Large-current output conductive output pole fixing device

Abstract

The utility model relates to the technical field of new energy, in particular to a large-current output conductive output pole fixing device. Comprising a laser welding flat cable, a battery pack locking connecting plate, a rubber-coated core structure fixing plate and a product fixing and mounting structure. Wherein the laser welding flat cable is connected with the battery pack locking connecting plate, an integrated structure comprising an aluminum layer and a copper layer is formed through an integrated forming process, and the outside of the integrated structure is subjected to nickel electroplating treatment; the product fixing and mounting structure is provided with barbs in various forms, so that the fixing effect is enhanced; and the rubber-coated core structure fixing plate is provided with bolt holes and is riveted with nuts, so that stable assembly is ensured. The effects of improving the electrical connection reliability, optimizing the heat dissipation performance and simplifying the assembly process are achieved, meanwhile, loosening is effectively prevented, and the overall safety and use convenience are improved.

Description

Technical Field

[0001] The present application relates to the field of new energy technology, and in particular to a device for fixing a conductive output pole with high current output. Background Art

[0002] In the field of new energy vehicles, with the continuous development of battery technology, the PACK battery pack, as one of the core components, has increasingly higher requirements in terms of energy transmission efficiency and safety. As an important component of the PACK battery pack, the CCS component undertakes the key functions of power distribution and management, and its performance directly affects the power performance and endurance of the vehicle. In order to ensure stable operation under high power output environment, the design of the conductive output pole fixing device is particularly important.

[0003] Traditionally, the fixation of high-current output conductive output poles mostly relies on simple metal plates with welding processes or stamping parts of a single material to achieve functional requirements. For example, the widely used aluminum material is welded with nickel sheets and then stamped, and then the initial assembly and positioning are completed with the help of a blister tray, and finally fixed by hot melting. In addition, there are some other common methods, such as pure copper conductors reinforced with insulating sleeves, or bent steel plates embedded in plastic frames to form a clamping structure.

[0004] However, these traditional practices generally face a problem, that is, due to the limitations of material properties and structural design, the products are prone to insufficient wear strength and the risk of loosening during actual application. This is especially true in the vibration environment generated by vehicle driving, which will affect the reliability and service life of the entire system.

[0005] Therefore, based on the above problems, the prior art needs to be improved. Utility Model Content

[0006] The purpose of the present application is to provide a high current output conductive output pole fixing device.

[0007] The above technical objectives of the present application are achieved through the following technical solutions: A high current output conductive output pole fixing device, comprising:

[0008] Laser welding wiring;

[0009] The battery pack locking connecting plate is connected to the laser welding cable and is used to lock tightly with the battery pack to provide a stable installation foundation for the entire device.

[0010] The rubber core structure fixing plate is connected to the battery pack locking connecting plate.

[0011] The product fixed installation structure is installed on the fixed plate of the rubber-coated core structure and is provided with an identifier for distinguishing the positive and negative poles.

[0012] By adopting the above technical solutions, the design of laser welding cable can effectively improve the conductivity, while reducing the traditional nickel welding process and precision cutting and stamping steps, reducing costs and improving efficiency; the battery pack locking connection plate is connected to the laser welding cable to ensure tight locking between the device and the battery pack, provide a stable installation foundation, and reduce the risk of loosening due to vehicle vibration; the rubber core structure fixing plate is connected to the battery pack locking connection plate, which not only enhances the overall structural strength, but also increases the conductive area and improves the current transmission capacity; the identifier for distinguishing between the positive and negative poles set on the product fixed installation structure effectively prevents installation errors and improves the safety and reliability of use.

[0013] Optionally, the laser welded cable, the battery pack locking connecting plate and the rubber core structure fixing plate are formed into an integrated structure through an integrated molding process, and the integrated structure consists of an aluminum layer with a thickness of two-thirds and a copper layer with a thickness of one-third.

[0014] By adopting the above technical solution, the laser welding wiring, battery pack locking connection plate and rubber core structure fixing plate are integrated into one, which improves the strength and stability of the overall structure, reduces the assembly process and improves production efficiency. The one-piece structure is composed of an aluminum layer and a copper layer, of which the aluminum layer accounts for two-thirds and the copper layer accounts for one-third, making full use of the advantages of the two metal materials. The aluminum layer has good conductivity and heat dissipation while reducing weight; the copper layer further enhances the conductivity, ensuring that the device can carry a larger current and meet the needs of instantaneous high-current charging of new energy vehicles.

[0015] Optionally, a groove is provided on the laser welding cable, and the groove removes the copper layer in the one-piece structure to expose the aluminum layer, so as to utilize the characteristics of the aluminum layer to meet specific conductivity or connection requirements.

[0016] By adopting the above technical solution, a sink groove is set on the laser welding cable, and the copper layer in the one-piece structure is removed to expose the aluminum layer, thereby utilizing the characteristics of the aluminum layer to meet specific conductivity or connection requirements. This design solution can give full play to the excellent conductivity and connection reliability of the aluminum layer, while ensuring high current transmission efficiency, reducing contact resistance, and improving the electrical performance and stability of the overall device.

[0017] Optionally, the outer surface of the one-piece structure is electroplated with nickel.

[0018] By adopting the above technical solution, the outer surface of the one-piece structure is electroplated with nickel, which can significantly improve the corrosion resistance of the product and extend the service life of the product under complex working conditions. At the same time, the electroplated nickel layer can also enhance the surface hardness and reduce wear, thereby ensuring the long-term stable operation of the device. In addition, this treatment method also improves the appearance quality of the one-piece structure and improves the overall reliability of the product.

[0019] Optionally, a barb is provided on the product fixing installation structure.

[0020] By adopting the above technical solution, the barbs are set on the fixed installation structure of the product, which can enhance the connection firmness between the fixing device and the installation object and effectively prevent loosening caused by vibration or external force. Specifically, the barb design increases the friction and mechanical bite force after assembly, thereby improving the stability of the overall structure, which is particularly suitable for application scenarios in the automotive environment that need to withstand frequent vibrations. In addition, this design also simplifies the installation process and improves assembly efficiency.

[0021] Optionally, there are a plurality of barbs, and the structures of the plurality of barbs are arranged in different forms; the barbs of different structures include differences in shape, size, inclination angle or arrangement.

[0022] By adopting the above technical solution, the design of multiple barbs enhances the connection reliability between the product's fixed installation structure and the assembly object. Specifically, different forms of barbs (including differences in shape, size, tilt angle or arrangement) can adapt to different stress conditions, thereby effectively preventing loosening caused by force in a single direction and significantly improving the overall stability of the fixing device. At the same time, this design also improves the versatility and applicability of the product and meets the fixing requirements under complex working conditions.

[0023] Optionally, bolt holes are provided on the fixing plate of the rubber-coated core structure.

[0024] By adopting the above technical solution, the effect of setting bolt holes on the fixing plate of the rubber core structure is achieved. This design enables the fixing plate to be reliably connected with other components through bolts, enhances the overall stability of the device, and facilitates assembly and maintenance operations, ensuring the firmness and convenience of the large current output conductive output pole fixing device in practical applications.

[0025] Optionally, nuts are riveted onto the fixing plate of the rubber-coated core structure at positions corresponding to the bolt holes.

[0026] By adopting the above technical solution, nuts are riveted on the corresponding bolt holes on the fixing plate of the rubber-coated core structure, making the product more stable and reliable during installation. Specifically, this design enhances the vibration resistance of the fixing device and effectively reduces the risk of loosening caused by vibration during vehicle driving, thereby improving the stability and safety of the overall structure. At the same time, this design simplifies the assembly process and improves production efficiency.

[0027] In summary, the present application includes at least one of the following beneficial technical effects:

[0028] 1. The one-piece structure of aluminum and copper layers not only improves the hardness and conductivity of the product, but also can carry a large current output of up to 450A, while reducing the product size, effectively meeting the needs of instantaneous high current charging of new energy vehicles;

[0029] 2. The design of the barb structure and the one-piece molding of the nut and the stainless steel sleeve significantly enhances the strength and stability of the fixing device, reduces the risk of loosening caused by vehicle vibration, and improves system reliability;

[0030] 3. The surface is treated with nickel electroplating, which greatly improves the corrosion resistance of the product, allowing the salt spray test to last up to 72 hours, extending the service life and adapting to complex working environments. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is a structural schematic diagram of a large current output conductive output pole fixing device;

[0032] Figure 2 It is a structural diagram of laser welding cable, battery pack locking connection plate and rubber core structure fixing plate;

[0033] Figure 3 It is a schematic diagram of the structure of the barb.

[0034] Reference numerals

[0035] 1. Laser welding wiring; 2. Battery pack locking connection plate; 3. Rubber core structure fixing plate; 4. Product fixing installation structure; 101. Aluminum layer; 102. Copper layer; 5. Gong sink groove; 6. Barb; 7. Bolt hole; 8. Nut. DETAILED DESCRIPTION

[0036] The present application is further described in detail below in conjunction with the accompanying drawings.

[0037] Embodiment 1, in this embodiment, refer to Figure 1-3 A high-current output conductive output pole fixing device includes a laser welding cable 1, a battery pack locking connection plate 2, a rubber core structure fixing plate 3 and a product fixing installation structure 4.

[0038] Specifically, the laser welded cable 1 is made of a copper-aluminum composite material, which adopts a standard configuration with a thickness ratio of 2:1, and uses an aluminum layer 101 with a thickness of two-thirds and a copper layer 102 with a thickness of one-third (copper-aluminum composite material 1060-OV2). This material has the good electrical conductivity and heat dissipation of aluminum and the excellent electrical conductivity of copper, providing an ideal foundation for the subsequent production of devices.

[0039] The laser welding cable 1, battery pack locking connection plate 2 and rubber core structure fixing plate 3 are made into an integrated structure by using metal stamping and one-piece molding process. During the stamping process, the mold accuracy and stamping parameters are precisely controlled to ensure the precise size and stable structure of each part, enhance the overall strength, reduce assembly processes and improve production efficiency.

[0040] On the integrally formed laser welded flat cable 1, the copper layer 102 at a specific location is precisely removed through CNC groove processing 5, so that the aluminum layer 101 is exposed to form grooves 5. This design utilizes the characteristics of the aluminum layer 101 to meet specific electrical conduction or connection requirements, reduce contact resistance, and improve high current transmission efficiency.

[0041] The outer surface of the one-piece structure is electroplated with nickel. Electroplating nickel can enhance the corrosion resistance of the product, allowing the product to last up to 72 hours in the salt spray test, extending its service life; at the same time, it increases the surface hardness, reduces wear, ensures long-term stable operation of the device, and improves the appearance quality.

[0042] Bolt holes 7 are provided on the fixing plate 3 of the rubber core structure, and nuts 8 are riveted with special riveting equipment at positions corresponding to the bolt holes 7. Ensure that the nuts 8 and the bolt holes 7 are tightly matched and riveted firmly, enhance the vibration resistance of the fixing device, facilitate subsequent bolt connection, simplify the assembly process, and improve the stability and safety of the overall structure.

[0043] The product fixing and mounting structure 4 is manufactured by injection molding process. During the manufacturing process, a plurality of barbs 6 of different forms are provided, and these barbs 6 are different in shape, size, inclination angle or arrangement. For example, some barbs 6 are designed to be sharp in shape to increase the bite force, some are larger in size to meet the needs of large-area fixing, and barbs 6 with different inclination angles provide anti-slip resistance in different directions. At the same time, identifiers for distinguishing between positive and negative poles, such as different colors or specific symbols, are provided on the product fixing and mounting structure 4. After the manufacturing is completed, the product fixing and mounting structure 4 is assembled with the processed one-piece molded structural components by bolt connection to complete the preparation of the fixing device.

[0044] When assembling the PACK battery pack of a new energy vehicle, the prepared battery pack locking connecting plate 2 of the fixing device is tightly locked with the battery pack. The structural design of the battery pack locking connecting plate 2 ensures a stable connection and provides a reliable installation foundation for the entire device. The product fixing installation structure 4 is used to fix other electrical components, and is tightly combined with the installation object through the barb 6 to prevent loosening due to vehicle vibration or external force. Accurately complete the electrical connection based on the positive and negative electrode identifiers to avoid reverse connection that affects the normal operation of the battery pack, thereby improving the safety and reliability of use.

[0045] Embodiment 2: This embodiment is different from the above embodiment in that: on the basis of the original copper-aluminum composite material, a trace amount of rare earth elements (such as cerium, the addition amount is 0.1%-0.3%) is added to the aluminum layer 101. Rare earth elements can refine the grain structure of aluminum, improve the stability of the aluminum layer 101 at extreme temperatures, enhance its anti-oxidation and anti-thermal expansion and contraction capabilities, and ensure that in an extreme temperature environment of -40°C to 85°C, the material performance fluctuation is minimal, and good electrical conductivity and heat dissipation performance are maintained.

[0046] A layer of thermally conductive insulating silicone pad is added between the rubber core structure fixing plate 3 and the battery pack locking connection plate 2. The silicone pad has high thermal conductivity (≥5W / (m・K)) and good insulation performance (breakdown voltage ≥15kV / mm), which can effectively conduct the heat generated by the battery pack to avoid local accumulation of heat and prevent electrical short circuits between different components. In low temperature environments, the flexibility of the silicone pad can compensate for the gaps caused by shrinkage of components and enhance structural stability; at high temperatures, it can effectively buffer the expansion stress of components and reduce the risk of structural damage caused by thermal stress.

[0047] According to the original process, the one-piece structure is prepared, and the groove 5 is processed on the laser welding cable 1, and the nickel plating is performed. After completion, the thermally conductive insulating silicone pad is pasted between the rubber core structure fixing plate 3 and the battery pack locking connection plate 2, and then the product fixing installation structure 4 is assembled. When used in new energy vehicle battery packs in extremely cold or hot areas, the reliability and durability of the device can be significantly improved, ensuring the stable operation of the battery pack under extreme temperatures.

[0048] Embodiment 3, this embodiment is different from the above embodiment in that: in view of the characteristics of thin air and poor heat dissipation conditions in high altitude areas, a layer of porous ceramic membrane is prepared on the surface of the aluminum layer 101 of the one-piece structure by micro-arc oxidation technology. The porosity of the ceramic membrane is controlled at 15%-25%, the thickness is 20-30μm, and it has good heat insulation and heat dissipation properties. Its porous structure can increase the heat dissipation area and promote heat dissipation. At the same time, the high hardness and chemical stability of the ceramic membrane can effectively resist the strong ultraviolet rays and wind and sand erosion in high altitude areas, and extend the service life of the device.

[0049] A circle of anti-wind and sand skirt is added to the product fixing and mounting structure 4. The skirt is made of fluororubber material that is flexible, wear-resistant and has a certain elasticity, and its height is 10-15mm. The skirt can effectively prevent wind and sand from entering the device, avoid the wear of the connection parts and conductive parts by wind and sand, ensure the close connection between the barb 6 and the installation object, and enhance the stability of the fixing device in the high-altitude wind and sand environment.

[0050] First, the aluminum layer 101 of the one-piece structure is subjected to micro-arc oxidation treatment, and then the subsequent steps of gong sink 5 processing, electroplating nickel treatment, etc. are carried out. When assembling the product fixing installation structure 4, the fluororubber skirt is installed on its edge. Used in battery packs of new energy vehicles, energy storage power stations and other equipment in high-altitude areas, it can effectively solve the heat dissipation and wind and sand erosion problems caused by the high-altitude environment, and ensure the stable operation of the large current output conductive output pole fixing device.

[0051] Embodiment 4, this embodiment is different from the above embodiments in that: for application scenarios with extremely high weight requirements (such as electric aircraft), the copper layer 102 in the one-piece structure is partially replaced with a carbon fiber reinforced copper-based composite material. Among them, the carbon fiber content is 10%-15% (volume fraction). The carbon fiber reinforced copper-based composite material has both the good conductivity of copper and the high strength and low density characteristics of carbon fiber. While ensuring the conductive performance, it can greatly reduce the weight of the device, which is 15%-20% lighter than the original device.

[0052] The entire device is potted using a potting process and fully encapsulated with silicone potting glue. The potting glue has a hardness of Shore A60-70 and a tensile strength of ≥3MPa. It has good electrical insulation properties (volume resistivity ≥10¹²Ω・cm) and waterproof and dustproof properties (protection level up to IP68). After potting, the device forms a sealed whole, effectively preventing the entry of external water vapor, dust and foreign matter, protecting the internal conductive and connection structures, and enhancing the overall structural strength of the device to resist external shocks and vibrations.

[0053] First, prepare an integrated structure containing carbon fiber reinforced copper-based composite materials, process the gong sink 5 and perform surface treatment, assemble the product fixing installation structure 4, and then perform the potting operation. It is used in battery packs of electric aircraft, high-performance electric vehicles and other equipment that have strict requirements on weight and protection level, which can not only meet the lightweight requirements, but also ensure reliable operation in complex environments, and improve the overall performance and safety of the equipment.

[0054] The embodiments of this specific implementation method are all preferred embodiments of the present application, and are not intended to limit the protection scope of the present application. Therefore, all equivalent changes made based on the structure, shape, and principle of the present application should be included in the protection scope of the present application.

Claims

1. A high current output conductive output pole fixing device, characterized in that: include: Laser welding cable (1); A battery pack locking connection plate (2) connected to the laser welding cable (1) and used to be tightly locked with the battery pack to provide a stable installation foundation for the entire device; A rubber core structure fixing plate (3) connected to the battery pack locking connection plate (2); The product fixing installation structure (4) is installed on the rubber-coated core structure fixing plate (3) and is provided with an identifier for distinguishing between positive and negative electrodes.

2. A high current output conductive output pole fixing device according to claim 1, characterized in that: The laser welded flat cable (1), the battery pack locking connection plate (2), and the rubber core structure fixing plate (3) are formed into an integrally formed structure through an integral forming process, and the integrally formed structure is composed of an aluminum layer (101) accounting for two thirds of the thickness and a copper layer (102) accounting for one third of the thickness.

3. A high current output conductive output pole fixing device according to claim 2, characterized in that: The laser welding cable (1) is provided with a gong sink groove (5).

4. A high current output conductive output pole fixing device according to claim 2, characterized in that: The outer surface of the integrally formed structure is electroplated with nickel.

5. A high current output conductive output pole fixing device according to claim 1, characterized in that: The product fixing and mounting structure (4) is provided with a barb (6).

6. A high current output conductive output pole fixing device according to claim 5, characterized in that: The barbs (6) are provided in plurality.

7. A high current output conductive output pole fixing device according to claim 1, characterized in that: The rubber-coated core structure fixing plate (3) is provided with bolt holes (7).

8. A high current output conductive output pole fixing device according to claim 7, characterized in that: Nuts (8) are riveted onto the rubber-coated core structure fixing plate (3) at positions corresponding to the bolt holes (7).

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