A quick-plug DC charging socket

Abstract

This application belongs to the field of automotive charging technology and discloses a quick-connect DC charging socket, including an insulator. A square plate fixed to the vehicle body is provided on the front side of the insulator. A circuit board is disposed within the insulator. The circuit board has six pin holes, one PE hole, two power holes, one low-voltage connector, and two temperature sensors. Pin contacts are disposed in the pin holes, and PE contacts are disposed in the PE holes. A blind hole is provided at the tail of the PE contact for crimping a PE cable. A power contact is disposed in the power hole, and a connecting piece is provided at the tail of the power contact for ultrasonic welding to the terminals of a DC cable. A pressure plate cover is provided on the rear side of the insulator, with DC and PE through holes on the pressure plate cover. A DC protection tube and a PE protection tube are correspondingly disposed on the rear side of the pressure plate cover. In this application, the tail of the PE contact is crimped to the PE cable, simplifying the assembly process; the tail of the power contact is ultrasonically welded to the terminals of the DC cable, reducing welding resistance to meet high-power charging requirements.

Description

Technical Field

[0001] This utility model relates to the field of automotive charging technology, and in particular to a quick-connect DC charging socket. Background Technology

[0002] New energy vehicles refer to automobiles that use unconventional vehicle fuels as a power source (or use conventional vehicle fuels and adopt new on-board power devices), and integrate advanced technologies in vehicle power control and drive to form vehicles with advanced technical principles, new technologies, and new structures. Currently, new energy vehicles in the market are mainly driven by electricity, so they are equipped with charging sockets to connect to the charging guns of charging piles to provide power to the vehicle's internal batteries.

[0003] With the rapid development of the new energy vehicle industry, DC fast charging technology has become the industry mainstream due to its high efficiency. As a core component of fast charging, the performance of the DC charging socket directly affects charging efficiency and safety. Currently, the PE contacts of DC charging sockets are connected by screws and welding plates, making assembly cumbersome; the power contacts are crimped to the cable, resulting in high contact resistance, increased charging temperature, and difficulty in meeting high-power charging demands. Utility Model Content

[0004] To address the aforementioned problems, this utility model provides a quick-connect DC charging socket.

[0005] The above-mentioned technical objective of this utility model is achieved through the following technical solution: A quick-connect DC charging socket includes an insulator. A square plate for fixed installation with a vehicle body is provided on the front side of the insulator. A circuit board is provided inside the insulator. The circuit board has 6 pin holes, 1 PE hole, 2 power holes, 1 low-voltage plug and 2 temperature sensors. Pin contacts are provided in the pin holes. The signals of all pin contacts and temperature sensors are transmitted to the low-voltage plug through the circuit board body. PE contacts are provided in the PE holes. A blind hole is provided at the tail of the PE contact for crimping PE cables. Power contacts are provided in the power holes. A connecting piece is provided at the tail of the power contact for ultrasonic welding to the terminals of DC cables. A pressure plate tail cover is provided on the rear side of the insulator. A DC through hole and a PE through hole are provided on the pressure plate tail cover. Claws are provided on the front side of the pressure plate tail cover corresponding to the DC through hole and the PE through hole. A DC protection tube and a PE protection tube are provided on the rear side of the pressure plate tail cover.

[0006] By adopting the above technical solution, an insulator, a square plate, a circuit board, and a pressure plate tail cover are set. A blind hole is set at the tail of the PE contact to be crimped and connected to the PE cable, which simplifies the assembly process. A connecting piece is set at the tail of the power contact to be ultrasonically welded to the terminal of the DC cable, which can reduce the welding resistance and meet the needs of high-power charging.

[0007] Furthermore, the insulator includes a tubular shell that is closed on the front side. The front sealing plate of the tubular shell has nine through holes corresponding to the circuit board and nine hollow insulating pillars that protrude forward. The bottom of the hollow insulating pillars is provided with a slot, and the bottom of the square plate is provided with a drainage hole.

[0008] By adopting the above technical solution, nine hollow insulating pillars are set on the tubular shell of the insulator to accommodate nine contacts respectively; grooves and drainage holes are provided to facilitate the drainage of water outside the socket and avoid affecting the electrical performance of the charging socket.

[0009] Furthermore, the front sealing plate has two guide posts, two mounting buckles, and several support bosses extending rearward from its rear side, and the circuit board has guide holes and mounting holes corresponding to the guide posts and mounting buckles.

[0010] By adopting the above technical solution, guide posts, guide holes, mounting clips, and mounting holes are set for guiding and fixing the circuit board, respectively; and support bosses are set for supporting the circuit board.

[0011] Furthermore, an arc-shaped isolation rib is provided on the rear side of the front sealing plate, protruding rearward from the inside of the through hole corresponding to the two power contacts.

[0012] By adopting the above technical solution and setting arc-shaped isolation ribs, the creepage distance between different polarities of the charging socket can be increased.

[0013] Furthermore, three metal springs are provided on the rear side of the circuit board next to the PE hole. The metal springs are connected to the pin contact through the circuit board body. The PE contact has a circular boss, which presses against the three metal springs.

[0014] By adopting the above technical solution, metal springs and circular bosses are provided to facilitate contact between the PE contact and the circuit board.

[0015] Furthermore, the DC cable is fitted with a DC sealing ring, a DC cable end cover, and a DC clamp. The DC sealing ring is pressed between the DC cable and the DC protection tube. The DC cable end cover has a wedge-shaped groove that engages with the DC clamp. The DC cable end cover has a through groove, and the DC protection tube has a corresponding wedge-shaped locking block. The wedge-shaped locking block and the through groove form a locking engagement.

[0016] By adopting the above technical solution, a DC sealing ring, a DC cable tail cover, and a DC cable clamp are provided for sealing and fixing the tail of the DC cable.

[0017] Furthermore, the PE cable is fitted with a PE sealing ring and a PE cable tail cover. The PE sealing ring is pressed between the PE cable and the PE protective tube. The PE cable tail cover is provided with an anti-deviation swing platform, a guide key, and a wedge-shaped guide block. The PE protective tube is provided with a guide notch and a guide groove corresponding to the guide key and the wedge-shaped guide block.

[0018] By adopting the above technical solution, a PE sealing ring and a PE cable tail cover are set for sealing and fixing the tail of the PE cable.

[0019] Furthermore, a sealing ring is provided on the front side of the pressure plate tail cover, and a connecting buckle is provided on the side of the pressure plate tail cover protruding towards the insulator. A triangular boss is correspondingly provided on the outer wall of the tubular shell, and the connecting buckle and the triangular boss form a snap-fit ​​engagement. Four connecting holes are provided at the front edge of the pressure plate tail cover, and screw holes are correspondingly provided at the rear end of the tubular shell. The connecting holes and screw holes are connected by screws.

[0020] By adopting the above technical solution, a sealing ring, connecting buckle, triangular boss, connecting hole, and screw hole are provided for the connection and fixation between the pressure plate tail cover and the insulator.

[0021] Furthermore, the pin contact, PE contact, and power contact are all provided with sealing bodies, which are used to seal the contact with the through hole on the front sealing plate.

[0022] By adopting the above technical solution, a sealing body is set up for sealing between the contact element and the through hole on the front sealing plate.

[0023] In summary, the present invention has the following beneficial effects: In this application, by setting an insulator, a square plate, a circuit board, and a pressure plate tail cover, and by setting a blind hole at the tail of the PE contact to be crimped and connected to the PE cable, the assembly process is simplified; by setting a connecting piece at the tail of the power contact to be ultrasonically welded to the terminal of the DC cable, the welding resistance can be reduced to meet the high-power charging requirements. Attached Figure Description

[0024] Figure 1 This is an exploded view of the overall structure of an embodiment of this utility model;

[0025] Figure 2 This is a schematic diagram of the structure of the insulator according to an embodiment of the present invention;

[0026] Figure 3 This is a schematic diagram of the insulator from another angle according to an embodiment of the present invention;

[0027] Figure 4 This is a schematic diagram of the structure of the square plate according to an embodiment of the present utility model;

[0028] Figure 5 This is a schematic diagram of the circuit board structure according to an embodiment of the present invention;

[0029] Figure 6 This is a schematic diagram of the circuit board from another angle according to an embodiment of this utility model;

[0030] Figure 7 This is a schematic diagram of the power contact and DC cable according to an embodiment of the present invention;

[0031] Figure 8 This is a schematic diagram of the structure of the PE contact and PE cable according to an embodiment of this utility model;

[0032] Figure 9 This is a schematic diagram of the structure of the pressure plate tail cover according to an embodiment of the present utility model;

[0033] Figure 10 This is a structural schematic diagram of the pressure plate tail cover from another angle in an embodiment of this utility model.

[0034] In the diagram: 10. Insulator; 11. Tubular shell; 12. Front cover plate; 13. Through hole; 14. Hollow insulating column; 141. Slotted groove; 15. Guide post; 16. Mounting clip; 17. Support boss; 18. Isolation rib plate; 101. Triangular boss; 102. Screw hole; 20. Square plate; 21. Drain hole; 22. Fixing hole; 30. Circuit board; 31. Pin hole; 32. PE hole; 33. Power hole; 34. Low voltage connector; 35. Temperature sensor; 36. Pin contact; 37. PE contact; 371. Blind hole; 372. Circular boss; 38. Power contact; 381. Connecting piece; 301. Guide hole; 302. Mounting hole; 303, metal spring; 304, chip resistor; 305, arc-shaped hole; 40, PE cable; 41, PE sealing ring; 42, PE cable end cover; 43, anti-deviation swing platform; 44, guide key; 45, wedge-shaped guide block; 50, DC cable; 51, DC sealing ring; 52, DC cable end cover; 53, DC cable clamp; 54, through groove; 60, pressure plate end cover; 61, DC through hole; 62, PE through hole; 63, clamp; 64, DC protection tube; 641, wedge-shaped block; 65, PE protection tube; 651, guide notch; 652, guide groove; 66, annular sealing ring; 67, connecting buckle; 68, connecting hole; 70, sealing body. Detailed Implementation

[0035] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0036] like Figure 1-10 As shown in the illustration, this application discloses a quick-connect DC charging socket, including an insulator 10, a square plate 20, a circuit board 30, and a pressure plate rear cover 60. The square plate 20 is disposed on the front side of the insulator 10 and has four fixing holes 22 for fixed installation with the vehicle body. Each of the four fixing holes 22 has a metal bushing embedded within it, which can withstand the axial force of the mounting nut. The circuit board 30 is disposed within the insulator 10 for signal integration. The pressure plate rear cover 60 is disposed on the rear side of the insulator 10 for sealing and protecting the circuit board 30.

[0037] Specifically, the circuit board 30 has six pin holes 31, one PE hole 32, two power holes 33, one low-voltage connector 34, and two temperature sensors 35. The temperature sensors 35 are soldered onto the circuit board 30 using SMT technology, closely attached to the temperature-sensing copper foil on the circuit board 30 to ensure temperature measurement accuracy. The six pin holes 31 are torsion spring holes, each containing a pin contact 36: CC1 pin contact 36, CC2 pin contact 36, A+ pin contact 36, A- pin contact 36, S+ pin contact 36, and S- pin contact 36. Signals from all pin contacts 36 and the temperature sensors 35 are transmitted to the low-voltage connector 34 through the circuit board 30 body. After the charging gun is inserted into the socket, the six signal pins of the charging gun contact the six pin contacts 36, and the low-voltage connector 34 connects to the vehicle control system via signal lines to achieve signal transmission.

[0038] A PE contact 37 is provided inside the PE hole 32, and a circular boss 372 is provided on the PE contact 37. Three metal springs 303 are provided on the rear side of the circuit board 30 next to the PE hole 32. The metal springs 303 are connected to the CC1 pin contact 36 through the body of the circuit board 30, and the circular boss 372 is pressed against the three metal springs 303. A 1000Ω surface mount resistor 304 is soldered on the circuit board 30 using SMT process. The PE contact 37 is connected to the surface mount resistor 304 and the CC1 pin hole 31 through the metal springs 303, the body of the circuit board 30, and the CC1 pin hole 31, thereby transmitting the signal of the PE contact 37 to the low voltage plug 34 through the CC1 pin contact 36. A blind hole 371 is provided at the tail of the PE contact 37. The PE contact 37 is crimped to the PE cable 40 through the blind hole 371, simplifying the assembly process.

[0039] A power contact 38 is provided inside the power port 33. The front end of the power contact 38 is a torsion spring hole for easy connection with the charging gun. The rear end of the power contact 38 is provided with a connecting piece 381. The power contact 38 is ultrasonically welded to the terminal of the DC cable 50 through the connecting piece 381, which can reduce the welding resistance to meet the needs of high-power charging. A circular stepped surface is provided on the power contact 38, which is used to contact the temperature measuring copper foil on the circuit board 30 to realize temperature acquisition.

[0040] The insulator 10 includes a tubular housing 11, with a front sealing plate 12 enclosed on the front side of the tubular housing 11. Nine through holes 13 are provided on the front sealing plate 12 corresponding to the circuit board 30, and nine hollow insulating posts 14 protrude forward accordingly. The hollow insulating posts 14 are used to accommodate contacts. A slot 141 is provided at the bottom of the hollow insulating posts 14, and a drainage hole 21 is provided at the bottom of the square plate 20 to facilitate the drainage of accumulated water outside the socket, preventing it from affecting the electrical performance of the charging socket.

[0041] Two guide posts 15 and two mounting clips 16 are provided rearwardly protruding from the rear side of the front cover plate 12. Guide holes 301 and mounting holes 302 are provided on the circuit board 30 corresponding to the guide posts 15 and mounting clips 16. The guide posts 15 and guide holes 301 form a guiding engagement to position the circuit board 30 during installation. The mounting clips 16 engage with the mounting holes 302 to achieve a fixed connection between the circuit board 30 and the insulator 10. Several support bosses 17 are provided rearwardly protruding from the rear side of the front cover plate 12 to support the circuit board 30. An arc-shaped isolation rib plate 18 is provided rearwardly protruding from the rear side of the front cover plate 12, inside the through holes corresponding to the two power contacts 38. An arc-shaped hole 305 is provided on the circuit board 30 accordingly. The arc-shaped isolation rib plate 18 increases the creepage distance between different polarities of the charging socket.

[0042] The pressure plate tail cover 60 is provided with a DC through hole 61 and a PE through hole 62, which are used for the DC cable 50 and PE cable 40 to pass through, respectively. A clamping claw 63 is provided on the front side of the pressure plate tail cover 60 corresponding to the DC through hole 61 and PE through hole 62 for axial positioning of the corresponding contact parts. A DC protection tube 64 and a PE protection tube 65 are provided on the rear side of the pressure plate tail cover 60 for sealing and fixing the rear ends of the DC cable 50 and PE cable 40, respectively. Specifically, the DC cable 50 is fitted with a DC sealing ring 51, a DC cable tail cover 52, and a DC clamp 53. The DC sealing ring 51 is pressed between the DC cable 50 and the DC protection tube 64 to seal the DC cable 50 and the DC protection tube 64, preventing foreign objects from entering. A wedge-shaped groove is provided inside the DC cable tail cover 52 to cooperate with the DC clamp 53, clamping the cable and preventing uneven compression deformation of the DC sealing ring 51 due to excessive cable sway. The DC cable end cover 52 is provided with a through groove 54, and the DC protection tube 64 is correspondingly provided with a wedge-shaped locking block 641. The wedge-shaped locking block 641 and the through groove 54 form a locking engagement, thereby fixing the DC cable end cover 52 on the pressure plate end cover 60. A PE sealing ring 41 and a PE cable end cover 42 are fitted onto the PE cable 40. The PE sealing ring 41 is pressed between the PE cable 40 and the PE protection tube 65 to seal the PE cable 40 and the PE protection tube 65 and prevent foreign objects from entering. The PE cable end cover 42 is provided with an anti-sway platform 43 to prevent excessive cable sway from causing uneven compression deformation of the PE sealing ring 41. The PE cable end cover 42 is also provided with a guide key 44 and a wedge-shaped guide block 45. The PE protective tube 65 is provided with a guide notch 651 and a guide groove 652 corresponding to the guide key 44 and the wedge-shaped guide block 45, so as to fix the PE cable end cover 42 on the pressure plate end cover 60.

[0043] A ring-shaped sealing ring 66 is provided on the front side of the pressure plate tail cover 60. The ring-shaped sealing ring 66 is coated with rubber and is used to seal the pressure plate tail cover 60 after it is engaged with the insulator 10. A connecting buckle 67 is provided on the side of the pressure plate tail cover 60 protruding towards the insulator 10. A triangular boss 101 is correspondingly provided on the outer wall of the tubular shell 11. The connecting buckle 67 and the triangular boss 101 form a snap-fit ​​engagement to achieve the initial connection between the pressure plate tail cover 60 and the insulator 10. Four connecting holes 68 are provided at the front edge of the pressure plate tail cover 60. A screw hole 102 is correspondingly provided at the rear end of the tubular shell 11. The connecting holes 68 and the screw holes 102 are connected by screws to achieve a tight connection between the pressure plate tail cover 60 and the insulator 10.

[0044] A further feature is that a plurality of blind holes 371 are provided within the cavity of the pressure plate tail cover 60, the blind holes 371 corresponding to the positions of the pin contact 36, for axial positioning of the pin contact 36. Reinforcing ribs are provided within the cavity of the pressure plate tail cover 60 to enhance the overall rigidity of the pressure plate tail cover 60. Sealing bodies 70 are provided on the pin contact 36, PE contact 37, and power contact 38, for sealing between the contact and the through hole 13 on the front sealing plate 12.

[0045] The installation steps of a quick-connect DC charging socket in this embodiment are as follows: First, the sealing body 70 is fitted onto the contact piece. Then, the six pin contacts 36 are assembled into the hollow insulating post 14 on the insulator 10, and the corresponding sealing body 70 is sealed to the through hole 13. Next, the circuit board 30 is assembled into the insulator 10, guided by the guide post 15 and guide hole 301, and the mounting buckle 16 is engaged with the mounting hole 302. The circuit board 30 is then pushed to the support boss 17 for fixation. Then, the connecting buckle 67 on the pressure plate tail cover 60 is fastened to the triangular boss 101 on the outer wall of the tubular housing 11, achieving a preliminary connection between the pressure plate tail cover 60 and the insulator 10. Finally, the power contact 38 is ultrasonically welded to the DC cable 50, and the DC sealing ring 51, DC cable clamp 53, and DC cable tail cover 52 are fitted onto the DC cable. On cable 50, insert the power contact 38 through the DC protection tube 64 on the pressure plate end cover 60, pass through the circuit board 30 and the insulator 10 to reach the corresponding hollow insulating column 14, and fix the DC cable end cover 52 to the DC protection tube 64; crimp the PE contact 37 to the PE cable 40, and put the PE sealing ring 41 and the PE cable end cover 42 on the PE cable 40; insert the PE contact 37 through the PE protection tube 65 on the pressure plate end cover 60, pass through the circuit board 30 and the insulator 10 to reach the corresponding hollow insulating column 14, and fix the PE cable end cover 42 to the PE protection tube 65; use screws to pass through the connecting hole 68 and engage with the screw hole 102 to fix the pressure plate end cover 60 to the insulator 10; snap the square plate 20 onto the insulator 10 and fix it with screws to complete the assembly of the entire socket.

[0046] The above description is merely a preferred embodiment of this utility model. The protection scope of this utility model is not limited to the above embodiments. All technical solutions falling within the scope of this utility model's concept are protected. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of this utility model should also be considered within the protection scope of this utility model.

Claims

1. A fast- plug DC charging outlet, characterized in that: The system includes an insulator (10), with a square plate (20) on the front side for fixed installation with the vehicle body. A circuit board (30) is disposed inside the insulator (10). The circuit board (30) has six pin holes (31), one PE hole (32), two power holes (33), one low-voltage connector (34), and two temperature sensors (35). A pin contact (36) is disposed inside the pin hole (31). Signals from all pin contacts (36) and temperature sensors (35) are transmitted to the low-voltage connector (34) through the circuit board (30). A PE contact (37) is disposed inside the PE hole (32). (37) A blind hole (371) is provided at the tail for crimping PE cable (40). A power contact (38) is provided in the power hole (33). A connecting piece (381) is provided at the tail of the power contact (38) for ultrasonic welding with the terminal of DC cable (50). A pressure plate tail cover (60) is provided on the rear side of the insulator (10). A DC through hole (61) and a PE through hole (62) are provided on the pressure plate tail cover (60). A clamp (63) is provided on the front side of the pressure plate tail cover (60) corresponding to the DC through hole (61) and the PE through hole (62). A DC protection tube (64) and a PE protection tube (65) are provided on the rear side of the pressure plate tail cover (60).

2. The fast-plug DC charging socket according to claim 1, characterized in that: The insulator (10) includes a tubular shell (11) that is closed on the front side. The front sealing plate (12) of the tubular shell (11) is provided with 9 through holes (13) corresponding to the circuit board (30) and 9 hollow insulating pillars (14) are provided forward. The bottom of the hollow insulating pillars (14) is provided with a slot (141) and the bottom of the square plate (20) is provided with a drain hole (21).

3. The fast-plug DC charging socket of claim 2, wherein: The front sealing plate (12) has two guide posts (15), two mounting buckles (16) and several support bosses (17) extending rearward from the rear side. The circuit board (30) has guide holes (301) and mounting holes (302) corresponding to the guide posts (15) and mounting buckles (16).

4. A quick-connect DC charging socket according to claim 2, characterized in that: The front sealing plate (12) is provided with an arc-shaped isolation rib plate (18) protruding rearward from the inside of the through hole corresponding to the two power contact members (38).

5. A quick-connect DC charging socket according to claim 1, characterized in that: Three metal springs (303) are provided on the rear side of the circuit board (30) next to the PE hole (32). The metal springs (303) are connected to the pin contact (36) through the body of the circuit board (30). A circular boss (372) is provided on the PE contact (37), and the circular boss (372) is pressed against the three metal springs (303).

6. A quick-connect DC charging socket according to claim 1, characterized in that: The DC cable (50) is fitted with a DC sealing ring (51), a DC cable end cover (52) and a DC clamp (53). The DC sealing ring (51) is pressed between the DC cable (50) and the DC protection tube (64). The DC cable end cover (52) is provided with a wedge-shaped groove that cooperates with the DC clamp (53). The DC cable end cover (52) is provided with a through groove (54). The DC protection tube (64) is provided with a corresponding wedge-shaped locking block (641). The wedge-shaped locking block (641) and the through groove (54) form a locking engagement.

7. A quick-connect DC charging socket according to claim 1, characterized in that: The PE cable (40) is fitted with a PE sealing ring (41) and a PE cable end cover (42). The PE sealing ring (41) is pressed between the PE cable (40) and the PE protective tube (65). The PE cable end cover (42) is provided with an anti-deviation swing platform (43), a guide key (44) and a wedge-shaped guide block (45). The PE protective tube (65) is provided with a guide notch (651) and a guide groove (652) corresponding to the guide key (44) and the wedge-shaped guide block (45).

8. A quick-connect DC charging socket according to claim 2, characterized in that: The pressure plate tail cover (60) is provided with an annular sealing ring (66) on the front side. The side of the pressure plate tail cover (60) is provided with a connecting buckle (67) protruding towards the insulator (10). The outer wall of the tubular shell (11) is provided with a triangular boss (101). The connecting buckle (67) and the triangular boss (101) form a snap-fit ​​engagement. The pressure plate tail cover (60) is provided with 4 connecting holes (68) at the front edge. The rear end of the tubular shell (11) is provided with a screw hole (102). The connecting holes (68) and the screw holes (102) are connected by screws.

9. A quick-connect DC charging socket according to claim 2, characterized in that: The pin contact (36), PE contact (37), and power contact (38) are all provided with sealing bodies (70), which are used to seal between the contact and the through hole (13) on the front sealing plate (12).

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