Non-liquid-cooled high-current heavy-duty connector

Abstract

This invention provides a non-liquid-cooled, high-current, heavy-duty connector, relating to the field of electrical connector technology, and solves the problem of low charging power in existing non-liquid-cooled charging connectors. The device includes mutually compatible socket and plug assemblies. Both the socket and plug assemblies are provided with at least two sets of power terminals. Each set of power terminals includes a positive power terminal and a negative power terminal. The cross-sectional area of ​​the wire used to accommodate the power terminals is not less than 120 mm², and the power terminals can carry an operating current of not less than 300 A. This invention, by employing a multi-set power terminal configuration, significantly reduces the heat generated on each power terminal, thereby enabling high-power charging even without liquid cooling.

Description

Technical Field

[0001] This invention relates to the field of electrical connector technology, and in particular to a non-liquid-cooled high-current heavy-duty connector. Background Technology

[0002] With the rapid popularization of new energy industrial vehicles, heavy-duty electric equipment, and high-power commercial vehicles, high-power DC charging technology has become an industry necessity. In heavy-duty charging scenarios, charging equipment must meet the requirements of high current, long distance, and high reliability.

[0003] Currently, conventional liquid-cooled, naturally heat-dissipating charging connectors generally suffer from the following technical defects due to limitations in the current carrying capacity and heat dissipation efficiency of the conductive terminals: Traditional liquid-cooled connectors often employ a single pair of positive and negative power terminals, concentrating a large current through a small number of conductive terminals, resulting in high current density, concentrated localized heat generation, and excessive temperature rise. To avoid overheating and burnout, the operating current must be limited, leading to low charging power and short transmission distance in liquid-cooled connectors. They cannot meet the demands of high-current fast charging and are ill-suited for long-distance, high-power charging scenarios in heavy-duty industrial equipment.

[0004] In summary, existing liquid-cooled charging connectors are limited by heat dissipation bottlenecks and have insufficient charging power, which cannot meet the current demand for high-power, long-distance, and high-efficiency fast charging of heavy-duty equipment. Therefore, there is an urgent need for a heavy-duty connector that can achieve stable transmission of high current under non-liquid-cooling conditions. Summary of the Invention

[0005] The purpose of this invention is to provide a non-liquid-cooled, high-current, heavy-duty connector, which solves the problem of low charging power in existing non-liquid-cooled charging connectors. The various technical effects of the preferred solutions among the many technical solutions provided by this invention are detailed below.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] The present invention provides a non-liquid-cooled high-current heavy-duty connector, comprising a mutually compatible socket assembly and a plug assembly. Both the socket assembly and the plug assembly are provided with at least two sets of power terminals. Each set of power terminals includes a positive power terminal and a negative power terminal. The cross-sectional area of ​​the wire to which the power terminal is adapted is not less than 120mm², and the power terminal is capable of carrying an operating current of not less than 300A.

[0008] Preferably, the cross-sectional area of ​​the power terminal adapter wire is 150 mm².

[0009] Preferably, it further includes a grounding terminal and a communication terminal disposed on the socket assembly and the plug assembly.

[0010] Preferably, the power terminal on the socket assembly is a female terminal, and the power terminal on the plug assembly is a male terminal, wherein the male terminal can be adapted to connect with the female terminal.

[0011] Preferably, the socket assembly includes a socket connecting core, a socket connecting plate assembly, and a connector, wherein the power terminal passes through the socket connecting core, the socket connecting core is disposed on the socket connecting plate assembly, and the socket connecting plate assembly is disposed within the connector.

[0012] Preferably, the socket connection plate assembly includes a socket plug plate and a socket limiting plate. The socket plug plate has a plug groove on its side, and the socket connecting core is inserted into the plug groove. A limiting protrusion is provided on the side wall of the plug groove, and a limiting groove is provided on the side wall of the socket connecting core. The limiting protrusion is inserted into the limiting groove. A limiting hole is provided on the limiting plate, and the socket connecting core passes through the limiting hole. Corresponding connecting holes are provided on the socket plug plate and the socket limiting plate.

[0013] Preferably, the plug assembly includes a plug connecting core, a plug connecting plate assembly, and a mounting shell, wherein the power terminal passes through the plug connecting core, the plug connecting core is disposed on the plug connecting plate assembly, and the plug connecting plate assembly is disposed within the mounting shell.

[0014] Preferably, the plug connection plate assembly includes a plug insertion plate and a plug limiting plate. The plug insertion plate has a insertion groove on its side, and the plug connecting core is inserted into the insertion groove. A limiting protrusion is provided on the side wall of the insertion groove, and a limiting groove is provided on the side wall of the plug connecting core. The limiting protrusion is inserted into the limiting groove. A limiting hole is provided on the limiting plate, and the plug connecting core passes through the limiting hole. Corresponding connection holes are provided on the plug insertion plate and the plug limiting plate.

[0015] Preferably, the connecting plate assembly includes a plug-in plate and a limiting plate. The plug-in plate has a plug-in groove on its side, and the connecting core is inserted into the plug-in groove. A limiting protrusion is provided on the side wall of the plug-in groove, and a limiting groove is provided on the side wall of the connecting core. The limiting protrusion is inserted into the limiting groove. A limiting hole is provided on the limiting plate, and the connecting core passes through the limiting hole. Corresponding connecting holes are provided on the plug-in plate and the limiting plate.

[0016] Preferably, the socket assembly is detachably provided with a socket dust cover, and the plug assembly is detachably provided with a plug dust cover.

[0017] Preferably, a latch is provided on the outer wall of the plug assembly, and a hook is provided on the outer wall of the socket assembly, wherein the latch can be hooked onto the hook.

[0018] The application employs the above technical solution and has at least the following beneficial effects: This application provides at least two sets of power terminals, each set including a positive power terminal and a negative power terminal. The cross-sectional area of ​​the wire used to connect the power terminals is not less than 120mm², and the power terminals can carry a working current of not less than 300A. By adopting the above technical solution, the working current of each power terminal can be reduced while maintaining the same total power as a traditional single-terminal connector. According to Joule's law, the heat generated by current passing through a conductor is proportional to the square of the current, which can reduce the heat generation on each power terminal by a factor of two. This can reduce the total heat generation by a factor of two, thereby increasing the charging power of the heavy-duty connector of this application while ensuring that the heat generation does not exceed that of a traditional single-terminal connector. This enables liquid-cooled charging connectors to achieve high-power charging.

[0019] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the split-state structure of the non-liquid-cooled high-current heavy-load connector provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the connection state structure of the non-liquid-cooled high-current heavy-load connector provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the non-liquid-cooled high-current heavy-duty connector with a dust cover provided in an embodiment of the present invention; Figure 4 This is a schematic diagram of the exploded structure of a non-liquid-cooled high-current heavy-load connector provided in an embodiment of the present invention; Figure 5 This is a front view structural diagram of the connection state of the connecting plate assembly provided in an embodiment of the present invention; Figure 6 This is a rear view structural diagram of the connection plate assembly connection state provided in an embodiment of the present invention; Figure 7This is a schematic diagram of the structure of the connecting plate assembly in a partially exploded state according to an embodiment of the present invention.

[0022] In the diagram: 1. Socket assembly; 2. Plug assembly; 3. Power terminal; 4. Grounding terminal; 5. Communication terminal; 6. Socket connecting core; 7. Connecting base; 8. Mounting shell; 9. Socket plug plate; 10. Socket limiting plate; 11. Plug groove; 12. Limiting protrusion; 13. Limiting groove; 14. Limiting hole; 15. Connecting hole; 16. Socket dust cover; 17. Plug dust cover; 18. Fastener; 19. Hook; 20. Plug connecting core; 21. Plug plug plate; 22. Plug limiting plate. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below. Obviously, the described embodiments are merely some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0024] A specific embodiment of the present invention provides a non-liquid-cooled high-current heavy-duty connector, combined with an attached... Figure 1 and attached Figure 2 As shown, it mainly includes a mutually compatible socket assembly 1 and a plug assembly 2. Both the socket assembly 1 and the plug assembly 2 are provided with at least two sets of power terminals 3. Each set of power terminals 3 includes a positive power terminal and a negative power terminal. By setting at least two sets of power terminals 3, the overall power is guaranteed while the current is shunted. According to the Joule law, the heat generated by the current passing through the conductor is proportional to the square of the current. It can be concluded that the heat generated by the non-liquid-cooled high-current heavy-duty connector after current shunting is lower than the heat generated by the connector with a single set of power terminals of the same power. Conversely, the total charging power can be increased while ensuring heat dissipation, so that the non-liquid-cooled charging connector can also achieve high-power charging.

[0025] Specifically, the cross-sectional area of ​​the power terminal 3 adapter wire in this application is not less than 120mm², so that the power terminal 3 can carry an operating current of not less than 300A. By using a large-diameter wire to carry a larger operating current, a larger charging power can be obtained.

[0026] In a specific embodiment of this application, the cross-sectional area of ​​the adapter wire for the power terminal 3 can be 150 mm². Of course, the cross-sectional area of ​​the adapter wire can be increased according to the actual situation, such as 180 mm², 200 mm², 250 mm², 300 mm², etc.

[0027] Specifically, the number of power terminals 3 in this application is four: two positive power terminals and two negative power terminals. The following explanation compares the non-liquid-cooled high-current heavy-duty connector provided in this application with a connector using a set of power terminals. Assuming the total power is the same, and the total current and voltage are also the same, according to Joule's law Q=I²Rt, the current passing through each terminal in the prior art is I1, while the current passing through each terminal in this application is I2. Since the prior art uses one set of terminals while this application uses two sets, I1=2I2, and Q1=I1²Rt; Q 2 = I²Rt; From this, we can obtain Q1 = 4Q2; In the case that the prior art has two terminals while this application has four terminals, the total heat generated by the prior art connector is still twice that of this application. Conversely, if the non-liquid-cooled high-current heavy-duty connector provided by this application has the same heat generation as the connector in the prior art, the current passing through each power terminal 3 of the non-liquid-cooled high-current heavy-duty connector provided by this application can still be increased, which can indirectly increase the charging power. In this way, the non-liquid-cooled high-current heavy-duty connector can also obtain a larger charging power.

[0028] In some embodiments, the number of power terminals 3 can be set to three, four, etc.

[0029] In some embodiments, a grounding terminal 4 and a communication terminal 5 are also included. Both the grounding terminal 4 and the communication terminal 5 are disposed on the socket assembly 1 and the plug assembly 2. The grounding terminal 4 is used to ensure the safety and stability of the connector during use. By tightly connecting the grounding terminal 4 to the socket assembly 1 and the plug assembly 2, safety hazards caused by excessive current or short circuits can be effectively prevented. The communication terminal 5 is used to realize signal transmission between devices, ensuring data accuracy and real-time performance, thereby improving the overall system operating efficiency.

[0030] In some embodiments, the power terminal 3 on the socket assembly 1 is a female terminal, and the power terminal 3 on the plug assembly 2 is a male terminal. The male terminal can be inserted into the female terminal and adapted to connect with the female terminal.

[0031] In some embodiments, in conjunction with the appendix Figure 1 , 24. The socket assembly 1 includes a socket connecting core 6, a socket connecting plate assembly, and a connector 7. The power terminal 3 passes through the socket connecting core 6, which protects the power terminal 3 and isolates different power terminals 3. A foolproof structure can also be provided on the outer wall of the socket connecting core 6. This foolproof design effectively prevents misoperation of the connector during insertion, ensuring correct mating of the socket assembly 1 and the plug assembly 2. By providing specific protrusions or grooves on the outer wall of the socket connecting core 6, unique directional matching can be achieved, thereby reducing assembly errors caused by human error. The socket connecting core 6 is mounted on the socket connecting plate assembly, which is located within the connector 7. The socket connecting plate assembly connects and fixes the socket connecting core 6, ensuring the stability of the power terminal 3 and thus its reliability.

[0032] Specifically, the socket connection plate assembly in this application includes a socket plug plate 9 and a socket limiting plate 10, in conjunction with the attached... Figure 5-7 The socket connection plate 9 has insertion slots 11 on its side, the number of which is the same as the number of power terminals 3. The insertion slots 11 can be located on opposite sides of the socket connection plate 9, allowing the socket connecting core 6 to be inserted into the insertion slots 11 from both sides. A limiting protrusion 12 is provided on the side wall of the insertion slot 11, and a limiting groove 13 is provided on the side wall of the socket connecting core 6. The limiting protrusion 12 is inserted into the limiting groove 13. The limiting protrusion 12 is a raised portion of the plate, while the limiting groove 13 is located within the socket connecting core 6. At the periphery of the middle part of the core 6, the insertion method of the limiting protrusion 12 and the limiting groove 13 can ensure the stable installation of the socket connecting core 6. The socket limiting plate 10 is provided with a limiting hole 14, and the socket connecting core 6 passes through the limiting hole 14. The setting of the socket limiting plate 10 can further limit the socket connecting core 6. The socket plug plate 9 and the socket limiting plate 10 are provided with corresponding connecting holes 15. Bolts can be inserted into the connecting holes 15, and the socket plug plate 9 and the socket limiting plate 10 are installed together into the connecting seat 7 by bolts.

[0033] In some embodiments, in conjunction with the appendix Figure 4 The plug assembly 2 includes a plug connecting core 20, a plug connecting plate assembly, and a mounting shell 8. The power terminal 3 passes through the plug connecting core 20. The structure of the plug connecting core 20 is similar to that of the plug connecting core 20 on the socket assembly 1 and can be adapted for connection. The plug connecting core 20 is disposed on the connecting plate assembly, and the connecting plate assembly is disposed in the mounting shell 8.

[0034] Specifically, the plug connection plate assembly in this application includes a plug insertion plate 21 and a plug limiting plate 22, which have the same structure as the socket connection plate assembly described above. The plug insertion plate 21 has insertion slots 11 on its side, the number of which is the same as the number of power terminals 3. The insertion slots 11 can be located on opposite sides of the plug insertion plate 21, allowing the plug connecting core 20 to be inserted into the insertion slots 11 from both sides. Limiting protrusions 12 are also provided on the sidewalls of the insertion slots 11, while limiting grooves 13 are provided on the sidewalls of the plug connecting core 20. The limiting protrusions 12 are inserted into the limiting grooves 13, and the limiting protrusions 12 are plate-shaped. The protruding part 12 and the limiting groove 13 are located on the periphery of the middle part of the plug connecting core 20. The plug connecting core 20 can be stably installed by the insertion of the limiting protrusion 12 and the limiting groove 13. The plug limiting plate 22 is provided with a limiting hole 14, and the plug connecting core 20 passes through the limiting hole 14. The setting of the plug limiting plate 22 can further limit the plug connecting core 20. The plug plug plate 21 and the plug limiting plate 22 are provided with corresponding connecting holes 15. Bolts can be inserted into the connecting holes 15. The plug plug plate 21 and the plug limiting plate 22 are installed together into the mounting shell 8 by bolts.

[0035] In some embodiments, as shown in the appendix Figure 3 As shown, the socket assembly 1 is detachably equipped with a socket dust cover 16, and the plug assembly 2 is detachably equipped with a plug dust cover 17. When not in use, the socket dust cover 16 and the plug dust cover 17 can respectively cover and protect the socket assembly 1 and the plug assembly 2, preventing dust or other impurities from entering the connector, thereby ensuring the reliability and safety of the connector in the next use. This design not only improves the durability of the equipment but also effectively reduces the frequency of maintenance and extends its service life. In addition, the detachable feature of the dust cover makes operation more convenient, allowing users to install or remove it at any time according to actual needs, adapting to different working environments.

[0036] In some embodiments, a latch 18 is provided on the outer wall of the plug assembly 2, and a hook 19 is provided on the outer wall of the socket assembly 1. The latch 18 can be hooked onto the hook 19. In use, a secure connection between the plug assembly 2 and the socket assembly 1 can be achieved by locking the latch 18 and the hook 19. This locking method is not only simple to operate, but also effectively prevents accidental loosening caused by external force or vibration, thereby improving the reliability of the connector in complex working environments. At the same time, the design of the latch 18 and the hook 19 also takes into account the need for quick disassembly.

[0037] In some embodiments, sealing rings are also provided on the socket assembly 1 and the plug assembly 2. Specifically, the socket assembly 1 has an annular protrusion that can be inserted into the plug assembly 2, and the sealing ring is fitted onto this annular protrusion. The plug assembly 2 has an annular groove inside, and the sealing ring is disposed in this annular groove. When the socket assembly 1 and the plug assembly 2 are plugged into each other, the sealing ring ensures the sealing between the socket assembly 1 and the plug assembly 2. Of course, when the socket dust cover 16 is inserted into the socket assembly 1 and the plug dust cover 17 is inserted into the plug assembly 2, the sealing ring can also achieve a good sealing effect, effectively preventing moisture, dust and other external impurities from entering the connector. This sealing design not only improves the connector's protection capability in harsh environments, but also further enhances the stability and safety of its electrical connection.

[0038] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between the components; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0039] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0040] In this invention, the terms "one embodiment," "some embodiments," "example," "specific example," and "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0041] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A non-liquid-cooled high-current heavy-duty connector, characterized in that, The device includes a mutually compatible socket assembly and a plug assembly. Both the socket assembly and the plug assembly are provided with at least two sets of power terminals. Each set of power terminals includes a positive power terminal and a negative power terminal. The cross-sectional area of ​​the wire to which the power terminal is adapted is not less than 120 mm². The power terminal is capable of carrying a working current of not less than 300 A. The socket assembly includes a socket connecting core, a socket connecting plate assembly, and a connector. The power terminal passes through the socket connecting core, the socket connecting core is disposed on the socket connecting plate assembly, and the socket connecting plate assembly is disposed within the connector. The socket connection plate assembly includes a socket plug plate and a socket limiting plate. The socket plug plate has a plug groove on its side, and the socket connecting core is inserted into the plug groove. The side wall of the plug groove has a limiting protrusion, and the side wall of the socket connecting core has a limiting groove. The limiting protrusion is inserted into the limiting groove. The limiting plate has a limiting hole, and the socket connecting core passes through the limiting hole. The socket plug plate and the socket limiting plate have corresponding connecting holes. The plug assembly includes a plug connecting core, a plug connecting plate assembly, and a mounting shell. The power terminal passes through the plug connecting core, the plug connecting core is disposed on the plug connecting plate assembly, and the plug connecting plate assembly is disposed within the mounting shell. The plug connection plate assembly includes a plug insertion plate and a plug limiting plate. The plug insertion plate has a insertion groove on its side, and the plug connecting core is inserted into the insertion groove. A limiting protrusion is provided on the side wall of the insertion groove, and a limiting groove is provided on the side wall of the plug connecting core. The limiting protrusion is inserted into the limiting groove. A limiting hole is provided on the limiting plate, and the plug connecting core passes through the limiting hole. Corresponding connection holes are provided on the plug insertion plate and the plug limiting plate.

2. The non-liquid-cooled high-current heavy-duty connector according to claim 1, characterized in that, The cross-sectional area of ​​the power terminal adapter wire is 150mm².

3. The non-liquid-cooled high-current heavy-duty connector according to claim 1, characterized in that, It also includes a grounding terminal and a communication terminal disposed on the socket assembly and the plug assembly.

4. The non-liquid-cooled high-current heavy-duty connector according to claim 1, characterized in that, The power terminal on the socket assembly is a female terminal, and the power terminal on the plug assembly is a male terminal, which can be adapted to connect with the female terminal.

5. The non-liquid-cooled high-current heavy-duty connector according to claim 1, characterized in that, The socket assembly is detachably provided with a socket dust cover, and the plug assembly is detachably provided with a plug dust cover.

6. The non-liquid-cooled high-current heavy-duty connector according to claim 1, characterized in that, The plug assembly has a latch lock on its outer wall, and the socket assembly has a hook on its outer wall, and the latch lock can be hooked onto the hook.

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