Sheet-shaped connection terminal, electric connection assembly and vehicle power system

Abstract

The utility model provides a sheet-shaped connection terminal, an electric connection assembly and a vehicle power system. The sheet-like connection terminal is formed by bending a flat conductor in a thickness direction thereof, and includes a first base section, a bent section, and a first connection section connected to each other. One end of the bent section is connected with the first base section, the other end of the bent section is connected with the first connecting section, and the bent section is of a structure protruding towards one side in the thickness direction relative to the first base section and the first connecting section. In any cross section cut in the thickness direction, the first base section and the first connecting section extend in the first direction. Therefore, in the sheet-shaped connection rotor, the bending section forms a flexible middle part between the first base section and the first connection section, so that the first connection section of the sheet-shaped connection terminal is easier to bend and deform relative to the base section under the condition of considering the cost. The utility model further provides an electric connection assembly and a vehicle power system which comprise the sheet-shaped connection terminal.

Description

Technical Field

[0001] This application relates to the structure of a vehicle powertrain system, specifically to the electrical connection structure between the battery pack and the motor within the vehicle powertrain system. Background Technology

[0002] Currently, in new energy vehicles, the vehicle power system includes an electric drive system and a battery pack that supplies power to the motor of the electric drive system. Specifically, the battery pack needs to be electrically connected to the motor via high-voltage cables and high-voltage connectors. In existing solutions, with the motor installed and its axis parallel to the horizontal plane, the plate-shaped connection terminals (e.g., copper busbars) of the motor controller are parallel to the horizontal plane, and the plate-shaped connection terminals of the high-voltage cable can be fixedly connected to the motor controller in an orientation parallel to the plate-shaped connection terminals of the motor controller.

[0003] As motor power demands increase, the current supplied by the battery pack to the motor also increases. This leads to larger high-voltage cables. To meet the bending radius and fixing requirements of the high-voltage cables within a limited space, the plate-shaped connectors of the high-voltage cables and the motor controller are angled before being connected, making it difficult to achieve a parallel connection. In this situation, connecting the plate-shaped connectors of the high-voltage cables to the motor controller using bolts or other connectors requires significant deformation of the high-voltage cable connectors, which is not only difficult to manufacture but also prone to connection instability. Modifying the structure of other components to accommodate the connection between these two plate-shaped connectors would significantly increase costs. Utility Model Content

[0004] This application was made in view of the deficiencies in the aforementioned technology.

[0005] One object of this application is to provide a sheet-like connecting terminal that, while taking cost into account, makes the connecting segment of the sheet-like connecting terminal easier to bend and deform relative to the base segment.

[0006] Another objective of this application is to provide an electrical connection assembly that enables a reliable fixed connection at an angle between the sheet-like connection terminals of a high-voltage cable and the sheet-like connection terminals of a motor controller, without substantially increasing costs.

[0007] Another object of this application is to provide a vehicle powertrain system including the above-described electrical connection components.

[0008] To achieve the above objectives, this application adopts the following technical solution.

[0009] This application provides a sheet-like connector formed by bending a flat conductor in its thickness direction, and includes a first base segment, a first connecting segment, and a bent segment connected to each other. One end of the bent segment is connected to the first base segment and the other end is connected to the first connecting segment. The bent segment is formed to bulge out toward one side of the first base segment and the first connecting segment in the thickness direction. In any cross-section taken along the thickness direction, the first base segment and the first connecting segment both extend along a first direction.

[0010] In one alternative, the first base segment and the first connecting segment are coplanar.

[0011] In another alternative, the bent segment is formed into a U-shape.

[0012] In another alternative embodiment, the bent segment includes a first bent portion, a second bent portion, and a third bent portion that are connected to each other.

[0013] In the cross section, the first bend extends from the first base segment along a second direction perpendicular to the first direction, the second bend extends from the first bend along the first direction, and the third bend extends from the second bend along the second direction to the first connecting segment.

[0014] In another alternative, the bent segment is formed into an arc shape.

[0015] This application also provides an electrical connection assembly for establishing an electrical connection between a motor controller and a battery pack cable, the electrical connection assembly comprising:

[0016] A first sheet-like connecting terminal, which is the sheet-like connecting terminal described in any of the above technical solutions, wherein a first base segment of the first sheet-like connecting terminal is used to connect to the cable; and

[0017] The second sheet-like connecting terminal includes a second base segment and a second connecting segment connected to each other. The second base segment is used to connect to the controller, and the second connecting segment is connected parallel to the first connecting segment of the first sheet-like connecting terminal.

[0018] In a cross-section taken along the thickness direction of the first sheet-like connecting terminal, the first base segment extends along a first direction, and the first connecting segment extends along a third direction that is not parallel to the first direction.

[0019] In one alternative approach, the plane containing the first connecting segment is used as the reference plane, and the first base segment and the bent segment are located on the same side relative to the reference plane.

[0020] In another alternative, a connector is also included, through which the first connecting segment and the second connecting segment are detachably secured together.

[0021] This application also provides a vehicle powertrain system, including the electrical connection component described in any of the above technical solutions.

[0022] In an alternative embodiment, a motor is also included, wherein the first connecting segment and the second connecting segment are parallel to the horizontal plane, provided that the axis of the motor is parallel to the horizontal plane.

[0023] This application provides a sheet-like connecting terminal. The sheet-like connecting terminal is formed by bending a flat conductor in its thickness direction, and includes a first base segment, a bent segment, and a first connecting segment connected to each other. One end of the bent segment is connected to the first base segment and the other end is connected to the first connecting segment. The bent segment is formed to bulge outwards relative to the first base segment and the first connecting segment in the thickness direction. In a cross-section taken along the aforementioned thickness direction, both the first base segment and the first connecting segment extend along a first direction. Thus, in the sheet-like connecting rotor according to this disclosure, the bent segment constitutes a flexible intermediate portion between the first base segment and the first connecting segment, thereby making it easier for the first connecting segment of the sheet-like connecting terminal to bend and deform relative to the base segment while taking cost into consideration.

[0024] This application provides an electrical connection assembly. This electrical connection assembly is used to achieve an electrical connection between a motor controller and a battery pack cable. The electrical connection assembly includes a first sheet-like connection terminal and a second sheet-like connection terminal, wherein the first sheet-like connection terminal is the sheet-like connection terminal according to this application, and the second sheet-like connection terminal includes a second base segment and a second connecting segment connected to each other. The second base segment is used for connection to the controller, and the second connecting segment is connected parallel to the first connecting segment of the first sheet-like connection terminal. Further, in a cross-section taken along the thickness direction of the first sheet-like connection terminal, the first base segment extends along a first direction, and the first connecting segment extends along a third direction that is not parallel to the first direction. During the process of connecting the first connecting segment to the second connecting segment, the first connecting segment can (but is not required to) bend relative to the first base segment, and the bending segment can adapt to this bending deformation, thereby allowing the first connecting segment to easily undergo a large-amplitude bending deformation relative to the first base segment. Thus, a reliable, angled fixed connection between the sheet-like connection terminal of the high-voltage cable and the sheet-like connection terminal of the motor controller can be achieved with minimal increase in cost.

[0025] This application also provides a vehicle powertrain system that includes the above-mentioned electrical connection components and has the same technical effects. Attached Figure Description

[0026] Figure 1A This is a schematic diagram illustrating a partial structure of an electrical connection assembly according to an embodiment of the present application, wherein the structure of the sheet-like connection terminal according to the present application is shown.

[0027] Figure 1B It shows Figure 1A A side view of the structure.

[0028] Figure 2A This is a schematic diagram illustrating a portion of the structure of a vehicle powertrain system according to an embodiment of this application.

[0029] Figure 2B It shows Figure 2A A partial perspective view of the vehicle's powertrain system, in which the first and second sheet-like connecting terminals are not connected.

[0030] Figure 2C It shows Figure 2A A partial perspective view of the vehicle's powertrain system, showing that the first and second sheet-like connecting terminals are connected.

[0031] Figure 2D It shows Figure 2C A side view of the first sheet-like connecting terminal in the connected state.

[0032] Explanation of reference numerals in the attached figures

[0033] 1 First sheet-shaped connecting terminal; 11 First base segment; 12 First connecting segment; 13 Bending segment; 131 First bending portion; 132 Second bending portion; 133 Third bending portion;

[0034] 2. Second plate-shaped connecting terminal; 21. Second base segment; 22. Second connecting segment;

[0035] 3. Connecting the substrate;

[0036] CA cables; MO motors;

[0037] D1 is the first direction; D2 is the second direction; D3 is the third direction. Detailed Implementation

[0038] Exemplary embodiments of this application are described below with reference to the accompanying drawings. It should be understood that these specific descriptions are for teaching those skilled in the art how to implement this application only, and are not intended to exhaust all possible methods of this application, nor to limit the scope of this application.

[0039] The following description, in conjunction with the accompanying drawings, will illustrate the sheet-like connecting terminal according to an embodiment of this application.

[0040] According to embodiments of this application, the sheet-like connecting terminal is formed by stamping a flat conductor (e.g., a copper busbar) such that a portion of the flat conductor is bent in the thickness direction of the flat conductor. Figure 1A and Figure 1B As shown, the sheet-like connecting terminal includes a first base segment 11, a first connecting segment 12, and a bent segment 13 connected to each other. The first base segment 11 and the first connecting segment 12 are coplanar, meaning that the center plane of the first base segment 11 in the thickness direction is coplanar with the center plane of the first connecting segment 12 in the thickness direction. Further, one end of the bent segment 13 is connected to the first base segment 11 and the other end is connected to the first connecting segment 12, such that the first base segment 11 and the first connecting segment 12 are fixedly connected to each other via the bent segment 13. In this embodiment, the bent segment 13 is formed in a U-shape, and the bent segment 13 is configured to protrude from one side of the first base segment 11 and the first connecting segment 12 in the thickness direction. Figure 1A and Figure 1B As shown, the bent segment 13 includes a first bent portion 131, a second bent portion 132, and a third bent portion 133 that are connected to each other.

[0041] In any cross-section taken along the thickness direction of the sheet-like connecting terminal (that is, the thickness direction of the first base segment 11), refer to Figure 1B Both the first base segment 11 and the first connecting segment 12 extend along the first direction D1. The first bend 131 extends from one end of the first base segment 11 along the second direction D2, which is perpendicular to the first direction D1, for a certain length. The second bend 132 extends from one end of the first bend 131 along the first direction D1 for a certain length. The third bend 133 extends from the second bend 132 along the second direction D2 to the first connecting segment 12. Furthermore, the first bend 131, the second bend 132, and the third bend 133 are connected by a circular arc transition. This helps to avoid excessive stress concentration at the connection points of the bends after the first connecting segment 12 bends relative to the first base segment 11.

[0042] In this way, the bent segment 13 forms a flexible intermediate portion between the first base segment 11 and the first connecting segment 12, thereby making it easier for the first connecting segment 12 of the sheet-like connecting terminal to bend and deform relative to the base segment while taking cost into account. It is understood that as long as the bent segment 13 can form a flexible intermediate portion between the first base segment 11 and the first connecting segment 12, the bent segment 13 can be formed in other structures and shapes. For example, in one alternative, the bent segment 13 can be formed in an arc shape, and in another alternative, the bent segment 13 can be formed in an S-shape or a wave shape.

[0043] The following description, in conjunction with the accompanying drawings, illustrates an electrical connection assembly according to an embodiment of this application, and a vehicle powertrain system including the electrical connection assembly.

[0044] like Figures 2A to 2C As shown, the electrical connection assembly according to an embodiment of this application is used to realize an electrical connection between the controller of a motor (MO) and the cable (CA) of a battery pack. The electrical connection assembly includes a first sheet-like connection terminal 1 and a second sheet-like connection terminal 2 connected to each other, wherein the first sheet-like connection terminal 1 is the sheet-like connection terminal described above according to the embodiment of this application. Furthermore, one first sheet-like connection terminal 1 and one second sheet-like connection terminal 2 constitute a pair of sheet-like connection terminals, and the electrical connection assembly may include, for example, two pairs of such sheet-like connection terminals, the two pairs of sheet-like connection terminals being arranged side-by-side at a distance and corresponding respectively to the live wire and neutral wire of the battery pack.

[0045] like Figure 2B and Figure 2C As shown, the first base segment 11 of the first sheet-like connecting terminal 1 is connected to the cable CA. The second sheet-like connecting terminal 2 includes a second base segment 21 and a second connecting segment 22 connected to each other. The second base segment 21 is connected to the controller of the motor MO, and the second connecting segment 22 is connected to the first connecting segment 12 in parallel. In a cross-section taken along the thickness direction of the first sheet-like connecting terminal 1 (first base segment 11), reference... Figure 2C and Figure 2D When the first connecting segment 12 and the second connecting segment 22 are connected to each other, the first base segment 11 extends along the first direction D1, and the first connecting segment 12 extends along a third direction D3 that is not parallel to the first direction D1. Here, the third direction D3 is not perpendicular to the first direction D1. The acute angle formed by the first direction D1 and the third direction D3 can be, for example, between 0 degrees and 45 degrees. Furthermore, with the plane where the first connecting segment 12 is located as the reference plane, the first base segment 11 and the bent segment 13 are located on the same side relative to the reference plane. This makes it easier for the bent segment 13 to absorb deformation stress and generate corresponding deformation during the bending deformation of the first connecting segment 12 relative to the first base segment 11.

[0046] To connect the first connecting segment 12 and the second connecting segment 22 to each other, the electrical connection assembly may further include a connector (e.g., a bolt) by which the first connecting segment 12 and the second connecting segment 22 are detachably fixed together. Accordingly, the first connecting segment 12 may have a first through hole, the second connecting segment 22 may have a second through hole, and the connecting base 3 may have a threaded hole that mates with the first and second through holes. The bolt passes through the first and second through holes to be inserted into the threaded hole and threadedly engaged with the connecting base 3, thereby fixing the first connecting segment 12 and the second connecting segment 22 together.

[0047] like Figure 2AAs shown, the vehicle powertrain system according to an embodiment of this application includes, in addition to the electrical connection components described above, a motor MO. After the motor MO is installed in place, the axis of the motor MO is parallel to the horizontal plane, and the first connecting segment 12 and the second connecting segment 22 are parallel to the horizontal plane.

[0048] The above embodiments are merely exemplary and are not intended to limit this application. Those skilled in the art can make various modifications and changes to the above embodiments based on the teachings of this application without departing from the scope of this application. The following supplementary descriptions are provided regarding the technical solutions of this application.

[0049] i. It is understood that in scenarios where the sheet-like connecting terminal according to this application is at a certain angle before being connected to other sheet-like connecting terminals, the connecting portion of the sheet-like connecting terminal according to this application is prone to significant bending deformation relative to its base. This results in a larger angle between the two sheet-like connecting terminals, which can be effectively compensated for by the bending section, thus making the connection arrangement more flexible. Furthermore, using the above solution eliminates the need for additional tools, saving corresponding costs.

[0050] It is understood that in some usage scenarios, before the sheet-like connecting terminal according to this application is connected to other sheet-like connecting terminals, or before the sheet-like connecting terminal is bent and deformed, the connecting segments of the two sheet-like connecting terminals can be parallel to each other (including approximately parallel).

[0051] ii. The vehicle powertrain system according to this application can be used in pure electric vehicles or hybrid vehicles.

Claims

1. A sheet-like connecting terminal, characterized in that, The sheet-like connecting terminal is formed by bending a flat conductor in its thickness direction and includes a first base segment, a first connecting segment, and a bent segment connected to each other. One end of the bent segment is connected to the first base segment and the other end is connected to the first connecting segment. The bent segment is formed to bulge out toward one side of the first base segment and the first connecting segment in the thickness direction. In any cross-section taken along the thickness direction, the first base segment and the first connecting segment both extend along a first direction.

2. The sheet-like connecting terminal according to claim 1, characterized in that, The first base segment and the first connecting segment are coplanar.

3. The sheet-like connecting terminal according to claim 1, characterized in that, The bent section is formed into a U-shape.

4. The sheet-like connecting terminal according to claim 3, characterized in that, The bent section includes a first bent portion, a second bent portion, and a third bent portion that are connected to each other. In the cross section, the first bend extends from the first base segment along a second direction perpendicular to the first direction, the second bend extends from the first bend along the first direction, and the third bend extends from the second bend along the second direction to the first connecting segment.

5. The sheet-like connecting terminal according to claim 1, characterized in that, The bent section is formed into an arc shape.

6. An electrical connection assembly for establishing an electrical connection between a motor controller and a battery pack cable, characterized in that, The electrical connection component includes: A first sheet-like connecting terminal, which is the sheet-like connecting terminal according to any one of claims 1 to 5, wherein a first base segment of the first sheet-like connecting terminal is used for connection with the cable; and The second sheet-like connecting terminal includes a second base segment and a second connecting segment connected to each other. The second base segment is used to connect to the controller, and the second connecting segment is connected parallel to the first connecting segment of the first sheet-like connecting terminal. In a cross-section taken along the thickness direction of the first sheet-like connecting terminal, the first base segment extends along a first direction, and the first connecting segment extends along a third direction that is not parallel to the first direction.

7. The electrical connection assembly according to claim 6, characterized in that, With the plane where the first connecting segment is located as the reference plane, the first base segment and the bending segment are located on the same side relative to the reference plane.

8. The electrical connection assembly according to claim 7, characterized in that, It also includes a connector, through which the first connecting segment and the second connecting segment are detachably fixed together.

9. A vehicle powertrain system, characterized in that, Includes the electrical connection component as described in any one of claims 6 to 8.

10. The vehicle power system according to claim 9, characterized in that, It also includes a motor, wherein, with the motor's axial direction parallel to the horizontal plane, the first connecting section and the second connecting section are parallel to the horizontal plane.

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