An integrated quick connect assembly, BDU, and method of manufacture

Abstract

The application provides an integrated quick plug connection assembly, a BDU and a processing method, relates to the technical field of BDUs, and comprises an upper shell made of plastic material, which is internally provided with a plurality of mounting cavities for accommodating relays and is provided with mounting openings for the coil contact pieces of the relays to pass through; a plurality of metal sampling pieces are embedded in the upper shell through an injection molding process, one end of a piece body of each of the metal sampling pieces extends out of the shell and forms a pin for being connected with a sampling terminal. The end of the piece body, which is away from the pin, is provided with an elastic structure that protrudes towards the mounting opening and is connected with the coil contact piece of the relay. Unlike the traditional PCB terminal connection mode, the metal sampling pieces are embedded in the upper shell in the application, and the elastic structure is used to achieve elastic connection with the coil contact piece of the relay, so that the influence of mechanical plugging on the connection stability is reduced, vibration and mechanical stress are effectively relieved, and reliable electrical connection in a vibrating environment such as vehicle driving can be ensured.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of automobile BDU, and in particular to an integrated quick plug connection assembly, a BDU and a processing method. BACKGROUND

[0002] With the continuous development of new energy automobile technology, the battery pack disconnect unit (BDU) as a key component in the power system of new energy automobiles, its function is increasingly important. The 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 realize these functions, the BDU needs to accurately collect the high-voltage signals of the battery pack and process the low-voltage control signals. Therefore, the high and low voltage signal connection mode inside the BDU is an important part that cannot be ignored in the design.

[0003] At present, in order to realize the high-voltage sampling and low-voltage control of the BDU, the internal connection of the BDU usually adopts the connection mode of wire harness, PCB board or FPC.

[0004] The wire harness connection is a traditional low-voltage control signal connection mode, which usually connects various electrical components with wires. The arrangement 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 standard, which can easily lead to poor electrical contact. Secondly, the wire harness is easily affected by external factors such as mechanical vibration, temperature change and tension during long-term use, and the cable and connection point may be worn, aged or loose, increasing the risk of system failure.

[0005] In order to improve the stability and integration of the connection, more and more BDU designs begin to use PCB connection. Through the main control circuit board and various electrical components, mainly using multi-way male and female terminal plug-in connection, for example, through the plug-in connection of the terminals on the control circuit board and the coil contact of the relay element, to realize the low-voltage signal control. However, the relay element and the main control circuit board of the BDU use multi-way male and female terminal plug-in connection, which will produce unpredictable large mechanical stress during assembly. During vehicle driving, due to the inability to effectively release the mechanical stress, the male and female terminals will fall off during the vibration process, affecting the normal work of the BDU. In addition, the multi-way male and female terminal plug-in connection of the relay element and the main control circuit board of the BDU will cause the electrical components, terminals and circuit boards to be installed in the battery pack disconnect unit, occupying a large space, making the entire battery pack disconnect unit bulky, and unable to realize thinning. SUMMARY

[0006] Therefore, the application provides an integrated quick plug connection assembly, a BDU and a processing method to solve the problem that the BDU main control circuit board of the battery pack circuit breaker unit and various relays are connected through a plurality of male and female terminal pairs, which can generate unpredictable large mechanical stress, causing the terminal to fall off and affecting the normal work of the BDU.

[0007] The technical scheme of the application is implemented as follows:

[0008] In a first aspect, the application provides an integrated quick plug connection assembly, comprising:

[0009] The upper shell is made of plastic material, and has a plurality of installation cavities inside, which are used for detachably accommodating relays.

[0010] A plurality of metal sampling pieces are arranged in the upper shell, and each of the metal sampling pieces comprises a piece body embedded in the upper shell through an injection molding process.

[0011] Preferably, one end of the piece body located at the installation port has a conductive piece, and the conductive piece has a first elastic piece cut therefrom.

[0012] Preferably, the conductive piece further has two second elastic pieces cut therefrom, and the two second elastic pieces are located on both sides of the first elastic piece.

[0013] Preferably, the first elastic piece comprises a guide segment, a connecting segment and an elastic segment.

[0014] Preferably, the plastic part, the metal sampling piece and the upper shell are integrally formed by a secondary injection molding process, the plastic part is located at the installation opening, the plastic part comprises an annular body, the elastic structure is located inside the annular body, the inside of the annular body has a limiting portion, and the limiting portion is in abutment with one end of the elastic segment away from the connecting segment.

[0015] Preferably, the inside of the installation opening is formed with a first annular step and a second annular step from bottom to top, the inner diameter of the second annular step is greater than that 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 inside wall of the bottom of the installation opening is further formed with a supporting portion flush with the first annular step, the supporting portion is used for supporting the first elastic sheet and the second elastic sheet.

[0016] 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 arranged on the sheet body, and through holes corresponding to the positions of the third positioning holes are arranged on the upper shell.

[0017] Preferably, the upper shell has a terminal connecting opening at the edge, and the pins of the plurality of sampling metal pieces are located in the terminal connecting opening.

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

[0019] In the third aspect, the application provides a processing method of the integrated BDU, comprising the following operation steps:

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

[0021] S2, obtaining the plastic part by an injection molding process;

[0022] S3, install the first elastic part and the second elastic part in the plastic part, then place the plastic part and the metal sampling sheet as a whole into a mold, and obtain the upper shell with the plastic part and the metal sampling sheet embedded in the upper shell through a secondary injection molding process;

[0023] S4, install the relay between the upper shell and the lower shell, and make the coil contact piece of the relay pass through the installation port of the upper shell and insert between the first elastic part and the second elastic part.

[0024] The present application has the following beneficial effects relative to the prior art:

[0025] (1) The integrated quick plug-in connection assembly adopts an elastic structure to elastically connect the relay coil contact piece, unlike the traditional male and female terminal plug-in connection on the PCB, which relies on mechanical plug-in connection, thereby reducing the influence of mechanical stress and vibration on connection stability. Even during vehicle driving, the vibration and mechanical stress received by the coil contact piece can be effectively alleviated through the elastic structure, thereby improving the reliable connection between the coil contact piece and the metal sampling sheet, and avoiding the risk of terminal falling off and poor connection on the existing PCB. (2) Compared with the traditional wire harness connection and PCB connection through multiple terminals, the metal sampling sheet is integrated in the upper shell, which not only effectively saves the space inside the BDU, but also makes the BDU more compact and light, meeting the requirements of modern automobiles for light weight and space saving.

[0026] (3) The symmetrical first elastic part and the 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 provides more uniform distribution of electrical connection pressure, avoiding fatigue or damage of a single elastic part due to excessive stress, thereby prolonging the service life of the assembly.

[0027] (4) By optimizing the structure of the elastic part, the insertion and contact stability of the coil contact piece of the relay are improved. The arc-shaped guide section ensures smooth entry of the contact piece into the elastic part, reducing the problem of poor connection; the inclined connection section provides a smooth contact surface, enhancing the contact force and electrical connection stability; the curved elastic section provides elastic pressure connection, adapting to slight displacement and vibration, and ensuring connection reliability. The overall design improves the adaptability, stability and durability of the assembly.

[0028] (5) By setting the plastic part, the injection molding part and the metal sampling piece are placed in the mold of the upper shell body, and the upper shell body with the plastic part and the metal sampling piece is obtained by the secondary injection molding process. At this time, the plastic part and the upper shell body are integrated, and the metal sampling piece is embedded in the upper shell body. Through this process, the plastic part, the metal sampling piece and the upper shell body are integrally formed, the process is simple, and the production efficiency is high. At the same time, the integrated quick plug connection assembly structure obtained by the process effectively prevents the elastic fatigue of the elastic part through the design of the limiting part in the plastic part, ensures that the first elastic part and the second elastic part can always provide stable elastic pressure connection, and realizes reliable electrical connection with the coil contact piece. This design optimizes the performance of the assembly in long-term use and vibration environment, prolongs the service life, and improves the reliability and stability of the overall connection.(6) The processing method of the integrated BDU disclosed by the application utilizes stamping, injection molding and secondary injection molding process to realize the integral molding of the plastic part, the metal sampling piece and the upper shell body, simplifies the production process and improves the production efficiency. At the same time, through the protection of the elastic structure by the plastic part and the design of the limiting part, the stability and reliability of the BDU in long-term use are ensured, especially in the vibration environment, which can provide continuous stable electrical connection. Therefore, the design not only optimizes the manufacturing process, but also significantly improves the performance and reliability of the product, and is suitable for high requirement electrical connection and power-off protection application. BRIEF DESCRIPTION OF DRAWINGS

[0029] In order to more clearly illustrate the technical solutions in the embodiments of the application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or prior art description. Obviously, the drawings in the following description only some embodiments of the application, and for those skilled in the art, without creative labor, other drawings can also be obtained from these drawings.

[0030] Figure 1 It is a first perspective view of the integrated quick plug connection assembly disclosed by the application.

[0031] Figure 2 It is a second perspective view of the integrated quick plug connection assembly disclosed by the application.

[0032] Figure 3 It is a perspective view of the upper shell body disclosed by the application.

[0033] Figure 4 It is a schematic view of the sampling metal piece and the plastic part assembly structure disclosed by the application.

[0034] Figure 5 It is a perspective view of the plastic part disclosed by the application.

[0035] Figure 6Figure 1 is a top view of the integrated quick plug connection assembly and relay assembly structure disclosed in the present application;

[0036] Figure 7 Figure 2 is a front view of the integrated quick plug connection assembly and relay assembly structure disclosed in the present application; Figure 6 Figure 3 is a sectional view along plane A-A of the integrated quick plug connection assembly and relay assembly structure disclosed in the present application;

[0037] Figure 8 Figure 4 is a sectional view along plane B-B of the integrated quick plug connection assembly and relay assembly structure disclosed in the present application; Figure 6 Figure 5 is a sectional view along plane B-B of the integrated quick plug connection assembly and relay assembly structure disclosed in the present application;

[0038] Figure 9 Figure 6 is a schematic diagram of the integrated BDU disassembly disclosed in the present application;

[0039] Figure 10 Figure 7 is a schematic diagram of the integrated BDU three-dimensional structure disclosed in the present application;

[0040] Reference signs:

[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 connecting port; 2, metal sampling sheet; 21, sheet body; 211, third positioning hole; 22, pin; 23, elastic structure; 24, conductive sheet; 25, first elastic sheet; 231, first elastic portion; 26, second elastic 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 technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0043] As shown in FIGS. 1-7, in combination with FIGS. 8-10, the embodiments of the present application disclose an integrated quick plug connection assembly, which comprises an upper shell 1 and a plurality of metal sampling sheets 2. Figure 1 Figure 2 4 As shown in FIGS. 1-7, in combination with FIGS. 8-10, the embodiments of the present application disclose an integrated quick plug connection assembly, which comprises an upper shell 1 and a plurality of metal sampling sheets 2.

[0044] ​​The upper shell 1 is made of plastic material, and a plurality of installation cavities 11 are formed in the upper shell 1, which are used for accommodating relays, and the installation cavities 11 are arranged so that the relays can be fixed therein and can be conveniently disassembled.

[0045] In some related prior art, the collection of low-voltage signals is connected through a wire harness and a coil contact P1, or connected through a PCB and a coil contact P1, both of which have disadvantages. Among them, the wire harness connection needs to be wired in the shell, which is limited by space and difficult to be neat and standard, and is prone to increase the risk of failure. At present, in the prior art, a terminal is pre-welded on the PCB, and then the terminal is plugged into each relay coil contact P1. This way, unpredictable large mechanical stress is generated during assembly, and the mechanical stress cannot be effectively released during vehicle driving. During the vibration process, the terminal will fall off, affecting the normal work of the BDU.

[0046] To solve the above problems, the present application introduces a plurality of metal sampling pieces 2 based on the upper shell 1, the metal sampling piece 2 includes a piece body 21 embedded in the upper shell 1 by injection molding process, one end of the piece body 21 extends outside the upper shell 1 and forms a pin 22, the pin 22 is used for connecting with the sampling terminal. The other end of the plurality of piece bodies 21 away from the pin 22 is located at the corresponding installation port 12, and the other end of the piece body 21 away from the pin 22 has a elastic structure 23 protruding upward above the installation port 12, the elastic structure 23 is used for connecting with the coil contact P1 of the relay.

[0047] By connecting the coil contact P1 of the plurality of relays with the elastic structure 23 of one metal sampling piece 2, and then directly plugging the sampling terminal into the pin 22 of the plurality of metal sampling pieces 2, the coil contact 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 the elastic structure 23 to elastically connect with the coil contact P1 of the relay, unlike the traditional male and female terminal plug-in connection on the PCB which relies on mechanical plug-in connection, the influence of mechanical stress and vibration on the stability of the connection is reduced. Even during vehicle driving, the vibration and mechanical stress received by the coil contact P1 can be effectively alleviated through the elastic structure 23, which improves the reliable connection between the coil contact P1 and the metal sampling piece 2, and avoids the risk of terminal falling off and poor connection on the existing PCB.

[0049] In addition, compared with the traditional wire harness connection and PCB connection through multi-way terminals, the integration of the metal sampling sheet 2 in the upper shell 1 not only effectively saves the space inside the BDU, but also makes the BDU as a whole more compact, light and thin, which meets the requirements of modern automobiles for light weight and space saving.

[0050] At the same time, since the metal sampling sheet 2 is integrated in the upper shell 1, during assembly, only the relay needs to be installed in the mounting cavity 11 of the upper shell 1, and then the coil contact P1 of the relay and the elastic structure 23 can be quickly connected, the assembly process is simple and efficient, and high assembly precision is not required. Since the elastic structure 23 has elastic deformation capability, the coil contact P1 has a large fault tolerance space when connected to the elastic structure 23, and the overall assembly efficiency is high.

[0051] As some preferred embodiments, refer to the accompanying drawings Figure 1 and 4 As shown in the drawings, the sheet body 21 has a conductive sheet 24 at one end of the mounting opening 12, the conductive sheet 24 has a first elastic sheet 25 formed by cutting, and the elastic structure 23 includes a first elastic portion 231 formed by bending the end of the first elastic sheet 25 upward, and the side of the first elastic portion 231 away from the first elastic 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 formed elastic structure 23, and the first elastic sheet 25 is formed by cutting, which means that the conductive sheet 24 forms the elastic sheet structure through precise cutting process during production. This design helps to improve the elasticity and shape memory capability of the elastic 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 precision and consistency of the metal sampling sheet 2.

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

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

[0055] To this end, the embodiment also discloses the following technical solutions. Specifically, referring to FIGS. 1-4, the embodiment further cuts two second elastic sheets 26 on the conductive sheet 24. The two second elastic sheets 26 are located on both sides of the first elastic sheet 25. The elastic structure 23 further includes a second elastic part 232 formed by bending the end of the second elastic sheet 26 upward. The second elastic part 232 and the first elastic part 231 are structurally symmetrical. The second elastic part 232 and the first elastic part 231 have a gap for the coil contact P1 of the relay to pass through. The gap is smaller than the thickness of the coil contact P1. The opposite sides of the first elastic part 231 and the second elastic part 232 are respectively used to contact the coil contact P1 of the relay. Figure 1 4 The second elastic part 232 is opposite to the first elastic part 231 to form a symmetrical structure. The symmetrical structure enables the second elastic part 232 and the first elastic part 231 to cooperate to contact the coil contact P1. After the coil contact P1 passes through the gap between the first elastic part 231 and the second elastic part 232, the coil contact P1 presses the first elastic part 231 and the second elastic part 232 in the horizontal direction. Since the first elastic part 231 and the second elastic part 232 are formed by bending the elastic sheet, they have good elastic potential, so that the first elastic part 231 and the second elastic part 232 can more firmly contact the coil contact P1, thereby enhancing the reliability of the electrical connection.

[0056] The symmetrical first elastic part 231 and the second elastic part 232 enable the entire elastic structure 23 to provide uniform force distribution during connection. This can effectively avoid poor electrical contact caused by external vibration, mechanical pressure, or temperature change. In addition, the double elastic parts can more evenly distribute the pressure of the electrical connection, avoiding fatigue or damage of a single elastic part due to excessive stress, thereby prolonging the service life of the component.

[0057] The symmetrical first elastic part 231 and the second elastic part 232 enable the entire elastic structure 23 to provide uniform force distribution during connection. This can effectively avoid poor electrical contact caused by external vibration, mechanical pressure, or temperature change. In addition, the double elastic parts can more evenly distribute the pressure of the electrical connection, avoiding fatigue or damage of a single elastic part due to excessive stress, thereby prolonging the service life of the component.

[0058] ​In the embodiment, the first elastic sheet 25 is located on one side of the conductive sheet 24, and the two second elastic sheets 26 are located on the other side of the conductive sheet 24. In this way, the conductive sheet 24 is punched to form the three elastic sheets at one time, and further, the elastic and size consistent elastic portions are formed by one-time stamping and bending, so as to ensure the contact stability between the elastic portion and the coil contact P1. In addition, the first elastic portion 231 abuts against one side of the coil contact P1, and the two second elastic portions 232 abut against the two edges on the other side of the coil contact P1. The structure arrangement makes the coil contact P1 have three contact force points, and ensures the stable force balance.

[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 specifically shown as follows, and the specific structure of the second elastic portion 232 is the same as that of the first elastic portion 231. Figure 4 As shown in the figure, the first elastic portion 231 includes a guide segment 2311, a connecting segment 2312, and an elastic segment 2313.

[0060] The end of the first elastic sheet 25 is bent upward to form the arc-shaped guide segment 2311. The arc-shaped structure of the guide segment 2311 enables the coil contact P1 of the relay to smoothly enter between the first elastic portion 231 and the second elastic portion 232 along the guide segment 2311, and reduces the situation that the coil cannot smoothly enter between the first elastic portion 231 and the second elastic portion 232 due to deviation or poor butt joint.

[0061] The connecting segment 2312 is located above the guide segment 2311 and is a straight segment structure inclined away from the first elastic sheet 25. The connecting segment 2312 provides a smooth contact surface for the coil contact P1 of the relay, so as to ensure that the relay contact can be firmly contacted with the elastic structure 23 and maintain stable electrical connection. The inclined arrangement of the connecting segment 2312 can make the process of inserting the coil contact P1 between the first elastic portion 231 and the second elastic portion 232 more smooth, reduce the friction or incomplete contact caused by angle misalignment, and when the coil contact P1 is completely inserted, the upper end of the connecting segment 2312 can more firmly abut against the coil contact P1, and the contact strength is higher.

[0062] The side of the connecting segment 2312 away from the first elastic sheet 25 is used to contact the coil contact P1 of the relay, the elastic segment 2313 is connected with the upper end of the connecting segment 2312, and the elastic segment 2313 is arc-shaped bent structure toward the first elastic sheet 25. The arrangement of the elastic segment 2313 enables the part to provide elastic reaction under stress, and forms elastic pressure connection with the relay contact. The curved structure not only improves the stability of the contact, but also enables the elastic portion to have better self-adaptability, especially under the action of slight displacement or vibration of the relay contact, so as to ensure the reliability of the connection.

[0063] By optimizing the structure of the elastic section, the insertion and contact stability of the relay coil contact P1 are improved. The arc-shaped guide section 2311 ensures smooth entry of the contact into the elastic section, reducing misalignment issues; the inclined connection section 2312 provides a smooth contact surface, enhancing contact force and electrical connection stability; the bent elastic section 2313 provides elastic compression, adapting to minor displacements and vibrations, ensuring 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 part 231 and the second elastic part 232 can provide a calibrated elastic compression, so that the first elastic part 231, the second elastic part 232 and the coil contact P1 can be stably and reliably connected, is because the arc-shaped guide section 2311, the inclined connecting section 2312 and the curved elastic section 2313 work together. However, when the BDU is used in a vehicle and is subjected to long-term vibration, the coil contact P1 will continuously apply pressure to the elastic parts on both sides in the horizontal direction. At this time, the first elastic part 231 and the second elastic part 232 will experience elastic fatigue, especially concentrated at the guide section 2311, because the guide section 2311 is in direct contact with the spring. When the entire elastic part undergoes elastic deformation for a long time, fatigue will occur at the guide section 2311. As a result, the connecting section 2312 and the elastic section 2313 will swing towards the spring, and the connecting section 2312 will tend to be vertical or tilted towards the corresponding spring. As a result, the entire elastic part will not be able to maintain an effective connection with the coil contact P1, and poor contact may occur.

[0065] To solve the above problems, please refer to the appendix. Figure 1 , 4 As shown in Figures 5, 6, 7, and 8, the solution adopted by the present invention is to introduce a plastic component 3 into the integrated quick-connect assembly in this embodiment. The plastic component 3 includes an annular body 31, the inner side of the annular body 31 has a through frame structure, and the inner side of the annular body 31 has a limiting part 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 segments 2313 on the first elastic part 231 and the second elastic part 232 that are away from the connecting segment 2312 both abut against the limiting part 32.

[0066] In order to enable the elastic structure 23 to be in stable contact within the annular body 31 and the limiting portion 32, it is necessary to fix the plastic part 3 at the installation port 12, so that the elastic segments 2313 in the first elastic portion 231 and the second elastic portion 232 can abut against the side wall of the limiting portion 32. Under a long-term vibration environment, the coil contact P1 exerts pressure on the two elastic portions, and the elastic segments 2313 elastically deform away from the coil contact P1. At the same time, the limiting portion 32 limits the large elastic deformation of the elastic segments 2313, supports the deformation of the elastic segments 2313, effectively disperses the deformation of the elastic segments 2313, avoids fatigue of the elastic segments 2313 after long-term deformation under stress, and ensures that the first elastic portion 231 and the second elastic portion 232 can always provide stable elastic pressure connection, thereby realizing reliable electrical connection with the coil contact P1. This design optimizes the performance of the quick plug-in connection assembly in a long-term use and vibration environment, prolongs 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 is plugged and unplugged multiple times, and the elastic portion does not lose elasticity and cause poor contact.

[0068] In order to realize the fixed connection of the plastic part 3 at the installation port 12 and the upper shell 1, as some embodiments, the plastic part 3 can be fixedly connected with the upper shell 1 by bolt locking or buckle connection, so as to realize the fixed connection of the plastic part 3 at the installation port 12 and the upper shell 1, and make the elastic structure 23 in the annular body 31. This way will make the plastic part 3 and the upper shell 1 have an assembly process, and the production efficiency is low.

[0069] In addition, although the metal sampling sheet 2 can be embedded in the upper shell 1 by insert injection molding, since the elastic portion is in a curved structure as a whole, the glue is easy to fill into the gap between the curved segment and the elastic sheet during mold injection, which will cause the elastic portion to lose the elastic pressure connection function. Therefore, the metal sampling sheet 2 cannot be punched and formed into the elastic structure 23 before being embedded in the upper shell 1, but only the metal sampling sheet 2 as a whole can be embedded in the upper shell 1, and then the conductive sheet 24 is punched again to obtain the elastic sheet and the elastic structure 23. This operation process obviously has more processes and high production efficiency.

[0070] In combination with the above problems, the metal sampling sheet 2 cannot be directly embedded in the upper shell 1 by the injection molding process after molding. In this embodiment, the metal sampling sheet 2 is first stamped, and then the plastic part 3 is obtained by the injection molding process. The elastic structure 23 of the metal sampling sheet 2 is installed inside the annular body 31, and at this time the conductive sheet 24 is at the bottom surface of the annular body 31. The injection molding part and the metal sampling sheet 2 are placed as a whole in the mold of the molded upper shell 1, and the upper shell 1 with the plastic part 3 and the metal sampling sheet 2 embedded in it is obtained by the secondary injection molding process. At this time, the plastic part 3 and the upper shell 1 are integrated, and the metal sampling sheet 2 is embedded in the upper shell 1. By this process, the plastic part 3, the metal sampling sheet 2 and the upper shell 1 are integrally molded, 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 sheet 2 is pre-installed inside the annular body 31, and then the two are placed as a whole in the mold. During the injection molding process, the plastic part 3 protects the elastic structure 23 inside, which can prevent the plastic from entering the elastic structure 23 inside the plastic part 3, thereby achieving the integration of the plastic part 3, the metal sampling sheet 2 and the upper shell 1. At the same time, the integrated quick plug-in connection assembly structure obtained by this process effectively prevents the elastic fatigue of the elastic part by the design of the limiting part 32 in the plastic part 3, ensuring that the first elastic part 231 and the second elastic part 232 can always provide stable elastic pressure connection, thereby realizing reliable electrical connection with the coil contact P1. This design optimizes the performance of the assembly in long-term use and vibration environment, prolongs the service life, and improves the reliability and stability of the overall connection.

[0072] In order to realize the secondary injection molding of the plastic part 3 and the upper shell 1, a first annular step 121 and a second annular step 122 are formed from bottom to top inside the installation port 12 in this embodiment. The inner diameter of the second annular step 122 is larger than that 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 installation port 12, the annular body 31 has a lip 311 at the lower part, the second annular step 122 has a groove 1220 for wrapping the lip 311, and the inner wall of the bottom of the installation port 12 is also formed with a support part 123 flush with the first annular step 121. The support part 123 is used to support the first elastic sheet 25 and the second elastic sheet 26.

[0073] In this embodiment, reference is made to the accompanying drawings Figure 1 , 3As shown in FIG. 7, the inner side of the mounting hole 12 is formed with a first annular step 121 and a second annular step 122 by the injection molding process. This is because the metal sampling sheet 2 and the plastic part 3 are placed in the injection mold from bottom to top in sequence, and 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, the plastic material wraps the lip 311, and then a groove 1220 is formed on the side wall of the second annular step 122, which makes the structure more firm after the secondary injection molding of the plastic part 3 and the upper shell 1, and can avoid the plastic part 3 from being pulled out of the upper shell 1. The support part 123 is formed by injection molding, and the support part 123 is located below the conductive sheet 24 and is flush with the first annular step 121. In this way, the support part 123 can support the first elastic sheet 25 and the second elastic sheet 26, and avoid the first elastic sheet 25 and the second elastic sheet 26 from being suspended at the mounting hole 12. At the same time, the limiting part 32 inside the annular body 31 can cooperate with the support part to compress the first elastic sheet 25 and the second elastic sheet 26, so as to ensure that only the elastic part of the elastic sheet end is elastically compressed, and improve the contact reliability between the elastic part and the coil contact P1.

[0074] It is worth noting that if there is no support part 123, the elastic sheet bottom surface is in a suspended state. In this way, when the relay is pulled out of the first elastic part 231 and the second elastic part 232, the elastic part will pull the elastic sheet downward to bend, which will cause damage to the elastic sheet, and thus the first elastic part 231 and the second elastic part 232 cannot maintain the original posture, which is not conducive to the reinsertion of the coil contact P1.

[0075] In order to ensure that the relative position of the plastic part 3 and the metal sampling sheet 2 does not change during the secondary injection molding, the embodiment is provided with the following scheme: at least two first positioning holes 241 are arranged at the corners of the conductive sheet 24, the annular body 31 is provided with a second positioning hole 312 corresponding to the position of the first positioning hole 241, and a plurality of third positioning holes 211 are arranged on the sheet body 21. The upper shell 1 is provided with a through hole 13 corresponding to the position of the third positioning hole 211.

[0076] Thus, when the metal sampling piece 2 is assembled into the mold of the upper shell 1, the first positioning hole 241 and the positioning needle in the mold are matched, and the third positioning hole 211 and the positioning needle in the mold are matched, so that the position of the conductive piece 24 and the piece body 21 in the mold is fixed, avoiding that the metal sampling piece 2 is displaced in the mold due to excessive injection pressure. After the metal sampling piece 2 is installed in the mold, the plastic part 3 is installed above the conductive piece 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, thereby ensuring that the relative position of the annular body 31 and the conductive body in the mold is fixed. The through hole 13 is provided on the upper shell 1, so that the positioning needle in the upper mold of the molded shell and the positioning column passing through the third positioning hole 211 in the lower mold are matched, and the piece body in the mold is reliably fixed.

[0077] As some preferred embodiments, the upper shell 1 has a terminal connection port 14 at the edge, and the plug pins 22 of the plurality of sampling metal pieces are located in the terminal connection port 14. In the embodiment, the plurality of sampling metal pieces are embedded in the upper shell 1, and the plug pins 22 of the plurality of sampling metal pieces are collected at the terminal connection port 14. In this way, the sampling terminal can be inserted into the terminal connection port 14 to establish reliable electrical connection with the plurality of plug pins 22, so as to ensure stable and accurate signal transmission and avoid the disadvantages of BDU low-voltage acquisition through a wire harness.

[0078] The application also discloses an integrated BDU, referring to the accompanying drawings Figure 9 and 10 As shown in the drawings, the integrated quick plug connection assembly described in the above embodiments is further provided with a lower shell 4 and a plurality of relays. 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 part of the relays 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 part 231 and the second elastic part 232. The outer side of the connecting section 2312 is in contact with the coil contact P1 of the relay, and the limiting part 32 is in contact 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 shell 4 and the plurality of relays, a BDU with 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 part 231 and the second elastic part 232 of the quick plug connection assembly, ensuring the stability and reliability of the electrical connection. The limiting part 32 provides support for the deformation of the elastic section 2313, which will limit the large elastic deformation of the elastic section 2313, effectively disperse the deformation of the elastic section 2313, avoid the fatigue of the elastic section 2313 after long-term stress deformation, ensure that the first elastic part 231 and the second elastic part 232 can always provide stable elastic pressure connection, so as to realize the reliable electrical connection with the coil contact P1. This design optimizes the performance of the BDU in long-term use and vibration environment, prolongs the service life, and improves the overall connection reliability and stability.

[0080] The application also discloses a processing method of the integrated BDU, which comprises the following operation steps:

[0081] S1, forming the sheet body 21, the pin 22 and the conductive sheet 24 of the metal sampling sheet 2 through a stamping process, then punching the first elastic sheet 25 and the second elastic sheet 26 on the conductive sheet 24 through a blanking process, and finally stamping 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 the 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, then placing the plastic part 3 and the metal sampling sheet 2 in the mold as a whole, and obtaining the upper shell 1 with the plastic part 3 and the metal sampling sheet 2 embedded in it through a secondary injection molding process;

[0084] S4, installing the relay between the upper shell 1 and the lower shell 4, and making the coil contact P1 of the relay pass through the mounting port 12 of the upper shell 1 and be inserted between the first elastic part 231 and the second elastic part 232.

[0085] By stamping the metal sampling piece 2 first, then obtaining the plastic part 3 through the injection molding process, the elastic structure 23 of the metal sampling piece 2 is pre-installed inside the annular body 31, and then the whole is placed in the mold, and through the 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 elastic structure 23 on the inside, preventing the plastic from passing through the plastic part 3 into the elastic structure 23, ensuring the integrity and functionality of the elastic structure 23. The design of the limiting part 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 compression, thereby achieving reliable electrical connection with the coil contact P1.

[0086] Through the processing method of this integrated BDU, using stamping, injection molding and secondary injection molding processes, the plastic part 3, the metal sampling piece 2 and the upper shell 1 are integrally formed, simplifying the production process and improving production efficiency. At the same time, through the protection of the plastic part 3 to the elastic structure 23 and the design of the limiting part 32, the stability and reliability of the BDU in long-term use are ensured, especially in a vibrating environment, it 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 connections and power protection applications.

[0087] The above only describes the preferred embodiments of the present application and is not intended to limit the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. An integrated quick-connect assembly, characterized in that, include: The upper housing (1) is made of plastic. The upper housing (1) has multiple mounting cavities (11) inside. The mounting cavities (11) are used to detachably accommodate the relay. The top surface of the upper housing (1) has a mounting opening (12) corresponding to the position of the mounting cavity (11) for the relay coil contact (P1) to pass through. Multiple metal sampling pieces (2) are provided. Each metal sampling piece (2) includes a piece body (21) embedded in the upper housing (1) by injection molding. One end of the piece body (21) extends out of the outer side of the upper housing (1) and forms a pin (22). The pin (22) is used to connect with the sampling terminal. The ends of the multiple pieces (21) away from the pin (22) are respectively located at the corresponding mounting ports (12). The ends of the pieces (21) away from the pin (22) have an elastic structure (23) protruding upward toward the mounting port (12). The elastic structure (23) is used to connect with the coil contact (P1) of the relay. The plate body (21) has a conductive plate (24) at one end of the mounting port (12), and the conductive plate (24) has a first elastic piece (25) formed by cutting. The elastic structure (23) includes a first elastic part (231) formed by bending the end of the first elastic piece (25) upward. 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. The conductive sheet (24) also has two second elastic pieces (26) formed by cutting. The two second elastic pieces (26) are located on both sides of the first elastic piece (25). The elastic structure (23) also includes a second elastic part (232) formed by bending the end of the second elastic piece (26) upward. The second elastic part (232) and the first elastic part (231) are symmetrical in structure. There is a gap between the second elastic part (232) and the first elastic part (231) for the coil contact (P1) of the relay to pass through. The opposite sides of the first elastic part (231) and the second elastic part (232) are respectively used to contact the coil contact (P1) of the relay. The first elastic part (231) includes a guide section (2311), a connecting section (2312) and an elastic section (2313). The end of the first spring piece (25) is bent upward to form an arc-shaped structure. The guide section (2311) is located above the guide section (2311) and is a straight section structure inclined away from the first spring piece (25). The side of the connecting section (2312) away from the first spring piece (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 curved in an arc shape towards the first spring piece (25). It also includes a plastic part (3), the plastic part (3), the metal sampling piece (2) and the upper shell (1) are integrally formed by a secondary injection molding process. The plastic part (3) is located at the mounting port (12). The plastic part (3) includes an annular body (31). The elastic structure (23) is located inside the annular body (31). The annular body (31) has a limiting part (32) inside. The limiting part (32) abuts against the end of the elastic segment (2313) away from the connecting segment (2312). The mounting opening (12) has a first annular step (121) and a second annular step (122) formed from bottom to top on the inner side. 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). The bottom inner side wall of the mounting opening (12) is also formed with a support part (123) that is flush with the first annular step (121). The support part (123) is used to support the first spring sheet (25) and the second spring sheet (26).

2. The integrated quick-connect assembly as described in claim 1, characterized in that: At least two first positioning holes (241) are provided at the corners of the conductive sheet (24), and a second positioning hole (312) corresponding to the position of the first positioning hole (241) is provided on the annular body (31). A plurality of third positioning holes (211) are provided on the sheet body (21), and a through hole (13) corresponding to the position of the third positioning hole (211) is provided on the upper shell (1).

3. The integrated quick-connect assembly as described in claim 1, characterized in that: The upper housing (1) has a terminal connection port (14) at its edge, and the pins (22) of the plurality of metal sampling plates are located in the terminal connection port (14).

4. An integrated BDU, characterized in that, The integrated quick-connect assembly according to any one of claims 1 to 3 further includes a lower housing (4) and a plurality of relays. The upper housing (1) is fixedly disposed on the lower housing (4). The plurality of relays are fixedly disposed between the upper housing (1) and the lower housing (4). At least a portion of the relays are located in the mounting cavity (11). The coil contact (P1) of the relays passes through the mounting port (12) and is located between the first elastic part (231) and the second elastic part (232). The outer side of the connecting section (2312) is in contact with the coil contact (P1) of the relays. The limiting part (32) abuts against the end of the elastic section (2313) away from the connecting section (2312).

5. A method for processing an integrated BDU as described in claim 4, characterized in that, The following steps are included: S1. The metal sampling sheet (2) body (21), pin (22) and conductive sheet (24) are formed by stamping process. Then, the first elastic sheet (25) and the second elastic sheet (26) are punched out on the conductive sheet (24) by stamping process. Finally, the first elastic sheet (25) and the second elastic sheet (26) are stamped and bent to form the first elastic part (231) and the second elastic part (232) respectively. S2. Obtain plastic parts through injection molding process (3); S3. The first elastic part (231) and the second elastic part (232) are installed in the plastic part (3), and then the plastic part (3) and the metal sampling piece (2) are placed into the mold as a whole, and the upper shell (1) with the plastic part (3) and the metal sampling piece (2) is obtained by secondary injection molding process. S4. Install the relay between the upper housing (1) and the lower housing (4), and make the coil contact (P1) of the relay pass through the mounting port (12) of the upper housing (1) and insert it between the first elastic part (231) and the second elastic part (232).

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