Integrated quick-plug connection assembly, BDU and processing method

Abstract

The invention provides an integrated quick-plug connection assembly, a BDU and a processing method, and relates to the technical field of BDUs, the integrated quick-plug connection assembly comprises an upper shell made of a plastic material, a plurality of mounting cavities are formed in the upper shell and used for accommodating relays, and mounting openings are formed for relay coil contact pieces to penetrate through; a plurality of metal sampling sheets are embedded in the upper shell through an injection molding process, and one end of a sheet body extends out of the shell and forms a pin for being connected with a sampling terminal. An elastic structure protruding towards the mounting opening is arranged at one end, away from the contact pin, of the sheet body and is connected with a relay coil contact sheet. Different from a traditional PCB terminal connection mode, the metal sampling piece is embedded in the upper shell, elastic connection is achieved through the elastic structure and the coil contact piece of the relay, the influence of mechanical plugging on connection stability is reduced, vibration and mechanical stress are effectively relieved, and reliable electrical connection in the vibration environment such as vehicle running is ensured.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile BDU, and in particular to an integrated quick-plug connection component, a BDU and a processing method. Background Art

[0002] With the continuous development of new energy vehicle technology, the battery disconnect unit (BDU) is a key component in the power system of new energy vehicles, and its function is becoming more and more important. BDU is mainly responsible for the charge and discharge control between the battery pack and the high-voltage system, circuit overload protection, battery monitoring and other tasks to ensure the safe and reliable operation of the high-voltage system under various working conditions. In order to achieve these functions, BDU needs to accurately collect the high-voltage signal of the battery pack and process the low-voltage control signal. Therefore, the connection method of high and low voltage signals inside the BDU is an important link in the design that cannot be ignored.

[0003] At present, in order to realize high-voltage sampling and low-voltage control of the BDU, the internal part of the BDU usually adopts a wiring harness connection, a PCB board connection or an FPC connection to electrically connect the high and low voltage signals.

[0004] Wire harness connection is a traditional low-voltage control signal connection method. Wires are usually used to connect various electrical components together. The layout and fixation of the wire harness inside the BDU are usually affected by space limitations and layout complexity. Especially in a small space, the arrangement of the wire harness is often difficult to be neat and standardized, which can easily lead to poor electrical contact. Secondly, the wire harness is easily affected by external factors such as mechanical vibration, temperature changes and tension during long-term use. Cables and connection points may wear, age or loosen, increasing the risk of system failure.

[0005] In order to improve the stability and integration of the connection, more and more BDU designs have begun to adopt PCB connection. The main control circuit board and various electrical components are mainly connected by multi-way male and female terminals. For example, the terminals on the control circuit board and the coil contacts on the relay components are plugged in to achieve low-voltage signal control. However, the relay components and the BDU main control circuit board are connected by multi-way male and female terminals, which will generate unpredictable large mechanical stress during the assembly process. During the driving of the vehicle, the mechanical stress cannot be effectively released, and the male and female terminals will fall off during the vibration process, affecting the normal operation of the BDU. In addition, the relay components and the BDU main control circuit board are connected by multi-way male and female terminals, which will cause the electrical components, terminals and circuit boards to be installed in the battery pack circuit breaker unit, occupying a large space, making the entire battery pack circuit breaker unit larger and unable to be thin and light. Summary of the invention

[0006] In view of this, the present invention proposes an integrated quick-plug connection assembly, BDU and processing method to solve the problem that the BDU main control circuit board of the battery pack circuit breaker unit is connected to various relays through multiple male and female terminals, which will generate unpredictable large mechanical stress, cause the terminals to fall off, and affect the normal operation of the BDU.

[0007] The technical solution of the present invention is achieved in this way:

[0008] In a first aspect, the present invention provides an integrated quick-connection assembly, comprising:

[0009] The upper shell is made of plastic material, and has a plurality of mounting cavities inside the upper shell. The mounting cavities are used to detachably accommodate the relays. The top surface of the upper shell is provided with mounting openings corresponding to the positions of the mounting cavities, and are used for the coil contacts of the relays to pass through;

[0010] Multiple metal sampling sheets, the metal sampling sheets include a sheet body embedded in the upper shell by an injection molding process, one end of the sheet body extends out of the outer side of the upper shell and is formed with a pin, the pin is used to connect with the sampling terminal, the ends of the multiple sheet bodies away from the pin are respectively located at the corresponding installation ports, and the end of the sheet body away from the pin has an elastic structure protruding above the installation port, and the elastic structure is used to connect with the coil contact of the relay.

[0011] On the basis of the above technical solution, preferably, the sheet body has a conductive sheet at one end of the mounting port, the conductive sheet has a first spring sheet formed by cutting, the elastic structure includes a first elastic portion formed by bending the end of the first spring sheet upward, and the side of the first elastic portion away from the first spring sheet is used to connect with the coil contact of the relay.

[0012] On the basis of the above technical solution, preferably, the conductive sheet also has two second spring sheets formed by cutting, and the two second spring sheets are located on both sides of the first spring sheet. The elastic structure also includes a second elastic part formed by bending the end of the second spring sheet upward, and the second elastic part and the first elastic part are symmetrical in structure. There is a gap between the second elastic part and the first elastic part for the coil of the relay to pass through, and the opposite sides of the first elastic part and the second elastic part are respectively used to contact the relay coil contact.

[0013] On the basis of the above technical solution, preferably, the first elastic part includes a guide section, a connecting section and an elastic section, the end of the first spring sheet is bent upward to form a guide section with an arc-shaped structure, the connecting section is located above the guide section, and is a straight section structure inclined in a direction away from the first spring sheet, the side of the connecting section away from the first spring sheet is used to contact the coil contact of the relay, the elastic section is connected to the upper end of the connecting section, and the elastic section is bent in an arc shape toward the direction of the first spring sheet.

[0014] On the basis of the above technical solution, preferably, it also includes a plastic part, and the plastic part, the metal sampling piece and the upper shell are integrally formed through a secondary injection molding process. The plastic part is located at the installation port, and the plastic part includes an annular body. The elastic structure is located inside the annular body, and the inner side of the annular body has a limiting portion, and the limiting portion conflicts with the end of the elastic section away from the connecting section.

[0015] On the basis of the above technical solution, preferably, the inner side of the installation port is respectively formed with a first annular step and a second annular step from bottom to top, the inner diameter of the second annular step is larger than the inner diameter of the first annular step, the conductive sheet is horizontally located in the first annular step, the lower part of the annular body is located in the second annular step, the lower part of the annular body has a lip, the side wall of the second annular step is formed with a groove for wrapping the lip, and the inner side wall of the bottom of the installation port is also formed with a support portion flush with the first annular step, and the support portion is used to support the first spring sheet and the second spring sheet.

[0016] On the basis of the above technical solution, preferably, at least two first positioning holes are arranged at the corners of the conductive sheet, second positioning holes corresponding to the positions of the first positioning holes are arranged on the annular body, a plurality of third positioning holes are opened on the sheet body, and through holes corresponding to the positions of the third positioning holes are opened on the upper shell.

[0017] On the basis of the above technical solution, preferably, a terminal connection port is provided at the edge of the upper shell, and a plurality of pins of the sampling metal sheet are located in the terminal connection port.

[0018] In a second aspect, the present invention provides an integrated BDU, comprising the integrated quick-plug connection assembly described in the first aspect, and also comprising a lower shell and a plurality of relays, wherein the upper shell is fixedly arranged on the lower shell, and the plurality of relays are fixedly arranged between the upper shell and the lower shell, at least a portion of the relay is located in the installation cavity, and the coil contact of the relay passes through the installation opening and is located between the first elastic part and the second elastic part, the outer side of the connecting section contacts the coil contact of the relay, and the limiting part conflicts with an end of the elastic section away from the connecting section.

[0019] In a third aspect, the present invention provides a method for processing an integrated BDU, comprising the following steps:

[0020] S1, forming a sheet body, a pin and a conductive sheet of the metal sampling sheet by a stamping process, then punching out a first spring sheet and a second spring sheet on the conductive sheet by a punching process, and finally punching and bending the first spring sheet and the second spring sheet to form a first elastic part and a second elastic part respectively;

[0021] S2, obtaining plastic parts through injection molding process;

[0022] S3, installing the first elastic part and the second elastic part in the plastic part, and then placing the plastic part and the metal sampling piece as a whole into the mold, and obtaining the upper shell with the plastic part and the metal sampling piece embedded therein through a secondary injection molding process;

[0023] S4. Install the relay between the upper housing and the lower housing, and allow the coil contact of the relay to pass through the installation opening of the upper housing and be inserted between the first elastic part and the second elastic part.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] (1) Since the integrated quick-plug connection assembly uses an elastic structure to elastically connect with the relay coil contact, instead of relying on mechanical plug-in connection like the traditional male and female terminal connection on the PCB, the impact of mechanical stress and vibration on the connection stability is reduced. Even when the vehicle is driving, the vibration and mechanical stress on the coil contact can be effectively alleviated by the elastic structure. While improving the reliable connection between the coil contact and the metal sampling piece, the risk of terminal detachment and poor connection on the existing PCB is avoided. (2) Compared with the traditional wiring harness connection and PCB connection through multi-way terminals, the metal sampling piece is integrated into the upper shell, which not only effectively saves space inside the BDU, but also makes the BDU more compact and thin as a whole, which meets the requirements of modern cars for lightweight and space saving.

[0026] (3) The symmetrically designed first elastic part and second elastic part provide uniform force distribution during the connection process. This can effectively avoid poor electrical contact caused by external vibration, mechanical pressure or temperature change. In addition, the double elastic part can distribute the pressure of the electrical connection more evenly, avoiding fatigue or damage caused by excessive force on a single elastic part, thereby extending the service life of the component.

[0027] (4) By optimizing the structure of the elastic part, the coil contact insertion and contact stability of the relay are improved. The arc-shaped guide section ensures that the contact piece enters the elastic part smoothly, reducing the problem of poor docking; the inclined connection section provides a smooth contact surface, enhances the contact force and electrical connection stability; the curved elastic section provides elastic crimping, adapts to small displacements and vibrations, and ensures connection reliability. The overall design improves the adaptability, stability and durability of the component.

[0028] (5) By setting the plastic parts, the injection molded parts and the metal sampling piece are placed as a whole in the mold of the upper shell, and the upper shell with the plastic parts and the metal sampling piece embedded is obtained through the secondary injection molding process. At this time, the plastic parts and the upper shell are integrated, and the metal sampling piece is embedded in the upper shell. Through this process, the plastic parts, the metal sampling piece and the upper shell are formed in one piece, the process is simple, and the production efficiency is high; at the same time, the integrated quick-plug connection component structure obtained by this process, the design of the limit part in the plastic part effectively prevents the elastic fatigue of the elastic part, ensures that the first elastic part and the second elastic part can always provide stable elastic crimping, so as to achieve reliable electrical connection with the coil contact piece. This design optimizes the performance of the component in long-term use and vibration environment, extends the service life, and improves the reliability and stability of the overall connection. (6) The processing method of the integrated BDU disclosed in the present invention utilizes stamping, injection molding and secondary injection molding processes to achieve the integrated molding of plastic parts, metal sampling pieces and the upper shell, simplifies the production process, and improves production efficiency. At the same time, the protection of the elastic structure by plastic parts and the design of the limiter ensure the stability and reliability of the BDU in long-term use, especially in a vibration environment, which can provide a continuous and stable electrical connection. Therefore, this design not only optimizes the manufacturing process, but also significantly improves the performance and reliability of the product, and is suitable for high-demand electrical connection and power-off protection applications. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0030] Figure 1 It is a schematic diagram of the three-dimensional structure from a first perspective of the integrated quick-plug connection assembly disclosed in the present invention;

[0031] Figure 2 It is a schematic diagram of the three-dimensional structure from a second viewing angle of the integrated quick-plug connection assembly disclosed in the present invention;

[0032] Figure 3 It is a schematic diagram of the three-dimensional structure of the upper shell disclosed in the present invention;

[0033] Figure 4 It is a schematic diagram of the assembly structure of the sampling metal sheet and the plastic part disclosed in the present invention;

[0034] Figure 5 It is a schematic diagram of the three-dimensional structure of the plastic part disclosed in the present invention;

[0035] Figure 6A top view of the integrated quick-connection assembly and relay assembly structure disclosed in the present invention;

[0036] Figure 7 for Figure 6 Plane section view at AA in the middle;

[0037] Figure 8 for Figure 6 Plane section view at BB in the middle;

[0038] Fig. 9 It is a schematic diagram of the integrated BDU disclosed in the present invention;

[0039] Fig.10 It is a schematic diagram of the three-dimensional structure of the integrated BDU disclosed in the present invention;

[0040] Reference numerals:

[0041] P. Relay; P1. Coil contact; 1. Upper shell; 11. Mounting cavity; 12. Mounting port; 121. First annular step; 122. Second annular step; 1220. Groove; 123. Support portion; 13. Through hole; 14. Terminal connection port; 2. Metal sampling sheet; 21. Sheet body; 211. Third positioning hole; 22. Insert pin; 23. Elastic structure; 24. Conductive sheet; 25. First spring sheet; 231. First elastic portion; 26. Second spring sheet; 232. Second elastic portion; 2311. Guide section; 2312. Connecting section; 2313. Elastic section; 241. First positioning hole; 3. Plastic part; 31. Annular body; 32. Limiting portion; 311. Lip; 312. Second positioning hole; 4. Lower shell. DETAILED DESCRIPTION

[0042] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0043] like Figure 1 As shown, combined Figure 2 and 4 As shown, an embodiment of the present invention discloses an integrated quick-plug connection assembly, including an upper shell 1 and a plurality of metal sampling sheets 2.

[0044] The upper shell 1 is made of plastic and has a plurality of mounting cavities 11 inside. These mounting cavities 11 are used to accommodate relays. The arrangement of the mounting cavities 11 allows the relays to be fixed therein and to be easily disassembled. The top surface of the upper shell 1 is provided with mounting openings 12 corresponding to the positions of the mounting cavities 11, for the coil contact P1 of the relay to pass through, so as to ensure that the coil contact P1 of the relay P can establish a connection with the low-voltage acquisition module.

[0045] In some related prior arts, the low-voltage signal is collected by connecting the wire harness and the coil contact P1, or by connecting the PCB board and the coil contact P1. Both methods have disadvantages. Among them, the wire harness connection requires wiring inside the housing, which is limited by space and difficult to be neat and standardized, and it is easy to increase the risk of failure. At present, in the prior art, the terminals are mostly pre-welded on the PCB board, and then the terminals and the coil contacts P1 of each relay are plugged in. This method will generate unpredictable large mechanical stress during the assembly process. During the driving process of the vehicle, the mechanical stress cannot be effectively released, and during the vibration process, the terminals will fall off, affecting the normal operation of the BDU.

[0046] In order to solve the above problems, the present invention introduces multiple metal sampling sheets 2 on the basis of the upper shell 1. The metal sampling sheets 2 include a sheet body 21 embedded in the upper shell 1 through an injection molding process. One end of the sheet body 21 extends out of the upper shell 1 and is formed with a plug pin 22. The plug pin 22 is used to connect with the sampling terminal. The ends of the multiple sheet bodies 21 away from the plug pin 22 are respectively located at the corresponding installation ports 12, and the ends of the sheet bodies 21 away from the plug pin 22 have an elastic structure 23 protruding above the installation port 12. The elastic structure 23 is used to connect with the coil contact P1 of the relay.

[0047] By connecting the coil contacts P1 of multiple relays to the elastic structure 23 of a metal sampling piece 2 respectively, and then directly plugging the sampling terminals into the pins 22 of multiple metal sampling pieces 2, the coil contacts P1 of the relay can establish a low-voltage signal path through the metal sampling piece 2 and the sampling terminal.

[0048] Since the integrated quick-plug connection assembly uses an elastic structure 23 to elastically connect with the relay coil contact P1, instead of relying on mechanical plug-in connection like the traditional male and female terminal plug-in connection on the PCB, the impact of mechanical stress and vibration on the connection stability is reduced. Even when the vehicle is driving, the vibration and mechanical stress on the coil contact P1 can be effectively alleviated by the elastic structure 23, while improving the reliable connection between the coil contact P1 and the metal sampling piece 2, avoiding the risk of terminal falling off and poor connection on the existing PCB.

[0049] In addition, compared with the traditional wiring harness connection and PCB connection through multi-way terminals, the metal sampling piece 2 is integrated into the upper shell 1, which not only effectively saves the space inside the BDU, but also makes the BDU as a whole more compact and thin, which meets the requirements of modern cars for lightweight and space saving.

[0050] At the same time, since the metal sampling piece 2 is integrated in the upper shell 1, during assembly, it is only necessary to install the relay in the installation cavity 11 of the upper shell 1, so that the coil contact P1 of the relay and the elastic structure 23 can be quickly connected. The assembly process is simple and efficient, and no high assembly precision is required. Since the elastic structure 23 has elastic deformation ability, the coil contact P1 has a larger fault tolerance space when connected to the elastic structure 23, and the overall assembly efficiency is higher.

[0051] As some preferred implementations, refer to the attached Figure 1 and 4 As shown, the sheet body 21 has a conductive sheet 24 at one end located at the mounting opening 12, and the conductive sheet 24 has a first spring sheet 25 cut and formed thereon. The elastic structure 23 includes a first elastic portion 231 formed by bending the end of the first spring sheet 25 upward, and the side of the first elastic portion 231 away from the first spring sheet 25 is used to connect with the coil contact P1 of the relay.

[0052] In this embodiment, the conductive sheet 24 is an important component of the molded elastic structure 23, and the first spring sheet 25 is formed by cutting, which means that the conductive sheet 24 is formed into a spring sheet structure by a precise cutting process during the production process. This design helps to improve the elasticity and shape memory of the spring sheet, so that it can better adapt to external changes (such as mechanical stress and vibration) when in contact. The cutting process can also optimize the production process and improve the manufacturing accuracy and consistency of the metal sampling sheet 2.

[0053] The first elastic part 231 formed by the upward bending of the end of the first elastic piece 25 is an important part of the elastic structure 23. The bent first elastic part 231 can make contact with the coil contact P1 of the relay during the connection process and maintain a stable electrical connection. Specifically, the side of the first elastic part 231 away from the first elastic piece 25 is used to connect with the coil contact P1 of the relay. According to this arrangement, the first elastic part 231 can firmly abut against the coil contact P1 because it is a bent structure, and at the same time, it has a tendency to deform toward the direction of the first elastic piece 25 when subjected to lateral extrusion force. Through this structural arrangement, the first elastic part 231 can adaptively adjust its position under a certain mechanical force in the vibration environment of the vehicle, thereby ensuring the reliability of always being connected to the coil contact P1.

[0054] In the above embodiment, after the relay is installed in the installation cavity 11 of the upper shell 1, the coil contact P1 of the relay passes through the installation opening 12 and fits against the side wall of the first elastic part 231. In this case, when the vehicle is in use and is in a vibration environment for a long time, the elastic force of the first elastic part 231 will weaken. Since only one side of the coil contact P1 is in contact with the first elastic part 231, there is a risk of poor contact, which may cause the BDU to fail to be used normally.

[0055] To this end, this embodiment also discloses the following technical solutions, for details, refer to the attached Figure 1 and 4 As shown, in this embodiment, two second elastic sheets 26 are cut and formed on the conductive sheet 24, and the two second elastic sheets 26 are located on both sides of the first elastic sheet 25. The elastic structure 23 also includes a second elastic portion 232 formed by bending the end of the second elastic sheet 26 upward. The second elastic portion 232 and the first elastic portion 231 are symmetrical in structure. There is a gap between the second elastic portion 232 and the first elastic portion 231 for the relay coil contact P1 to pass through, and the gap is smaller than the thickness of the coil contact P1, and the opposite sides of the first elastic portion 231 and the second elastic portion 232 are respectively used to contact the relay coil contact P1.

[0056] With such a technical solution, in addition to the original first elastic sheet 25, two second elastic sheets 26 are added to the conductive sheet 24. These second elastic sheets 26 are designed on both sides of the first elastic sheet 25, so that the overall structure is more symmetrical and has better mechanical balance and stability. The second elastic portion 232 is opposite to the first elastic portion 231 to form a symmetrical structure. This symmetrical structure enables the second elastic portion 232 and the first elastic portion 231 to cooperate to achieve contact with the coil contact P1. When the coil contact P1 passes through the gap between the first elastic portion 231 and the second elastic portion 232, the coil contact P1 squeezes the first elastic portion 231 and the second elastic portion 232 in the horizontal direction. Since the first elastic portion 231 and the second elastic portion 232 are themselves formed by bending elastic sheets, they have good elastic potential energy, so that the first elastic portion 231 and the second elastic portion 232 can more firmly contact with the coil contact P1, thereby enhancing the reliability of the electrical connection.

[0057] The symmetrically designed first elastic part 231 and second elastic part 232 provide uniform force distribution during the connection process. This can effectively avoid poor electrical contact caused by external vibration, mechanical pressure or temperature change. In addition, the double elastic part arrangement allows the pressure of the electrical connection to be more evenly distributed, avoiding fatigue or damage caused by excessive force on a single elastic part, thereby extending the service life of the component.

[0058] In this embodiment, the first spring sheet 25 is located on one side of the conductive sheet 24, and the two second spring sheets 26 are located on the other side of the conductive sheet 24. In this way, it is convenient to punch the conductive sheet 24 once to form three spring sheets. Furthermore, it is also convenient to form an elastic part with the same elasticity and size by punching and bending once, so as to ensure the contact stability between the elastic part and the coil contact sheet P1. In addition, the first elastic part 231 abuts against one side of the coil contact sheet P1, and the two second elastic parts 232 abut against the two edges of the other side of the coil contact sheet P1. Such a structural setting enables the coil contact sheet P1 to have three contact force points, so as to ensure the force balance and stability.

[0059] In the above embodiment, the structures of the first elastic portion 231 and the second elastic portion 232 are symmetrical. The specific structure of the first elastic portion 231 is shown in detail below. Figure 4 As shown, the first elastic portion 231 includes a guiding section 2311 , a connecting section 2312 and an elastic section 2313 .

[0060] The end of the first spring piece 25 is bent upward to form an arc-shaped guide section 2311. The arc-shaped structure of the guide section 2311 enables the coil contact P1 of the relay to smoothly enter between the first elastic part 231 and the second elastic part 232 along the guide section 2311, thereby reducing the possibility that the coil cannot smoothly enter between the first elastic part 231 and the second elastic part 232 due to deviation or poor docking.

[0061] The connecting section 2312 is located above the guide section 2311 and is a straight section structure that is inclined in a direction away from the first elastic sheet 25. The connecting section 2312 provides a smooth contact surface for the relay coil contact P1, ensuring that the relay contact can firmly contact the elastic structure 23 and maintain a stable electrical connection. The connecting section 2312 is tilted, which can make the process of inserting the coil contact P1 between the first elastic part 231 and the second elastic part 232 smoother, reducing friction or incomplete contact caused by incorrect angles. At the same time, when the coil contact P1 is fully inserted, the upper end of the connecting section 2312 can more forcefully resist the coil contact P1, and the contact strength is higher.

[0062] The side of the connecting section 2312 away from the first elastic sheet 25 is used to contact the relay coil contact P1, and the elastic section 2313 is connected to the upper end of the connecting section 2312, and the elastic section 2313 is curved in an arc shape toward the first elastic sheet 25. The setting of the elastic section 2313 enables this part to provide elastic response when subjected to force, forming an elastic crimping with the relay contact. This bending structure not only improves the stability of the contact, but also enables the elastic part to have better adaptability, especially under the action of slight displacement or vibration of the relay contact, to ensure the reliability of the connection.

[0063] By optimizing the structure of the elastic part, the insertion and contact stability of the coil contact P1 of the relay are improved. The arc-shaped guide section 2311 ensures that the contact piece enters the elastic part smoothly, reducing the problem of poor docking; the inclined connection section 2312 provides a smooth contact surface, enhances the contact force and electrical connection stability; the curved elastic section 2313 provides elastic crimping, adapts to small displacements and vibrations, and ensures connection reliability. The overall design improves the adaptability, stability and durability of the component.

[0064] In the above embodiment, the reason why the first elastic portion 231 and the second elastic portion 232 can provide a correct elastic crimping so that the first elastic portion 231, the second elastic portion 232 and the coil contact piece P1 can be stably and reliably connected is that the arc-shaped guide section 2311, the inclined connecting section 2312 and the curved elastic section 2313 cooperate with each other. However, when the BDU is subjected to long-term vibration during use on the vehicle, the coil contact piece P1 will continuously apply pressure to the elastic portions on both sides in the horizontal direction. At this time, elastic fatigue will occur in the first elastic portion 231 and the second elastic portion 232, especially concentrated in the guide section 2311, because the guide section 2311 is in direct contact with the spring sheet. When the entire elastic portion undergoes elastic deformation for a long time, fatigue will occur in the guide section 2311. In this way, the connecting section 2312 and the elastic section 2313 will swing toward the spring sheet, and the connecting section 2312 will tend to be vertical or tilted toward the corresponding spring sheet. In this way, the entire elastic portion will not be able to maintain an effective connection with the coil contact piece P1, and poor contact may occur.

[0065] In order to solve the above problems, refer to the attached Figure 1 , 4 As shown in Figures 5, 6, 7 and 8, the solution adopted by the present invention is to introduce a plastic part 3 on the integrated quick-plug connection assembly of the present embodiment, and the plastic part 3 includes an annular body 31. The inner side of the annular body 31 is a through frame structure, and the inner side of the annular body 31 has a limiting portion 32. The inner side of the annular body 31 is used to install the elastic structure 23. At the same time, the ends of the elastic sections 2313 on the first elastic section 231 and the second elastic section 232 away from the connecting section 2312 are both in conflict with the limiting portion 32.

[0066] In order to make the elastic structure 23 able to stably contact the limiting part 32 in the annular body 31, the plastic part 3 needs to be fixed at the installation port 12, so that the elastic section 2313 in the first elastic part 231 and the second elastic part 232 can abut against the side wall of the limiting part 32. In a long-term vibration environment, the coil contact P1 applies pressure to the elastic parts on both sides, and the elastic section 2313 elastically deforms in a direction away from the coil contact P1. At the same time, the limiting part 32 will limit the large elastic deformation of the elastic section 2313, provide support for the deformation of the elastic section 2313, effectively disperse the deformation of the elastic section 2313, and avoid fatigue of the elastic section 2313 after long-term stress deformation, ensuring that the first elastic part 231 and the second elastic part 232 can always provide stable elastic crimping, thereby achieving reliable electrical connection with the coil contact P1. This design optimizes the performance of the quick-connect assembly in long-term use and vibration environments, extends the service life, and improves the reliability and stability of the overall connection.

[0067] At the same time, when the relay needs to be repaired, the coil contact P1 can be plugged in and out for many times without causing the elastic part to lose its elasticity and thus causing poor contact.

[0068] In order to achieve a fixed connection between the plastic part 3 and the upper shell 1 at the installation opening 12, as some embodiments, the plastic part 3 can be locked with the upper shell 1 by bolts, or a snap-on connection method, so that the plastic part 3 is fixedly connected to the upper shell 1 at the installation opening 12, and the elastic structure 23 is located in the annular body 31. This method will result in an assembly process for the plastic part 3 and the upper shell 1, and the production efficiency is relatively low.

[0069] In addition, although the metal sampling piece 2 can be embedded in the upper shell 1 by insert injection molding, since the elastic part is in a curved structure as a whole, the rubber material is easy to fill the gap between the curved section and the spring piece during mold injection molding, which will cause the elastic part to lose its elastic crimping effect. Therefore, before the metal sampling piece 2 is embedded in the upper shell 1, the elastic structure 23 cannot be punched out. The metal sampling piece 2 can only be embedded in the upper shell 1 as a thin sheet, and then the conductive sheet 24 can be punched out for the second time to obtain the spring piece and the elastic structure 23. This operation process obviously has more steps and higher production efficiency.

[0070] In view of the above problem, the metal sampling piece 2 cannot be directly embedded in the upper shell 1 through the injection molding process after molding. The method adopted in this embodiment is to first stamp the metal sampling piece 2, and then obtain the plastic part 3 through the injection molding process, and install the elastic structure 23 of the metal sampling piece 2 on the inner side of the annular body 31. At this time, the conductive sheet 24 is on the bottom surface of the annular body 31. The injection molded part and the metal sampling piece 2 are placed as a whole in the mold of the molded upper shell 1. Through the secondary injection molding process, the upper shell 1 embedded with the plastic part 3 and the metal sampling piece 2 is obtained. At this time, the plastic part 3 and the upper shell 1 are integrated, and the metal sampling piece 2 is embedded in the upper shell 1. Through this process, the plastic part 3, the metal sampling piece 2 and the upper shell 1 are formed in one piece, the process is simple, and the production efficiency is high.

[0071] It is worth noting that, since the plastic part 3 is first injection molded, the elastic structure 23 of the metal sampling piece 2 is pre-installed on the inner side of the annular body 31, and then the two are placed in the mold as a whole. During the injection molding process, the plastic part 3 protects the inner elastic structure 23, which can prevent the rubber from passing over the plastic part 3 and entering the elastic structure 23, thereby well realizing the integral molding of the plastic part 3, the metal sampling piece 2 and the upper shell 1. At the same time, the design of the limit part 32 in the plastic part 3 effectively prevents the elastic fatigue of the elastic part through the integrated quick-plug connection component structure obtained by this process, ensuring that the first elastic part 231 and the second elastic part 232 can always provide stable elastic crimping, thereby achieving reliable electrical connection with the coil contact piece P1. This design optimizes the performance of the component in long-term use and vibration environments, extends the service life, and improves the reliability and stability of the overall connection.

[0072] In order to realize secondary injection molding of the plastic part 3 and the upper shell 1, the present embodiment respectively forms a first annular step 121 and a second annular step 122 from bottom to top on the inner side of the mounting opening 12, the inner diameter of the second annular step 122 is larger than the inner diameter of the first annular step 121, the conductive sheet 24 is horizontally located in the first annular step 121, the lower part of the annular body 31 is located in the second annular step 122, the upper part of the annular body 31 extends above the mounting opening 12, the lower part of the annular body 31 has a lip 311, the side wall of the second annular step 122 is formed with a groove 1220 for wrapping the lip 311, and the inner side wall of the bottom of the mounting opening 12 is also formed with a support portion 123 flush with the first annular step 121, the support portion 123 is used to support the first spring sheet 25 and the second spring sheet 26.

[0073] In this embodiment, refer to the attached Figure 1 , 3As shown in Figure 7, the first annular step 121 and the second annular step 122 are respectively formed on the inner side of the installation opening 12 through the injection molding process. Therefore, the metal sampling sheet 2 and the plastic part 3 are placed in the injection mold from bottom to top in sequence. After the secondary injection molding, the plastic material wraps the conductive sheet 24 to form the first annular step 121, and the plastic material wraps the annular body 31 to form the second annular step 122. Since the edge of the annular body 31 has a lip 311, after the plastic material wraps the lip 311, a groove 1220 is formed on the side wall of the second annular step 122. This makes the structural strength of the plastic part 3 and the upper shell 1 stronger after the secondary injection molding, and can prevent the plastic part 3 from escaping from the upper shell 1. The support portion 123 is formed by injection molding, and the support portion 123 is located below the conductive sheet 24 and flush with the first annular step 121. In this way, the support portion 123 can support the first spring sheet 25 and the second spring sheet 26 to prevent the first spring sheet 25 and the second spring sheet 26 from being suspended in the installation opening 12. At the same time, the limiting portion 32 on the inner side of the annular body 31 can cooperate with the supporting portion to compress the first spring sheet 25 and the second spring sheet 26 to ensure that only the elastic portion at the end of the spring sheet is elastically crimped, thereby improving the contact reliability between the elastic portion and the coil contact P1.

[0074] It is worth noting that if there is no support portion 123, the bottom surface of the spring is in a suspended state. In this way, when the relay is pulled out from the first elastic portion 231 and the second elastic portion 232, the elastic portion will pull the spring to bend downward, causing damage to the spring, and then the first elastic portion 231 and the second elastic portion 232 cannot maintain their original posture, which is not conducive to the coil contact P1 being inserted and connected again.

[0075] In order to ensure that the relative positions of the plastic part 3 and the metal sampling sheet 2 remain unchanged during the secondary injection molding, the scheme set in this embodiment is: at least two first positioning holes 241 are set at the corners of the conductive sheet 24, and the annular body 31 is provided with second positioning holes 312 corresponding to the positions of the first positioning holes 241, and the sheet body 21 is provided with a plurality of third positioning holes 211, and the upper shell 1 is provided with through holes 13 corresponding to the positions of the third positioning holes 211.

[0076] Therefore, when the metal sampling sheet 2 is assembled into the mold of the upper shell 1, the first positioning hole 241 can cooperate with the positioning pin in the mold, and the third positioning hole 211 can cooperate with the positioning pin in the mold, so that the conductive sheet 24 and the sheet body 21 can be fixed in position in the mold, so as to avoid excessive injection pressure, which may cause the metal sampling sheet 2 to shift in the mold. After the metal sampling sheet 2 is installed in the mold, the plastic part 3 is installed above the conductive sheet 24, so that the positioning column passing through the first positioning hole 241 passes through the second positioning hole 312 on the annular body 31, so as to ensure that the annular body 31 and the conductive body are fixed relative to the mold. The upper shell 1 is provided with a through hole 13, so that the positioning pin in the upper mold of the molding shell and the positioning column passing through the third positioning hole 211 in the lower mold can cooperate to achieve reliable fixation of the sheet body in the mold.

[0077] As some preferred embodiments, the upper shell 1 has a terminal connection port 14 at the edge, and the pins 22 of the multiple sampling metal sheets are located in the terminal connection port 14. In this embodiment, multiple sampling metal sheets are embedded in the upper shell 1, and the pins 22 of the multiple sampling metal sheets are assembled at the terminal connection port 14. In this way, it is convenient to insert the sampling terminal into the terminal connection port 14 and establish a reliable electrical connection with the multiple pins 22, thereby ensuring stable and accurate signal transmission, and avoiding the disadvantages of BDU low-voltage collection through the wiring harness. At the same time, the sampling terminal is plug-in connected, and the operation flexibility is stronger.

[0078] The present invention also discloses an integrated BDU. Fig. 9 and 10 As shown, it includes the integrated quick-plug connection assembly described in the above embodiment, and also includes a lower shell 4 and multiple relays. The upper shell 1 is fixedly arranged on the lower shell 4, and the multiple relays are fixedly arranged between the upper shell 1 and the lower shell 4. At least a part of the relay is located in the installation cavity 11, and the coil contact P1 of the relay passes through the installation port 12 and is located between the first elastic portion 231 and the second elastic portion 232. The outer side of the connecting section 2312 contacts the coil contact P1 of the relay, and the limiting portion 32 conflicts with the end of the elastic section 2313 away from the connecting section 2312.

[0079] By combining the integrated quick-plug connection assembly with the lower housing 4 and multiple relays, a BDU with a compact structure and high connection reliability is formed. The coil contact P1 of the relay passes through the mounting port 12 and contacts the first elastic portion 231 and the second elastic portion 232 of the quick-plug connection assembly, ensuring the stability and reliability of the electrical connection. The limiting portion 32 provides support for the deformation of the elastic segment 2313, which will limit the large elastic deformation of the elastic segment 2313, effectively disperse the deformation of the elastic segment 2313, and avoid fatigue of the elastic segment 2313 after long-term stress deformation, ensuring that the first elastic portion 231 and the second elastic portion 232 can always provide stable elastic crimping, thereby achieving a reliable electrical connection with the coil contact P1. This design optimizes the performance of the BDU in long-term use and vibration environments, extends its service life, and improves the reliability and stability of the overall connection.

[0080] The present invention also discloses a processing method of an integrated BDU, comprising the following steps:

[0081] S1, forming the sheet body 21, the pin 22 and the conductive sheet 24 of the metal sampling sheet 2 by a stamping process, then punching out the first elastic sheet 25 and the second elastic sheet 26 on the conductive sheet 24 by a punching process, and finally punching and bending the first elastic sheet 25 and the second elastic sheet 26 to form the first elastic part 231 and the second elastic part 232 respectively;

[0082] S2, obtaining a plastic part 3 through an injection molding process;

[0083] S3, installing the first elastic part 231 and the second elastic part 232 in the plastic part 3, and then placing the plastic part 3 and the metal sampling piece 2 as a whole into the mold, and obtaining the upper shell 1 embedded with the plastic part 3 and the metal sampling piece 2 through a secondary injection molding process;

[0084] S4 , installing the relay between the upper housing 1 and the lower housing 4 , and allowing the coil contact P1 of the relay to pass through the installation opening 12 of the upper housing 1 and be inserted between the first elastic portion 231 and the second elastic portion 232 .

[0085] The metal sampling piece 2 is first stamped out, and then the plastic part 3 is obtained through an injection molding process. The elastic structure 23 of the metal sampling piece 2 is pre-installed on the inner side of the annular body 31, and then the whole is placed in the mold. Through a secondary injection molding process, the plastic part 3, the metal sampling piece 2 and the upper shell 1 are integrally formed. This method simplifies the process and improves production efficiency. During the secondary injection molding process, the plastic part 3 protects the inner elastic structure 23 to prevent the rubber from crossing the plastic part 3 and entering the elastic structure 23, thereby ensuring the integrity and functionality of the elastic structure 23. The design of the limiting portion 32 in the plastic part 3 effectively prevents elastic fatigue of the elastic part, ensuring that the first elastic part 231 and the second elastic part 232 can always provide stable elastic crimping, thereby achieving a reliable electrical connection with the coil contact piece P1.

[0086] Through this integrated BDU processing method, the plastic part 3, the metal sampling piece 2 and the upper shell 1 are integrally formed by stamping, injection molding and secondary injection molding processes, which simplifies the production process and improves production efficiency. At the same time, the protection of the elastic structure 23 by the plastic part 3 and the design of the limiter 32 ensure the stability and reliability of the BDU in long-term use, especially in a vibration environment, and can provide a continuous and stable electrical connection. Therefore, this design not only optimizes the manufacturing process, but also significantly improves the performance and reliability of the product, and is suitable for high-demand electrical connection and power-off protection applications.

[0087] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. An integrated quick-connect assembly, characterized in that: include: The upper shell (1) is made of plastic material, and has a plurality of mounting cavities (11) inside, the mounting cavities (11) being used to detachably accommodate relays, and a mounting opening (12) corresponding to the position of the mounting cavities (11) is provided on the top surface of the upper shell (1) for allowing the coil contact pieces (P1) of the relay to pass through; A plurality of metal sampling sheets (2), wherein the metal sampling sheets (2) include a sheet body (21) embedded in an upper shell (1) by an injection molding process, one end of the sheet body (21) extends out of the outer side of the upper shell (1) and is formed with a plug pin (22), and the plug pin (22) is used to connect with a sampling terminal, and one end of the plurality of sheet bodies (21) away from the plug pin (22) is respectively located at a corresponding installation opening (12), and one end of the sheet body (21) away from the plug pin (22) has an elastic structure (23) protruding toward the top of the installation opening (12), and the elastic structure (23) is used to connect with a coil contact sheet (P1) of a relay.

2. The integrated quick-connect assembly according to claim 1, characterized in that: The sheet body (21) has a conductive sheet (24) at one end located at the mounting opening (12), the conductive sheet (24) has a first spring sheet (25) formed by cutting, the elastic structure (23) comprises a first elastic portion (231) formed by bending the end of the first spring sheet (25) upward, and the side of the first elastic portion (231) away from the first spring sheet (25) is used to connect to the coil contact sheet (P1) of the relay.

3. The integrated quick-connect assembly according to claim 2, wherein: The conductive sheet (24) also has two second spring sheets (26) formed by cutting, and the two second spring sheets (26) are located on both sides of the first spring sheet (25). The elastic structure (23) also includes a second elastic portion (232) formed by bending the end of the second spring sheet (26) upward, and the second elastic portion (232) and the first elastic portion (231) are symmetrical in structure. There is a gap between the second elastic portion (232) and the first elastic portion (231) for the coil contact piece (P1) of the relay to pass through, and the opposite sides of the first elastic portion (231) and the second elastic portion (232) are respectively used to contact the coil contact piece (P1) of the relay.

4. The integrated quick-connect assembly according to claim 3, characterized in that: The first elastic portion (231) comprises a guiding section (2311), a connecting section (2312) and an elastic section (2313); the end of the first elastic sheet (25) is bent upward to form a guiding section (2311) with an arc-shaped structure; the connecting section (2312) is located above the guiding section (2311) and is a straight section structure inclined in a direction away from the first elastic sheet (25); a side of the connecting section (2312) away from the first elastic sheet (25) is used to contact the coil contact (P1) of the relay; the elastic section (2313) is connected to the upper end of the connecting section (2312), and the elastic section (2313) is bent in an arc-shaped structure in the direction of the first elastic sheet (25).

5. The integrated quick-connect assembly according to claim 4, characterized in that: It also includes a plastic part (3), wherein the plastic part (3), the metal sampling sheet (2) and the upper shell (1) are integrally formed by a secondary injection molding process, wherein the plastic part (3) is located at the mounting opening (12), and the plastic part (3) includes an annular body (31), wherein the elastic structure (23) is located on the inner side of the annular body (31), and wherein the inner side of the annular body (31) has a limiting portion (32), wherein the limiting portion (32) is in conflict with an end of the elastic section (2313) away from the connecting section (2312).

6. The integrated quick-connect assembly according to claim 5, characterized in that: The inner side of the installation opening (12) is respectively formed with a first annular step (121) and a second annular step (122) from bottom to top, the inner diameter of the second annular step (122) is larger than the inner diameter of the first annular step (121), the conductive sheet (24) is horizontally located in the first annular step (121), the lower part of the annular body (31) is located in the second annular step (122), the lower part of the annular body (31) has a lip (311), the side wall of the second annular step (122) is formed with a groove (1220) for wrapping the lip (311), and the inner side wall of the bottom of the installation opening (12) is also formed with a support portion (123) flush with the first annular step (121), and the support portion (123) is used to support the first elastic sheet (25) and the second elastic sheet (26).

7. The integrated quick-connect assembly according to claim 6, characterized in that: At least two first positioning holes (241) are arranged at the corners of the conductive sheet (24), second positioning holes (312) corresponding to the positions of the first positioning holes (241) are arranged on the annular body (31), a plurality of third positioning holes (211) are opened on the sheet body (21), and through holes (13) corresponding to the positions of the third positioning holes (211) are opened on the upper shell (1).

8. The integrated quick-connect assembly according to claim 1, wherein: The upper shell (1) has a terminal connection port (14) at the edge thereof, and a plurality of insertion pins (22) of the sampling metal sheet are located in the terminal connection port (14).

9. An integrated BDU, characterized in that: The invention comprises an integrated quick-plug connection assembly as described in any one of claims 5 to 8, and further comprises a lower shell (4) and a plurality of relays, wherein the upper shell (1) is fixedly arranged on the lower shell (4), and the plurality of relays are fixedly arranged between the upper shell (1) and the lower shell (4), at least a portion of the relay is located in the installation cavity (11), and the coil contact (P1) of the relay passes through the installation opening (12) and is located between the first elastic portion (231) and the second elastic portion (232), the outer side of the connecting section (2312) contacts the coil contact (P1) of the relay, and the limiting portion (32) conflicts with the end of the elastic section (2313) away from the connecting section (2312).

10. A method for processing an integrated BDU as claimed in claim 9, characterized in that: The steps are as follows: S1, forming a sheet body (21), a plug pin (22) and a conductive sheet (24) of a metal sampling sheet (2) by a stamping process, then punching out a first spring sheet (25) and a second spring sheet (26) on the conductive sheet (24) by a punching process, and finally punching and bending the first spring sheet (25) and the second spring sheet (26) to form a first elastic portion (231) and a second elastic portion (232) respectively; S2, obtaining a plastic part (3) through an injection molding process; S3, installing the first elastic part (231) and the second elastic part (232) in the plastic part (3), then placing the plastic part (3) and the metal sampling piece (2) as a whole in a mold, and obtaining an upper shell (1) embedded with the plastic part (3) and the metal sampling piece (2) through a secondary injection molding process; S4. Install the relay between the upper housing (1) and the lower housing (4), and allow the coil contact piece (P1) of the relay to pass through the installation opening (12) of the upper housing (1) and be inserted between the first elastic part (231) and the second elastic part (232).

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