High-power charging socket for new energy automobile

Abstract

The invention discloses a high-power charging socket for a new energy automobile. The high-power charging socket comprises a socket panel module, an upper assembly module and a lower assembly module, wherein the upper assembly module and the lower assembly module are mounted on the socket panel module; the socket panel module is used for sealing, preventing dust and water in a non-charging state, providing plugging guide and mechanical locking for the charging gun in a charging process, and realizing stable opening and closing of the protective cover through a damper; the upper assembly module is inserted into the first opening of the panel shell in a limiting manner and is used for direct current charging; and the lower assembly module is inserted into the second opening of the panel shell in a limiting manner and is used for realizing megawatt charging together with the upper assembly module. According to the charging socket, super-fast charging can be realized, and the charging time is remarkably shortened; meanwhile, the overall mechanical strength and the electrical reliability of the product are improved through optimization design; and a modular design concept is adopted, so that the product has the characteristics of high efficiency, high safety and convenience in maintenance, and the requirements of future new energy automobiles on an ultra-fast charging technology are met.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of new energy vehicle charging facilities, in particular to a high-power charging socket for new energy vehicles. BACKGROUND

[0002] With the global energy structure adjustment and the enhancement of environmental protection consciousness, the new energy vehicle industry has ushered in rapid development. As the core infrastructure of new energy vehicles, the efficiency and reliability of charging technology are directly related to user experience and market prospects of products. At present, the new energy vehicles on the market generally need to be connected with charging guns through vehicle-mounted charging sockets during charging, so as to receive electric energy from the power grid or charging piles.

[0003] At present, the mainstream charging technology is mainly divided into alternating current slow charging (AC slow charging) and direct current fast charging (DC fast charging) according to the power level. However, even the existing direct current fast charging technology, the power level is generally below 250kW, and it usually takes a long time to fully charge the vehicle. Such charging speed is acceptable for daily commuting, but in long-distance travel, business operation and other scenarios, the long charging waiting time means the reduction of operation efficiency and the waste of huge time cost.

[0004] The charging socket of the prior art has the following main defects:

[0005] (1) Power limitation, slow charging: the materials, design and heat dissipation capacity of the existing charging socket and its internal components cannot support the long-term stable transmission of megawatt (MW) and above super large power current. The physical structure limits the improvement of charging power, which makes it difficult to greatly shorten the battery charging time and cannot meet the technical needs of future super-fast charging.

[0006] (2) Structural strength and reliability problems: to cope with large current transmission, the charging socket needs to withstand higher thermal load and electrical stress. The existing socket structure may have problems such as overheating, accelerated aging, mechanical deformation and the like under long-term large current work, which affects the safety and stability of electrical connection and exists safety hazards.

[0007] (3) Lack of modularity and scalability: the existing charging socket adopts an integrated or fixed design, which is difficult to maintain and upgrade. If some parts are damaged or need to adapt to new charging standards, the entire assembly often needs to be replaced, which is costly and inconvenient. The design does not fully consider the compatibility and expansion capability of future technology iteration.

[0008] Therefore, there is an urgent need for a new charging socket solution that can support super-fast charging, has high safety and reliability, and adopts a modular design to facilitate maintenance and upgrading, so as to fundamentally alleviate user anxiety and promote the rapid development of the new energy vehicle industry. SUMMARY

[0009] In order to solve the above technical problems, the purpose of the present application is to provide a high-power charging socket for new energy vehicles, which aims to achieve ultra-fast charging and significantly shorten the charging time; at the same time, the overall mechanical strength and electrical reliability of the product are improved through optimization design; and the modular design concept is adopted, so that the product has the characteristics of high efficiency, high safety and convenient maintenance, thereby meeting the demand of future new energy vehicles for ultra-fast charging technology.

[0010] The present application solves the above problems by the following technical solutions:

[0011] A high-power charging socket for new energy vehicles, comprising: a socket panel module, and an upper assembly module and a lower assembly module mounted on the socket panel module; the socket panel module is used to seal dust and water in a non-charging state, provide plug-in guidance and mechanical locking for the charging gun during the charging process, and realize smooth opening and closing of the protective cover through a damper; comprising: a panel shell with a first opening and a second opening, and an upper protective cover component and a lower protective cover component, the upper protective cover of the upper protective cover component and the lower protective cover of the lower protective cover component are respectively hinged with the panel shell to open and seal the first opening and the second opening; the upper assembly module is used for direct current charging and is limitingly inserted into the first opening of the panel shell; the lower assembly module is used for use with the upper assembly module to realize megawatt charging and is limitingly inserted into the second opening of the panel shell; and the upper assembly module and the lower assembly module are fixed to the panel shell by an insulator fixing bolt, so as to lock and fix one end of the upper assembly module and the lower assembly module in the panel shell.

[0012] As a further improvement, the upper assembly module comprises: an upper insulator, an upper PCB board, an upper tail cover, and an upper fixing plate assembly formed by a terminal assembly and an upper heat-conducting silica gel assembly mounted on the upper fixing plate, an upper insulator sealing ring is sleeved on the front end of the upper insulator, the upper fixing plate assembly is limitingly inserted into the upper insulator from the rear end of the upper insulator, and the upper fixing plate is fixed in the upper insulator by an upper fixing plate screw, the upper PCB board is installed on the rear side of the upper fixing plate away from the upper insulator by an upper PCB board fixing screw, so that the contact pin of the upper PCB board is inserted into the tail part of the signal terminal and is in contact with the crown spring through the upper fixing plate; the upper tail cover is buckled on the rear end of the upper insulator, and the upper power terminal is arranged through the upper tail cover; the upper heat-conducting silica gel assembly is in direct contact with the upper power terminal and the temperature sensor on the upper PCB board, so as to monitor the charging temperature after the plug-in interface on the upper PCB board is inserted into the low-voltage plug-in.

[0013] As a further improvement thereof, the lower assembly module comprises a lower insulator, a lower heat-conductive silica gel, a lower power terminal, a lower fixing plate and a lower tail cover, the lower insulator is sleeved with a lower insulator sealing ring at the front end thereof, the lower heat-conductive silica gel is arranged in the lower insulator at the rear end thereof through the lower PCB plate, the lower power terminal is installed on the lower fixing plate and is jointly and limitingly inserted into the lower insulator, the lower power terminal extends out of the lower tail cover at the rear end thereof, and the lower tail cover is buckled on the rear end of the lower insulator.

[0014] The temperature sensor of the lower PCB plate and the lower power terminal are in direct contact with the lower heat-conductive silica gel, so as to monitor the charging temperature after the plug-in interface of the lower PCB plate is inserted into the low-voltage plug-in.

[0015] As a further improvement thereof, the lower PCB plate is arranged in the lower insulator at the rear end thereof through a lower PCB plate fixing screw;

[0016] And / or the lower fixing plate is installed on the rear end of the lower insulator through a lower fixing plate fixing screw.

[0017] As a further improvement thereof, the upper protective cover component is further provided with an upper protective cover sealing gasket, and the upper protective cover sealing gasket is embedded on the side of the upper protective cover close to the panel shell; the lower protective cover component is further provided with a lower protective cover sealing ring, and the lower protective cover sealing ring is sleeved on the outside of the side of the lower protective cover close to the panel shell.

[0018] As a further improvement thereof, the front side of the panel shell is further hingedly provided with a lock catch component, so as to control the closing of the upper protective cover and the lower protective cover through the lock catch component.

[0019] As a further improvement thereof, the lock catch component comprises a lock catch, a lock catch torsion spring and a lock catch pin shaft, the outer sides of the first opening and the second opening of the panel shell are respectively formed with a lock catch component mounting port for arranging the lock catch component, the lock catch torsion spring is arranged in the torsion spring mounting hole of the lock catch, and the lock catch pin shaft is inserted into the lock catch, so as to hingedly mount the lock catch component on the panel shell, so as to control the closing of the upper protective cover and the lower protective cover.

[0020] As a further improvement thereof, the sealing groove on the rear side of the panel shell is arranged with a panel sealing ring, so as to realize the sealing between the entire socket panel module and the vehicle body when the entire socket panel module is installed on the vehicle body.

[0021] As a further improvement thereof, the charging socket is further provided with a grounding wire, and the grounding wire is fixed and locked with the upper assembly module or the lower assembly module through a grounding wire fixing bolt.

[0022] As a further improvement, the socket panel module is further provided with a damper, a protective cover torsion spring and a protective cover pin shaft, the upper protective cover component and the lower protective cover component are arranged in alignment with the hinge seats on the panel shell, and the protective cover pin shaft sequentially passes through the hinge seats on the panel shell, the upper protective cover component, the damper, the torsion spring and the lower protective cover component in sequence, so as to hinge the upper protective cover and the lower protective cover on the panel shell at the same time.

[0023] Compared with the prior art, the application has the following advantages and beneficial effects:

[0024] (1) The application adopts three module designs, which can be assembled in parallel, independently tested, and easily troubleshooted and repaired, greatly improving production and maintenance efficiency.

[0025] (2) The terminal is fixed by the fixing plate and the insulator, the connection is strong, the shock resistance is good, and high reliability is achieved; the design of multiple sealing rings ensures high protection level.

[0026] (3) The upper assembly module and the lower assembly module both introduce heat-conducting rubber pads, which efficiently conduct the heat generated by large current from the metal terminal to the larger metal fixing plate and insulator shell for dissipation, which is the key to realize megawatt-level continuous charging without overheating. The integrated PCB board realizes real-time monitoring of the charging state, temperature and connection, provides intelligent protection for safe and fast charging, and improves intelligence. The structure and connection relationship of the charging socket are precise and rigorous, which together ensure the excellent performance of the megawatt charging socket in terms of fast charging time, high product strength and modular design. BRIEF DESCRIPTION OF DRAWINGS

[0027] Figure 1 is a shaft side view of a high-power charging socket for a new energy vehicle in the application;

[0028] Figure 2 is another shaft side view of a high-power charging socket for a new energy vehicle in the application;

[0029] Figure 3 is an exploded schematic view of a high-power charging socket for a new energy vehicle in the application;

[0030] Figure 4 is an open state view of the upper and lower protective covers in the application;

[0031] Figure 5 is a closed state view of the upper and lower protective covers in the application;

[0032] Figure 6 is an A-A sectional view of the socket panel module in the application;

[0033] Figure 7 is a B-B sectional view of the socket panel module in the application;

[0034] Figure 8 is the structural schematic diagram of the upper assembly module in the application;

[0035] Figure 9 is the sectional view of the upper assembly module in the application;

[0036] Figure 10 is the structural schematic diagram of the lower assembly module in the application;

[0037] Figure 11 is the sectional view of the lower assembly module in the application;

[0038] Figure 12 is the schematic diagram of the upper plug-in position and the lower plug-in position in the application;

[0039] Figure 13 is the schematic diagram of each sealing part in the application;

[0040] Figure 14 is the schematic diagram of the crown spring fitting of the upper PCB board contact pin and the tail part of the signal terminal in the application.

[0041] The figure mark: 1, warning label; 2, lower protective cover; 3, upper protective cover; 4, lower protective cover sealing ring; 5, upper protective cover sealing gasket; 6, damper; 7, lock catch; 8, protective cover torsional spring; 9, protective cover pin shaft; 10, lock catch torsional spring; 11, lock catch pin shaft; 12, faceplate housing; 13, faceplate sealing ring; 14, insulator fixing bolt; 15, upper insulator sealing ring; 16, upper insulator; 17, signal terminal; 18, ground terminal; 19, upper power terminal; 20, left heat-conducting adhesive gasket; 21, right heat-conducting adhesive gasket; 22, upper fixing plate; 23, upper fixing plate screw; 24, upper PCB board; 25, upper PCB board fixing screw; 26, upper tail cover; 27, ground wire; 28, ground wire fixing bolt; 29, lower insulator sealing ring; 30, lower insulator; 31, lower heat-conducting silicone; 32, lower PCB board fixing screw; 33, lower PCB board; 34, lower power terminal; 35, lower fixing plate; 36, lower fixing plate fixing screw; 37, lower tail cover; 38, socket faceplate module; 39, upper assembly module; 40, lower assembly module; 41, terminal sealing ring; 42, car-end megawatt socket mounting plate; 43, upper PCB board contact pin. DETAILED DESCRIPTION

[0042] The technical solutions in the embodiments of the application will be clearly and completely described below with reference to the drawings in the embodiments of the application. Obviously, the described embodiments are only part of the embodiments of the application, rather than all the embodiments of the application. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative work fall within the protection scope of the application.

[0043] Example:

[0044] As attached Figures 1 to 14 As shown, a high-power charging socket for new energy vehicles adopts a modular design, mainly consisting of three modules: a socket panel module 38, an upper component module 39, and a lower component module 40. The upper component module 39 and the lower component module 40 are installed on the socket panel module 38. The modular design facilitates division of labor in assembly, testing, and maintenance, significantly improving production efficiency and reliability. After each module is assembled independently, they are then assembled together to form a complete, high-performance charging socket. The socket panel module is used to provide a sealed, dustproof, and waterproof environment when not charging. During charging, it provides insertion guidance and mechanical locking for the charging gun and achieves smooth opening and closing of the protective cover through a damper. It includes: a panel housing with a first opening and a second opening, an upper protective cover component, and a lower protective cover component. The upper protective cover of the upper protective cover component and the lower protective cover of the lower protective cover component are respectively hinged to the panel housing to open and seal the first and second openings. The upper component module is used for DC charging and is inserted into the first opening of the panel housing. The lower component module is used together with the upper component module to achieve megawatt charging and is inserted into the second opening of the panel housing. The upper component module and the lower component module are respectively fixed to the panel housing by insulator fixing bolts to lock one end of the upper component module and the lower component module into the panel housing.

[0045] The socket panel module 38 is the external interface and the first protection mechanism of the entire charging socket, and its core function is to provide plug-in guidance and mechanical locking for the charging gun during the charging process, and to achieve smooth opening and closing of the protective cover through the damping system, thereby improving the seniority and user experience of the product. The socket panel module 38 includes a warning label 1, a lower protective cover 2, an upper protective cover 3, a lower protective cover sealing ring 4, an upper protective cover sealing pad 5, a damper 6, a lock catch 7, a protective cover torsional spring 8, a protective cover pin shaft 9, a lock catch torsional spring 10, a lock catch pin shaft 11, a panel housing 12, and a panel sealing ring 13, etc. Among them, the upper protective cover component is composed of the upper protective cover 3, the warning label 1 and the upper protective cover sealing pad 5, the warning label 1 is arranged on the outer side of the upper protective cover 3, i.e. the left side, and the upper protective cover sealing pad 5 is embedded on the right side of the upper protective cover 3 for sealing and opening and closing with the first opening of the panel housing 12; the lower protective cover component is composed of the lower protective cover 2 and the lower protective cover sealing ring 4 for sealing and opening and closing with the second opening of the panel housing 12; the lock catch component is composed of the lock catch 7, the lock catch torsional spring 10 and the lock catch pin shaft 11, the outer sides of the first opening and the second opening of the panel housing 12 are respectively formed with a lock catch component mounting port for arranging the lock catch component, the lock catch torsional spring 10 is arranged in the torsional spring mounting hole of the lock catch 7, and the lock catch pin shaft 11 is inserted into the lock catch 7 to hingedly install the lock catch component on the panel housing 12, so as to control the closing of the upper protective cover 3 and the lower protective cover 2; the upper protective cover 3 and the lower protective cover 2 are hingedly arranged on the panel housing 12 through the damper 6, the protective cover torsional spring 8 and the protective cover pin shaft 9 to realize opening and closing.

[0046] The assembly process of the socket panel module 38 is as follows:

[0047] (1) Assembly of the upper and lower protective cover components:

[0048] The upper protective cover component: the warning label 1 and the upper protective cover sealing pad 5 are sequentially attached or embedded on the corresponding clamping groove or plane of the upper protective cover 3 to form an upper protective cover component integrating warning and sealing. The lower protective cover component: the lower protective cover sealing ring 4 is pressed into the sealing groove specially designed on the back of the lower protective cover 2 to form a lower protective cover component, thereby ensuring the sealing performance when it is closed.

[0049] (2) Assembly and installation of the lock catch component:

[0050] One end of the lock catch torsion spring 10 is inserted or snapped into the torsion spring installation hole of the lock catch 7, forming the lock catch component; the torsion spring provides the automatic reset elastic force for the lock catch. The assembled lock catch component is inserted into the lock catch component installation port reserved on the side of the panel housing 12 from the front direction, which is designed to be in contact with the charging gun lock tongue. The lock catch pin shaft 11 is inserted, which passes through the shaft holes on both sides of the panel housing and the shaft hole in the middle of the lock catch, hinging the lock catch component on the panel housing. The two feet of the lock catch torsion spring are respectively rested on the inside of the panel housing and the lock catch, giving the lock catch the tendency to automatically return after being pressed down.

[0051] (3) Hinge of the protective cover assembly and the panel housing:

[0052] The protective cover torsion spring 8 and the damper 6 are respectively installed near the installation position reserved for the protective cover pin shaft 9 on the panel housing 12. The damper provides a buffering force, making the opening and closing action of the protective cover smooth and slow, avoiding sudden opening or falling. The protective cover torsion spring provides opening assistance or closing resistance for the protective cover, usually working in cooperation with the damper. Then the pre-assembled upper protective cover component and lower protective cover component are aligned with the hinge seat above the panel housing 12 from the front direction. Finally, the protective cover pin shaft 9 is inserted through the hinge holes of the panel housing's hinge seat, the upper protective cover component, the damper / torsion spring, and the lower protective cover component in turn, finally hinging the upper protective cover and the lower protective cover on the panel housing. At this point, the upper protective cover and the lower protective cover can rotate around the protective cover pin shaft to realize the opening and closing function.

[0053] (4) Final sealing:

[0054] Finally, the panel seal ring 13 is pressed into the sealing groove on the back of the panel housing 12. This panel seal ring 13 is used to achieve sealing between the vehicle end megawatt socket installation plate 42 when the entire socket panel module is installed on the vehicle, preventing external moisture and dust from entering the vehicle interior from the installation gap.

[0055] The upper assembly module 39 is one of the core electrical modules of the charging socket, used for direct current single charging, responsible for signal transmission, grounding and part of power transmission, and integrates intelligent detection circuit. It includes: upper insulator sealing ring 15, upper insulator 16, signal terminal 17, grounding terminal 18, upper power terminal 19, left heat-conducting rubber pad 20, right heat-conducting rubber pad 21, upper fixing plate 22, upper fixing plate screw 23, upper PCB 24, upper PCB fixing screw 25, and upper tail cover 26. The upper insulator 16 is sleeved with an upper insulator sealing ring 15 at one end; the terminal assembly is composed of the signal terminal 17, the grounding terminal 18 and the upper power terminal 19, and each terminal of the terminal assembly is sleeved with a terminal sealing ring 41 to realize terminal sealing; the left heat-conducting rubber pad 20 and the right heat-conducting rubber pad 21 form an upper heat-conducting silica gel assembly, which is used to conduct heat of the terminals to the fixing plate for heat dissipation; the terminal assembly and the heat-conducting silica gel assembly are installed on the upper fixing plate 22 to form an upper fixing plate assembly; the upper fixing plate assembly is jointly inserted into the upper insulator 16 from the other end, and the upper fixing plate 22 is fixed in the other end of the upper insulator 16 by the upper fixing plate screw 23. The upper PCB 24 is installed on the side of the upper fixing plate 22 away from the upper insulator 16 by the upper PCB fixing screw 25, so that the upper PCB contact pin 43 is inserted into the tail of the signal terminal 17 through the upper fixing plate 22 to adhere to the crown spring; the upper tail cover 26 covers the other end of the upper insulator 16, and the upper power terminal 19 penetrates through the upper tail cover 26.

[0056] The upper PCB contact pin is connected with the signal terminal 17, and after the plug-in interface position of the upper PCB is inserted into the vehicle end low-voltage plug-in, the charging signal feedback control is realized.

[0057] The assembly process of the upper assembly module 39 is as follows:

[0058] First, the upper insulator sealing ring 15 is installed into the upper insulator 16 to ensure the sealing of the socket panel module interface; then the signal terminal 17, the grounding terminal 18, the upper power terminal 19, the left heat-conducting rubber pad 20 and the right heat-conducting rubber pad 21 are installed into the upper fixing plate 22 to form an upper fixing plate assembly. The installed upper fixing plate assembly is installed into the inner cavity of the upper insulator 16, and is locked and fixed by the upper fixing plate screw 23 after being installed in place to ensure the accuracy and stability of the position of the terminals. Then the upper PCB 24 is installed on the upper fixing plate 22, the contact pin of the upper PCB 24 is inserted into the tail of the signal terminal 17 to adhere to the crown spring to realize high-reliability elastic contact electrical connection, and is locked and fixed by the upper PCB fixing screw 25 after being installed in place. Finally, the upper tail cover 26 is installed to be buckled with the upper insulator 16, and the lower power terminal rear end protrudes from the lower tail cover to close the rear end of the upper insulator and provide protection.

[0059] The lower assembly module 40 mainly undertakes the task of large power current transmission, and the structural design focuses on large current bearing and heat management, including: a lower insulator sealing ring 29, a lower insulator 30, a lower heat-conducting silica gel 31, a lower PCB plate fixing screw 32, a lower PCB plate 33, a lower power terminal 34, a lower fixing plate 35, a lower fixing plate fixing screw 36, and a lower tail cover 37; wherein the lower insulator sealing ring 29 is sleeved on one end of the lower insulator 30, the lower heat-conducting silica gel 31 is pressed on the other end of the lower insulator 30 through the lower PCB plate 33 and the lower PCB plate fixing screw 32, the lower power terminal 34 is installed on the lower fixing plate 35 and is inserted into the lower insulator 30, the lower heat-conducting silica gel 31 is in contact with one end of the lower power terminal 34, and the lower fixing plate 35 is fixed to the other end of the lower insulator 30 through the lower fixing plate fixing screw 36; the lower tail cover 37 is buckled with the lower insulator 30.

[0060] The assembly process of the lower assembly module 40 is as follows:

[0061] The lower insulator sealing ring 29 is installed on the lower insulator 30, the lower heat-conducting silica gel 31 is laid in the preset position of the lower insulator 30, then the lower PCB plate 33 is fixed and pressed on the lower heat-conducting silica gel 31 through the lower PCB plate fixing screw 32 to establish an efficient heat conduction path; then the lower power terminal 34 is installed on the lower fixing plate 35 and then installed in the lower insulator 30, and after installation, it is fixed through the lower fixing plate fixing screw 36; finally, the lower tail cover 37 is buckled with the lower insulator 30 to complete the sealing.

[0062] After the installation of several module assemblies is completed, the upper assembly module 39 is first installed from the rear into the first opening of the socket panel module 38, and then the lower assembly module 40 is installed from the rear into the second opening of the socket panel module 38, and the upper insulator 16 and the lower insulator 30 are fixed to the panel shell 12 through the insulator fixing bolt 14 to lock and fix the upper assembly module and the lower assembly module, and finally the grounding wire 27 is installed on the upper tail cover 26 of the charging socket and fixed and locked through the grounding wire fixing bolt 28 to ensure safety in use.

[0063] As a preferred, the upper heat-conducting silica gel assembly is in direct contact with the upper power terminal 19, and is in direct contact with the temperature sensor on the upper PCB plate 24, so as to monitor the charging temperature after the plug-in interface on the upper PCB plate 24 is plugged into the low-voltage plug-in terminal. The lower heat-conducting silica gel 31 is embedded in the lower insulator 30, and the temperature sensor of the lower PCB plate 33 and the lower power terminal 34 are in direct contact with the lower heat-conducting silica gel 31, so as to monitor the charging temperature after the plug-in interface of the lower PCB plate 33 is plugged into the low-voltage plug-in terminal.

[0064] Experiments are conducted on the charging socket, and the following is a summary and analysis of the core test items and data:

[0065] I. Excellent electrical performance, meeting megawatt-level high-power requirements:

[0066] Insulation resistance: Under all extreme test conditions (including after protection level testing), the insulation resistance between terminals ranges from 2.1×10 4 MΩ to 1.3×10 5 MΩ, far exceeding the standard requirement of ≥500 MΩ, indicating excellent insulation material quality and design, effectively preventing electric leakage and demonstrating superior insulation performance.

[0067] Dielectric strength: Under a voltage of up to 3500V AC (between power terminals) and 1500V AC (between signal terminals) for 1 minute, all samples have no breakdown, no flashover, and extremely low leakage current (≤0.02mA, far below the standard of <5mA), proving strong voltage resistance and safety margin, and demonstrating strong high-voltage resistance.

[0068] Effective temperature rise control and successful heat dissipation design: This is a key indicator for megawatt charging. Under the severe test of 1000A and 800A current, the maximum temperature rise of the power terminals (DC+, DC-, DC1+, DC1-) is far below the limit of ≤50K. Data example: In the 1000A test, the highest temperature rise appears on the DC+ terminal, which is 25.9K; under the 800A continuous current, the highest temperature rise is 26.4K. This indicates that the conductive material and heat dissipation design (such as the use of thermal adhesive pads) of the socket can effectively control the heat generated by large current, and is the basis for achieving megawatt-level charging.

[0069] II. Precise and reliable intelligent temperature monitoring system:

[0070] High monitoring accuracy: The standard requires an accuracy of not more than ±5℃. Actual measurement data shows that the difference between the readings and the standard thermocouple is mostly between -3.7K and +3.7K, and most of the differences are within ±3K, with an accuracy better than the national standard. Fast response: The temperature response time of all thermistors is <25s, which can quickly capture temperature changes and provide timely feedback for overheat protection.

[0071] Its mechanical structure is solid and durable, the protective cover has a long service life, and it can adapt to harsh environments such as high and low temperatures. Its sealing performance reaches the highest protection level (IP68), providing full safety protection. Its intelligent temperature monitoring system is precise and reliable, providing double protection for safe charging. All test results meet or exceed the established technical requirements, and the overall judgment is that it is qualified. This charging socket is an advanced charging connection device with mature technology, reliable performance, and high safety factor, effectively solving the industry pain points mentioned in the background technology, such as "low charging power and long charging time", and providing a solid technical foundation for super-fast charging of new energy vehicles.

[0072] The application discloses a high-power charging socket for a new energy vehicle, which adopts three module designs, can be assembled in parallel, tested independently, and is easy to troubleshoot and maintain, thereby greatly improving production and maintenance efficiency. Terminals are fixed by a fixing plate and an insulator, connection rigidity is high, and the socket has good shock resistance, and high reliability is achieved. Multiple sealing ring designs guarantee high protection levels. The upper assembly module and the lower assembly module introduce heat-conducting rubber pads, heat generated by large current is efficiently conducted to the larger metal fixing plate and the insulator shell for dissipation, which is the key to realize megawatt-level continuous charging without overheating. An integrated PCB board realizes real-time monitoring of charging status, temperature and connection, provides intelligent protection for safe and fast charging, and improves intelligence. The structure of the charging socket is close and rigorous, and the charging socket has excellent performance in fast charging time, high product strength and modular design.

[0073] Although the application has been described with reference to the explanatory embodiments thereof, the above-described embodiments are merely preferred embodiments of the application, and the embodiments of the application are not limited to the above-described embodiments. It should be understood by those skilled in the art that many other modifications and embodiments can be designed, and these modifications and embodiments will fall within the scope and spirit of the principles disclosed in the present application.

Claims

1. A high-power charging socket for a new energy vehicle, characterized in that, The application relates to a socket panel module and an upper assembly module and a lower assembly module installed on the socket panel module. The socket panel module is used for dustproof and waterproof sealing in a non-charging state, provides plug-in guidance and mechanical locking for a charging gun during a charging process, and realizes smooth opening and closing of a protective cover through a damper; the socket panel module comprises a panel shell with a first opening and a second opening, and an upper protective cover component and a lower protective cover component, wherein the upper protective cover of the upper protective cover component and the lower protective cover of the lower protective cover component are respectively hinged to the panel shell to open and seal the first opening and the second opening. The upper assembly module is used for direct current charging and is limitingly inserted into the first opening of the panel shell; the lower assembly module is used for megawatt charging together with the upper assembly module and is limitingly inserted into the second opening of the panel shell; and the upper assembly module and the lower assembly module are respectively fixed to the panel shell through insulating body fixing bolts to lock and fix one end of the upper assembly module and the lower assembly module in the panel shell. The upper assembly module comprises an upper insulating body, an upper PCB board, an upper tail cover, and an upper fixed plate assembly formed by a terminal assembly and an upper heat-conducting silica gel assembly installed on the upper fixed plate, an upper insulating body sealing ring is sleeved on the front end of the upper insulating body, the upper fixed plate assembly is limitingly inserted into the upper insulating body from the rear end of the upper insulating body, and the upper fixed plate is fixed in the upper insulating body through upper fixed plate screws, the upper PCB board is installed on the rear side of the upper fixed plate away from the upper insulating body through upper PCB board fixing screws, the contact pin of the upper PCB board is inserted into the tail part of the signal terminal and is in contact with the crown spring through the upper fixed plate, the upper tail cover is buckled on the rear end of the upper insulating body, and the upper power terminal penetrates through the upper tail cover, the upper heat-conducting silica gel assembly is in direct contact with the upper power terminal and the temperature sensor on the upper PCB board, so that the charging temperature is monitored after the upper PCB board is inserted into the low-voltage plug-in interface.

2. The high-power charging socket for a new energy vehicle according to claim 1, wherein, The lower assembly module comprises a lower insulating body, a lower heat-conducting silica gel, a lower power terminal, a lower fixed plate and a lower tail cover, a lower insulating body sealing ring is sleeved on the front end of the lower insulating body, the lower heat-conducting silica gel is pressed into the rear end of the lower insulating body through a lower PCB board, the lower power terminal is installed on the lower fixed plate and is limitingly inserted into the lower insulating body, the rear end of the lower power terminal protrudes out of the lower tail cover, and the lower tail cover is buckled on the rear end of the lower insulating body.

3. The high-power charging socket for new energy vehicles according to claim 1, characterized in that, The temperature sensor of the lower PCB board and the lower power terminal are in direct contact with the lower heat-conducting silica gel, so that the charging temperature is monitored after the lower PCB board is inserted into the low-voltage plug-in interface. The lower PCB board presses the lower heat-conducting silica gel into the rear end of the lower insulating body through a lower PCB board fixing screw.

4. The high-power charging socket for new energy vehicles according to claim 3, characterized in that, And / or the lower fixed plate is installed on the rear end of the lower insulating body through a lower fixed plate fixing screw. The upper protective cover component is further provided with an upper protective cover sealing gasket, and the upper protective cover sealing gasket is embedded on the side of the upper protective cover close to the panel shell; the lower protective cover component is further provided with a lower protective cover sealing ring, and the lower protective cover sealing ring is sleeved on the side of the lower protective cover close to the panel shell.

5. The high-power charging socket for new energy vehicles according to any one of claims 1-4, characterized in that, The front side of the panel shell is further hingedly provided with a lock component to control the closing of the upper protective cover and the lower protective cover through the lock component.

6. The high-power charging socket for new energy vehicles according to any one of claims 1-4, characterized in that, ​ 7. The high power charging socket for new energy vehicles according to claim 6, characterized in that, The lock catch component comprises a lock catch, a lock catch torsion spring and a lock catch pin shaft, the outer side of the first opening and the second opening of the panel shell is respectively formed with a lock catch component mounting port for mounting the lock catch component, the lock catch torsion spring is arranged in the torsion spring mounting hole of the lock catch, and the lock catch pin shaft is inserted into the lock catch to hingedly mount the lock catch component on the panel shell, so as to control the closing of the upper protective cover and the lower protective cover.

8. The high-power charging socket for new energy vehicles according to any one of claims 1-4, characterized in that, A panel sealing ring is arranged in the sealing groove on the rear side of the panel shell, so as to realize sealing with the vehicle body when the entire socket panel module is mounted on the vehicle body.

9. The high-power charging socket for new energy vehicles according to any one of claims 1-4, characterized in that, The charging socket is further provided with a grounding wire, and the grounding wire is fixed and locked with the upper assembly module or the lower assembly module through a grounding wire fixing bolt.

10. The high-power charging socket for new energy vehicles according to any one of claims 1-4, characterized in that, The socket panel module is further provided with a damper, a protective cover torsion spring and a protective cover pin shaft, the upper protective cover component and the lower protective cover component are arranged in the hinged seat on the panel shell in sequence, and the protective cover pin shaft sequentially passes through the hinged seat of the panel shell, the upper protective cover component, the damper, the torsion spring and the lower protective cover component, so as to simultaneously hinge the upper protective cover and the lower protective cover on the panel shell.

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