Liquid-cooled charging station end power conversion connector

Abstract

The utility model discloses a liquid-cooled charging station end power conversion connector. The charging station end power conversion connector comprises two liquid cooling terminal modules and a shell assembly, the liquid cooling terminal module comprises an outer pipe made of a polymer plastic material and a jack piece made of a metal material, the outer pipe is integrally formed outside the jack piece in an injection molding mode, the middle of an axial pipe hole of the outer pipe is in clearance connection with the peripheral wall of the jack piece, the pipe hole is integrally connected with the two axial ends of the jack piece in an injection molding mode, and a closed cooling ring groove is formed. One end of each outer pipe is provided with a liquid inlet and a liquid outlet which are communicated with the cooling ring groove, and the liquid inlet and the liquid outlet are communicated with a liquid inlet and outlet pipe of a cooling liquid circulating system; and the two liquid cooling terminal modules are fixedly connected in the shell assembly. The electric connector has the advantages that the structure is simple, the heat dissipation capability is good, the temperature rise of the connector is reduced, the current-carrying capability of the connector is effectively improved, the temperature when a battery pack is charged is reduced, and the safety performance is high.

Description

TECHNICAL FIELD

[0001] The utility model relates to the field of battery swap connector, especially to a liquid cooling charging station end battery swap connector. BACKGROUND

[0002] With the rapid popularization of new energy products, the battery swap connector is widely used in the efficient transmission of electric energy and charging and discharging. At present, the steady-state current of the battery pack charging in the battery swap station is about 300A. People increasingly pursue to reduce the charging time, so it is necessary to improve the steady-state current to more than 400A (such as 450A, 550A). The defects are as follows: first, when the charging current is improved, the size of the terminal contact needs to be increased to improve the current-carrying capacity. The size of the connector will be larger, and the installation opening size will also be very large, so the battery capacity of the battery pack will be reduced, and the endurance of the electric vehicle will be reduced; second, when the charging current is improved, more heat is generated, and the heat dissipation capacity of the connector needs to be higher. The heat dissipation of the current connector is slow, and the heat cannot be quickly discharged. The temperature rise value of the large current working condition will be much higher than 55K. The conventional increase of the terminal cross-sectional area and the cable cross-sectional area cannot meet the performance requirements, and the cost is greatly increased; third, the high temperature of the battery leads to the reduction of the battery performance, and affects the service life of the product. Therefore, the current cooling structure cannot meet the demand of large power, and is easy to appear hot, overheat and even ablation, which has safety hidden danger. SUMMARY

[0003] In order to solve one or more of the above problems, the utility model provides a liquid cooling charging station end battery swap connector.

[0004] According to one aspect of the utility model, the liquid cooling charging station end battery swap connector comprises: a plurality of liquid cooling terminal modules and a shell assembly.

[0005] The liquid cooling terminal module comprises an outer tube of high molecular plastic material and a jack of metal material. The outer tube is integrally injection molded with the jack. The middle section of the axial tube hole of the outer tube is connected with the outer peripheral wall of the jack with a gap, and the upper positioning ring and the lower positioning ring at both ends of the tube hole are integrally injection molded with the axial two ends of the jack to form a closed cooling ring groove. Each outer tube is provided with a liquid inlet and a liquid outlet which are connected with the cooling ring groove. The liquid inlet and the liquid outlet are connected with the inlet and outlet liquid pipes of the cooling liquid circulation system.

[0006] The plurality of liquid cooling terminal modules are fixedly connected in the shell assembly.

[0007] In some embodiments, the upper end of the middle body of the jack forms a small-diameter upper connecting section, and the lower end forms a small-diameter lower connecting section. The inner ring wall of the upper positioning ring is integrally injection molded to connect the upper connecting section, and the inner ring wall of the lower positioning ring is integrally injection molded to connect the lower connecting section.

[0008] In some embodiments, the upper end of the intermediate body and the upper connecting section form an upper shaft shoulder, and the inner hole edge of the upper positioning ring extends vertically inward to form an inner ring sleeve which is integrally injection molded with the outer wall of the upper connecting section and is attached to the upper shaft shoulder at the lower end.

[0009] In some embodiments, the lower end of the intermediate body and the lower connecting section form a lower shaft shoulder, and the upper wall of the lower positioning ring is attached to the lower shaft shoulder; the lower shaft shoulder is also provided with a conical groove, and the upper end of the upper positioning ring is provided with a convex rib which is integrally injection molded with the conical groove.

[0010] In some embodiments, the liquid inlet and the liquid outlet are straight-angle bent pipes which are integrally and symmetrically formed on the outer wall of the outer tube, and the pipe holes of the straight-angle bent pipes are connected to the two sides of the end of the cooling ring groove; the lotus-shaped interface at the outer end of the straight-angle bent pipe is connected to the inlet and outlet liquid pipes of the cooling liquid circulation system by interference insertion.

[0011] In some embodiments, the central screw thread at the upper end of the jack plug is connected to the copper bar by a first screw;

[0012] or the fixed groove at the lower end of the jack plug cavity is connected to the spring leaf by interference.

[0013] or the outer wall of the outer tube is also provided with a positioning shaft shoulder.

[0014] In some embodiments, a turbulent structure is arranged in the cooling ring groove.

[0015] In some embodiments, the turbulent structure divides the cooling ring groove into a plurality of vertical guide grooves which are symmetrically arranged on both sides of the transverse center line of the liquid inlet and the liquid outlet; the guide passage openings of the guide grooves on each side are alternately arranged at the upper end and the lower end; the guide grooves on each side are connected through the guide passage openings at the upper end and the guide passage openings at the lower end, forming a double-circulation cooling passage arranged on the outer peripheral wall of the jack plug.

[0016] In some embodiments, the turbulent structure includes a plurality of guide fins which are integrally connected to the inner wall of the cooling ring groove; the plurality of guide fins are circumferentially arrayed and symmetrically arranged about the transverse center line of the liquid inlet and the liquid outlet, dividing the cooling ring groove into a plurality of vertical guide grooves; one end of each guide fin is integrally connected to the end wall of the pipe hole, and the other end forms a guide passage opening with the other end wall of the pipe hole.

[0017] In some embodiments, the outer tube is made of PPS material, and the jack plug is made of red copper;

[0018] The cooling liquid is dimethyl silicone oil or transformer oil.

[0019] This liquid-cooled charging station-side battery swapping connector adopts an integrated liquid-cooled terminal module, which has excellent heat dissipation capabilities, reduces connector temperature rise, effectively improves connector current carrying capacity, and lowers the temperature of the battery pack during charging. Its advantages are: First, the connector has excellent heat dissipation capabilities, adapts to high steady-state current charging, and has a simple structure with small overall dimensions of terminals, cables, and the connector itself, requiring no increase in the size of the mounting opening, thus effectively ensuring the battery pack's capacity and guaranteeing the electric vehicle's range. Second, the cooling ring groove completely covers the heat-generating area, enabling rapid heat dissipation and effectively controlling the temperature rise within a reasonable range, keeping battery performance stable at its optimal level. It also offers high safety performance and a long product lifespan, suitable for high current carrying capacity requirements that traditional structures cannot meet. Third, the outer tube is injection-molded into a single insert via upper and lower positioning rings, achieving precise installation and ensuring the accuracy and sealing of the cooling ring groove. Attached Figure Description

[0020] Figure 1 This is a three-dimensional schematic diagram of a liquid-cooled charging station-end battery swapping connector according to one embodiment of the present invention.

[0021] Figure 2 for Figure 1 A three-dimensional schematic diagram of the liquid-cooled terminal module shown;

[0022] Figure 3 for Figure 2 A top view of the liquid-cooled terminal module shown.

[0023] Figure 4 for Figure 3 A schematic cross-sectional view of the liquid-cooled terminal module shown in Figure AA;

[0024] Figure 5 for Figure 2 The diagram shows a front view of the liquid-cooled terminal module.

[0025] Figure 6 for Figure 5 BB cross-sectional view of the liquid-cooled terminal module shown;

[0026] Figure 7 for Figure 5 CC cross-sectional view of the liquid-cooled terminal module shown;

[0027] Figure 8 for Figure 4 A schematic diagram of the upper circulation path of the cooling ring groove shown;

[0028] Figure 9 for Figure 4 A schematic diagram of the lower circulation path of the cooling ring groove shown;

[0029] Liquid cooling terminal module 01, cooling ring groove 011, flow guide groove 012, flow guide through port 013;

[0030] Outer tube 1, tube hole 100, upper positioning ring 101, lower positioning ring 102, inner ring sleeve 103, convex rib 104, liquid inlet 11, liquid outlet 12, pagoda interface 13, positioning shaft shoulder 14;

[0031] Receptacle 2, intermediate body 20, upper link segment 21, lower link segment 22, upper shaft shoulder 23, lower shaft shoulder 24, conical groove 25, plug-in cavity 26, central thread 27, fixing groove 28;

[0032] First screw 3, reed 4, flow guide fin 5;

[0033] Housing assembly 02, fixed shell 021, inner floating shell 022. DETAILED DESCRIPTION

[0034] The utility model will be further described in detail below in combination with the drawings. It should be noted that the words "front", "back", "left", "right", "up" and "down" used in the following description refer to the directions in the drawings, and the words "inner" and "outer" refer to the directions towards or away from the geometric center of a particular component.

[0035] Figures 1 to 9 A liquid-cooled charging station end battery replacement connector according to an embodiment of the utility model is schematically shown. As shown in the figure, the liquid-cooled charging station end battery replacement connector comprises: a plurality of liquid cooling terminal modules 01 and a housing assembly 02.

[0036] The liquid cooling terminal module 01 comprises an outer tube 1 made of high-molecular plastic material and a receptacle 2 made of metal material. The outer tube 1 is preferably made of PPS material, which has the characteristics of high mechanical strength, high temperature resistance, good thermal stability, high thermal conductivity coefficient, etc. The receptacle 2 is preferably made of red copper.

[0037] The receptacle 2 is integrally injection molded outside the outer tube 1, and the middle section of the axial tube hole 100 of the outer tube 1 is connected with the gap between the outer peripheral wall of the receptacle 2, and the upper positioning ring 101 and the lower positioning ring 102 at both ends of the tube hole 100 are integrally injection molded with the axial both ends of the receptacle 2, forming a closed cooling ring groove 011. A turbulent structure is preferably arranged in the cooling ring groove 011, which can increase the flow rate of the cooling liquid and increase the heat dissipation effect.

[0038] Each outer tube 1 is provided with a liquid inlet 11 and a liquid outlet 12 that communicate with the cooling ring groove 011, and the liquid inlet 11 and the liquid outlet 12 communicate with the inlet and outlet liquid pipes of the cooling liquid circulation system. The cooling liquid is preferably dimethyl silicone oil or transformer oil, which has good heat conduction capacity.

[0039] A plurality of liquid-cooled terminal modules 01 are fixedly connected in the shell assembly 02. Preferably, the shell assembly 02 comprises an outer fixed shell 021 and an inner floating shell 022, and the liquid-cooled terminal module 01 is fixedly connected to the inner floating shell 022.

[0040] The liquid-cooled charging station terminal connector has a liquid-cooled terminal module with an integrated structure, good heat dissipation capacity, reduced connector temperature rise, effectively improved connector current-carrying capacity, and reduced battery pack charging temperature. Its beneficial effects are: first, the connector has good heat dissipation capacity, is suitable for high steady-state current charging, and the cooling ring groove 011 is formed by integrally injection molding the jack 2 into the outer pipe 1, the structure is simple, the overall size of the terminal, cable and connector is small, and the installation opening size does not need to be increased, thereby effectively ensuring the battery capacity of the battery pack and ensuring the endurance of the electric vehicle; second, the cooling ring groove 011 is integrally covered on the heat generation area, which can quickly discharge heat and effectively control the temperature rise within a reasonable range, so that the battery performance is stable at the best performance, and the product has high safety performance and long service life, and is suitable for high current demand that cannot be met by traditional structures; third, the outer pipe 1 integrally injection molds the jack 2 outside the upper positioning ring 101 and the lower positioning ring 102, thereby realizing precise installation and ensuring the precision and sealing degree of the cooling ring groove 011.

[0041] Further, the jack 2 comprises an inner hollow intermediate body 20, the upper end of the intermediate body 20 is formed into a small-diameter upper connecting section 21 by removing material, and the lower end is formed into a small-diameter lower connecting section 22 by removing material, the inner ring wall of the upper positioning ring 101 integrally injection molds and connects the upper connecting section 21, and the inner ring wall of the lower positioning ring 102 integrally injection molds and connects the lower connecting section 22. Its beneficial effects are: this setting facilitates the close fixing of the jack 2 and the outer pipe 1.

[0042] Preferably, the connection between the upper end of the intermediate body 20 and the upper connecting section 21 forms an upper shaft shoulder 23, the inner hole edge of the upper positioning ring 101 extends inwardly and perpendicularly to form an inner ring sleeve 103, the inner ring sleeve 103 integrally injection molds the outer wall of the upper connecting section 21 and the lower end abuts against the upper shaft shoulder 23. Its beneficial effects are: the inner ring sleeve 103 and the upper shaft shoulder 23 increase the connection area and the connection strength, and ensure the close fixed connection of the two.

[0043] Preferably, the connection between the lower end of the intermediate body 20 and the lower connecting section 22 forms a lower shaft shoulder 24, and the upper wall of the lower positioning ring 102 abuts against the lower shaft shoulder 24; the lower shaft shoulder 24 is further provided with a conical groove 25, and the upper end of the upper positioning ring 101 is provided with a convex rib 104 integrally injection molded with the conical groove 25. Its beneficial effects are: this setting further improves the positioning and covering capacity, and ensures the close fixed connection of the two.

[0044] Further, the liquid inlet 11 and the liquid outlet 12 are straight-angle bent pipes integrally and symmetrically formed on the outer wall of the outer pipe 1, the pipe hole of the straight-angle bent pipe is communicated with both sides of the end head of the cooling ring groove 011, and the straight-angle bent pipe facilitates the layout of other components; preferably, the outer end head of the straight-angle bent pipe is formed with a number of circular platforms to form a pagoda interface 13, and the two pagoda interfaces are connected with the inlet and outlet liquid pipes of the cooling liquid circulation system through interference insertion. The beneficial effect is that the pagoda interface 13 can improve the fastening of the connection.

[0045] Further, the insertion hole part 2 is formed with a cylindrical insertion cavity 26 and a central thread 27 at the upper end, and the nut of the first screw 3 is located in the insertion cavity 26, the threaded column of the first screw 3 is connected with the central thread hole 27 at the lower end and is exposed on the upper end wall of the insertion hole part 2 at the upper end to connect the copper bar, thereby realizing the copper handle connection.

[0046] Further, the fixed groove 28 at the lower end of the insertion cavity 26 is tensioned to interfere with the spring leaf 4; the spring leaf 4 is preferably a rotary spring structure. The beneficial effect is that the rotary spring connection is reliable, and the plug-in and plug-out life is up to 10,000 times or more.

[0047] Further, the outer wall of the outer pipe 1 is also provided with a positioning shaft shoulder 14. The beneficial effect is that the installation precision of the liquid cooling terminal module 01 is improved.

[0048] Further, the turbulent structure divides the cooling ring groove 011 into a plurality of vertical guide grooves 012, and the plurality of guide grooves 012 are symmetrically arranged on both sides of the horizontal center line of the liquid inlet 11 and the liquid outlet 12; the guide flow ports 013 of the guide grooves 012 on each side are alternately arranged at the upper end and the lower end; the guide grooves 012 on each side are connected through the guide flow ports 013 at the upper end and the guide flow ports 013 at the lower end in sequence, thereby forming a double-circulation cooling passage arranged on the outer peripheral wall of the insertion hole part 2. Preferably, the turbulent structure includes a plurality of guide vanes 5 integrally connected with the inner wall of the cooling ring groove 011, the plurality of guide vanes 5 are arranged in a circular array and are symmetric about the horizontal center line of the liquid inlet 11 and the liquid outlet 12, thereby dividing the cooling ring groove 011 into a plurality of vertical guide grooves 012, one end of each guide vane 5 is integrally connected with the end wall of the pipe hole 100 and the other end forms a guide flow port 013 with the other end wall of the pipe hole 100. Specifically, the outer wall of the guide vane 5 is integrally connected with the pipe hole 100 and the inner wall is integrally connected with the outer wall of the insertion hole part 2, the upper end of the guide vane 5 on both sides of the liquid inlet 11 and the liquid outlet 12 is integrally connected with the upper end wall of the pipe hole 100 and the lower end forms a guide flow port 013 with the lower end wall of the pipe hole 100, the upper end head of the guide vane 5 in the middle of each side is alternately connected with the upper end wall of the pipe hole 100 to form a guide flow port 013 or is integrally connected with the pipe hole 100, and the lower end head is alternately integrally connected with the upper end wall of the pipe hole 100 or is connected with the lower end wall of the pipe hole 100 to form a guide flow port 013. The beneficial effect is that the arrangement can uniformly and quickly dissipate heat and will not cause local high temperature.

[0049] Preferably, several guide vanes 5 are located on the radial section of the jack 2. The advantage is that the arrangement facilitates installation and production, and has strong guiding ability and small resistance.

[0050] Further, the inner floating shell 022 is three-dimensionally floatingly connected in the outer fixed shell 021, specifically, the inner floating shell 022 is connected to the inner wall of the outer fixed shell 021 through a vertical spring elastic floating assembly, and adjusts the vertical distance relative to the outer fixed shell 021 in vertical floating, and the spring and the outer fixed shell 021 are arranged in a horizontal plane and are inclined to perform XY fine adjustment floating, thereby realizing the three-dimensionally floating function during splicing. The advantage is that the arrangement ensures that the plug-in can be well fixed even if there is a position deviation.

[0051] Further, the inner floating shell 022 is three-dimensionally floatingly connected in the outer fixed shell 021, specifically, the inner floating shell 022 is connected to the inner wall of the outer fixed shell 021 through a vertical spring elastic floating assembly, and adjusts the vertical distance relative to the outer fixed shell 021 in vertical floating, and the spring and the outer fixed shell 021 are arranged in a horizontal plane and are inclined to perform XY fine adjustment floating, thereby realizing the three-dimensionally floating function during splicing. The advantage is that the arrangement ensures that the plug-in can be well fixed even if there is a position deviation.

[0052] The above only describes some embodiments of the present application. For those skilled in the art, without departing from the inventive concept, a number of modifications and improvements can be made, which are all within the protection scope of the present application.

Claims

1. A liquid-cooled charging station-side battery swapping connector, characterized in that, Includes: multiple liquid-cooled terminal modules (01) and housing assembly (02); The liquid-cooled terminal module (01) includes an outer tube (1) made of polymer plastic and a metal plug-in part (2). The outer tube (1) is integrally injection molded to form the plug-in part (2). The middle section of the axial tube hole (100) of the outer tube (1) is connected to the outer peripheral wall of the plug-in part (2) with a gap. The upper positioning ring (101) and the lower positioning ring (102) at both ends of the tube hole (100) are integrally injection molded to connect the axial ends of the plug-in part (2) to form a closed cooling ring groove (011). Each outer tube (1) has an inlet (11) and an outlet (12) at one end that are connected to the cooling ring groove (011). The inlet (11) and the outlet (12) are connected to the inlet and outlet pipes of the coolant circulation system. Multiple liquid-cooled terminal modules (01) are fixedly connected inside the housing assembly (02).

2. The liquid-cooled charging station-side battery swapping connector according to claim 1, characterized in that, The middle body (20) of the socket component (2) has a small-diameter upper connecting section (21) at the upper end and a small-diameter lower connecting section (22) at the lower end. The inner ring wall of the upper positioning ring (101) is integrally injection molded to connect the upper connecting section (21), and the inner ring wall of the lower positioning ring (102) is integrally injection molded to connect the lower connecting section (22).

3. The liquid-cooled charging station-side battery swapping connector according to claim 2, characterized in that, The upper end of the intermediate body (20) and the upper connecting section (21) form an upper shoulder (23). The inner hole edge of the upper positioning ring (101) extends vertically inward to form an inner ring sleeve (103). The inner ring sleeve (103) is integrally injection molded to connect to the outer wall of the upper connecting section (21) and its lower end is attached to the upper shoulder (23).

4. The liquid-cooled charging station-side battery swapping connector according to claim 2, characterized in that, The lower end of the intermediate body (20) and the lower connecting section (22) form a lower shoulder (24), and the upper wall of the lower positioning ring (102) fits against the lower shoulder (24); a conical groove (25) is also provided at the lower shoulder (24), and the upper end of the upper positioning ring (101) is provided with a protruding rib (104) integrally injection molded and connected to the conical groove (25).

5. The liquid-cooled charging station-side battery swapping connector according to claim 1, characterized in that, The inlet (11) and outlet (12) are integrally symmetrically formed right-angle bends on the outer wall of the outer tube (1). The pipe holes of the right-angle bends are connected to both sides of the end of the cooling ring groove (011). The pagoda interface (13) at the outer end of the right-angle bends is connected to the inlet and outlet pipes of the coolant circulation system by interference fitting.

6. The liquid-cooled charging station-side battery swapping connector according to claim 1, characterized in that, The center thread (27) at the upper end of the socket (2) is connected to the copper busbar by the first screw (3); Or the fixing groove (28) at the lower end of the insertion cavity (26) of the insertion part (2) is interference connected to the spring (4); Alternatively, the outer wall of the outer tube (1) may also be provided with a positioning shoulder (14).

7. A liquid-cooled charging station-side battery swapping connector according to claim 1, characterized in that, The cooling ring groove (011) is equipped with a turbulence structure.

8. A liquid-cooled charging station-side battery swapping connector according to claim 7, characterized in that, The turbulent structure divides the cooling ring groove (011) into several vertical guide grooves (012). Several guide grooves (012) are symmetrically arranged on both sides of the transverse center line of the liquid inlet (11) and the liquid outlet (12). The guide openings (013) of each guide groove (012) are alternately arranged at the upper and lower ends. The guide grooves (012) on each side are connected through the guide openings (013) at the upper end and the guide openings (013) at the lower end, forming a double circulation cooling path set on the outer peripheral wall of the insertion part (2).

9. A liquid-cooled charging station-side battery swapping connector according to claim 8, characterized in that, The turbulence structure includes several guide vanes (5) integrally connected to the inner wall of the cooling ring groove (011). The several guide vanes (5) are arranged in a circumferential array and are symmetrical about the transverse center line of the liquid inlet (11) and the liquid outlet (12), dividing the cooling ring groove (011) into several vertical guide grooves (012). One end of each guide vane (5) is integrally connected to the end wall of the pipe hole (100), and the other end forms a guide opening (013) with the other end wall of the pipe hole (100).

10. A liquid-cooled charging station-side battery swapping connector according to any one of claims 1 to 9, characterized in that, The outer tube (1) is made of PPS material, and the socket (2) is made of copper. The coolant is dimethyl silicone oil or transformer oil.

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