulcanization pressure is 10 MPa to 20 MPa; the latex is natural latex, polyisoprene latex, emulsified latex of isoprene rubber, and natural latex modified with graphene oxide.

2. An electric vehicle battery charging device according to claim 1, characterized in that: The preparation process of the microporous foam material is specifically as follows: high-temperature and high-pressure carbon dioxide gas is introduced into a polypropylene material matrix, and the prepared micron-sized micron pores are then molded.

3. The electric vehicle battery charging device according to claim 1, characterized in that: The first layer is formed by plasma spraying or radio frequency magnetron sputtering onto the metal outer surface of the power connection line of the charging device, the metal outer surfaces at both ends of the charging connection line, and the metal outer surfaces of each connector, and is then heated by high-temperature gas.

4. The electric vehicle battery charging device according to claim 1, characterized in that: The second layer is a metal outer surface coated with a mixed molten salt or boron nitride by evaporation to spraying or sputtering; the third layer of oxide film is coated on the second layer of the metal outer surface at room temperature.

5. The electric vehicle battery charging device according to claim 1, characterized in that: The buffer thermal insulation pad is provided with a promoter and an antioxidant, and the height of the buffer thermal insulation pad, i.e., the thickness of the cushion layer, is greater than or equal to 2 mm and less than or equal to 10 mm, and / or the thickness of the surface coating of the mixed molten salt or boron nitride is less than or equal to 100 μm.

6. A method for using the on-board battery charging device of an electric vehicle as claimed in any one of claims 1 to 5, characterized in that: It includes electrical connection and charging; the electrical connection includes: connecting one end of the power connection line to the power plug of the AC power source, connecting the other end of the power connection line to the first connector; electrically connecting the first connector to the second connector, the second connector is then connected to the charger in the charging module, and the charger is electrically connected to the third connector; electrically connecting the third connector to the fourth connector; electrically connecting one end of the charging connection line to the fourth connector, and the other end to the fifth connector; electrically connecting the fifth connector to the sixth connector; electrically connecting the sixth connector to the gun head connector; The charging specifically includes: the power plug is connected to the power supply, the first and second connectors are electrically connected by plugging, the third and fourth connectors are electrically connected by plugging, the fifth and sixth connectors are electrically connected by plugging, the gun head connector of the charging gun is connected to the charging port of the battery on the electric vehicle, and the charging device as a whole forms a charging path to charge the battery on the electric vehicle.

7. A method for using an electric vehicle battery charging device according to claim 6, characterized in that: Including charging mode and power supply mode; The charging mode is specifically as follows: checking whether the sixth connector is in full contact with the charging connection line, and after confirmation, connecting the gun head connector to the charging port of the vehicle battery; the charging gun in the power supply mode also includes an electric energy conversion unit and one or more output sockets; The power supply mode is specifically as follows: the gun head connector is electrically connected to the charging port of the vehicle battery, and the output end of the power conversion unit is electrically connected to one or more output sockets to convert the power of the vehicle battery into direct current or alternating current, and provide battery power output to the outside through one or more output sockets.

8. A method for using an electric vehicle battery charging device according to claim 7, characterized in that: Separate and disconnect the sixth connector electrically connected to the charging gun from the fifth connector electrically connected to the charging cable, connect the input end of the power conversion unit to the charging port of the vehicle battery through the gun head connector of the charging gun, and electrically connect the output end of the output power conversion unit to one or more output sockets to convert the power of the vehicle battery into direct current or alternating current, and provide and output the battery power to the outside through one or more output sockets; The electric energy conversion unit includes a DC-DC converter and / or a DC-AC converter; the output socket is a DC socket and / or an AC socket, which is used to provide DC output or AC output to the outside, or to provide AC and DC output at the same time; the charging connection line is a cable including 2, 3 or 5 power conductors, and the power conductor is a rare earth alloy conductor containing copper or aluminum; the charging connection line is a cable including one or more signal lines; the charging module also includes a charging monitoring unit for detecting and displaying the charging information of the charger during the charging process and for monitoring the actual state of charge SOC of the battery to obtain relevant charging information; the charging module also includes a leakage protection unit for cutting off the charging line and stopping the charging operation when the cable is powered off, or has a leakage fault, or a surge fault; a one-button power-off switch is arranged on the housing of the charging module, and the one-button power-off switch is connected to the leakage protection unit, and when pressed, the leakage protection unit is triggered to cut off the charging line.

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