Connector for vehicle battery pack and method of manufacturing the same

Abstract

The invention discloses a connector for a vehicle battery pack, and the connector comprises an insulating seat which comprises a plugging groove suitable for receiving a plug; the pair of connecting terminals are fixed on the insulating seat and are suitable for being electrically connected to the vehicle battery pack and the plug accommodated in the plug-in groove, so that the vehicle battery pack is electrically connected with the plug accommodated in the plug-in groove; the electric heating element is at least provided with an arrangement section embedded in the insulating seat, and the two ends of the electric heating element are electrically connected with the pair of connecting terminals respectively, so that the electric heating element is suitable for being electrically connected with the vehicle battery pack through the pair of connecting terminals and heating the insulating seat after being electrified. According to the connector for the vehicle battery pack, the electric heating element is introduced into the insulating seat, the insulating seat is heated and subjected to heat preservation, water vapor in air is prevented from being condensed and attached to the insulating seat, and meanwhile the manufacturing method of the connector for the vehicle battery pack is simple, convenient and economical.

Description

Technical Field

[0001] This invention belongs to the field of vehicle technology, and particularly relates to connectors for vehicle battery packs and methods for manufacturing the same. Background Technology

[0002] The high-voltage connector of an electric vehicle's battery pack connects the battery pack and delivers electrical energy to various onboard devices. The insulating seat of the high-voltage connector has a slot for the plug to be inserted. During vehicle use, excessive humidity and / or sudden temperature changes in the environment surrounding the high-voltage connector (e.g., the vehicle suddenly enters an environment with a temperature significantly higher than the connector's surface temperature) can cause condensation on the connector's insulating seat, forming water accumulation. Therefore, the insulating seat of the high-voltage connector is preferably arranged (slanted) downwards to facilitate water drainage. However, due to space limitations, some high-voltage connector insulating seats are inevitably arranged (slanted) upwards, making it difficult for water to drain. Prolonged adhesion of condensed water on the insulating seat (especially near the slot area) poses an insulation risk, potentially leading to leakage and unstable power supply. Conventional manual inspection and water removal methods are time-consuming, labor-intensive, and may also pose a risk of electric shock. Summary of the Invention

[0003] To address the aforementioned technical problems, this invention proposes a connector for vehicle battery packs and a method for manufacturing the same. This connector for vehicle battery packs can effectively avoid the problem of condensation and water accumulation, and its manufacturing method is easy to operate.

[0004] Therefore, according to one aspect of the technical concept of the present invention, a connector for a vehicle battery pack is provided, comprising: an insulating base including a insertion slot adapted to receive a plug; a pair of connecting terminals fixed on the insulating base and adapted to be electrically connected to the vehicle battery pack and the plug received in the insertion slot, so as to electrically connect the vehicle battery pack to the plug received in the insertion slot; and a heating element having at least an arrangement section embedded in the insulating base, and both ends of the heating element being electrically connected to the pair of connecting terminals, such that the heating element is adapted to be electrically connected to the vehicle battery pack through the pair of connecting terminals and to heat the insulating base when energized.

[0005] Based on the above-described technical concept, the present invention may further include any one or more of the following optional forms.

[0006] According to some optional configurations, the surface temperature of the heating element after being energized does not exceed 50°C.

[0007] According to some alternative configurations, the heating element is constructed as a heating wire.

[0008] According to some alternative forms, the insulating base includes a base and an annular wall extending from the base, the base and the annular wall together defining the insertion slot, and the arrangement section of the heating element is arranged in the base and / or the annular wall.

[0009] According to some alternative configurations, the heating element is constructed as a heating wire.

[0010] According to some alternative configurations, the arrangement section extends continuously in a bent manner within the base and / or the annular wall.

[0011] In some alternative configurations, the insulating base is integrally made of plastic.

[0012] According to some alternative configurations, the connector is constructed as a high-voltage connector.

[0013] According to another aspect of the technical concept of the present invention, a method for manufacturing a connector for a vehicle battery pack is provided, comprising the following steps: providing a heating element and a pair of connecting terminals; electrically connecting both ends of the heating element to the pair of connecting terminals respectively; manufacturing an insulating base and forming a insertion groove on the insulating base; fixing the pair of connecting terminals on the insulating base and embedding the arrangement section of the heating element in the insulating base.

[0014] According to some alternative forms, the insulating base is manufactured by integral injection molding of plastic, and during the injection molding process of the insulating base, the pair of connecting terminals are fixed on the insulating base, and the arrangement section of the heating element is embedded in the insulating base.

[0015] The connector for vehicle battery packs of the present invention introduces an electric heating element into an insulating base, and simultaneously energizes the electric heating element through a connecting terminal, so that the electric heating element converts electrical energy into heat energy to heat and insulate the insulating base, preventing the condensation and adhesion of moisture in the air on the insulating base. At the same time, the manufacturing method of the connector for vehicle battery packs of the present invention is simple and economical. Attached Figure Description

[0016] Features, advantages and other aspects of the various embodiments of the present invention will become more apparent from the accompanying drawings and the following detailed description, in which several embodiments of the invention are shown by way of example and not limitation, and in the drawings, the same reference numerals denote the same or similar parts.

[0017] Figure 1 This is a schematic diagram of an exemplary embodiment of a connector for a vehicle battery pack according to the present invention;

[0018] Figure 2 yes Figure 1A perspective sectional view of a connector for a vehicle battery pack is shown.

[0019] Figure 3 yes Figure 1 An exploded view of the connector used for a vehicle battery pack is shown.

[0020] Figure 4 yes Figure 3 A perspective sectional view of the insulating base of the connector for a vehicle battery pack is shown.

[0021] Figure 5 This is a perspective cross-sectional view of another exemplary embodiment of the connector for a vehicle battery pack according to the present invention;

[0022] Figure 6 yes Figure 5 A schematic diagram showing the heating element and connection terminals of a connector for a vehicle battery pack;

[0023] Figure 7 This is a schematic diagram of an exemplary embodiment of a method for manufacturing a connector for a vehicle battery pack according to the present invention.

[0024] Reference numerals: 100-insulating base; 110-base; 120-annular wall; 121-inner surface of annular wall; 122-outer surface of annular wall; 130-insertion slot; 141, 142-accommodating slots; 150-chamber; 210, 220-connecting terminals; 210A, 220A-fixed portion of connecting terminal; 210B, 220B-free portion of connecting terminal; 310-heating element; 311-arrangement section of heating element; 312A, 312B-end section of heating element; I-connector for vehicle battery pack. Detailed Implementation

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0026] It should be noted that if the embodiments of the present invention involve directional indication, the directional indication is only used to explain the relative positional relationship and movement of the components in a certain specific posture. If the specific posture changes, the directional indication will also change accordingly.

[0027] Furthermore, the technical solutions of the various embodiments can be combined with each other, but only if they are feasible for those skilled in the art. If the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0028] Given that condensation may occur on the high-voltage connectors of electric vehicle battery packs, leading to leakage and power supply problems, which may affect vehicle handling and pose safety hazards, this invention proposes a connector for vehicle battery packs to conveniently eliminate the problem of condensation. Furthermore, it also proposes a method for manufacturing the connector for vehicle battery packs.

[0029] Figures 1 to 4An exemplary connector I for a vehicle battery pack according to the present invention is shown, comprising an insulating base 100, a pair of connecting terminals 210, 220, and a heating element 310. The insulating base 100 includes a insertion slot 130 for receiving a plug electrically connected to an on-board device, and a connector 131 for electrical connection with the plug can be provided in the insertion slot 130. The pair of connecting terminals 210, 220 may be constructed as elongated members, such as rods, bars, etc., and each has a fixed portion / fixed end 210A, 220A and a free portion / free end 210B, 220B offset from or opposite to the fixed portions 210A, 220A. A pair of connecting terminals 210 and 220 can be fixed to the insulating base 100 via their fixing portions 210A and 220A. For example, the insulating base 100 has two receiving slots 141 and 142 to respectively receive and fix the fixing portions 210A and 220A of the pair of connecting terminals 210 and 220. The fixing portions 210A and 220A can be electrically connected to the connector 131, so that the pair of connecting terminals 210 and 220 can be electrically connected (e.g., via the connector 131) to the plug received in the plug slot 130. At the same time, the free portions 210B and 220B of the pair of connecting terminals 210 and 220 can extend outside the insulating base 100, and the pair of connecting terminals 210 and 220 can be electrically connected to the positive and negative terminals of the vehicle battery pack via their free portions 210B and 220B, respectively, so that the plug received in the plug slot 130 (e.g., via the connector 131) can be electrically connected to the vehicle battery pack. The insulating base 100 may further define a substantially enclosed channel / chamber 150, which may extend within the insulating base 100 and be open only at its two ends to communicate with the two receiving slots 141, 142 respectively. The heating element 310 may have at least an arrangement section 311, which can be fully built into / embedded in the insulating base 100 by passing through the channel / chamber 150. The two ends of the heating element 310 may extend out of the chamber 150 and be electrically connected to a pair of connecting terminals 210, 220 (e.g., the fixing portions 210A, 220A of the pair of connecting terminals 210, 220), respectively. For example, the two ends of the heating element 310 may be electrically connected to the fixing portions 210A, 220A of the pair of connecting terminals 210, 220 at or near the junction of the channel / chamber 150 and the receiving slots 141, 142 by means of welding, wire screws, or even just surface contact. Subsequently, the heating element 310 can be electrically connected to the positive and negative terminals of the vehicle battery pack via a pair of connection terminals 210, 220.

[0030] After the vehicle is started, the battery pack supplies power to the outside world through a pair of connection terminals 210 and 220, and the power goes to various vehicle devices through the plug. At the same time, since the heating element 310 is electrically connected to the positive and negative terminals of the vehicle battery pack through a pair of connection terminals 210 and 220, the heating element 310 is also energized. After the heating element 310 / arrangement section 311 is energized, it starts to work, converting electrical energy into heat energy to heat the insulating base 100. The heating element 310 works and generates heat, and its surface temperature can not exceed 50°C, including 15°C, 20°C, 25°C, 30°C, 35°C, 40°C, 45°C, 50°C, etc., as well as the range with any two of the above temperature values ​​as endpoints, such as 15°C to 50°C, 20°C to 45°C, etc. The heating element 310 / arrangement section 311 generates heat and transfers it to the insulating base 100, making the surface temperature of the insulating base 100 higher than the ambient temperature. For example, the surface temperature of the insulating base 100 is set between 10°C and 45°C, including 10°C, 15°C, 20°C, 25°C, 30°C, 35°C, 40°C, and 45°C, as well as intervals with any two of these temperature values ​​as endpoints. In this way, the heating element 310 generates heat such that the surface temperature of the insulating base 100 is higher than the ambient temperature, without generating excessive heat and consuming too much power, and without damaging the insulating base (e.g., when the insulating base is made of plastic). The heating element 310 remains operational until the vehicle is powered off and the battery pack no longer supplies power to the outside world through the pair of connection terminals 210 and 220. During the operation of the heating element 310, the heat generated by the heating element 310 is transferred to the insulating base 100, keeping the insulating base 100 at a relatively high temperature. The surface temperature of the insulating base 100 is higher than the ambient temperature, thus preventing moisture in the air from condensing and adhering to the surface of the insulating base 100. For any water that may have already adhered to the insulating base 100 (such as water condensing during vehicle shutdown), the heating element 310 can conveniently evaporate and remove it, thus avoiding the manual removal methods commonly used in the prior art and eliminating the insulation and electric shock risks caused by water accumulation. Therefore, compared to conventional vehicle battery pack connectors, the connector I of this invention offers greater flexibility in installation on the battery pack. It can be arranged with the insulating base (slanted) facing upwards or downwards, without worrying about water accumulation. It should be understood that the connector I for vehicle battery packs of the present invention is particularly suitable for being constructed as a high-voltage connector for vehicle battery packs. In this case, a high voltage difference can be present between a pair of connecting terminals 210, 220, which can generate sufficient current on the heating element 310 to ensure that the heating element 310 dissipates enough heat to heat the surface of the insulating base 100 to a sufficiently high temperature, thereby preventing the condensation and adhesion of water vapor in the air on the surface of the insulating base 100 or evaporating and removing water that has already adhered to the surface of the insulating base 100.

[0031] At the same time, such as Figure 7 As shown, the present invention also proposes a method for manufacturing a connector I for a vehicle battery pack, which can be carried out according to the following steps:

[0032] S1: Provides heating element 310 and a pair of connecting terminals 210, 220;

[0033] S2: Connect the two ends of the heating element 310 to a pair of connecting terminals 210 and 220 (e.g., the fixed portions 210A and 220A of the pair of connecting terminals 210 and 220 respectively);

[0034] S3: Manufacture an insulating base 100 and form a plug groove 130 on the insulating base 100, fix a pair of connecting terminals 210, 220 (e.g., the fixing portions 210A, 220A of a pair of connecting terminals 210, 220) on the insulating base 100, and embed the arrangement section 311 of the heating element 310 in the insulating base 100.

[0035] The above manufacturing method is simple and economical, and can quickly produce the connector I for vehicle battery packs of the present invention without incurring too much time and financial cost.

[0036] Reference Figures 1 to 4In some embodiments, the insulating base 100 may include a base 110 and an annular wall 120. The base 110 may be plate-shaped, and the annular wall 120 extends from the base 110. For example, the annular wall 120 extends vertically from one side of the plate-shaped base 110, thereby defining the aforementioned insertion groove 130 together with the base 110. The opposite side of the plate-shaped base 110 may have or have two receiving grooves 141, 142, and the fixing portions 210A, 220A of a pair of connecting terminals 210, 220 may be inserted into and fixed in the two receiving grooves 141, 142, respectively. It should be understood that the receiving slots 141 and 142 may or may not penetrate the base 110, and the connector 131 may be electrically connected to the fixing portions 210A and 220A of a pair of connecting terminals 210 and 220 via a corresponding channel (similar to a channel / chamber 150) communicating with the receiving slots 141 and 142. On the other hand, the annular wall 120 may have an inner surface 121 facing the insertion slot 130 and an outer surface 122 facing away from the insertion slot 130. The insertion slot 130 can receive the plug, and the annular wall 120 / inner surface 121 is in close contact with the plug to prevent the plug from falling out and to provide isolation to prevent accidental contact with the live terminals in the insertion slot 130 and electric shock in certain circumstances. The arrangement section 311 of the heating element 310 can be arranged in the base 110 and / or the annular wall 120. For example, the arrangement section 311 of the heating element 310 can be arranged in the region between the inner surface 121 and the outer surface 122 of the annular wall 120. The heating element 310 / arrangement section 311 works and transfers heat to the annular wall 120, which can prevent water vapor in the air from condensing and adhering to the surface of the annular wall 120, especially preventing water vapor in the air from condensing and adhering to the outer surface 122 of the annular wall 120.

[0037] In some embodiments, the heating element 310 may be configured as a heating wire and include an arrangement section 311 and two end sections 312A, 312B. The two end sections 312A, 312B are located at both ends of the heating element 310 and are electrically connected to a pair of connecting terminals 210, 220 (such as their fixing portions 210A, 220A), respectively. The arrangement section 311 is located between the two end sections 312A, 312B and may be arranged in the base 110 and / or the annular wall 120. In some embodiments, the arrangement section 311 of the heating element 310 may be arranged substantially uniformly in the base 110 and / or the annular wall 120, for example, as shown in the figure. Figure 5 and Figure 6As shown, the arrangement section 311 of the heating element 310, which is constructed as a heating wire, can be continuously bent and extended in the base 110 and / or the annular wall 120. Specifically, the arrangement section 311 is continuously bent and extended in the cavity 150 in the base 110 and / or the annular wall 120 (the cavity 150 is also correspondingly constructed to be continuously bent and extended in the base 110 and / or the annular wall 120), while the two end sections 312A and 312B extend out of the cavity 150, enter the receiving grooves 141 and 142 in the base 110, and are electrically connected to the fixing portions 210A and 220A of a pair of connecting terminals 210 and 220, respectively. Of course, in some embodiments, the two end sections 312A, 312B may not extend beyond the chamber 150, but are electrically connected at the junction of the chamber 150 and the receiving grooves 141, 142 to the fixed portions 210A, 220A of a pair of connecting terminals 210, 220. As another form of bending extension of the arrangement section, in some other embodiments not shown, for heating elements constructed as heating wires, the arrangement section may be constructed in a helical shape formed by multiple turns of coil, such that the arrangement section can be helically arranged in the base and / or spirally wound around the annular wall circumferentially. It should be understood that, in this document, bending broadly includes the meanings of bending, turning, meandering, and similar terms. It should be understood that the arrangement of the heating element 310 or the arrangement section 311 in the annular wall 120 also serves to strengthen the annular wall 120, better preventing deformation or damage to the annular wall 120.

[0038] It should be understood that the receiving grooves 141, 142 and the chamber 150 in the insulating base 100 can be formed and reserved during the manufacturing process of the insulating base 100 to accommodate the fixing portions 210A, 220A of the connecting terminals 210, 220 and the heating element 310 / arrangement section 311, for example, the receiving grooves 141, 142 and the chamber 150 can be specially formed on the insulating base 100. However, more preferably, the insulating base 100 (including the base 110 and the annular wall 120) can be integrally made of plastic (the plastic may include one or more of polyamide plastic, polypropylene plastic, polystyrene plastic, polypropylene plastic, etc.) and wrap the fixing portions 210A, 220A of the connecting terminals 210, 220 and the heating element 310 / arrangement section 311. Thus, in some embodiments, in step S3 described above, the insulating base 100 can be integrally injection molded from plastic. During the injection molding process of the insulating base 100, the heating element 310 / arrangement section 311 and the fixing portions 210A and 220A of the pair of connecting terminals 210 and 220 are placed in the mold cavity, and then molten plastic is injected into the mold cavity, filling the mold cavity completely. Since the fixing portions 210A and 220A of the pair of connecting terminals 210 and 220 and the heating element 310 / arrangement section 311 occupy a certain space, the molten plastic cannot occupy this space but can wrap around the fixing portions 210A and 220A of the pair of connecting terminals 210 and 220 and the heating element 310 / arrangement section 311 (thereby forming the aforementioned receiving grooves 141 and 142 and chamber 150). Thus, after the molten plastic solidifies / solidifies to form the insulating base 100, the fixing portions 210A and 220A of a pair of connecting terminals 210 and 220 are fixed to the insulating base 100 by injection molding, and the arrangement section 311 of the heating element 310 is embedded in the insulating base 100 by injection molding.

[0039] It should be understood that the above description of the preferred embodiments is quite detailed, but it should not be considered as a limitation on the scope of protection of this invention. Those skilled in the art, under the guidance of this invention, can make substitutions or modifications without departing from the scope of protection of the claims of this invention, and all such substitutions or modifications fall within the scope of protection of this invention. The scope of protection of this invention should be determined by the appended claims.

Claims

1. A connector (I) for a vehicle battery pack, characterized in that, include: An insulating base (100) includes a insertion slot (130) adapted to receive a plug; A pair of connecting terminals (210, 220) are fixed on the insulating base (100) and adapted to be electrically connected to the vehicle battery pack and the plug received in the plug slot (130) to electrically connect the vehicle battery pack to the plug received in the plug slot (130). The heating element (310) has at least one arrangement section (311) embedded in the insulating base (100), and both ends of the heating element (310) are electrically connected to the pair of connecting terminals (210, 220), such that the heating element (310) is adapted to be electrically connected to the vehicle battery pack through the pair of connecting terminals (210, 220) and to heat the insulating base (100) when energized.

2. The connector (I) for a vehicle battery pack according to claim 1, characterized in that, The surface temperature of the heating element (310) after being energized is not higher than 50°C.

3. The connector (I) for a vehicle battery pack according to claim 1 or 2, characterized in that, The heating element (310) is constructed as a heating wire.

4. The connector (I) for a vehicle battery pack according to claim 1 or 2, characterized in that, The insulating base (100) includes a base (110) and an annular wall (120) extending from the base (110), the base (110) and the annular wall (120) together defining the insertion slot (130), and the arrangement section (311) of the heating element (310) is arranged in the base (110) and / or the annular wall (120).

5. The connector (I) for a vehicle battery pack according to claim 4, characterized in that, The heating element (310) is constructed as a heating wire.

6. The connector (I) for a vehicle battery pack according to claim 5, characterized in that, The arrangement section (311) is continuously bent and extended in the base (110) and / or the annular wall (120).

7. The connector (I) for a vehicle battery pack according to claim 1, characterized in that, The insulating base (100) is integrally made of plastic.

8. The connector (I) for a vehicle battery pack according to claim 1, characterized in that, The connector (I) is constructed as a high-voltage connector.

9. A method for manufacturing a connector for a vehicle battery pack, comprising manufacturing a connector (I) for a vehicle battery pack according to any one of claims 1 to 8, characterized in that, Includes the following steps: Provides a heating element (310) and a pair of connection terminals (210, 220); The two ends of the heating element (310) are electrically connected to the pair of connecting terminals (210, 220) respectively; An insulating base (100) is manufactured and a socket (130) is formed on the insulating base (100). The pair of connecting terminals (210, 220) are fixed on the insulating base (100) and the arrangement section (311) of the heating element (310) is embedded in the insulating base (100).

10. The method for manufacturing a connector for a vehicle battery pack according to claim 9, characterized in that, The insulating base (100) is manufactured by integral injection molding of plastic, and during the injection molding process of the insulating base (100), the pair of connecting terminals (210, 220) are fixed on the insulating base (100), and the arrangement section (311) of the heating element (310) is embedded in the insulating base (100).

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