A charging module

Abstract

This invention relates to the field of charging equipment and discloses a charging module, comprising: a housing; a connector including a connecting section and a tapered section, the rear end of the connecting section being connected to the front side of the housing, and multiple conductive contacts being arranged around the rear side of the tapered section, with a connecting channel provided within the connecting section; a heat dissipation assembly with a heat dissipation channel inside; an electrical component electrically connected to the multiple conductive contacts; and a connecting shell with a cooling cavity inside, a mating connector being provided on the rear side of the connecting shell, a mating groove being provided on the rear side of the mating connector, and a mating channel communicating with the cooling cavity being provided at the bottom of the mating groove, the tapered section being inserted into the mating groove, and a contactor being provided on the rear side of the mating connector corresponding to the positions of the multiple conductive contacts. When installing the housing, this invention allows for rapid positioning of the housing, mating connection of the cooling structure, and electrical mating connection by directly utilizing the cooperation between the connector and the mating connector, effectively improving the efficiency and convenience of installing the charging module into the cabinet.

Description

Technical Field

[0001] This invention relates to the field of charging equipment, and more particularly to a charging module. Background Technology

[0002] The charging module is the core component of DC charging equipment for new energy vehicles. It is the basic unit for power conversion, including rectification, inversion, and filtering, and its main function is to convert AC power from the grid into DC power suitable for battery charging. During installation, the entire charging module typically needs to be housed in a cabinet. This requires aligning and connecting the charging module to the cabinet's mounting structure, as well as aligning the cooling connectors (for liquid flow or ventilation) within the module. This process leads to low installation efficiency and frequent misalignment. Especially when the cooling connectors are not properly aligned, poor heat dissipation can occur, affecting the normal operation of the charging module. Therefore, there is an urgent need for a charging module that allows for easier and faster alignment and connection. Summary of the Invention

[0003] The purpose of this invention is to provide a charging module to solve one or more technical problems existing in the prior art, and at least provide a beneficial option or create conditions.

[0004] A charging module according to a first aspect of the present invention includes: a housing; a connector including a connecting section and a tapered section connected to the front end of the connecting section, the rear end of the connecting section being connected to the front side of the housing, the tapered section having a tapered surface that gradually narrows forward on its outer side, a plurality of conductive contacts being arranged around the rear side of the tapered section, a connecting channel being provided within the connecting section, the connecting channel extending to the tapered section; a heat dissipation assembly disposed within the housing, the heat dissipation assembly having a heat dissipation channel inside, the heat dissipation channel being connected to the connecting channel; and an electrical assembly. The electrical components are electrically connected to the multiple conductive contacts and are housed within the housing. A connecting shell has a cooling chamber inside. A connector is located on the rear side of the connecting shell, and a mating groove is located on the rear side of the connector. The bottom of the mating groove has a mating channel communicating with the cooling chamber. The tapered section is inserted into the mating groove. A contactor is located on the rear side of the connector corresponding to the multiple conductive contacts. Each contactor has a reciprocating contact piece, which can extend to abut against or move away from the multiple conductive contacts.

[0005] This technical solution has at least the following beneficial effects: the connecting shell is pre-installed inside the charging pile's cabinet; the contact plates inside multiple connectors can be connected to the circuitry within the cabinet; the cooling chamber is connected to an external cooling air source or coolant supply source; the electrical components used for rectification, inversion, filtering, and other power conversions are installed inside the shell, ensuring electrical connections between the electrical components and multiple conductive contacts; then, the shell and connecting shell are connected and aligned. Specifically, the connector and mating head are aligned so that the tapered section enters the mating groove on the rear side of the mating head. The tapered section serves as the connection alignment mechanism, while the contact plates inside the multiple connectors on the rear side of the mating head are in a state away from the mating groove, allowing the tapered section to... The conical segment can be fully inserted and connected into the docking slot. At this time, the docking channel and the heat dissipation channel are interconnected. Then, the contact plates inside the multiple connectors move into the docking slot, so that the multiple contact plates contact the multiple conductive contacts respectively, realizing the power supply to the electrical components inside the housing. The multiple contact plates also block and limit the conical segment, effectively preventing the conical segment from coming out of the docking slot. In this way, when installing the housing, the mutual cooperation of the connector and the docking head can directly realize the rapid positioning of the housing, the matching connection of the cooling structure, and the electrical matching connection, effectively improving the efficiency and convenience of installing the charging module into the rack, and also helping to improve the stability of the internal heat dissipation operation of the charging module.

[0006] According to some embodiments of the present invention, the front end of the connector is formed with a spherical portion, and a connecting groove is provided on the rear side of the connecting shell. The spherical portion is fitted into the connecting groove, and the mating channel extends through the spherical portion. By fitting the spherical portion into the connecting groove, the orientation of the connector can be adjusted. When installing the housing, the tapered section can be accurately inserted into the connecting groove, guiding the connector to fit into the mating groove. This effectively improves the convenience and accuracy of alignment during housing installation and connection.

[0007] According to some embodiments of the present invention, a transition groove is provided between the cooling cavity and the docking groove in the connecting shell. A connecting hose is provided in the transition groove, with its front end connected to the cooling cavity and its rear end connected to the docking channel. When the spherical part rotates in the connecting groove, the connecting hose provides a flexible connection structure between the cooling cavity and the docking groove, ensuring that the docking channel and the cooling cavity remain in communication, thereby improving the overall stability of installation and use.

[0008] According to some embodiments of the present invention, an elastic sealing sleeve is provided in the mating groove, the shape of the elastic sealing sleeve being adapted to the shape of the mating groove, and the tapered segment abutting against the inner side of the elastic sealing sleeve. The elastic sealing sleeve can fill the assembly gap between the tapered segment and the mating groove, improving the ease of installation of the tapered segment in the mating groove. Furthermore, since the elastic sealing sleeve itself can generate a certain amount of elastic deformation, when the connector is installed in the mating groove, the elastic sealing sleeve can be elastically compressed and deformed, thereby making the conductive contacts fit more tightly with the connector head and maintaining the stability of the electrical connection during use.

[0009] According to some embodiments of the present invention, a drain groove is provided on the inner rear side of the elastic sealing sleeve, the drain groove extending around the elastic sealing sleeve, and a collection pipe is provided on the bottom side of the connector corresponding to the drain groove. A drain hole communicating with the collection pipe is provided on the bottom side of the drain groove. The drain groove provides a space for collecting leakage from the elastic sealing sleeve between the connector and the mating groove. When the elastic sealing sleeve fails after prolonged use, seepage occurs between the connection channel and the heat dissipation channel, spreading outward to the drain groove. At this time, the coolant can flow downward along the drain groove to the drain hole, and then flow downward from the drain hole to the collection pipe. The coolant is further recovered through the collection pipe, which effectively prevents electrical short circuits caused by coolant leakage, greatly improving overall safety.

[0010] According to some embodiments of the present invention, a sealing strip is provided in the drain groove, the sealing strip extending from one side of the drain hole to the other side, and the sealing strip has a hollow structure. The hollow sealing strip has strong elastic deformation capability, which can not only enhance the sealing performance of the sealing strip at the position of the drain groove and the conical section, preventing the coolant from further seeping outward, but also provide a gap for coolant flow between the sealing strip and the two sides of the drain groove, ensuring that the coolant can flow downward to the drain hole at this position, and then enter the collection pipe for recycling.

[0011] According to some embodiments of the present invention, the connector includes an electromagnetic lock connected to the rear side of the connector. The electromagnetic lock has a retractable latch, and the contact piece is connected to the latch. In the de-energized state, the latch extends close to the conductive contact. In the energized state, the latch retracts away from the conductive contact. The connector contains a drive source that can drive the contact piece to reciprocate. Specifically, an electromagnetic lock is provided on the rear side of the connector. The electromagnetic lock has a retractable latch. In the energized state, the latch retracts away from the opening of the mating groove. At this time, the latch drives the contact piece away from the conductive contact. Since the latch no longer blocks the mating groove, the connector can enter the mating groove. When the connector is de-energized, the latch extends to the opening of the mating groove. At this time, the latch drives the contact piece close to and abuts against the conductive contact, and uses the latch to block the mating groove, preventing the connector from coming out of the mating groove. This realizes the switching of the conductive contact and blocks and limits the connector.

[0012] According to some embodiments of the present invention, a buffer sleeve is provided on the outer side of the connecting section, and the locking tongue can extend to abut against the buffer sleeve. When the locking tongue drives the contact plate to contact the conductive contact, the locking tongue abuts against the buffer sleeve, and the buffer sleeve provides elastic cushioning for the locking tongue, reducing the noise generated when the locking tongue moves to its position.

[0013] According to some embodiments of the present invention, a first control valve is provided in the connection channel, and a second control valve is provided in the docking channel. Before the charging module is installed in the cabinet, and when coolant is used to cool the electrical components inside the housing, both the first and second control valves are closed, thus sealing the interior of the connection channel and the docking channel. After the charging module is installed in the cabinet, the first and second control valves are opened, allowing the interior of the connection channel and the docking channel to communicate with each other, thereby enabling the coolant to circulate within the charging module and the cooling chamber.

[0014] According to some embodiments of the present invention, the heat dissipation assembly includes a plurality of heat dissipation plates disposed within the housing, and each of the plurality of heat dissipation plates is provided with a heat dissipation channel. The heat dissipation plates increase the heat absorption area inside the housing, thus better absorbing the heat generated by the electrical components. Heat exchange is then conducted between the heat exchange medium inside the plurality of heat dissipation plates and the cooling chamber, thereby improving the heat dissipation efficiency inside the housing. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly explained below. Obviously, the described drawings are only a part of the embodiments of the present invention, and not all of them. Those skilled in the art can obtain other design schemes and drawings based on these drawings without creative effort.

[0016] Figure 1 This is a side view of the present invention.

[0017] Figure 2 yes Figure 1 A schematic diagram of the AA cross-sectional structure.

[0018] Figure 3 yes Figure 2 A magnified view of part B.

[0019] In the attached diagram: 1-housing, 2-connector, 21-connecting section, 22-conical section, 23-conductive contact, 24-connecting channel, 25-buffer sleeve, 31-heat dissipation channel, 32-heat dissipation plate, 41-connecting shell, 411-connecting groove, 412-transition groove, 42-cooling cavity, 43-butting connector, 431-docking channel, 44-connecting hose, 45-elastic sealing sleeve, 451-sealing strip, 46-collecting pipe, 51-electric contact plate, 52-electromagnetic lock, 521-locking tongue. Detailed Implementation

[0020] The following will clearly and completely describe the concept, specific structure, and technical effects of the present invention in conjunction with embodiments and accompanying drawings, so as to fully understand the purpose, features, and effects of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, not all of them. Other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are all within the scope of protection of the present invention. Furthermore, all connection relationships mentioned herein do not simply refer to direct connection of components, but rather to the ability to form a better connection structure by adding or reducing connecting accessories according to specific implementation conditions. The various technical features in this invention can be combined interactively without contradicting each other.

[0021] Reference Figures 1 to 3According to a first aspect of the present invention, a charging module includes: a housing 1; a connector 2, which includes a connecting section 21 and a tapered section 22 connected to the front end of the connecting section 21, the rear end of the connecting section 21 being connected to the front side of the housing 1, the tapered section 22 having a tapered surface that gradually narrows forward on its outer side, and a plurality of conductive contacts 23 being arranged around the rear side of the tapered section 22, a connecting channel 24 being provided inside the connecting section 21 and extending to the tapered section 22; a heat dissipation assembly disposed inside the housing 1, the heat dissipation assembly having a heat dissipation channel 31 inside, the heat dissipation channel 31 being connected to the connecting channel 24; and an electrical assembly disposed inside the housing 1. Electrically connected to multiple conductive contacts 23, in practical applications, the electrical components include a controller, drive circuit, auxiliary power supply, rectifier and filter elements, etc.; a connecting shell 41, which has a cooling chamber 42 inside, a connector 43 is provided on the rear side of the connecting shell 41, a docking groove is provided on the rear side of the connector 43, and a docking channel 431 communicating with the cooling chamber 42 is provided at the bottom of the docking groove. The tapered section 22 is inserted into the docking groove. A contactor is provided on the rear side of the connector 43 corresponding to the positions of multiple conductive contacts 23. Each of the multiple contactors has a reciprocating contact piece 51, which can extend to abut against or move away from the multiple conductive contacts 23.

[0022] In this charging module, the connecting shell 41 is pre-installed in the charging pile cabinet. The contact plates 51 in multiple connectors can be connected to the circuit in the cabinet. The cooling chamber 42 is connected to an external cooling air source or coolant supply source. The electrical components used for power conversion such as rectification, inversion, and filtering are installed in the housing 1, and an electrical connection is formed between the electrical components and multiple conductive contacts 23. Then, the housing 1 and the connecting shell 41 are connected and aligned. Specifically, the connector 2 and the mating connector 43 are aligned so that the tapered section 22 enters the mating groove on the rear side of the mating connector 43. The tapered section 22 serves as the connection alignment. The contact plates 51 in the multiple connectors on the rear side of the mating connector 43 are in a state away from the mating groove, so that the tapered section 22... It can be fully inserted and connected into the docking slot. At this time, the docking channel 431 and the heat dissipation channel 31 are interconnected. Then, the contact plates 51 in the multiple connectors move into the docking slot, so that the multiple contact plates 51 contact the multiple conductive contacts 23 respectively, so as to energize the electrical components in the housing 1. The multiple contact plates 51 also block and limit the conical section 22, effectively preventing the conical section 22 from falling out of the docking slot. In this way, when the housing 1 is installed, the connector 2 and the docking head 43 can be used to achieve quick positioning of the housing 1, matching connection of the cooling structure and electrical matching connection, which effectively improves the efficiency and convenience of installing the charging module into the cabinet, and is conducive to improving the stability of the internal heat dissipation operation of the charging module.

[0023] When the housing 1 is installed into the cabinet, the assembly gap between the two allows the housing 1 to move, which may cause inaccurate alignment when the housing 1 is moved into the installation position. To improve the accuracy of the mating between the connector 2 and the mating groove, in this embodiment, the front end of the connector 43 is formed with a spherical part, and a connecting groove 411 is provided on the rear side of the connecting shell 41. The spherical part is fitted into the connecting groove 411, and the mating channel 431 extends through the spherical part. Through the cooperation between the spherical part and the connecting groove 411, the orientation of the connector 43 can be adjusted. When installing the housing 1, the tapered section 22 can be accurately inserted into the connecting groove 411, and the connector 2 is guided to fit into the mating groove. This effectively improves the convenience and accuracy of alignment when installing and connecting the housing 1.

[0024] Furthermore, the connecting shell 41 is provided with a transition groove 412 between the cooling cavity 42 and the docking groove. A connecting hose 44 is disposed within the transition groove 412. The front end of the connecting hose 44 is connected to the cooling cavity 42, and the rear end of the connecting hose 44 is connected to the docking channel 431. When the spherical part rotates within the connecting groove 411, the connecting hose 44 provides a flexible connection structure between the cooling cavity 42 and the docking groove, ensuring that the docking channel and the cooling cavity 42 remain interconnected, thereby improving the overall stability of installation and use.

[0025] To improve the tightness of the fit between the connector 2 and the mating groove, in this embodiment, an elastic sealing sleeve 45 is provided inside the mating groove. The shape of the elastic sealing sleeve 45 is adapted to the shape of the mating groove, and the tapered segment 22 abuts against the inner side of the elastic sealing sleeve 45. The elastic sealing sleeve 45 can fill the assembly gap between the tapered segment 22 and the mating groove, improving the ease of installation of the tapered segment 22 in the mating groove. Furthermore, since the elastic sealing sleeve 45 itself can generate a certain amount of elastic deformation, when the connector 2 is installed into the mating groove, the elastic sealing sleeve 45 can be elastically compressed and deformed, thereby making the conductive contact 23 fit more tightly with the connector head and maintaining the stability of the electrical connection during use.

[0026] When coolant is introduced as the heat exchange medium, it is necessary to ensure the sealing between connector 2 and the mating groove. Therefore, in this embodiment, a drain groove is provided on the inner rear side of the elastic sealing sleeve 45, extending around the elastic sealing sleeve 45. A collection pipe 46 is provided on the bottom side of the mating joint 43 corresponding to the position of the drain groove, and a drain hole connected to the collection pipe 46 is provided on the bottom side of the drain groove. The drain groove provides a space for collecting leakage from the elastic sealing sleeve 45 between connector 2 and the mating groove. After long-term use, the elastic sealing sleeve 45 fails, and seepage occurs between the connecting channel 24 and the heat dissipation channel 31, spreading outward to the drain groove. At this time, the coolant can flow down along the drain groove to the drain hole and then flow down from the drain hole to the collection pipe 46. The coolant is further recovered through the collection pipe 46, which can effectively prevent electrical short circuits caused by coolant leakage and greatly improve overall safety.

[0027] The elastic sealing sleeve 45 at the drain groove position can be a partially disconnected structure or only partially connected. To enhance the sealing effect at this position, in this embodiment, a sealing strip 451 is provided inside the drain groove. The sealing strip 451 extends from one side of the drain hole to the other side of the drain hole, and the sealing strip 451 is a hollow structure. The hollow sealing strip 451 has strong elastic deformation capability, which can both enhance the sealing performance between the sealing strip 451 and the conical section 22 at the drain groove position, preventing further outward leakage of coolant, and provide a gap for coolant flow between the sealing strip 451 and the two sides of the drain groove, ensuring that the coolant can flow downward to the drain hole at this position, and then enter the collection pipe 46 for recycling.

[0028] The connector has a structure that can drive the contact plate 51 to reciprocate. Specifically, the connector includes an electromagnetic lock 52 connected to the rear side of the connector 43. The electromagnetic lock 52 has a retractable latch 521. The contact plate 51 is connected to the latch 521. When the electromagnetic lock 52 is de-energized, the latch 521 extends close to the conductive contact 23. When the electromagnetic lock 52 is energized, the latch 521 retracts away from the conductive contact 23. The connector contains a drive source that can drive the contact piece 51 to reciprocate. Specifically, an electromagnetic lock 52 is provided on the rear side of the connector 43. The electromagnetic lock 52 has a retractable locking tongue 521. When energized, the locking tongue 521 of the electromagnetic lock 52 retracts away from the groove of the docking slot. At this time, the locking tongue 521 drives the contact piece 51 away from the conductive contact 23. Since the locking tongue 521 no longer blocks the docking slot, the connector 2 can enter the docking slot. When the connector is de-energized, the locking tongue 521 of the electromagnetic lock 52 extends to the groove of the docking slot. At this time, the locking tongue 521 drives the contact piece 51 to approach and abut against the conductive contact 23, and uses the locking tongue 521 to block the docking slot, so that the connector 2 cannot come out of the docking slot. In this way, the conductive contact 23 can be energized and de-energized, and the connector 2 can be blocked and limited.

[0029] In some embodiments, a buffer sleeve 25 is provided on the outer side of the connecting segment 21, and the locking tongue 521 can extend to abut against the buffer sleeve 25. When the locking tongue 521 drives the contact piece 51 to contact the conductive contact 23, the locking tongue 521 abuts against the buffer sleeve 25, and the buffer sleeve 25 provides elastic cushioning for the locking tongue 521, reducing the noise generated when the locking tongue 521 moves to its position.

[0030] In some embodiments, a first control valve is provided in the connection channel 24, and a second control valve is provided in the docking channel 431. When coolant is used to dissipate heat and cool the electrical components inside the housing 1, before the charging module is installed in the rack, the first and second control valves are closed, thereby sealing the interior of the connection channel 24 and the docking channel 431. After the charging module is installed in the rack, the first and second control valves are opened, and the interior of the connection channel 24 and the docking channel 431 are interconnected, allowing the coolant to circulate within the charging module and the cooling chamber 42.

[0031] The heat dissipation assembly has a structure that allows the heat exchange medium to flow, thereby removing heat from inside the housing 1. Specifically, the heat dissipation assembly includes multiple heat dissipation plates 32 disposed within the housing 1, and each of the multiple heat dissipation plates 32 has a heat dissipation channel 31 disposed therewith. The heat dissipation plates 32 increase the heat absorption area inside the housing 1, which can better absorb the heat generated by the electrical components. In this way, heat exchange occurs between the heat exchange medium inside the multiple heat dissipation plates 32 and the cooling cavity 42, thereby improving the heat dissipation efficiency inside the housing 1.

[0032] The preferred embodiments of the present invention have been described in detail above, but the present invention is not limited to the embodiments described. Those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit of the present invention, and these equivalent modifications or substitutions are all included within the scope defined by the claims of this application.

Claims

1. A charging module, characterized in that: include: Casing (1); The connector (2) includes a connecting section (21) and a tapered section (22) connected to the front end of the connecting section (21). The rear end of the connecting section (21) is connected to the front side of the housing (1). The tapered section (22) has a tapered surface that gradually narrows forward on its outer side. A plurality of conductive contacts (23) are arranged around the rear side of the tapered section (22). A connecting channel (24) is provided inside the connecting section (21) and the connecting channel (24) extends to the tapered section (22). A heat dissipation component is disposed inside the housing (1), and a heat dissipation channel (31) is provided inside the heat dissipation component, and the heat dissipation channel (31) is connected to the connection channel (24). An electrical component is disposed within the housing (1) and electrically connected to a plurality of conductive contacts (23); a connecting shell (41) is provided with a cooling chamber (42) inside, a connector (43) is provided on the rear side of the connecting shell (41), a mating groove is provided on the rear side of the connector (43), and a mating channel (431) communicating with the cooling chamber (42) is provided at the bottom of the mating groove, the conical section (22) is inserted into the mating groove, and the mating channel (431) is connected to the heat dissipation channel. (31) In the interconnected state, the rear side of the connector (43) is provided with a contactor corresponding to the position of the multiple conductive contacts (23). The multiple contactors each have a reciprocating contact piece (51). The multiple contact pieces (51) can extend to abut against the conductive contacts (23) or leave the multiple conductive contacts (23). When the multiple contact pieces (51) extend to abut against the conductive contacts (23), the multiple contact pieces (51) block and limit the conical section (22). The front end of the connector (43) is formed with a spherical part, and the rear side of the connecting shell (41) is provided with a connecting groove (411). The spherical part is fitted into the connecting groove (411), and the docking channel (431) extends through the spherical part.

2. A charging module according to claim 1, characterized in that: The connecting shell (41) is provided with a transition groove (412) between the cooling chamber (42) and the docking groove. A connecting hose (44) is provided in the transition groove (412). The front end of the connecting hose (44) is connected to the cooling chamber (42), and the rear end of the connecting hose (44) is connected to the docking channel (431).

3. A charging module according to claim 1, characterized in that: An elastic sealing sleeve (45) is provided in the docking groove. The shape of the elastic sealing sleeve (45) is adapted to the shape of the docking groove. The tapered section (22) abuts against the inner side of the elastic sealing sleeve (45).

4. A charging module according to claim 3, characterized in that: The elastic sealing sleeve (45) is provided with a drain groove on the inner rear side. The drain groove extends around the elastic sealing sleeve (45). The bottom side of the connector (43) is provided with a collection pipe (46) corresponding to the position of the drain groove. The bottom side of the drain groove is provided with a drain hole connected to the collection pipe (46).

5. A charging module according to claim 4, characterized in that: A sealing strip (451) is provided inside the drain trough. The sealing strip (451) extends from one side of the drain hole to the other side of the drain hole. The sealing strip (451) has a hollow structure.

6. A charging module according to claim 1, characterized in that: The contactor includes an electromagnetic lock (52) connected to the rear side of the connector (43). The electromagnetic lock (52) has a retractable latch (521). The contact piece (51) is connected to the latch (521). When the electromagnetic lock (52) is de-energized, the latch (521) extends close to the conductive contact (23). When the electromagnetic lock (52) is energized, the latch (521) retracts away from the conductive contact (23).

7. A charging module according to claim 6, characterized in that: The connecting section (21) is fitted with a buffer sleeve (25) on the outside, and the locking tongue (521) can extend to abut against the buffer sleeve (25).

8. A charging module according to claim 1, characterized in that: A first control valve is provided in the connection channel (24), and a second control valve is provided in the docking channel (431).

9. A charging module according to claim 1, characterized in that: The heat dissipation assembly includes a plurality of heat dissipation plates (32) disposed within the housing (1), and the heat dissipation channels (31) are respectively disposed within the plurality of heat dissipation plates (32).

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