Spliceable balanced end-of-charge terminal module and scalable power plug and charge-discharge combination plug and battery pack

Abstract

The application relates to an electrical connecting device in the technical field of batteries, and discloses a splicable balanced charging terminal module, an extensible power plug, a charging and discharging combined plug and a battery pack. The splicable balanced charging terminal module comprises an insulating shell and at least one electric terminal arranged in the insulating shell; at least one group of opposite sides of the insulating shell is respectively provided with a slide rail part protruding from the side and a slide groove part recessed in the side, and the shape of the slide rail part is matched with the shape of the slide groove part; wherein the slide rail part is configured to be detachably and slidably inserted into the slide groove part of another balanced charging terminal module or into a corresponding slide groove part of a power plug.

Description

Technical Field

[0001] This invention relates to electrical connection devices in the field of battery technology, and more particularly to a splicable balanced charging terminal module, an expandable power plug, a charging and discharging combination plug, and a battery pack. Background Technology

[0002] With the widespread application of lithium-ion batteries in power tools, new energy vehicles, and energy storage systems, higher demands are placed on the safety, efficiency, and convenience of battery pack charging and discharging management. During battery pack operation, two independent electrical connections are typically required: one is the main power circuit connection for high-current charging and discharging; the other is the balance charging circuit connection for monitoring the voltage of each series-connected cell to achieve equalization management. Currently, common technical solutions for achieving these functions in relevant application scenarios are mainly as follows: First, the main power supply circuit (charging / discharging) and the monitoring circuit (voltage acquisition) are typically implemented using physically separate connector assemblies. For example, a separate power plug and socket are used to handle high current switching, while a separate set of balanced charging plugs and sockets with a fixed number of pins is used for voltage acquisition. This approach results in the need for two independent connection interfaces on a single battery pack or device.

[0003] Second, the number of pins on the balanced charging connector used for voltage acquisition is determined during the design and manufacturing phase. Various fixed-specification balanced charging connectors exist on the market, such as 3-pin, 4-pin, 5-pin, and 6-pin connectors, each corresponding to a specific number of battery cells. To meet the needs of different battery configurations, manufacturers must design and manufacture these different specifications of products separately.

[0004] During the research process of this invention, the inventors discovered that the aforementioned prior art solutions have some inherent limitations in practice. Functional separation designs typically mean a greater number of connectors and more complex wiring, occupying limited internal space. Independent high-current connectors may face challenges in structural design regarding increasing single-point contact area and reliability. Furthermore, the fixed pin count design of balanced charging connectors means that to cover various battery packs from low to high string counts, a product series with multiple models needs to be maintained, which puts pressure on mold development, material management, and inventory costs. Simultaneously, end users also need to equip their devices with connectors of corresponding specifications when facing different battery packs, limiting flexibility. Summary of the Invention

[0005] One of the objectives of this invention is to provide a connectable balanced charging terminal module, an expandable power plug, a charging / discharging combination plug, and a battery pack.

[0006] In a first aspect, an embodiment of the present invention provides a connectable balanced charging terminal module, comprising: An insulating housing, and at least one electrical terminal disposed within the insulating housing; On at least one set of opposite sides of the insulating housing, there are respectively a slide rail portion protruding from the side and a slide groove portion recessed into the side, and the shape of the slide rail portion matches the shape of the slide groove portion. The slide rail is configured to be detachably slidably inserted into the slide groove of another balanced charging terminal module, or detachably slidably inserted into the corresponding slide groove on a power plug.

[0007] Optionally, the cross-sections of the slide rail portion and the slide groove portion are complementary dovetail shapes.

[0008] Optionally, the slide rail portion and the slide groove portion are respectively provided on two sets of opposite sides of the insulating housing.

[0009] Optionally, each of the said groove portions has a first end and a second end that are opposite to each other along its length. The first end is an open slot facing the end face of the insulating housing, which serves as a connector. The second end is a closed end located on the side where it is located.

[0010] Optionally, the plug-in function of the electrical terminal is a male terminal.

[0011] Optionally, the plug-in function of the electrical terminal is a female terminal.

[0012] Optionally, the female terminal is provided with at least one elastic contact piece, the elastic conductor contact piece having a contact portion that intersects with the insertion direction of the electrical terminal.

[0013] 8. The connectable balanced charging terminal module according to claim 7, characterized in that, The contact portion is a bent portion, and the angle formed between the bent portion and the insertion direction is an acute angle or an obtuse angle.

[0014] 9. The connectable balanced charging terminal module according to claim 7, characterized in that, The electrical terminal also has a welded portion extending from the end of the housing opposite to the plug end.

[0015] Secondly, an embodiment of the present invention provides an expandable power plug for a battery pack, comprising: Insulating base, The positive and negative power terminals are fixed within the insulating base. An anti-mis-insertion mating part is provided at the insertion end of the insulating base. And an extended connection portion provided on at least one outer side of the insulating base; The extended connection portion is a slide rail portion or a slide groove portion extending along the first direction; The slide rail or slide groove has a main body segment extending along the first direction. The main body segment has a starting end and an ending end on the insulating base. The starting end is formed as an open end, and the ending end is a closed end opposite to the starting end.

[0016] 11. An expandable power connector for a battery pack according to claim 10, characterized in that, The anti-misinsertion mating part is an insulating protrusion or an insulating groove.

[0017] 12. An expandable power connector for a battery pack according to claim 10, characterized in that, The cross-section of the anti-misinsertion mating part is V-shaped.

[0018] 13. An expandable power connector for a battery pack according to claim 10, characterized in that, The cross-section of the slide rail or slide groove is dovetail-shaped.

[0019] 14. An expandable power connector for a battery pack according to claim 13, characterized in that, When the extended connection portion is the sliding groove portion, the closed end is a closed end wall formed at the end of the sliding groove portion in the length direction; When the extended connection portion is the slide rail portion, the closed end is a retaining wall formed on the insulating base and protruding outward from the end of the slide rail portion.

[0020] 15. An expandable power plug for a battery pack according to any one of claims 10 to 14, characterized in that, The extended connection portion is formed on both of the two opposite outer surfaces of the insulating base.

[0021] 16. An expandable power connector for a battery pack according to claim 15, characterized in that, The positive and negative terminals of the power supply are male terminals; The insulating base has a mounting cavity, and the inner wall of the mounting cavity has an axial locking protrusion. The male terminal is provided with a groove or locking point that engages with the axial locking protrusion to restrict the axial movement of the male terminal.

[0022] 17. An expandable power connector for a battery pack according to claim 15, characterized in that, The axial retaining protrusions provided on the inner wall of the mounting cavity include two sets, front and rear. The male terminal has two locking structures on its outer periphery, one at the front and one at the back, to achieve bidirectional axial positioning of the male terminal.

[0023] 18. An expandable power connector for a battery pack according to claim 15, characterized in that, The positive and negative terminals of the power supply are female terminals; The female terminal is a one-piece molded metal conductor, comprising: One base part, Two parallel cantilever arms extending from the base portion toward the insertion end, and Contact portion formed at the free end of each of the aforementioned cantilever arms; The contact portions on the two cantilever arms are arranged opposite to each other to form a flexible socket for clamping the male terminal.

[0024] 19. An expandable power connector for a battery pack according to claim 18, characterized in that, The contact portion of each cantilever free end is formed by bending inward.

[0025] 20. An expandable power connector for a battery pack according to claim 19, characterized in that, The bent portion of the contact area is U-shaped. The two U-shaped openings face each other, and the resilient socket is located between the bottoms of the two U-shapes.

[0026] 21. An expandable power connector for a battery pack according to claim 10, characterized in that, The end of the insulating base facing away from the connector is also connected to a wire sheath, which is snapped into the insulating base.

[0027] 22. An expandable power connector for a battery pack according to claim 10, characterized in that, The outer wall of the insulating base is provided with a recessed or protruding part that facilitates hand gripping and operation.

[0028] Thirdly, an embodiment of the present invention provides a charging and discharging connector for a battery pack, comprising: The expandable power connector for a battery pack as described in any one of claims 10 to 22, and At least one splicable balanced charging terminal module as described in any one of claims 1 to 9; At least one of the balanced charging terminal modules is detachably slidably connected to the extended connection portion on the outside of the power plug via a slide rail or slide groove thereon.

[0029] 24. The charging and discharging connector for a battery pack according to claim 23, characterized in that, At least one outer side of the insulating base of the power plug has at least two of the aforementioned balanced charging terminal modules. Located on the same outer surface, any two adjacent balanced charging terminal modules are spliced ​​together by their opposing slide rails and slide grooves to form a module array. At least one of the balanced charging terminal modules in the module array is connected to the power plug.

[0030] 25. The charging and discharging connector for a battery pack according to claim 24, characterized in that, The balanced charging terminal module or the module array is spliced ​​on both opposite outer surfaces of the insulating base of the power plug.

[0031] Fourthly, an embodiment of the present invention provides a battery pack comprising: At least two cells connected in series, and The charging and discharging combination plug according to any one of claims 23 to 25; The positive and negative terminals of the charging and discharging connector are electrically connected to the total positive and negative terminals of the battery pack, respectively, for charging and discharging. The electrical terminals of each balanced charging terminal module on the charging and discharging combination plug are electrically connected to the voltage acquisition points between the corresponding battery cells, for monitoring the voltage of each battery cell or battery cell group.

[0032] 27. The battery pack according to claim 26, characterized in that, The number of balanced charging terminal modules on the charging and discharging combination plug corresponds to the number of battery cells connected in series or the required number of voltage sampling points.

[0033] As can be seen from the above, the modular balanced charging terminal module of this embodiment breaks the limitation of the fixed number of PINs in traditional balanced charging plugs. It allows for splicing using standardized modules, and can flexibly combine plugs with 3PIN, 4PIN, 5PIN, 6PIN or even more PINs according to the number of battery strings (e.g., 2S to 7S), achieving the versatility of "one for many".

[0034] Manufacturers only need to create one mold to produce this standardized module, which can cover the needs of all battery packs with different numbers of pins. This eliminates the huge cost of creating separate molds for each fixed number of pins and simplifies material management and inventory. In addition, the splicing method between the outer sides of the module allows multiple electrical connection points to be closely arranged horizontally, which greatly reduces the overall volume and space occupied compared to multiple independent plugs. Attached Figure Description

[0035] The accompanying drawings, which are provided to further illustrate the invention and form part of this application, do not constitute an undue limitation of the invention.

[0036] Figure 1 , 2 Figures 3 and 4 are schematic diagrams of the three-dimensional structure, exploded structure, and axial cross-sectional structure of the splicable balanced charging terminal module (male plug-in) provided in the embodiments of the present invention. Figure 4 , 5 6 and 7 are schematic diagrams of the two-dimensional structure, exploded structure and axial cross-sectional structure of the splicable balanced charging terminal module (mother plug-in) provided in the embodiment of the present invention, respectively. Figures 8-12 These are schematic diagrams of the front view, rear view, three-dimensional view, exploded structure, and axial sectional view of the expandable power plug (male plug) provided in the embodiments of the present invention. Figures 13-17 These are schematic diagrams of the front view, rear view, three-dimensional view, exploded structure, and axial sectional view of the expandable power plug (male plug) provided in the embodiments of the present invention. Figure 18 , 19 20 is a three-dimensional structure and axial cross-sectional view of the expandable power plug provided in the embodiment of the present invention when the male plug and female plug are connected and after connection. Figure 21 , 22 Figures 23 and 24 are schematic diagrams of the three-dimensional structure, axial fit structure, and cross-sectional structure of the charging and discharging combination plug provided in the embodiments of the present invention when the male plug and female plug are connected and after connection.

[0037] Figure 25 This is a circuit diagram of the battery pack and the electrical terminals of the combination plug in this embodiment.

[0038] 11: Insulating housing; 12: Electrical terminal; 14: Slide rail section; 15: Slide groove section; 16: Open slot; 17: Closed end; 18: Elastic contact piece; 21: Insulating base; 22: Positive power terminal; 23: Negative power terminal; 24: Anti-misinsertion mating part; 25: Extension connection part; 26: Base part; 27: Cantilever; 28: Contact part. Detailed Implementation

[0039] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. Here, the illustrative embodiments and descriptions of the present invention are used to explain the present invention, but are not intended to limit the present invention.

[0040] Example 1: A modular balanced charging terminal module that can be spliced ​​together.

[0041] See Figures 1-7 .

[0042] The modular balanced charging terminal module of this embodiment includes an insulating housing 11 and at least one electrical terminal 12 embedded therein. The insulating housing 11 is typically integrally molded from flame-retardant, high-strength engineering plastics (such as PA66 or PBT) using an injection molding process. The electrical terminal 12 is made of a metal material with good electrical conductivity (such as brass or phosphor bronze), with its front end forming a plug-in functional part for electrical connection, and its rear end being available for soldering wires or connecting with other connectors.

[0043] On at least one set of opposing sides of the insulating housing 11, a slide rail portion 14 protruding from the side and a slide groove portion 15 recessed into the side are respectively machined. The slide rail portion 14 and the slide groove portion 15 are matched (or adapted) to each other in shape. This means that the slide rail portion 14 on one module is precisely designed in terms of size and profile so that it can be smoothly and detachably slidably inserted into the slide groove portion 15 of another identical module.

[0044] In application, users can use multiple identical balanced charging terminal modules according to the number of voltage sampling points required by the battery pack. Mechanical splicing of two modules is achieved by aligning the slide rail 14 on the side of one module along a straight direction (first direction) and pushing it into the slide groove 15 on the side of another module. This process requires no tools and is simple to operate. Multiple modules can be connected end-to-end in this way to form a linear module array. The independent electrical terminals 12 inside each module provide the required number of electrical connection points.

[0045] The balanced charging terminal module of this embodiment can not only be spliced ​​with similar balanced charging terminal modules, but the slide rail portion 14 on the outer side of the balanced charging terminal module of this embodiment is also designed to slide into the corresponding slide groove portion 15 provided on the side of a dedicated power plug (which will be described in detail in subsequent embodiments). This allows the balanced charging function module to be directly integrated into the main power plug as an expansion component, achieving a high degree of integration of physical space and function.

[0046] As can be seen from the above, the modular balanced charging terminal module of this embodiment breaks the limitation of the fixed number of pins in traditional balanced charging plugs. It allows for splicing using standardized modules, and can flexibly combine plugs with 3-pin, 4-pin, 5-pin, 6-pin or even more pins according to the number of battery strings (e.g., 2S to 7S), achieving the versatility of "one for many".

[0047] Manufacturers only need to create one mold to produce this standardized module, which can cover the needs of all battery packs with different numbers of pins. This eliminates the huge cost of creating separate molds for each fixed number of pins and simplifies material management and inventory. In addition, the splicing method between the outer sides of the module allows multiple electrical connection points to be closely arranged horizontally, which greatly reduces the overall volume and space occupied compared to multiple independent plugs.

[0048] As an illustration of this embodiment, the cross-sections of the slide rail portion 14 and the slide groove portion 15 are complementary dovetail shapes. That is, the cross-section of the slide rail portion 14 is similar to a trapezoid or dovetail, wider at the top and narrower at the bottom; while the cross-section of the slide groove portion 15 is a perfectly matching inverted trapezoidal groove. This shape provides good guidance and effectively prevents the module from loosening or detaching in a plane perpendicular to the insertion direction after splicing. The dovetail fit provides a mechanical self-locking effect, and its resistance to vibration and accidental pull-out is significantly better than that of a simple rectangular slider. The dovetail-shaped conical design makes the insertion alignment error tolerance high and the splicing process smooth.

[0049] It should be noted that the mating shape of the slide rail portion 14 and the slide groove portion 15 in this embodiment is not limited to a dovetail shape. In other embodiments, a T-shaped groove and a T-shaped tenon can be used, or an arc-shaped protrusion and a groove can be used, as long as it can achieve detachable sliding insertion and provide sufficient connection stability. However, experimental verification has shown that the dovetail design achieves the best balance in terms of tensile strength, ease of processing, and splicing feel.

[0050] More preferably, in this embodiment, the insulating housing 11 of the balanced charging plug module has slide rails 14 and grooves 15 on both sets of opposite sides. Specifically, one side of the front and rear sides of the module (with the horizontal left and right direction as a reference) has a horizontal slide rail 14, and the other side has a horizontal groove 15; at the same time, the upper and lower sides of the module also adopt the same arrangement. This allows the module to not only be spliced ​​with similar modules or power plugs in the front and rear direction, but also to be expanded in the vertical direction. Moreover, with the above-mentioned expansion design on both sets of opposite sides in this embodiment, the splicing method of the module is more flexible. Users can not only perform one-dimensional linear splicing, but also two-dimensional planar array splicing. For example, two modules can be spliced ​​into a short row in the vertical direction, and then three such short rows can be spliced ​​with the power plug in the front and rear direction to quickly form a compact array with 6 collection points. This design greatly improves the flexibility of combination and the diversity of spatial layout. The dual-sided expansion design makes the module a true "building block" unit, supporting one-dimensional and two-dimensional combinations to adapt to more complex wiring needs and compact spaces.

[0051] As an illustration of this embodiment, referring to the figures, the sliding section 15 of the balanced charging plug module in this embodiment has two ends along its length: a first end (starting end) and a second end (ending end). The first end is an open slot 16 facing one end face of the insulating housing 11, which is defined as the module's insertion end side (i.e., the exposed side of the electrical terminals 12). The open slot 16 serves as an inlet channel. The second end is a closed end 17. This closed end 17 is the terminal of the recessed structure of the sliding section 15 inside the housing side; it is a solid blocking wall. When the sliding rail 14 of one module is inserted through the open slot 16 of the sliding section 15 of another module and pushed forward, the end of the sliding rail 14 eventually abuts against this closed end 17 inside the sliding section 15. The closed end 17 acts as a physical limiter, defining the final relative position between modules (or between a module and a power plug), ensuring proper connection and preventing over-insertion or internal stress due to continued pushing or vibration. This design ensures the consistent position of each module within the splicing array, thereby guaranteeing the accuracy of the relative positions of the internal electrical terminals 12, which is crucial for the reliability of electrical connections. Simultaneously, it prevents damage to the internal structure of the housing or deformation of the electrical terminals 12 due to excessive installation force. Furthermore, this design provides users with a clear sense of the "end point" during splicing, offering clear operational feedback.

[0052] See Figures 1-6As shown in the illustration, the balanced charging plug module of this embodiment can be a male plug, that is, the electrical terminal 12 provided in the module is a male terminal. The male terminal is usually a cylindrical or sheet-shaped metal conductor, and its front end (the plug-in side) is in the shape of a probe, sheet or cylinder, for insertion into the mating female terminal.

[0053] When multiple male terminal modules are spliced ​​together, their front-end male terminals are arranged in a row or an array formed by splicing multiple rows, together forming a multi-PIN male connector. This male connector can be plugged into a housing that integrates multiple female terminals (i.e., the "female balance charger" in subsequent embodiments) to achieve rapid connection of multiple voltage acquisition lines.

[0054] See Figures 4-7 As shown in the illustration, the balanced charging plug module of this embodiment can also be a female plug, that is, the electrical terminal 12 provided in the module is a female terminal. The female terminal is stamped from a highly elastic and highly conductive metal material (such as tin-phosphor bronze). Its structural design is used to reliably receive and connect to the male terminal from the "balanced charging plug module male plug".

[0055] As an illustration of this embodiment, at least one elastic contact piece 18 can be provided inside the female terminal. This elastic contact piece 18, as the main part of the electrical conductor, has a key contact portion 28. Its extending direction intersects with, rather than is parallel to, the overall insertion direction of the electrical terminal 12 (i.e., the direction in which the male terminal is inserted).

[0056] Furthermore, the contact portion 28 is specifically a bent portion. This bent portion is formed by bending a portion of the elastic contact piece 18 at a specific angle. Preferably, the angle between the bent portion and the insertion direction is designed to be acute or obtuse, so that when the male terminal is inserted along the insertion direction, the bent portion can effectively convert the axial insertion force into elastic deformation and contact pressure perpendicular to the insertion direction. When the male terminal is inserted into the female terminal module, the male terminal first contacts the bent portion. Because the bent portion forms an angle with the insertion direction, the continued advancement of the male terminal forces the bent portion to undergo elastic deformation, the direction of which is mainly perpendicular to the insertion direction. This deformation stores elastic energy within the bent portion, thereby generating a continuous and stable radial clamping force applied to the side of the male terminal, thus forming a low-resistance, high-reliability electrical contact.

[0057] It should be noted that the specific form of the bend that achieves elastic contact can be varied. For example, it can be a simple "V" shaped bend or a gently sloping arc-shaped protrusion. The elastic contact piece 18 itself can also be a single-arm cantilever structure, with its free end forming the contact portion 28 through bending; or it can be a two-finger fork structure, with each finger end having a bend. Regardless of the specific form, as long as the extension direction of its contact portion 28 intersects with the insertion direction and can generate effective radial contact force, it falls within the protection scope of this invention.

[0058] To verify the advantages of this flexible bending design, comparative tests were conducted: Test subject: A) The present invention has a female terminal with an acute-angle bend; B) Traditional vertical contact type (no bend or right angle bend) female terminal.

[0059] Test items: contact resistance stability (before and after insertion / removal), insertion / removal force (N), durability (cycles).

[0060] result: Contact resistance stability: After 1000 insertion and removal cycles, the average increase in contact resistance for Solution A is less than 0.2 mΩ; while for Solution B, the average increase exceeds 0.5 mΩ. This invention improves stability by over 60%.

[0061] Insertion and extraction force: Solution A has a smoother insertion and extraction force, with a maximum insertion and extraction force that is about 15% lower than Solution B. This results in a better user experience, making the insertion and extraction process smoother and with moderate force, thus extending the service life of the terminals and housings.

[0062] Durability: In simulated vibration tests, the contact resistance fluctuation range of Option A is less than ±5%, which is far superior to ±15% of Option B.

[0063] As can be seen from the above, Design A, which converts axial motion into radial elastic force through bending, provides adaptive contact pressure and is more resistant to vibration and fretting corrosion. Design A also offers better tolerance for manufacturing tolerances of the male terminals, ensuring good contact even with slight deviations in the male terminal dimensions.

[0064] As an illustration of this embodiment, regardless of whether the balanced charging plug module of this embodiment is a male or female plug, the electrical terminal 12 extends with a welding section at the end of the housing facing away from the plug end. This welding section can be designed as a through hole (for wire welding), a cup shape (for embedding wire core welding), or a sheet shape, exposed in the space or slot reserved at the tail of the insulating housing 11, to facilitate welding of wires.

[0065] Example 2: Expandable power connector for battery packs.

[0066] See Figures 8-20 .

[0067] This embodiment provides an expandable power plug for a battery pack. This plug serves as a carrier for the main charging and discharging circuit, and integrates a modular expansion connection 25, enabling integration with the aforementioned balanced charging terminal module.

[0068] The expandable power plug of this embodiment has an insulating base 21 as its main body, which is typically injection molded from a high-strength, high-flame-retardant insulating material (such as high-temperature resistant nylon or PPS). Inside the insulating base 21, a positive power terminal 22 and a negative power terminal 23 are fixedly disposed. These two terminals are specifically designed to carry the large currents of battery charging and discharging, and therefore are typically made of thick-walled, high-conductivity metal materials (such as high-conductivity copper alloys), with a cross-sectional area significantly larger than that of the balance charging terminals.

[0069] The insulating base 21 has a mis-insertion prevention mating part 24 at the socket end for connection with the mating plug. This structure ensures that the plug can only be connected to the mating socket in the one correct direction, preventing serious safety accidents caused by reverse polarity.

[0070] An extended connection portion 25 is also formed on at least one outer surface of the insulating base 21. The extended connection portion 25 is specifically configured as a slide rail portion or slide groove portion extending along a first direction (generally parallel to the insertion direction). The size and specifications of this connection portion are fully matched and compatible with the corresponding connection portion (slide groove portion 15 or slide rail portion 14) on the side of the aforementioned splicable balanced charging terminal module.

[0071] In application, this power plug not only completes the electrical connection of the main circuit through the power terminals at its plug end, but also adds physical expansion capability to the system through the expansion connection part 25 on its side. When it is necessary to add voltage monitoring function to the battery pack, the user only needs to slide the assembled balance charging terminal module (or module array) into the corresponding expansion connection part 25 on the side of the power plug along the first direction mentioned above through the slide rail part 14 or slide groove part 15 on its side to complete the physical integration. The main power plug provides a stable mechanical base and electrical bus platform for the entire expansion module array. The expansion module array and the main plug are connected by a sliding fit structure, which has high connection strength and good stability, and is superior to simple snap-fit ​​or magnetic auxiliary fixing methods. The integration of high current transmission and modular expansion interface is realized on a single plug body, which overturns the traditional design that requires two independent plugs and greatly saves installation space. The user can decide the number of balance charging modules to be connected on site (from 0 to more) according to the specific number of battery packs, realizing the configurability of the power plug itself, and one plug can adapt to multiple battery pack models.

[0072] As an illustration of this embodiment, the anti-misfit mating part 24 is preferably a specific geometric structure disposed at the plug end of the insulating base 21. In a preferred embodiment, this structure is an insulating protrusion with a V-shaped cross-section (corresponding to the male plug) or an insulating groove with a V-shaped cross-section (corresponding to the female plug). Here, "V-shaped" generally refers to the angle formed by the intersection of two planes, including acute and obtuse V-shapes. The key is that it is asymmetrical or has a specific orientation, so that only mating parts with complementary shapes can be fully inserted. When the male plug is mated with the female plug, the V-shaped protrusion on the male plug must be aligned with the V-shaped groove on the female plug for it to be inserted smoothly. Any attempted misalignment (such as a 180-degree rotation) will prevent insertion due to the interference of the V-shaped bevel. This purely mechanical anti-misfit design eliminates the possibility of reversed power polarity due to human negligence.

[0073] It should be noted that the anti-misfit structure in this embodiment is not limited to a V-shape. It can also be any convex-concave fit structure with unique direction, such as trapezoidal fit with trapezoid, offset fit of semi-circular key and keyway. However, the V-shaped structure is the preferred choice due to its simple processing, good guiding properties, and intuitive and reliable error prevention effect.

[0074] As can be seen from the above, the expandable power plug of this embodiment provides a polarity protection that requires no electronic components and never fails, making it particularly suitable for high-energy-density applications such as battery packs where reverse connection has serious consequences. Users can immediately sense whether the alignment is correct by touch during insertion, eliminating the need for visual inspection and improving the user experience. As an illustration of this embodiment, the positive power terminal 22 and negative power terminal 23 located within the insulating base 21 can, but are not limited to, be integrally injection molded with the insulating base 21, ensuring a stable and reliable connection.

[0075] As an illustration of this embodiment, the cross-section of the extension connection portion 25 (slide rail portion or slide groove portion) located on the outer side of the expandable power plug is preferably dovetail-shaped. This is completely consistent with the shape of the connection portion on the balanced charging terminal module, together forming a unified mechanical interface standard within the system. The dovetail-shaped bevel provides superior pull-out retention force.

[0076] The extended connection portion 25 (slide rail portion or slide groove portion) has a main body section extending in a first direction along the same direction as the insert plate, with its two ends being the starting end of the open end and the end of the closed end 17, respectively.

[0077] When the extended connection portion 25 is a sliding groove portion, its closed end is a closed end wall formed at the end of the sliding groove portion along its length. This end wall is perpendicular to the sliding direction, forming a robust stop surface.

[0078] When the extended connection part 25 is a slide rail part, its closed end is a retaining wall formed on the insulating base and protruding outward from the end of the slide rail part. This retaining wall extends from the side of the slide rail part and also serves to limit the sliding of the mating parts.

[0079] This closed-end structure ensures that when the balance charging module slides into the power plug, it forms a clear, insurmountable endpoint. This not only prevents internal mechanism collisions caused by over-insertion, but more importantly, it precisely defines the position of each balance charging module relative to the power plug reference, thereby guaranteeing the relative positional tolerance between the electrical terminals on all expansion modules and the power terminals on the power plug. This ensures the alignment accuracy and reliability when the final combination plug is inserted into the mating socket.

[0080] As an illustration of this embodiment, at least one extension connection portion 25 is formed on each of the two opposite outer surfaces (e.g., the upper and lower surfaces) of the insulating base 21 of the expandable power plug in this embodiment, with the extension connection portions 25 on both sides facing away from each other. This means that the power plug can simultaneously attach a balanced charging module array to both sides.

[0081] For example, a single power plug can connect three balance charging modules to its top surface and three more to its bottom surface. This allows a single power plug to provide an extremely high-density interface configuration with a total of 8 connection points: "2 power terminals + 6 balance charging terminals," sufficient to cover most lithium-ion battery pack applications from 2 to 7 packs (n+1 points are needed to monitor n battery packs). Users can freely choose to connect modules simultaneously to the top, bottom, or sides, depending on the total number of battery packs connected in series.

[0082] As can be seen from the above, the scalable power plug of this embodiment maximizes the number of available sampling points without increasing the size of the plug itself, thus meeting the needs of high-series-count battery packs. It allows the sampling harnesses to be distributed on both sides of the plug, which is beneficial for the wiring and routing management of cables inside the battery pack, reducing harness crossings and tangles.

[0083] As a further illustration of this embodiment, this embodiment also provides an implementation of the power plug as a "power male plug".

[0084] In this embodiment, the positive and negative power terminals are male terminals. They are typically two large, cylindrical or blade-shaped conductors, and their surfaces may be silver-plated or gold-plated to reduce contact resistance and improve corrosion resistance.

[0085] To ensure the stability of the high-current terminals under frequent insertion and removal, the insulating base 21 has a precise mounting cavity. The male terminal has an annular groove or protrusion, and the inner wall of the mounting cavity has an axial locking protrusion that mates with it. Preferably, the axial locking protrusion includes a front locking protrusion and a rear locking protrusion spaced apart along the axial direction. Correspondingly, the male terminal has a front locking structure and a rear locking structure (such as two grooves). When the male terminal is inserted into place from the rear of the mounting cavity, the front and rear locking protrusions respectively engage with the front and rear locking structures, forming a bidirectional axial lock. This design eliminates the possibility of axial movement of the terminal due to force during use, ensuring a constant contact depth, which is crucial for the stability and safety of high-current connections.

[0086] As a further illustration of this embodiment, this embodiment also provides an implementation of the power plug as a "power female plug".

[0087] In this embodiment, the positive and negative terminals of the power supply are female terminals. The female terminal is integrally stamped and bent from a single piece of high conductivity and high elasticity copper alloy sheet (such as tellurium copper or chromium zirconium copper), without riveting or welding points, ensuring optimal current path and mechanical strength.

[0088] Its structure includes: a base portion 26 (for fixation and conductivity), two parallel cantilever arms 27 (main elastic members extending from the base portion 26), and contact portions 28 located at the free ends of the cantilever arms 27. The contact portion 28 at the free end of each cantilever arm 27 forms a U-shaped bend by bending inwards (i.e., in the opposite direction of the two cantilever arms 27). These two U-shaped structures are spatially parallel: their closed ends 17 (i.e., the bottom of the U-shape) are located side-by-side on the same side (near the front of the free end of the cantilever arm 27), while their open ends are located side-by-side on the other side (bent back towards the root of the cantilever arm 27). Between these two parallel U-shaped structures, a flexible socket for the female terminal is formed.

[0089] When the male terminal is inserted into this parallel double U-shaped structure, both U-shapes are simultaneously pushed outwards, and the cantilever 27 itself undergoes elastic bending. This design transforms a single insertion force into distributed elastic pressure in four directions, maximizing the contact area.

[0090] When the male terminal is inserted into this flexible socket, it simultaneously contacts the opposing inner arms of the two U-shaped structures. The insertion of the male terminal expands these two opposing U-shaped arms, causing them to elastically deform, thereby creating a strong and stable contact pressure perpendicular to the insertion direction (radial). This structure is equivalent to establishing four parallel flexible contact points in the current path, achieving a doubling of contact area and reliability.

[0091] Experimental comparison: Test subject: A) The present invention features parallel double U-shaped contact female terminals; B) Traditional single-arm cantilever high-current female terminal.

[0092] Test conditions: Continuously pass a 100A DC current and monitor the temperature rise.

[0093] Results: For the same volume, the temperature rise of the terminal pair in Solution A is more than 40% lower than that in Solution B. Under rated temperature rise limits, the continuous current carrying capacity of a single terminal in Solution A can exceed 150A, while that in Solution B is typically below 100A.

[0094] Contact resistance: Scheme A is stable below 0.1mΩ, which is only 1 / 3 to 1 / 2 of that of Scheme B.

[0095] As an illustration of this embodiment, a preferred manufacturing process for a power female connector is also provided. The power female connector is manufactured using an insert molding process. First, the stamped female terminal is precisely placed in the mold cavity. Then, molten insulating plastic material is injected into the mold. Under high pressure, the plastic encapsulates the base 26 and part of the structure of the female terminal. After cooling, an insulating base 21 and a terminal are formed as a single integrated component. Using this method, the plastic and metal are bonded at the microscopic level, resulting in a terminal pull-out resistance far exceeding that of later press-fit structures. This completely prevents moisture or dust from entering through the gaps between the terminal and the plastic shell, improving the product's environmental resistance. The position of the terminal within the plastic shell is ensured by the mold, resulting in excellent consistency and precise alignment with the male connector.

[0096] As an illustration of this embodiment, a cable sheath can also be provided at one end of the insulating base 21 facing away from the connector (i.e., the tail). The cable sheath is usually made of soft PVC or rubber material and is firmly connected to the snap-fit ​​connection structure (such as a claw and a groove) at the tail of the insulating base 21 by means of snaps on it. The inside of the cable sheath may have, but is not limited to, stepped holes, for gripping the cable sheath tightly, dispersing the bending stress of the cable, and preventing stress from being directly transmitted to the terminal soldering point, greatly reducing the risk of internal wire breakage due to cable bending.

[0097] As an illustration of this embodiment, the outer wall of the insulating base 21 may be further designed with recesses or protrusions to facilitate hand gripping. This could be longitudinal anti-slip knurling, a wavy curved surface, or symmetrical finger grip recesses. This design increases the friction between the fingers and the plug during insertion and removal, providing a stable grip even if the user's hands are sweaty or oily, making insertion and removal operations easier and more reliable.

[0098] Example 3: Charging and discharging combination plug.

[0099] See Figures 21-24 .

[0100] The charging and discharging combination plug of this embodiment consists of the expandable power plug described in detail in Embodiment 2 and at least one splicable balanced charging terminal module described in detail in Embodiment 1.

[0101] The positive and negative terminals 22 and 23 within the expandable power plug serve as high-current charging and discharging channels for the main circuit (positive and negative terminals) of the battery pack. The point terminals within each connectable balance charging terminal module provide voltage acquisition points. The balance charging terminal module is detachably slidably inserted into the corresponding extended connection portion 25 (slide groove 15 or slide rail 14) on the outer side of the insulating base 21 of the power plug via a slide rail portion 14 or slide groove portion 15 on the side of its insulating housing 11, along a specific direction (a first direction in the same direction as the insertion direction).

[0102] Users can determine the required number of voltage sampling points (usually S+1) based on the number of series (S number) of the target battery pack, and then take out the corresponding number of balance charging terminal modules. These modules are then slid into the side extension connection portion 25 of the power plug one by one or in groups through their standardized side interfaces until the bottom of the slide rail portion 14 (or slide groove portion 15) of each module contacts and is limited by the closed end 17 of the extension connection portion 25. At this point, the two power terminals of the power plug and the electrical terminals 12 of all the connected balance charging modules together form an integrated multi-pin connection interface.

[0103] This combination plug can be directly used as a single component to be plugged into the corresponding integrated socket (female end) on the battery pack casing, thereby simultaneously completing the connection of the main power supply and all voltage acquisition lines.

[0104] This solution allows users to connect both power and signal lines simultaneously by simply plugging and unplugging a single combination plug, completely eliminating the cumbersome and error-prone process of operating multiple plugs separately in traditional solutions, significantly improving the user experience. All electrical connections are completed in a single plug-in action, reducing the number of independent connection points and lowering the probability of system failures due to loose connections, contamination, or damage to individual interfaces. The lateral modular integration method achieves a high degree of condensation of connectivity functions in three-dimensional space, freeing up more space for the valuable BMS (Battery Management System) layout and heat dissipation within the battery pack.

[0105] In application, the required number of balanced charging terminal modules are first externally spliced ​​together via their side rails 14 and grooves 15 to form a pre-assembled module array before being connected to the power plug. For example, for a 6S battery pack, seven modules can be connected end-to-end in a straight line. Then, this complete module array is slidably inserted into the side extension connection 25 of the power plug in one go via the rail 14 (or groove 15) of one of the end modules. This method allows for delicate module splicing work (such as welding sampling lines) to be completed on the workbench before final assembly with the power plug. It is particularly suitable for assembly in confined spaces or for mass production using automated equipment. The module array, as a more rigid whole, has better guidance when spliced ​​with the power plug and is less prone to jamming.

[0106] For example, taking the assembly of a 7-pin (6S) balanced charging harness and its integration into a power plug as an example, the traditional method requires preparing a 7-pin fixed balanced charging plug, soldering 7 wires, and then separately processing the power plug. Using the solution in this embodiment, the user only needs to take 7 modules, solder the wires, assemble them into an array, and then connect them to the power plug. Practice has shown that the total assembly time using this embodiment is reduced by an average of 35% compared to the traditional method, mainly due to the savings in accurately arranging and fixing multiple loose wires to the correct positions.

[0107] This embodiment supports offline pre-assembly and assembly line operations, making it suitable for large-scale production and reducing labor costs and error rates. If a data acquisition channel is damaged, the entire module array can be disassembled, the faulty module replaced, and then reassembled, making maintenance convenient and cost-effective. Regardless of the number of voltage sampling points required, the splicing method is completely identical, greatly simplifying production tools and operating instructions.

[0108] As an illustration of this embodiment, this embodiment provides a high-integration-density charging and discharging combination plug. Its power plug has extension connection portions 25 on both opposite outer surfaces. A first balanced charging terminal module or module array (e.g., 3 modules) is attached to its first outer surface (e.g., the upper surface), while another second balanced charging terminal module or module array (e.g., 3 modules) is attached to its second outer surface (e.g., the lower surface). This allows a single combination plug to provide a total of 2 (positive and negative power terminals) + N1 (upper module) + N2 (lower module) electrical connection points.

[0109] Taking the most common battery packs used in drones and power tools as an example (2S-7S), a preferred configuration is as follows: the power plug body provides two power terminals, positive and negative; three balance charging modules are attached to its upper side (forming four sampling points: P0, P1, P2, P3); and three balance charging modules are attached to its lower side (forming four sampling points: P3, P4, P5, P6). Here, the module arrays on the upper and lower sides are connected in parallel inside the plug through a shared electrical connection point (e.g., P3), thus providing a total of eight physical connection points, which can fully monitor seven series-connected cells S1, S2...S7 (requiring eight sampling points). By soldering only the required sampling lines, this same combination plug physical structure can seamlessly adapt to battery packs from 2S to 7S.

[0110] Example 4: A battery pack including a combination plug.

[0111] See Figure 25 .

[0112] The battery pack in this embodiment includes: Cell pack: Multiple lithium-ion cells S1, S2...Sn are connected in series to form a battery pack with a total positive electrode (B+) and a total negative electrode (B-).

[0113] Charge / discharge connector: As detailed in Example 3, the charge / discharge connector serves as the external electrical interface of the battery pack and is fixedly installed on the battery pack casing.

[0114] Its electrical connections are as follows: Main circuit connection: The main positive terminal (B+) of the battery pack is soldered or screwed to the soldering part of the power positive terminal 22 of the combination plug through a large cross-section wire; the main negative terminal (B-) is similarly connected to the power negative terminal 23.

[0115] Voltage acquisition circuit connection: The voltage acquisition points between every two adjacent cells in the battery pack (e.g., B1, B2, ..., Bn) are soldered to the electrical terminals 12 of each balance charging terminal module via corresponding sampling wires. The order of the acquisition points corresponds one-to-one with the physical order of the modules in the array.

[0116] The combination plug is securely fixed in the pre-drilled opening in the battery pack casing via mounting ears or snap-fit ​​structures on its insulating base 21. Its connector protrudes from the casing for easy insertion and removal; the tail end with a protective sleeve is located inside the casing and connects to the internal wiring harness.

[0117] When an external charger or load is plugged into the corresponding socket of this combination plug, the following synchronous electrical connection occurs: The high-current contacts of the external socket are connected to the positive and negative terminals of the power supply of the combination plug to establish the main energy channel.

[0118] Multiple signal pins in the external socket are connected to the electrical terminals 12 of each balanced charging module on the combination plug, transmitting the voltage signals of all cells S1, S2...Sn in the battery pack to the external BMS or monitoring circuit in real time.

[0119] Thanks to the anti-misinsertion structure, reverse polarity is impossible during this process. The entire battery pack can safely and completely perform all functions of charging, discharging, and intelligent monitoring through this single interface.

[0120] A comparative test was conducted between the 7S battery pack (nominal 25.9V) using the combination plug of this invention and the traditional dual-plug battery pack: Connection reliability after drop test: After a 6-sided directional drop test from a height of 1 meter, the contact resistance change rate of all sampling points in the present invention is <3%, and the voltage reading does not fluctuate; in the traditional solution, 30% of the samples show momentary disconnection at individual sampling points.

[0121] High-rate discharge temperature rise: Under continuous discharge at 3C rate, the temperature rise of the terminal area of ​​the combination plug of the present invention is 15-20°C lower than that of the traditional solution, proving that its high-current path impedance is lower and its heat dissipation is better.

[0122] Anti-misoperation test: When a user attempts to insert the device in reverse, the solution of this invention cannot be inserted 100% of the time; the traditional solution relies on visual identification by the user, which poses a risk of misoperation.

[0123] The above embodiments do not constitute a limitation on the scope of protection of this technical solution. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the above embodiments should be included within the scope of protection of this technical solution.

Claims

1. A modular balanced charging terminal module, characterized in that, include: An insulating housing, and at least one electrical terminal disposed within the insulating housing; On at least one set of opposite sides of the insulating housing, there are respectively a slide rail portion protruding from the side and a slide groove portion recessed into the side, and the shape of the slide rail portion matches the shape of the slide groove portion. The slide rail is configured to be detachably slidably inserted into the slide groove of another balanced charging terminal module, or detachably slidably inserted into the corresponding slide groove on a power plug.

2. The connectable balanced charging terminal module according to claim 1, characterized in that, The cross-sections of the slide rail and the slide groove are complementary dovetail shapes.

3. The connectable balanced charging terminal module according to claim 2, characterized in that, The slide rail and the slide groove are respectively provided on the two sets of opposite sides of the insulating housing.

4. The splicable balanced charging terminal module according to claim 1, 2, or 3, characterized in that, Each of the aforementioned groove portions has a first end and a second end that are opposite to each other along its length. The first end is an open slot facing the end face of the insulating housing, which serves as a connector. The second end is a closed end located on the side where it is located.

5. The splicable balanced charging terminal module according to claim 1, 2, or 3, characterized in that, The connector of the electrical terminal is a male terminal.

6. The connectable balanced charging terminal module according to claim 1, 2, or 3, characterized in that, The connector of the electrical terminal is a female terminal.

7. The splicable balanced charging terminal module according to claim 6, characterized in that, The female terminal is provided with at least one elastic contact piece, and the elastic conductor contact piece has a contact portion that intersects with the insertion direction of the electrical terminal.

8. An expandable power plug for a battery pack, characterized in that, include: Insulating base, The positive and negative power terminals are fixed within the insulating base. An anti-mis-insertion mating part is provided at the insertion end of the insulating base. And an extended connection portion provided on at least one outer side of the insulating base; The extended connection portion is a slide rail portion or a slide groove portion extending along the first direction; The slide rail or slide groove has a main body segment extending along the first direction. The main body segment has a starting end and an ending end on the insulating base. The starting end is formed as an open end, and the ending end is a closed end opposite to the starting end.

9. A charging and discharging connector for a battery pack, characterized in that, include: The expandable power connector for a battery pack as described in any one of claims 10 to 22, and At least one splicable balanced charging terminal module as described in any one of claims 1 to 9; At least one of the balanced charging terminal modules is detachably slidably connected to the extended connection portion on the outside of the power plug via a slide rail or slide groove thereon.

10. A battery pack, characterized in that, include: At least two cells connected in series, and The charging and discharging combination plug according to any one of claims 23 to 25; The positive and negative terminals of the charging and discharging connector are electrically connected to the total positive and negative terminals of the battery pack, respectively, for charging and discharging. The electrical terminals of each balanced charging terminal module on the charging and discharging combination plug are electrically connected to the voltage acquisition points between the corresponding battery cells, for monitoring the voltage of each battery cell or battery cell group.

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