Charging seat current-carrying terminal structure and manufacturing method thereof

Abstract

The invention relates to the technical field of connecting terminals, and discloses a charging seat current-carrying terminal structure and a manufacturing method thereof, the charging seat current-carrying terminal structure comprises a plurality of partial load cables, and two opposite ends of the partial load cables are provided with first connecting ports; the plurality of wiring terminals are provided with second connecting ports, and the second connecting ports are fixedly connected with the first connecting ports; the busbar is provided with a wiring end face part, one end, far away from the second connecting port, of each wiring terminal is also provided with a third connecting port, and the plurality of wiring terminals are fixedly connected with the wiring end face part of the busbar through the third connecting ports. By dispersing the conductive paths, the flexibility and shock resistance of the structure are remarkably improved, so that the electric automobile effectively absorbs vibration stress, the abrasion and loosening risks of the connecting ports and the plugging points are reduced, and the situation that the current-carrying component is bent to cause sudden change of resistance is effectively prevented.

Description

Technical Field

[0001] The present invention relates to the technical field of connection terminals, and in particular to a current-carrying terminal structure of a charging base and a manufacturing method thereof. Background Art

[0002] With the increasing awareness of environmental protection and the advancement of technology, the electric vehicle market is gradually expanding, and the demand for its supporting charging infrastructure is also increasing. At present, electric vehicle charging technology is developing towards high efficiency and high power transmission to meet the needs of fast charging of the new generation of electric vehicles. Among charging equipment, the charging stand is a key component that connects the power supply to the electric vehicle battery, and its performance directly affects the charging efficiency and safety. The standard charging stand needs to be able to carry high current while ensuring stable and reliable power transmission so that electric vehicles can be charged in a shorter time.

[0003] The ultra-high power transmission of electric vehicles on the market is mainly achieved through the liquid-cooled cables and liquid-cooled guns at the charging end to increase the charging current power; however, it is still difficult to achieve ultra-high power transmission at the load-end charging station. At present, some companies have begun to use copper rods, copper bars, aluminum rods, aluminum bars and other metal components as current-carrying conduction terminals in the charging station to achieve high-power transmission, ensuring sufficient current-carrying capacity and low resistance. However, relying on rigid metal components as current-carrying components, the vibration of the vehicle during the driving of electric vehicles makes it easy for the current-carrying components to produce tiny relative movements, resulting in wear and loosening of the plug-in points at both ends, and even bending of the current-carrying components. The stress concentration at the bending point causes a sudden change in resistance, which reduces the charging efficiency and increases the overall energy consumption of the system.

[0004] Therefore, it is necessary to provide a charging seat current-carrying terminal structure and a manufacturing method thereof to solve the problems of wear, looseness and bending caused by the use of rigid metal components in the above-mentioned charging seat current-carrying terminals. Summary of the invention

[0005] The main purpose of the present invention is to provide a charging seat current-carrying terminal structure and a manufacturing method thereof, aiming to solve the technical problems mentioned in the above background technology.

[0006] The present invention adopts the following technical solutions: A charging seat current-carrying terminal structure and a manufacturing method thereof, comprising: A plurality of load-sharing cables, wherein two opposite ends of the load-sharing cables are provided with first connection ports; A plurality of connection terminals, each of which is provided with a second connection port, and the second connection port is fixedly connected to the first connection port; A busbar, wherein the busbar is provided with a terminal face, and a third connection port is further provided at one end of the terminal away from the second connection port, and a plurality of the terminals are fixedly connected to the terminal face of the busbar through the third connection port, wherein the busbar is used to connect to an external current-carrying component.

[0007] Furthermore, the wiring terminal is a copper tube terminal, the second connection port is cylindrical, the second connection port is sleeved on the outside of the first connection port, and the second connection port is crimped and fixed to the first connection port.

[0008] Furthermore, a connection transition portion is disposed around the connection between the second connection port and the first connection port, and the connection transition portion is filled with solder, and the solder is fixedly connected to the first connection port and the second connection port.

[0009] Furthermore, the connection terminal is an ultrasonic welding terminal, the second connection port is flat, and the second connection port is fixed to the first connection port by welding.

[0010] Furthermore, the third connection port is flat and has a first connection hole. The terminal surface of the busbar has a second connection hole corresponding to the first connection hole. A first connecting piece is inserted through the first connection hole and the second connection hole to fix the terminal to the busbar.

[0011] Furthermore, a mounting portion extends from an end face of the terminal surface facing away from the first connector, the mounting portion is provided with a mounting hole, a second connector is passed through the mounting hole, and the second connector is detachably connected to an external current-carrying component to fix the busbar to the external current-carrying component.

[0012] The present invention also provides a method for manufacturing a current-carrying terminal structure of a charging cradle, which is used to manufacture the current-carrying terminal structure of the charging cradle as described in any one of the above items, comprising: Providing a plurality of load-sharing cables and wiring terminals, wherein first connection ports are arranged at two opposite ends of the load-sharing cables and a second connection port is arranged at one end of the wiring terminal; The first connection port and the second connection port are brought into contact with each other, and the first connection port and the second connection port are fixed by crimping or welding; A busbar and a first connector are provided, a terminal face portion is provided on the busbar, and a third connection port is provided on the other end of the terminal, a first connection hole is provided on the third connection port, a second connection hole is provided on the terminal face portion, the third connection port is overlapped to the terminal face portion, and the first connector is inserted into the first connection hole and the second connection hole; A second connector is provided, a mounting portion is arranged on an end face of the busbar away from the terminal face, a mounting hole is opened on the mounting portion, and the second connector is inserted into the mounting hole to enable the busbar to be detachably connected to the external current-carrying component.

[0013] Furthermore, the step of bringing the first connection port into contact with the second connection port and fixing the first connection port and the second connection port by crimping specifically includes: A copper tube terminal is used as a wiring terminal, and a second connection port of the wiring terminal is sleeved on the outside of the first connection port, and the first connection port is pressed and connected with the second connection port by a crimping pliers; Providing a tin bar, surrounding a connecting transition portion at a connection between an end of the second connecting port and the first connecting port, and winding the tin bar to the connecting transition portion; The tin bar is heated to a preset temperature by a high-frequency eddy current heating device, so that the tin bar melts and completely fills the connecting transition portion; Stop heating to allow the molten tin bar to cool and solidify naturally, thereby forming a firm connection with the first connection port and the second connection port; The step of contacting the first connection port with the second connection port and fixing the first connection port with the second connection port by welding specifically includes: Using an ultrasonic welding terminal as a connecting terminal, overlapping the second connecting port of the connecting terminal on the outer side of the first connecting port; Using ultrasonic welding equipment to enable the welding head to clamp the first connection port and the second connection port with a preset pressure; Applying ultrasonic vibration to the welding head at a preset frequency and a preset amplitude to cause the contact surfaces of the first connection port and the second connection port to generate heat and melt by high-speed friction; Allowing the welding head to maintain a preset pressure on the first connection port and the second connection port for a preset time to ensure that the molten material is evenly spread; The ultrasonic vibration is stopped to allow the first connection port and the second connection port to cool and solidify naturally.

[0014] Furthermore, the step of overlapping the third connection port to the wiring terminal surface and inserting the first connection member into the first connection hole and the second connection hole specifically includes: Performing surface pretreatment on the terminal face and the third connection port using a plasma processing device; Align the first connection hole with the second connection hole, and insert the first connection member into the first connection hole and the second connection hole; After the third connection port is fixedly connected to the terminal surface, the connection terminal and the busbar are encapsulated with a preset insulating material.

[0015] Furthermore, the manufacturing method also includes the step of performing a mechanical strength test on the current-carrying terminal structure of the charging seat, including: Clamping the load-sharing cable and the busbar based on a force measuring device, and applying gradually increasing mechanical loads to the load-sharing cable and the busbar in opposite directions; Obtaining the relative displacement between the load-sharing cable and the bus bar under various mechanical load conditions; If the load-sharing cable and the bus are not loose, and the relative displacement is within a preset range, the mechanical strength of the current-carrying terminal structure of the charging seat is determined to be qualified; if any of the conditions is not met, the mechanical strength of the current-carrying terminal structure of the charging seat is determined to be unqualified.

[0016] Beneficial effects: In the present invention, a number of load-sharing cables are used to replace traditional rigid metal components as current-carrying components, and the conductive paths are dispersed to significantly improve the flexibility and shock resistance of the structure. During the driving of the electric vehicle, the load-sharing cables have a certain degree of softness and can effectively absorb and alleviate the vibration stress caused by the vibration of the vehicle, thereby reducing the risk of wear and loosening of the connection ports and plug points, and can effectively prevent the current-carrying components from bending and causing sudden changes in resistance. The configuration of multiple load-sharing cables enables the current to be evenly distributed, which not only improves the current-carrying capacity of the terminals, but also reduces the loss caused by resistance, thereby ensuring efficient transmission of the charging process. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 is a schematic diagram of the overall structure of an embodiment of the present invention; Figure 2 is a partial cross-sectional view of the present invention; Figure 3 is a schematic diagram of a busbar of the present invention; Figure 4 is a partial cross-sectional view of the terminal block of the present invention; Figure 5 is a schematic diagram of a connection terminal of the present invention being an ultrasonic welding terminal; Figure 6 is a flow chart of another embodiment of the present invention; Wherein: 1. load-sharing cable; 11. first connection port; 2. terminal; 21. second connection port; 22. third connection port; 23. first connection hole; 3. busbar; 31. terminal face; 32. second connection hole; 33. mounting portion; 34. mounting hole; 4. connection transition portion; 5. first connection piece; 6. second connection piece; The realization of the purpose, functional features and advantages of the present invention will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0018] It should be understood that the specific embodiments described herein are only used to explain the present invention, and are not used to limit the present invention.

[0019] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, the meaning of "multiple" is two or more, unless otherwise clearly and specifically defined.

[0020] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection, a direct connection, or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0021] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being "above", "above" and "above" a second feature includes that the first feature is directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature. A first feature being "below", "below" and "below" a second feature includes that the first feature is directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.

[0022] Embodiment 1: Reference Figures 1 to 3The present invention proposes a charging seat current-carrying terminal structure and a manufacturing method thereof, comprising: a plurality of load-sharing cables 1, wherein the load-sharing cables 1 are provided with first connection ports 11 at opposite ends thereof; A plurality of connection terminals 2, each of which is provided with a second connection port 21, and the second connection port 21 is fixedly connected to the first connection port 11; The busbar 3 is provided with a terminal face portion 31, and the end of the terminal 2 away from the second connection port 21 is also provided with a third connection port 22, and a plurality of the terminal 2 are fixedly connected to the terminal face portion 31 of the busbar 3 through the third connection port 22, wherein the busbar 3 is used to be connected to an external current-carrying component.

[0023] In the above embodiment, the sharing cables 1 are arranged in such a way that the two ends of each sharing cable 1 are respectively connected to the first connection port 11 of a terminal 2 and the second connection port 21 of another terminal 2, forming a continuous current-carrying path. In this way, the current load can be effectively dispersed and the current carrying capacity of the charging station can be improved. In addition, the terminal surface 31 of the bus 3 is designed to accommodate the third connection ports 22 of multiple terminals 2, so as to realize the parallel connection of multiple sharing cables 1, further enhancing the current transmission efficiency of the current-carrying terminal structure. Preferably, the terminal 2 of the present application is set to three. In practical applications, this structural design can adapt to charging requirements of different powers and ensure the stability and reliability of the charging station.

[0024] By using several load-sharing cables 1 to replace traditional rigid metal components as current-carrying parts, the flexibility and seismic resistance of the structure are significantly improved by dispersing the conductive path, so that during the driving of the electric vehicle, the load-sharing cables 1 have a certain degree of softness, which can effectively absorb and alleviate the vibration stress caused by the vibration of the vehicle, thereby reducing the risk of wear and loosening of the connection ports and plug points, and can also effectively prevent the current-carrying parts from bending and causing sudden changes in resistance. The configuration of multiple load-sharing cables 1 allows the current to be evenly distributed, which not only improves the current-carrying capacity of the terminals, but also reduces the loss caused by resistance, ensuring efficient transmission during the charging process. Therefore, by using multiple load-sharing cables 1 in parallel, the problems of difficult fixing, difficult bending and wiring, large size, and difficult heat dissipation of oversized cables can be effectively avoided.

[0025] refer to Figure 4 In one embodiment, the wiring terminal 2 is a copper tube terminal, the second connection port 21 is cylindrical, the second connection port 21 is sleeved on the outside of the first connection port 11, and the second connection port 21 is crimped and fixed to the first connection port 11.

[0026] In the above embodiment, the inner diameter of the copper tube terminal is slightly larger than the outer diameter of the first connection port 11, so that the copper tube terminal can be tightly sleeved on the outside of the first connection port 11. In this way, a good electrical contact is formed between the copper tube terminal and the first connection port 11, and the cylindrical structure of the copper tube terminal also provides sufficient mechanical strength to withstand large currents and mechanical stresses. In addition, the material of the copper tube terminal is selected as copper because copper has good electrical conductivity and corrosion resistance, which helps to improve the stability and service life of the entire charging station current-carrying terminal structure.

[0027] In one example, a connection transition portion 4 is disposed around the connection between the second connection port 21 and the first connection port 11 . The connection transition portion 4 is filled with solder, and the solder is fixedly connected to the first connection port 11 and the second connection port 21 .

[0028] In the above embodiment, the connection transition portion 4 can ensure that the connection between the first connection port 11 and the second connection port 21 is more firm and reliable. The filling of solder not only enhances the stability of the electrical connection, but also improves the strength of the mechanical connection. In practical applications, it can effectively prevent the connection from loosening or breaking due to excessive current or mechanical stress, thereby ensuring the performance stability and safety of the current-carrying terminal of the charging seat during long-term use. In addition, the use of solder also simplifies the assembly process, reduces production costs, and improves production efficiency.

[0029] refer to Figure 5 In one embodiment, the connection terminal 2 is an ultrasonic welding terminal, the second connection port 21 is flat, and the second connection port 21 is fixed to the first connection port 11 by welding.

[0030] In the above embodiment, when the terminal 2 adopts an ultrasonic welding terminal, the connection between the terminal 2 and the second connection port 21 is more precise and firm. The flat design of the second connection port 21 is not only convenient for close cooperation with the terminal 2, but also can better disperse the welding stress during the welding process, thereby reducing the damage to the connection part caused by stress concentration. In addition, compared with traditional welding methods, ultrasonic welding technology has the advantages of fast welding speed, small heat-affected zone, and high welding strength, which further improves the reliability and durability of the current-carrying terminal of the charging seat. Through the application of this structural design and welding technology, the current-carrying terminal of the charging seat has been significantly improved in terms of current transmission efficiency and long-term stability.

[0031] In one embodiment, the third connection port 22 is flat, and a first connection hole 23 is formed in the third connection port 22. A second connection hole 32 corresponding to the first connection hole 23 is formed on the terminal surface 31 of the bus 3. A first connecting member 5 is inserted into the first connection hole 23 and the second connection hole 32 to fix the terminal 2 to the bus 3.

[0032] In the above embodiment, the first connecting member 5 can be a bolt, a screw or other forms of fasteners. Through this connection method, the connection between the terminal 2 and the bus 3 is not only firm and reliable, but also easy to disassemble and maintain. In addition, the flat third connection port 22 design also helps to disperse the stress during connection and reduce damage to the connection parts caused by long-term use or current shock. This structural design enables the current-carrying terminal of the charging seat to maintain stable connection performance when subjected to large currents, thereby ensuring the safe and efficient operation of the entire charging system.

[0033] refer to Figure 3 In one embodiment, a mounting portion 33 is extended from one end face of the terminal surface portion 31 away from the first connecting member 5, and the mounting portion 33 is provided with a mounting hole 34. The mounting hole 34 is penetrated by a second connecting member 6, and the second connecting member 6 is detachably connected to the external current-carrying component so that the bus 3 is fixedly connected to the external current-carrying component.

[0034] In the above embodiment, the second connecting member 6 can be a bolt, a screw or other forms of fasteners. This design allows the busbar 3 to be quickly connected and disconnected from external current-carrying components, which is convenient for the installation, maintenance and upgrading of the equipment. At the same time, the provision of the mounting portion 33 increases the flexibility of the connection, so that the busbar 3 can adapt to external current-carrying components of different sizes and shapes, thereby improving the scope of application and compatibility of the charging station current-carrying terminal. In this way, the charging station current-carrying terminal is not only optimized in structure, but also more diversified in function, meeting the use requirements in different scenarios.

[0035] refer to Figure 6 The present invention also provides a method for manufacturing a charging seat current-carrying terminal structure, which is used to manufacture a charging seat current-carrying terminal structure as described in any one of the above items, comprising: S1: providing a plurality of load-sharing cables 1 and wiring terminals 2, and providing first connection ports 11 at two opposite ends of the load-sharing cables 1 and providing a second connection port 21 at one end of the wiring terminals 2; S2: contacting the first connection port 11 with the second connection port 21, and fixing the first connection port 11 with the second connection port 21 by crimping or welding; S3: Provide a busbar 3 and a first connector 5, set a terminal face portion 31 on the busbar 3, and set a third connection port 22 on the other end of the terminal 2, open a first connection hole 23 on the third connection port 22, open a second connection hole 32 on the terminal face portion 31, overlap the third connection port 22 to the terminal face portion 31, and insert the first connector 5 into the first connection hole 23 and the second connection hole 32; S4: Provide a second connector 6, set a mounting portion 33 on an end face of the bus 3 away from the terminal face portion 31, and open a mounting hole 34 on the mounting portion 33, insert the second connector 6 into the mounting hole 34, so that the bus 3 can be detachably connected to the external current-carrying component.

[0036] In the above embodiment, the load-sharing cable 1 and the wiring terminal 2 are fully prepared in S1 to ensure that their quality and specifications meet the design requirements. Connection ports are respectively set at both ends of the load-sharing cable 1 and one end of the wiring terminal 2. These ports are the key parts of the subsequent connection. In step S2, the first connection port 11 and the second connection port 21 are firmly connected by crimping or welding to ensure the stability and conductivity of the connection. In step S3, the preparation and installation of the bus 3 and the first connector 5 are the core links in the entire production process. It is necessary to accurately overlap the third connection port 22 with the wiring terminal surface 31, and ensure the alignment of the first connection hole 23 and the second connection hole 32 to facilitate the insertion of the first connector 5. Finally, in step S4, the installation of the second connector 6 needs to accurately pass through the installation hole 34 of the bus 3 to ensure the detachable connection between the bus 3 and the external current-carrying component, which not only facilitates the subsequent maintenance and replacement, but also improves the flexibility and practicality of the entire charging seat current-carrying terminal structure. Through the above steps, a charging seat current-carrying terminal structure that meets the design requirements can be efficiently manufactured.

[0037] In one embodiment, the step of bringing the first connection port 11 into contact with the second connection port 21 and fixing the first connection port 11 and the second connection port 21 by crimping specifically includes: A copper tube terminal is used as the wiring terminal 2, and the second connection port 21 of the wiring terminal 2 is sleeved on the outside of the first connection port 11, and the first connection port 11 and the second connection port 21 are pressed and connected by a crimping pliers; Provide a tin bar, and surround a connecting transition portion 4 at a connection between an end of the second connecting port 21 and the first connecting port 11, and wrap the tin bar around the connecting transition portion 4; The tin bar is heated to a preset temperature by a high-frequency eddy current heating device, so that the tin bar is melted and completely fills the connecting transition portion 4; Stop heating to allow the melted tin bar to cool and solidify naturally, thereby forming a firm connection with the first connection port 11 and the second connection port 21; The step of contacting the first connection port 11 and the second connection port 21 and fixing the first connection port 11 and the second connection port 21 by welding specifically includes: An ultrasonic welding terminal is used as the connection terminal 2, and the second connection port 21 of the connection terminal 2 is overlapped on the outer side of the first connection port 11; Using ultrasonic welding equipment to enable the welding head to clamp the first connection port 11 and the second connection port 21 with a preset pressure; Applying ultrasonic vibration to the welding head at a preset frequency and a preset amplitude, so that the contact surfaces of the first connection port 11 and the second connection port 21 are rubbed at high speed to generate heat and melt; The welding head is made to maintain the first connection port 11 and the second connection port 21 with a preset pressure for a preset time to ensure that the molten material is evenly diffused; The ultrasonic vibration is stopped to allow the first connection port 11 and the second connection port 21 to cool and solidify naturally.

[0038] In the above embodiments, each step specifically includes two types of fixed connection methods of the first connection port 11 and the second connection port 21, namely, crimping or welding. In the crimping method, the use of the crimping pliers ensures the tightness and stability of the connection, while the molten filling of the tin bar further enhances the conductivity and durability of the connection part. In the welding method, the use of ultrasonic welding terminals achieves rapid and uniform melting through the heat generated by high-frequency vibration, ensuring the strength and reliability of the connection part. The selection of these two connection methods not only improves production efficiency, but also ensures product quality and safety. In addition, by optimizing the design of the terminal block 2, the contact resistance can be further reduced and the overall current conduction efficiency can be improved. In practical applications, crimping or welding methods can be flexibly selected according to different usage environments and requirements to achieve the best electrical connection effect.

[0039] In one embodiment, the step of overlapping the third connection port 22 to the wiring terminal surface 31 and inserting the first connection member 5 into the first connection hole 23 and the second connection hole 32 specifically includes: Performing surface pretreatment on the terminal face portion 31 and the third connection port 22 using a plasma processing device; Align the first connecting hole 23 with the second connecting hole 32, and insert the first connecting member 5 into the first connecting hole 23 and the second connecting hole 32; After the third connection port 22 is fixedly connected to the wiring terminal surface portion 31 , the wiring terminal 2 and the busbar 3 are encapsulated with a preset insulating material.

[0040] In the above embodiment, the plasma treatment device cleans and activates the surface of the terminal face 31 and the third connection port 22 by generating plasma, thereby improving the surface adhesion and chemical activity. The pretreatment step is essential to ensure a good electrical connection between the terminal 2 and the busbar 3, and can remove the oxide layer and impurities on the surface, providing a clean and active interface for subsequent fixed connection.

[0041] The use of a preset insulating material to encapsulate the terminal block 2 and the busbar 3 can not only protect the electrical connection from the influence of the external environment, such as humidity, dust and chemical corrosion, but also provide additional mechanical protection to prevent physical damage. The selection of the encapsulation material needs to consider factors such as its insulation performance, temperature resistance, chemical resistance and mechanical strength to ensure long-term and stable protection of the electrical connection.

[0042] In one embodiment, the manufacturing method further includes the step of performing a mechanical strength test on the current-carrying terminal structure of the charging seat, including: The load-sharing cable 1 and the busbar 3 are clamped by a force measuring device, and a gradually increasing mechanical load is applied to the load-sharing cable 1 and the busbar 3 in opposite directions; Obtaining the relative displacement between the load-sharing cable 1 and the bus bar 3 under various mechanical load conditions; If the sharing cable 1 and the bus 3 are not loose, and the relative displacement is within a preset range, the mechanical strength of the current-carrying terminal structure of the charging seat is determined to be qualified; if any of the conditions is not met, the mechanical strength of the current-carrying terminal structure of the charging seat is determined to be unqualified.

[0043] In the above embodiment, through the mechanical strength test, it can be ensured that the current-carrying terminal structure of the charging seat can withstand certain mechanical stresses without damage or performance degradation in actual use. This testing step is an indispensable part of the entire production process and is directly related to the reliability and safety of the product. During the test, the gradually enhanced mechanical load simulates the tension and pressure that may occur in actual use, ensuring the stability and durability of the product under extreme conditions. Through this series of tests, unqualified products can be screened out, ensuring that only the current-carrying terminal structure of the charging seat that meets the mechanical strength standards can enter the market, thereby providing consumers with safer and more reliable products.

[0044] The above description is only a preferred embodiment of the present invention, and does not limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made by using the contents of the present invention specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. A charging seat current-carrying terminal structure, characterized in that: include: A plurality of load-sharing cables (1), wherein two opposite ends of the load-sharing cables (1) are provided with first connection ports (11); A plurality of connection terminals (2), each of the connection terminals (2) being provided with a second connection port (21), the second connection port (21) being fixedly connected to the first connection port (11); A busbar (3), wherein the busbar (3) is provided with a terminal end surface (31), and an end of the terminal (2) away from the second connection port (21) is further provided with a third connection port (22), and a plurality of the terminal (2) are fixedly connected to the terminal end surface (31) of the busbar (3) via the third connection port (22), wherein the busbar (3) is used to be connected to an external current-carrying component.

2. A charging seat current-carrying terminal structure according to claim 1, characterized in that: The wiring terminal (2) is a copper tube terminal; the second connection port (21) is cylindrical; the second connection port (21) is sleeved on the outside of the first connection port (11); and the second connection port (21) and the first connection port (11) are crimped and fixed.

3. A charging seat current-carrying terminal structure according to claim 2, characterized in that: A connecting transition portion (4) is arranged around the connection between the second connecting port (21) and the first connecting port (11), the connecting transition portion (4) is filled with solder, and the solder is fixedly connected to the first connecting port (11) and the second connecting port (21).

4. A charging seat current-carrying terminal structure according to claim 1, characterized in that: The connection terminal (2) is an ultrasonic welding terminal, the second connection port (21) is flat, and the second connection port (21) is fixed to the first connection port (11) by welding.

5. The current-carrying terminal structure of a charging seat according to claim 1, characterized in that: The third connection port (22) is flat, and is provided with a first connection hole (23). The connection end surface (31) of the busbar (3) is provided with a second connection hole (32) corresponding to the first connection hole (23). A first connection member (5) is inserted through the first connection hole (23) and the second connection hole (32) so as to fix the connection terminal (2) and the busbar (3).

6. A charging seat current-carrying terminal structure according to claim 5, characterized in that: An end face of the terminal surface (31) facing away from the first connecting member (5) extends with a mounting portion (33), the mounting portion (33) is provided with a mounting hole (34), a second connecting member (6) is passed through the mounting hole (34), and the second connecting member (6) is detachably connected to an external current-carrying component so that the busbar (3) is fixedly connected to the external current-carrying component.

7. A method for manufacturing a current-carrying terminal structure of a charging seat, used for manufacturing the current-carrying terminal structure of the charging seat as claimed in any one of claims 1 to 6, characterized in that: include: A plurality of load-sharing cables (1) and wiring terminals (2) are provided, wherein first connection ports (11) are arranged at two opposite ends of the load-sharing cables (1), and a second connection port (21) is arranged at one end of the wiring terminal (2); The first connection port (11) and the second connection port (21) are brought into contact with each other, and the first connection port (11) and the second connection port (21) are fixed by crimping or welding; A busbar (3) and a first connecting member (5) are provided, a terminal face portion (31) is provided on the busbar (3), and a third connecting port (22) is provided on the other end of the connecting terminal (2), a first connecting hole (23) is provided in the third connecting port (22), a second connecting hole (32) is provided in the terminal face portion (31), the third connecting port (22) is overlapped to the terminal face portion (31), and the first connecting member (5) is inserted into the first connecting hole (23) and the second connecting hole (32); A second connecting member (6) is provided, a mounting portion (33) is provided on an end surface of the busbar (3) away from the terminal surface portion (31), a mounting hole (34) is provided in the mounting portion (33), and the second connecting member (6) is inserted into the mounting hole (34) so ​​that the busbar (3) is detachably connected to an external current-carrying component.

8. A method for manufacturing a current-carrying terminal structure of a charging seat according to claim 7, characterized in that: The step of bringing the first connection port (11) and the second connection port (21) into contact with each other and fixing the first connection port (11) and the second connection port (21) by crimping specifically comprises: A copper tube terminal is used as a wiring terminal (2), and a second connection port (21) of the wiring terminal (2) is sleeved on the outside of the first connection port (11), and the first connection port (11) and the second connection port (21) are crimped and connected using a crimping pliers; Providing a tin bar, surrounding a connecting transition portion (4) at a connection point between an end of the second connecting port (21) and the first connecting port (11), and winding the tin bar onto the connecting transition portion (4); Using a high-frequency eddy current heating device to heat the tin bar to a preset temperature, so that the tin bar melts and completely fills the connecting transition portion (4); Stop heating to allow the molten tin bar to cool and solidify naturally, thereby forming a firm connection with the first connection port (11) and the second connection port (21); The step of bringing the first connection port (11) and the second connection port (21) into contact with each other and fixing the first connection port (11) and the second connection port (21) by welding specifically comprises: An ultrasonic welding terminal is used as a connecting terminal (2), and a second connecting port (21) of the connecting terminal (2) is overlapped on the outer side of the first connecting port (11); Using ultrasonic welding equipment, the welding head clamps the first connection port (11) and the second connection port (21) at a preset pressure; Applying ultrasonic vibration to the welding head at a preset frequency and a preset amplitude, so that the contact surfaces of the first connection port (11) and the second connection port (21) are rubbed at high speed to generate heat and melt; The welding head is made to maintain the first connection port (11) and the second connection port (21) at a preset pressure for a preset time to ensure that the molten material is evenly diffused; The ultrasonic vibration is stopped, so that the first connection port (11) and the second connection port (21) are naturally cooled and solidified.

9. The method for manufacturing a current-carrying terminal structure of a charging seat according to claim 7, characterized in that: The step of overlapping the third connection port (22) to the connection terminal surface (31) and inserting the first connection member (5) into the first connection hole (23) and the second connection hole (32) specifically comprises: Performing surface pretreatment on the connection terminal surface (31) and the third connection port (22) using plasma processing equipment; Aligning the first connection hole (23) with the second connection hole (32), and inserting the first connection member (5) into the first connection hole (23) and the second connection hole (32); After the third connection port (22) is fixedly connected to the wiring terminal surface (31), the wiring terminal (2) and the busbar (3) are encapsulated using a preset insulating material.

10. A method for manufacturing a current-carrying terminal structure of a charging seat according to claim 7, characterized in that: The manufacturing method also includes the step of performing a mechanical strength test on the current-carrying terminal structure of the charging seat, including: The load-sharing cable (1) and the busbar (3) are clamped by a force measuring device, and a gradually increasing mechanical load is applied to the load-sharing cable (1) and the busbar (3) in opposite directions; Obtaining the relative displacement between the load-sharing cable (1) and the busbar (3) under various mechanical load conditions; If the load-sharing cable (1) and the busbar (3) are not loose, and the relative displacement is within a preset range, the mechanical strength of the current-carrying terminal structure of the charging seat is determined to be qualified; if any of the conditions is not met, the mechanical strength of the current-carrying terminal structure of the charging seat is determined to be unqualified.

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