A charging circuit integrated with a puller and a manufacturing method thereof

Abstract

This invention relates to a dual-circuit integrated car charger with a pull-cord design and its manufacturing method. The car charger includes a housing, a mainboard, a winding reel, a positive terminal, and a negative terminal. The winding reel includes a turntable with a front and a back. The front is in close contact with a first circuit board. The turntable is equipped with a spiral spring and carries a charging cable. One side of the first circuit board has multiple concentric elastic guide rings, and the other side has multiple solder feet or terminals electrically connected to the multiple concentric elastic guide rings. At least one side of the mainboard has multiple concentric conductive rings, each of which is in one-to-one contact with a concentric elastic guide ring and maintains elastic contact during rotation. The winding reel, the first circuit board, and the concentric elastic and conductive rings are integrated into the main body of the car charger, resulting in a compact overall structure that saves space, reduces product thickness and weight, makes it smaller and easier to carry, and is easy to manufacture, low in cost, and can be mass-produced quickly, improving production efficiency.

Description

Technical Field

[0001] This invention relates to the field of charger technology, specifically to a dual-circuit integrated vehicle charger with a pull-cord and its manufacturing method. Background Technology

[0002] With the rapid development of technology, cars have become a primary mode of transportation, especially for long-distance travel. Chargers are an essential accessory for such journeys, and car chargers offer greater convenience. Existing car chargers are available with or without pull cables; to facilitate use by both front and rear passengers, car chargers with pull cables are increasingly favored by users.

[0003] Since cable pulling or winding mechanisms are already mature products, existing cable pulling car chargers typically integrate the conventional cable pulling module directly into the car charger, and then connect the car charger motherboard and the cable pulling module through a flexible wire board. This results in a larger overall thickness, especially when dual cable pulling modules are required, making the whole device appear even more bulky. Summary of the Invention

[0004] In view of this, a dual-circuit integrated vehicle charger with a pull-wire design, small size, easy manufacturing, and low cost is provided, as well as its manufacturing method.

[0005] A dual-circuit integrated car charger with a pull-cord design includes a housing, a mainboard, a winding reel, a positive terminal, and a negative terminal. The winding reel is wound with a stretchable charging cable. The winding reel includes a turntable with a front and a back. The front is in close contact with a first circuit board, and the back has a loop for winding the charging cable. A spiral spring is provided inside the loop, with its inner end connected to a shaft and its outer end connected to the winding reel. The shaft is mounted on the housing or the mainboard. The front surface of the first circuit board has multiple concentric elastic guide rings, and the rear surface of the first circuit board relative to the front surface has... The device has multiple solder feet or terminals; the multiple solder feet or terminals are respectively electrically connected to multiple concentric elastic conductive rings through multiple internal lines of the first circuit board; the inner end of the charging cable is directly or indirectly electrically connected to the solder feet or terminals; at least one side of the car charger main board is formed with multiple concentric conductive rings, and the multiple concentric conductive rings are electrically connected to the charging circuit on the car charger main board through internal and external circuits of the car charger main board; the multiple concentric conductive rings are in one-to-one elastic contact with the multiple concentric elastic conductive rings, and each concentric conductive ring maintains electrical contact with the corresponding concentric elastic conductive ring when the winding disc rotates.

[0006] Furthermore, the first circuit board is provided with multiple punched holes or blind holes, and the multiple concentric elastic guide rings are formed on the first circuit board by punching away the connecting parts between the rings of the multi-way integrated guide ring front body; each punched hole or blind hole position corresponds to a connecting part.

[0007] Furthermore, the first circuit board is also provided with multiple solder pads or positioning plates. Each of the concentric elastic guide rings is attached to the front surface of the first circuit board through a corresponding solder pad or positioning plate. One end of the internal circuit of the first circuit board is connected to each guide ring through the solder pad or positioning plate, and the other end is connected to the solder foot or terminal.

[0008] Furthermore, the housing has a central support ring on the inner wall facing the ring portion. The main body of the spiral spring is filled in the inner cavity of the ring portion. The central support ring abuts against or closely approaches the side of the spiral spring facing the housing to prevent the spiral spring from shifting or dislodging during cable pulling. The outer diameter of the central support ring is smaller than the inner diameter of the ring portion. The housing also has at least one outer support ring on the inner wall facing the ring portion. Each outer support ring is concentrically arranged with the central support ring. Each outer support ring abuts against or closely approaches the multiple coils of conductive wire wound around the ring portion to prevent the conductive wire from shifting or dislodging during cable pulling. Multiple ribs extend radially from the outer wall of the central support ring and connect in series with each outer support ring. The housing also has an outer wall on the inner wall facing the ring portion to house the entire charging cable winding structure and turntable. The car charger mainboard is fixedly mounted on the housing.

[0009] Furthermore, the turntable has windows at the locations of the plurality of solder feet or terminals to expose the plurality of solder feet or terminals on the first circuit board to the back of the turntable, facilitating connection to a charging cable by wiring or soldering.

[0010] Furthermore, the winding reel can be single or two, the housing has mounting holes, the first end of the shaft is mounted in the mounting holes of the housing, and the second end of the shaft extends out through the turntable and the first circuit board and is close to, abuts against, or inserts into the car charger mainboard; when there are two winding reels, there are simultaneously two spiral springs, two charging cables, two first circuit boards, two sets of multi-channel concentric conductive rings, and two sets of multi-channel concentric elastic guide rings, all symmetrically arranged on both sides of the car charger mainboard with the car charger mainboard as the center, and the two sets of multi-channel concentric elastic guide rings are respectively formed on two surfaces of the car charger mainboard.

[0011] Furthermore, the car charger mainboard has a stop assembly around the concentric conductive rings of the multiple circuits. The front of the turntable has a guide groove around the periphery of the first circuit board. The stop assembly includes a T-shaped slider and a T-shaped groove. The T-shaped groove is configured to hold the T-shaped end of the T-shaped slider, allowing the straight end of the T-shaped slider to protrude and slide along the groove. The sliding direction of the T-shaped slider is radial to the turntable. The guide groove includes a first ring guide groove and a second ring guide groove that are essentially concentric, with the concentricity being the center of the turntable. The first ring guide groove and the second ring guide groove have a confluence point, which is equipped with a check valve. The check valve is configured to stop the T-shaped slider when it retracts along the first or second ring guide groove. The entire check valve is triangular at one end and fishtail-shaped at the other.

[0012] Furthermore, the two sides of the car charger mainboard have elongated grooves formed around the concentric conductive rings. The two turntables, facing the mainboard, each have guide grooves on the periphery of their respective first circuit boards. The length of the elongated groove extends radially along the concentric conductive rings. Each elongated groove is fitted with a double-groove component, which includes an upper double-groove rail and a lower double-groove rail, and is equipped with a slider. The slider has two parallel protruding rings in the middle, and its two ends protrude from both sides of the car charger mainboard and can move within the corresponding guide grooves. The upper and lower double-groove rails are... The slide is symmetrically arranged so that the two protruding rings of the slide member respectively engage with the upper double-groove rail and the lower double-groove rail, thereby allowing the slide member to slide smoothly without dislodging. The guide groove includes a first ring guide groove and a second ring guide groove that are basically concentric, with the concentricity being the center of the turntable. The first ring guide groove and the second ring guide groove have a confluence point, and the confluence point is provided with a check part. The check part is constructed such that when the T-shaped slide member retracts along the first ring guide groove or the second ring guide groove, it is blocked by the check part and stops. The entire check part is triangular at one end and fishtail-shaped at the other end.

[0013] Furthermore, the car charger mainboard includes a main body and a neck. Multiple concentric conductive rings are attached to the main body. Each concentric conductive ring and each concentric elastic conductive ring is sheet-shaped with a thickness of 0.1mm-0.5mm. The multiple concentric conductive rings and multiple concentric elastic conductive rings are pre-stamped and then attached to the car charger mainboard. The multiple concentric elastic conductive rings and the multiple concentric conductive rings are coplanar. The main body has multiple through holes around its perimeter. The housing includes a front housing and a rear housing. The front housing and / or the rear housing has screw holes. Fasteners are inserted through the through holes and screw holes to install the car charger mainboard. The main body has multiple electronic components and a charging interface. The positive and negative terminals are respectively located in the neck.

[0014] Furthermore, a method for manufacturing the dual-circuit integrated car charger with cable as described above is provided, characterized by comprising the following steps: S10, injection molding a turntable and a ring portion, the ring portion being integrally formed on the back of the turntable, and forming a shaft hole on the turntable, thereby forming a winding reel; S20, a car charger mainboard is manufactured, in which internal circuits, external circuits, and a charging circuit are formed inside and on the surface of the car charger mainboard, and multiple electronic components, positive terminals, negative terminals, and a charging interface are set, so that the internal circuits and external circuits are connected and finally connected to the charging circuit; multiple concentric conductive rings with a predetermined thickness are formed on at least one side of the car charger mainboard, and the multiple concentric conductive rings are electrically connected to the charging circuit on the car charger mainboard through the internal and external circuits of the car charger mainboard. S30, fabricate a first circuit board, forming pads or positioning pads on multiple circumferences of the front surface of the first circuit board, forming multiple internal circuits inside the first circuit board and electrically connecting the multiple internal circuits to the multiple pads or positioning pads respectively, forming punch holes or blind holes between pads or positioning pads of adjacent circumferences; and forming multiple solder feet or multiple terminals on the rear surface of the first circuit board, with each pad or terminal corresponding to one of the internal circuits. S40, a metal sheet of predetermined thickness is stamped into a multi-ring shape, with at least one spring piece stamped or at least one elastic contact welded onto each ring. During stamping, a connecting portion is retained between adjacent rings, so that the rings are connected as a whole through at least one connecting portion. Then, the multi-ring sheet is attached to the front surface of the first circuit board, with each ring attached to a corresponding pad or positioning pad and the connecting portion corresponding to the position of the punched hole or blind hole. The connecting portion between the rings is then stamped off to form a first circuit board with multiple concentric elastic guide rings. The center of the first circuit board and the multiple concentric elastic guide rings has a pre-formed shaft hole. The mounting method includes welding or bonding. S50, a shaft is mounted on the housing or the mainboard of the car charger; the turntable and the first circuit board with multiple concentric elastic guide rings are fitted onto the shaft and the multiple concentric conductive rings are respectively in one-to-one elastic contact with the multiple concentric elastic guide rings; a spiral spring is installed in the ring and one end of the spiral spring is connected to the shaft and the other end is connected to the winding disc; the charging cable is connected to multiple solder feet or multiple terminals; S60, at least one support ring is formed on the inner wall of the housing to assemble and fix the housing and the car charger main board, and each support ring is correspondingly close to or abuts against the spiral spring and the charging cable. The panel covering the top of the housing is installed so that the charging cable and the interface on the car charger main board are exposed outside the panel; thus forming the pull-wire car charger dual-circuit integrated car charger.

[0015] The aforementioned dual-circuit integrated car charger with cable has at least the following beneficial effects: 1. This application directly integrates the winding disc, the first circuit board, and the concentric elastic guide ring into the main body of the car charger, avoiding the bulky overall structure caused by the conventional modular structure. It makes full use of the internal space of the car charger, and integrates the main circuit of the car charger (such as electronic circuits including charging circuits and electronic components) with the conductive ring, and then elastically integrates it with the first circuit board with the concentric elastic guide ring. The overall structure is compact and saves space. 2. The car charger product of this application directly eliminates the front and rear covers in the traditional cable pull module, and directly uses the inner wall of the shell to support the charging cable and the spiral spring, further compressing the space; specifically, the overall thickness of the car charger of this application is reduced by more than 1 / 3. According to actual measurement, the overall thickness of the car charger of this application is reduced by 1cm-2.5cm. As a result, the overall car charger is lighter and smaller, which greatly facilitates users to carry it. 3. The front and rear surfaces of the first circuit board have conductive rings or circuits respectively. Multiple solder feet or terminals on the rear surface are directly connected to the charging cable, eliminating the need for flexible circuit board adapters and omitting intermediate adapters. This saves space and costs, reduces manufacturing processes, and improves the reliability of electrical contact and signal transmission. 4. Both the multi-channel concentric conductive rings and the multi-channel concentric elastic conductive rings mentioned above can be stamped and then mounted on the corresponding circuit board or car charger motherboard. This manufacturing process is mature, convenient, and low-cost, and can be mass-produced quickly. Moreover, the simultaneous molding of multiple rings and the fact that each ring has a certain thickness, compared to traditional printed coils, increases the thickness by at least one order of magnitude, thus making them more wear-resistant, improving product lifespan, increasing contact reliability, and enhancing product quality and user experience. Attached Figure Description

[0016] Figure 1 This is a three-dimensional exploded view of a pull-cord car charger with dual circuits integrated into a car charger according to Embodiment 1 of the present invention.

[0017] Figure 2 yes Figure 1 A three-dimensional exploded view of the integrated dual-circuit car charger with cable, taken from another perspective.

[0018] Figure 3 This is a three-dimensional exploded view of the integrated dual-circuit car charger with cable provided in Embodiment 2 of the present invention.

[0019] Figure 4 yes Figure 3 A three-dimensional exploded view of the integrated dual-circuit car charger with cable, taken from another perspective.

[0020] Figure 5 yes Figure 1 A magnified schematic diagram of part A in the middle.

[0021] Figure 6 yes Figure 3 A magnified schematic diagram of part B in the middle section.

[0022] In the picture, 100, 200, Dual-circuit integrated car charger with cable; 10, Car charger mainboard; 101, Front shell; 102, Rear shell; 105, Mounting post; 12, Main body; 13, Neck; 107, Panel; 108, Screw post; 17, Long slot; 115, Rib; 121, Central support ring; 122, Outer support ring; 128, Outer wall; 15, Concentric elastic guide ring; 152, Spring; 16, Concentric conductive ring; 18, Charging interface; 19, Electronic components; 20, Winding reel; 21, Turntable; 22, Cable guide groove; 221, No. 222. First ring guide groove; 224. Check valve; 225. Check valve edge; 226. Confluence; 227. Upper stop tip; 228. Lower stop tip; 23. Ring; 24. Spiral spring; 27. Solder foot or terminal; 28. Window; 31. First circuit board; 33. Solder foot; 34. Solder pad; 35. Punch; 41. Positive electrode; 42. Negative electrode; 45. Double groove component; 46. Upper double groove rail; 47. Lower double groove rail; 50. Stop assembly; 52. T-shaped slider; 53. T-slot; 56. Slider; 561. Convex ring; 58, 58a. Shaft; 61. Charging cable. Detailed Implementation

[0023] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0024] Please see Figures 1 to 2 This illustration shows an embodiment of the present invention: a dual-circuit integrated car charger 100, comprising a housing, a mainboard 10, a winding reel 20, a positive electrode 41, and a negative electrode 42. The winding reel 20 winds a stretchable charging cable 61. The winding reel 20 includes a turntable 21, which has a front and a back. The front is in close contact with a first circuit board 31, and the back has a loop 23 for winding the charging cable 61. A spiral spring 24 is provided inside the loop 23, and the inner end of the spiral spring 24 is connected to... A shaft 58 is connected at its outer end to the winding reel 21; the shaft 58 is mounted on the housing or the car charger mainboard 10; the front surface of the first circuit board 31 forms multiple concentric elastic guide rings 15, and the rear surface of the first circuit board 31 relative to the front surface has multiple solder feet or multiple terminals; the multiple solder feet or terminals are respectively electrically connected to the multiple concentric elastic guide rings 15 through multiple internal lines of the first circuit board 31; the inner end of the charging cable 61 is directly or indirectly electrically connected to the solder feet or terminals; the example shown in the figure shows multiple solder feet 33. At least one side of the car charger mainboard 10 forms multiple concentric conductive rings 16, and the multiple concentric conductive rings 16 are electrically connected to the charging circuit on the car charger mainboard 10 through the internal lines of the car charger mainboard 10. The multiple concentric conductive rings 16 are in one-to-one elastic contact with the multiple concentric elastic guide rings 15, and when the winding reel 20 rotates, each concentric conductive ring 16 maintains electrical contact with the corresponding concentric elastic guide ring 15.

[0025] Specifically, the first circuit board 31 is provided with a plurality of punched holes 35 or blind holes, as illustrated in the figure, which shows a punched hole 35 penetrating through the first circuit board 31. The multiple concentric elastic guide rings 15 are formed on the first circuit board 31 by punching away the connecting portions between the rings of the multi-linked guide ring front body. Preferably, each punched hole 35 or blind hole corresponds to a connecting portion.

[0026] In some preferred embodiments, the first circuit board 31 is further provided with multiple pads or positioning pads. Each of the concentric elastic guide rings 15 is mounted to the front surface of the first circuit board 31 via a corresponding pad or positioning pad. One end of the internal circuitry of the first circuit board 31 is connected to each guide ring via the pad or positioning pad, and the other end is connected to a solder pad 33 or terminal 27. Each ring can be bonded to the front surface of the first circuit board 31 via at least one pad, i.e., via two or more arc-shaped pads 34. Figure 3 Example: Pad 34, preferably arc-shaped or multiple block-shaped, that is, partially overlapping with the guide ring. Setting multiple pads 34 can fix each ring to the first circuit board 31, and at the same time, it can conduct electricity. When a positioning plate is used, the positioning plate is preferably conductive adhesive, which is also arc-shaped or block-shaped.

[0027] Specifically, the housing has a central support ring 121 on the inner wall surface facing the ring portion 23. The main body of the spiral spring 24 is filled in the inner cavity of the ring portion 23. The central support ring 121 abuts against or closely approaches the side of the spiral spring 24 facing the housing to prevent the spiral spring 24 from shifting or dislodging during the pulling motion. The outer diameter of the central support ring 121 is smaller than the inner diameter of the ring portion 23, that is, the position of the central support ring 121 corresponds to the inner side of the ring portion 23. Preferably, the housing also has at least one outer support ring 122 on the inner wall surface facing the ring portion 23. The at least one outer support ring 122 is concentrically arranged with the central support ring 121. Each outer support ring 122 is used to abut against or closely approach the multiple turns of conductive wire wound around the ring portion 23 to prevent the conductive wire from shifting or dislodging during the pulling motion. Multiple ribs 115 extend radially from the outer wall of the central support ring 121 and connect in series with each of the outer support rings 122; the housing also has an outer wall 128 on the inner wall facing the ring portion 23 to accommodate the entire charging cable 61 winding structure and the turntable 21. When using a single outer support ring 122, a circular washer is preferably used between the outer support ring 122 and the spiral spring 24 or the charging cable winding structure. The circular washer has a hole to fit onto the shaft 58 to better support the spiral spring 24 and the charging cable winding structure.

[0028] In some specific embodiments, the turntable 21 has windows 28 at the locations of the plurality of solder feet or terminals 27 to expose the plurality of solder feet or terminals 27 on the first circuit board 31 to the back of the turntable 21, facilitating connection to the charging cable 61 by wiring or soldering. Typical charging cables or charging interfaces have five leads or pins; therefore, the example shown in the figure has five paths. The multiple concentric conductive rings 16 and the multiple concentric elastic conductive rings 15 are all five independent rings, and the plurality of solder feet or terminals 27 are also five in number.

[0029] Preferably, the winding reel 20 is a single unit, the housing has a mounting post 105, the first end of the shaft 58 is mounted in the mounting post 105 of the housing, and the second end extends through the turntable 21 and the first circuit board 31 and is close to, abuts against, or inserted into the car charger mainboard 10. The example shown is insertion into the car charger mainboard 10. The shaft 58 has a mounting groove for mounting the inner end of the spiral spring 24. Specifically, the first end of the shaft 58 has an anti-rotation structure. For example, the first end of the shaft 58 has a diameter larger than the main body of the shaft 58, the end is cylindrical and has two symmetrical straight surfaces, and the wall of the mounting post 105 also has a straight wall surface to prevent rotation and ensure secure fixation.

[0030] Preferably, such as Figure 1 , Figure 2 and Figure 5 As shown, the car charger mainboard 10 has a stop assembly 50 around the concentric conductive rings 16. The front of the turntable 21 has a guide groove 22 around the periphery of the first circuit board 31. The stop assembly 50 includes a T-shaped slider 52 and a T-shaped groove 53. The T-shaped groove 53 is configured to lock the T-shaped end of the T-shaped slider 52, allowing the straight end of the T-shaped slider 52 to protrude and slide along the T-shaped groove 53. The sliding direction of the T-shaped slider 52 is radial to the turntable 21. The guide groove 22 includes a first annular guide groove 221 and a second annular guide groove 222 that are basically concentrically arranged, with the concentricity being the center of the turntable 21. The first annular guide groove 221 and the second annular guide groove 222 have a confluence 226. The confluence 226 is provided with a stop part 224. The stop part 224 is configured such that when the T-shaped slider 52 retracts along the first annular guide groove 221 or the second annular guide groove 222, it is blocked and paused by the stop part 224. The entire stop part 224 is triangular at one end and fishtail-shaped at the other end.

[0031] Specifically, the upper edge of the stop portion 224 is the lower edge of the first annular guide groove 221, and the lower edge of the stop portion 224 is the upper edge of the first annular guide groove 221. The upper and lower edges of the stop portion 224 form an acute angle at one end of the confluence 226. The first annular guide groove 221 and the second annular guide groove 222 are connected at the other end of the stop portion 224. The stop portion has a stop edge 225 at the connection point, and the stop edge 225 is concave. The stop edge 225 has an upper stop tip 227 and a lower stop tip 228. The upper stop tip 227 faces the middle of the left portion of the first annular guide groove 221, and the lower stop tip 228 faces the middle of the left portion of the second annular guide groove 222. When the T-shaped slider 52 retracts along the first annular guide groove 221 or the second annular guide groove 222, it is stopped by the upper stop tip 227 or the lower stop tip 228.

[0032] Preferably, the car charger mainboard 10 includes a main body 12 and a neck 13. Multiple concentric conductive rings 16 are attached to the main body. Each concentric conductive ring 16 and each concentric elastic conductive ring 15 is sheet-shaped with a thickness of 0.1mm-0.5mm. Both the multiple concentric conductive rings 16 and the multiple concentric elastic conductive rings 15 are pre-stamped and then attached to the car charger mainboard 10. The multiple concentric elastic conductive rings 15 are coplanar, and the multiple concentric conductive rings 16 are coplanar. The car charger motherboard 10 is fixedly mounted on the housing. Specifically, the main body 12 of the car charger motherboard has multiple through holes around its perimeter. The housing includes a front shell 101 and a rear shell 102. The front shell 101 and / or the rear shell 102 are provided with screw holes 108. The car charger motherboard 10 is mounted by fasteners passing through the through holes and screw holes 108. The main body 12 is provided with multiple electronic components 19 and a charging interface 18. The positive electrode 41 and the negative electrode 42 are respectively located on the neck 13.

[0033] In another specific embodiment, for example Figure 3 and Figure 4 The dual-circuit integrated car charger 200 of Embodiment 2 shown has basically the same structure and function as the dual-circuit integrated car charger 100 of Embodiment 1. The main difference is that it adopts two sets of winding structures and two sets of multi-loop structures and other related assembly structures. Figure 3 , Figure 4 and Figure 1 , Figure 2 The same components are labeled with the same component designation, and will not be described again here. Specifically, as shown in the figure, there are two winding coils 20, two spiral springs 24, two charging cables 61, two first circuit boards 31, two sets of multi-channel concentric conductive rings 16, and two sets of multi-channel concentric elastic guide rings 15, all of which are symmetrically arranged on both sides of the car charger main board 10 with the main board 10 as the center. The two sets of multi-channel concentric elastic guide rings 15 are respectively formed on two surfaces of the car charger main board 10.

[0034] In this second embodiment, since two sets of the above-mentioned structures are used, the shaft 58a in this second embodiment is slightly different from the shaft 58 in the first embodiment. The main structure and function are basically the same. The difference is that the shaft 58a in this second embodiment passes through the mainboard 10 of the car charger and is installed into the mounting holes 105 of the housing at both ends. Specifically, the inner walls of the front housing 101 and the rear housing 102 are respectively provided with mounting holes 105 to install the two ends of the shaft 58a.

[0035] The stop assembly in this second embodiment is basically similar in structure and function to the stop assembly in the first embodiment, except that the stop assembly in this second embodiment uses a double-groove component 45 and a slider 56. Specifically, both sides of the car charger mainboard 10 also have long grooves 17 around the concentric conductive rings 16, and the two turntables 21 facing the front of the car charger mainboard 10 also have guide grooves 22 around the corresponding first circuit board 31. The length of the long groove 17 extends radially to the concentric conductive rings 16, and the double-groove component 45 is mounted in the long groove 17. Figure 6 As shown, the dual-groove component 45 includes an upper dual-groove rail 46 and a lower dual-groove rail 47, and is equipped with a slider 56. The slider 56 has two parallel protruding rings 561 in the middle. The two ends of the slider 56 protrude from the two sides of the car charger mainboard 10 and can move in the corresponding guide grooves 22. The upper dual-groove rail 46 and the lower dual-groove rail 47 are symmetrically arranged so that the two protruding rings 561 of the slider 56 respectively engage with the upper dual-groove rail 46 and the lower dual-groove rail 47, thereby allowing the slider 56 to slide smoothly without disengaging. The guide grooves 22 in the two embodiments are basically the same and will not be described in detail here. The upper dual-groove rail 46 and the lower dual-groove rail 47 each have two sliding grooves, and each sliding groove holds one slider. The upper dual-groove rail 46 and the lower dual-groove rail 47 are connected together at least at the same end to prevent the slider 56 from disengaging or to limit the stroke of the slider 56. Of course, the two side walls of the long groove 17 can also limit the two endpoints of the stroke of the slider 56. The slider 56 rolls in the upper double groove rail 46 and the lower double groove rail 4 by means of two convex rings 561. At the same time, the two convex rings 561 hold the slider 56 in place, realizing bidirectional sliding and anti-return operation.

[0036] Another aspect of the present invention provides a method for manufacturing a dual-circuit integrated vehicle charger with a pull-cord design, which includes the following steps.

[0037] S10, a turntable 21 and a ring portion 23 are injection molded, the ring portion 23 being integrally molded on the back of the turntable 21, and a shaft hole 59 is formed on the turntable 21, thereby forming a winding spool 20. The winding spool 20 is preferably made of plastic, which allows the turntable 21 and the ring portion 23 to be integrally injection molded, and related structures such as the guide groove 22 can also be integrally injection molded.

[0038] S20, a car charger mainboard 10 is fabricated. Internal circuitry, external circuitry, and a charging circuit are formed inside and on the surface of the mainboard 10, respectively. Multiple electronic components 19, a positive electrode 41, a negative electrode 42, and a charging interface 18 are also provided. The internal and external circuitry are connected and ultimately connected to the charging circuitry. Multiple concentric conductive rings 16 are formed on at least one side of the mainboard 10. These multiple concentric conductive rings 16 are electrically connected to the charging circuitry on the mainboard 10 through the internal and external circuitry. S30, a first circuit board 31 is fabricated, with pads or positioning pads formed on multiple circumferences of the front surface of the first circuit board 31. Multiple internal circuits are formed inside the first circuit board 31, and each of the internal circuits is electrically connected to a corresponding pad or positioning pad. Punches 35 or blind holes are formed between adjacent pads or positioning pads; in this embodiment, punches 35 are used. Multiple solder pads or terminals 27 are formed on the rear surface of the first circuit board 31, with each pad or terminal 27 corresponding to one of the internal circuits.

[0039] S40, a metal sheet of predetermined thickness is stamped into multiple rings. At least one spring piece 152 is stamped on each ring, or at least one elastic contact is welded onto it. During stamping, a connecting portion is retained between adjacent rings, allowing the rings to be connected as a single unit through at least one connecting portion. Then, the integrated multi-ring sheet is mounted onto the front surface of the first circuit board 31, with each ring mounted on a corresponding pad or positioning pad, and the connecting portion corresponding to the position of the punched hole 35 or blind hole. The connecting portions between the rings are then stamped away to form a first circuit board 31 with multiple concentric elastic guide rings 15. A shaft hole 59 is pre-formed at the center of the first circuit board 31 and the multiple concentric elastic guide rings 15. The mounting method includes welding or bonding. The thickness of the metal sheet is 0.1mm - 0.5mm.

[0040] S50, a shaft 58 is mounted on the housing or the mainboard 10 of the car charger; the turntable 21 and the first circuit board 31 with multiple concentric elastic guide rings 15 are fitted onto the shaft 58, and the multiple concentric conductive rings 16 are respectively in one-to-one elastic contact with the multiple concentric elastic guide rings 15; a spiral spring 24 is installed in the ring portion 23, and one end of the spiral spring 24 is connected to the shaft 58 and the other end is connected to the winding reel 21, specifically the ring portion 23 connected to the winding reel 20; the charging cable 61 is connected to multiple solder feet or multiple terminals 27.

[0041] S60, at least one support ring 122 is formed on the inner wall of the housing to assemble and fix the housing and the car charger main board 10, and each support ring 122 is correspondingly close to or abuts against the spiral spring 24 and the charging cable 61. The panel 107 covering the top of the housing is installed, so that the interface on the charging cable 61 and the car charger main board 10 is exposed outside the panel 107; thus forming the pull-cord car charger dual-circuit integrated car charger.

[0042] The structure, function, and quantity of components in each step are as described above and will not be repeated here. The manufacturing method of the cable-operated dual-circuit integrated vehicle charger adopts a system process in which the vehicle charger main board, the first circuit board, and two rings are formed together, eliminating the need to purchase cable-operated modules. At the same time, it utilizes relatively mature stamping and molding processes to manufacture the vehicle charger. The applicant of this application has proven through practice that the entire manufacturing process is convenient to operate, greatly reduces production costs, and can be industrialized for mass production, thereby improving production efficiency.

[0043] It should be noted that the present invention is not limited to the above-described embodiments. Based on the inventive spirit of the present invention, those skilled in the art can make other changes, and these changes made in accordance with the inventive spirit of the present invention should be included within the scope of protection claimed by the present invention.

Claims

1. A dual-circuit integrated car charger with a pull-cord design, comprising a housing, a mainboard, a winding reel, a positive terminal, and a negative terminal, wherein a stretchable charging cable is wound on the winding reel; characterized in that, The winding reel includes a turntable having a front and a back. The front is in close contact with a first circuit board, and the back has a loop for winding the charging cable. A spiral spring is provided inside the loop. The inner end of the spiral spring is connected to a shaft, and the outer end is connected to the winding reel. The shaft is mounted on the housing or the mainboard of the car charger. The front surface of the first circuit board has multiple concentric elastic conductive rings, and the rear surface of the first circuit board relative to the front surface has multiple solder feet or multiple terminals; the multiple solder feet or terminals are respectively electrically connected to the multiple concentric elastic conductive rings through multiple internal lines of the first circuit board; the inner end of the charging cable is directly or indirectly electrically connected to the solder feet or terminals. At least one side of the car charger main board has multiple concentric conductive rings. The multiple concentric conductive rings are electrically connected to the charging circuit on the car charger main board through internal and external circuits. The multiple concentric conductive rings are in one-to-one elastic contact with the multiple concentric elastic conductive rings, and each concentric conductive ring maintains electrical contact with the corresponding concentric elastic conductive ring when the winding disk rotates.

2. The dual-circuit integrated car charger with cable as described in claim 1, characterized in that, The first circuit board has multiple punched holes or blind holes. The multiple concentric elastic guide rings are formed on the first circuit board by punching away the connecting parts between the rings of the multi-linked guide ring front body. Each punched hole or blind hole position corresponds to a connecting part.

3. The dual-circuit integrated car charger with cable as described in claim 1, characterized in that, The first circuit board is also provided with multiple solder pads or positioning plates. Each of the concentric elastic guide rings is attached to the front surface of the first circuit board through a corresponding solder pad or positioning plate. One end of the internal circuit of the first circuit board is connected to each guide ring through the solder pad or positioning plate, and the other end is connected to the solder foot or terminal.

4. The dual-circuit integrated car charger with cable as described in claim 1, characterized in that, The housing has a central support ring on its inner wall facing the ring portion. The main body of the spiral spring is filled in the inner cavity of the ring portion. The central support ring abuts against or is close to the side of the spiral spring facing the housing to prevent the spiral spring from shifting or coming off during cable pulling. The outer diameter of the central support ring is smaller than the inner diameter of the ring portion. The housing also has at least one outer support ring on its inner wall facing the ring portion. Each outer support ring is concentrically arranged with the central support ring. Each outer support ring abuts against or is close to the multiple coils of conductive wire wound around the ring portion to prevent the conductive wire from shifting or coming off during cable pulling. Multiple ribs extend radially from the outer wall of the central support ring and are connected in series with each outer support ring. The housing also has an outer wall on its inner wall facing the ring portion to house the entire charging cable winding structure and turntable. The car charger mainboard is fixedly mounted on the housing.

5. A dual-circuit integrated car charger with a pull-cord design as described in claim 1, characterized in that, The turntable has windows at the locations of the plurality of solder feet or terminals to expose the plurality of solder feet or terminals on the first circuit board to the back of the turntable, facilitating connection to a charging cable by wiring or soldering.

6. A dual-circuit integrated car charger with a pull-cord design as described in claim 1, characterized in that, The winding reel can be single or two. The housing has mounting holes. The first end of the shaft is mounted in the mounting holes of the housing. The second end of the shaft extends out through the turntable and the first circuit board and is close to, abuts against, or is inserted into the car charger mainboard. When there are two winding reels, there are two spiral springs, two charging cables, two first circuit boards, two sets of multi-channel concentric conductive rings, and two sets of multi-channel concentric elastic guide rings, all symmetrically arranged on both sides of the car charger mainboard with the car charger mainboard as the center. The two sets of multi-channel concentric elastic guide rings are respectively formed on two surfaces of the car charger mainboard.

7. A dual-circuit integrated car charger with a pull-cord design as described in claim 1, characterized in that, The car charger mainboard has a stop assembly around the concentric conductive rings. The front of the turntable has a guide groove around the periphery of the first circuit board. The stop assembly includes a T-shaped slider and a T-shaped groove. The T-shaped groove is designed to hold the T-shaped end of the T-shaped slider, allowing the straight end of the T-shaped slider to protrude and slide along the T-shaped groove. The sliding direction of the T-shaped slider is radial to the turntable. The guide groove includes a first ring guide groove and a second ring guide groove that are basically concentric, with the concentricity being the center of the turntable. The first ring guide groove and the second ring guide groove have a confluence point. The confluence point is equipped with a check valve. The check valve is designed to stop the T-shaped slider when it retracts along the first or second ring guide groove. The entire check valve is triangular at one end and fishtail-shaped at the other end.

8. A dual-circuit integrated car charger with a pull-cord design as described in claim 6, characterized in that, The car charger mainboard has elongated grooves on both sides around the concentric conductive rings. The two turntables, facing the mainboard, each have guide grooves on the periphery of their respective first circuit boards. The elongated grooves extend radially along the concentric conductive rings. Each groove is fitted with a double-groove component, which includes an upper double-groove rail and a lower double-groove rail, and a slider. The slider has two parallel protruding rings in the middle, and its two ends protrude from both sides of the mainboard and can move within the corresponding guide grooves. The upper and lower double-groove rails are vertically aligned. The slide is configured such that the two protruding rings of the slide member respectively engage with the upper double-groove rail and the lower double-groove rail, thereby allowing the slide member to slide smoothly without dislodging. The guide groove includes a first ring guide groove and a second ring guide groove arranged basically concentrically, with the concentricity being the center of the turntable. The first ring guide groove and the second ring guide groove have a confluence point, and the confluence point is provided with a check part. The check part is constructed such that when the T-shaped slide member retracts along the first ring guide groove or the second ring guide groove, it is blocked and paused by the check part. The entire check part is triangular at one end and fishtail-shaped at the other end.

9. A dual-circuit integrated car charger with a pull-cord design as described in claim 7, characterized in that, The car charger mainboard includes a main body and a neck. Multiple concentric conductive rings are attached to the main body. Each concentric conductive ring and each concentric elastic conductive ring is sheet-shaped with a thickness of 0.1mm-0.5mm. The multiple concentric conductive rings and multiple concentric elastic conductive rings are pre-stamped and then attached to the car charger mainboard. The multiple concentric elastic conductive rings are coplanar, and the multiple concentric conductive rings are coplanar. The main body is provided with multiple through holes around its perimeter. The housing includes a front shell and a rear shell. The front shell and / or the rear shell is provided with screw holes and studs. Fasteners are passed through the through holes and screw holes to install the car charger motherboard. The main body is provided with multiple electronic components and a charging interface. The positive electrode and the negative electrode are respectively located on the neck.

10. A method for manufacturing a dual-circuit integrated vehicle charger with a pull-cord design as described in claim 1, characterized in that, Includes the following steps: S10, injection molding a turntable and a ring portion, the ring portion being integrally formed on the back of the turntable, and forming a shaft hole on the turntable, thereby forming a winding reel; S20, a car charger mainboard is manufactured, in which internal circuits, external circuits, and a charging circuit are formed inside and on the surface of the car charger mainboard, and multiple electronic components, positive terminals, negative terminals, and a charging interface are set, so that the internal circuits and external circuits are connected and finally connected to the charging circuit; multiple concentric conductive rings with a predetermined thickness are formed on at least one side of the car charger mainboard, and the multiple concentric conductive rings are electrically connected to the charging circuit on the car charger mainboard through the internal and external circuits of the car charger mainboard. S30, fabricate a first circuit board, forming pads or positioning pads on multiple circumferences of the front surface of the first circuit board, forming multiple internal circuits inside the first circuit board and electrically connecting the multiple internal circuits to the multiple pads or positioning pads respectively, forming punch holes or blind holes between pads or positioning pads of adjacent circumferences; and forming multiple solder feet or multiple terminals on the rear surface of the first circuit board, with each pad or terminal corresponding to one of the internal circuits. S40, a metal sheet of predetermined thickness is stamped into a multi-ring shape, with at least one spring piece stamped or at least one elastic contact welded onto each ring. During stamping, a connecting portion is retained between adjacent rings, so that the rings are connected as a whole through at least one connecting portion. Then, the multi-ring sheet is attached to the front surface of the first circuit board, with each ring attached to a corresponding pad or positioning pad and the connecting portion corresponding to the position of the punched hole or blind hole. The connecting portion between the rings is then stamped off to form a first circuit board with multiple concentric elastic guide rings. The center of the first circuit board and the multiple concentric elastic guide rings has a pre-formed shaft hole. The mounting method includes welding or bonding. S50, a shaft is mounted on the housing or the mainboard of the car charger; the turntable and the first circuit board with multiple concentric elastic guide rings are fitted onto the shaft and the multiple concentric conductive rings are respectively in one-to-one elastic contact with the multiple concentric elastic guide rings; a spiral spring is installed in the ring and one end of the spiral spring is connected to the shaft and the other end is connected to the winding disc; the charging cable is connected to multiple solder feet or multiple terminals; S60, at least one support ring is formed on the inner wall of the housing to assemble and fix the housing and the car charger main board, and make each support ring approach or abut against the spiral spring and the charging cable respectively, and install the panel covering the top of the housing so that the charging cable and the interface on the car charger main board are exposed outside the panel. This forms the aforementioned dual-circuit integrated vehicle charger with pull cable.

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