A high-voltage box capable of supporting single-gun large-current fast charging

Abstract

This application discloses a high-voltage box supporting single-gun high-current fast charging, comprising a high-voltage box body, a charging cable, and a metal connector. A charging circuit copper busbar is disposed inside the high-voltage box body. The charging cable is connected to a terminal piece, which has a through hole and is located inside the high-voltage box body, and is in close contact with the charging circuit copper busbar. One end of the metal connector passes through the through hole and is connected to the charging circuit copper busbar; the other end of the metal connector has a cap that presses against the terminal piece, ensuring a tight fit between the terminal piece and the charging circuit copper busbar. The high-voltage box provided by this application, supporting single-gun high-current fast charging, increases the contact area between the terminal piece and the charging circuit copper busbar, enabling the connection between the charging circuit copper busbar and the charging cable to withstand a larger current. This allows the high-voltage box of this application to fast charge electric vehicles with large battery capacities, significantly improving charging efficiency.

Description

Technical Field

[0001] This utility model relates to the field of charging equipment technology, and in particular to a high-voltage box that can support single-gun high-current fast charging. Background Technology

[0002] High-voltage boxes typically use quick-connect connectors for wiring. The quick-connect connector's socket includes a socket sleeve and a conductive terminal at the base located in the middle of the socket sleeve. The connector's head includes a connector sleeve and a conductive terminal at the tip located in the middle of the connector sleeve. During insertion, the contact area between the base and head conductive terminals is small. If the charging current is high, significant heat is generated at the electrical connection point between the base and head conductive terminals. Furthermore, the socket and connector sleeves enclose the connection point, causing the heat to accumulate inside the sleeves and making it difficult to dissipate. Excessive heat accumulation leads to a high temperature rise at the connection point, affecting the connector's performance and lifespan. Therefore, the structure of the quick-connect connector limits its current-carrying capacity. Consequently, when charging vehicles with large battery capacities, multiple charging guns are needed simultaneously to achieve fast charging. However, this operation is relatively cumbersome, and the internal space of the high-voltage box is limited, making it impossible to arrange multiple sets of plug terminals. Ordinary high-voltage boxes cannot achieve fast charging when charging vehicles with large battery capacities, which greatly reduces the fast charging efficiency of the entire battery system. Utility Model Content

[0003] To solve the above-mentioned technical problems, this utility model provides a high-voltage box that can support single-gun high-current fast charging.

[0004] The present invention adopts the following technical solution:

[0005] A high-voltage box that supports single-gun high-current fast charging includes:

[0006] The high-voltage box body has a charging circuit copper busbar inside.

[0007] A charging cable is connected to a terminal piece, the terminal piece having a through hole, the terminal piece being located inside the high-voltage box body, and the terminal piece being in contact with the copper busbar of the charging circuit;

[0008] A metal connector, one end of which passes through the through hole and is connected to the charging circuit copper busbar, and the other end of which has a cap that presses against the terminal piece, so that the terminal piece and the charging circuit copper busbar fit tightly together.

[0009] Optionally, the terminal piece has a connecting portion and a fitting portion;

[0010] The connecting part is used to connect with the charging cable, the bonding part is sheet-shaped, the bonding part is bonded to the copper busbar of the charging circuit, and the bonding part has the through hole;

[0011] The cap body is pressed against the fitting part.

[0012] Optionally, the connecting part includes a sleeve;

[0013] Each conductive wire of the charging cable is inserted into the sleeve;

[0014] The sleeve is deformed by extrusion and pressed to fix the charging cable.

[0015] Optionally, the connecting part is sheet-shaped, and each conductive wire of the charging cable is laid flat on one side surface of the connecting part along the thickness direction and welded to the connecting part.

[0016] Optionally, the high-voltage box body has a main box body and a cover body;

[0017] The main housing has a cavity and an opening communicating with the cavity, and the charging circuit copper busbar is located inside the cavity and exposed to the opening;

[0018] The cover is detachably connected to the main box and covers the opening.

[0019] Optionally, the main box body includes a large box body and a small box body;

[0020] The large box and the small box are connected;

[0021] The cavity includes a large cavity disposed within the large box and a small cavity disposed within the small box;

[0022] The charging circuit copper busbar is at least partially located within the small cavity;

[0023] The opening is provided on the small box.

[0024] Optionally, the small box has a peripheral sidewall that encloses two openings, one of which is connected to the large box, and the other opening has a flanged edge that connects to the peripheral sidewall.

[0025] The cover is detachably connected to the flange.

[0026] Optionally, the flange plate is provided with multiple connection holes;

[0027] Multiple fasteners have one end passing through the cover and connected to the connection hole, while the other end of each fastener is confined to the cover.

[0028] Optionally, the peripheral sidewall is provided with a wire hole and a fixing member;

[0029] The charging cable passes through the through hole, and the fastener secures the charging cable.

[0030] Optionally, the fastener includes a fixed body and a movable body;

[0031] The fixing body is fixed to the peripheral side wall, and the fixing body has a cylindrical body communicating with the wire hole, and the cylindrical body has a retainer;

[0032] The movable body is sleeved on the charging cable, and the movable body has a claw;

[0033] The movable body can be fitted onto the cylinder, and the claw can be engaged with the card seat.

[0034] By adopting the above technical solution, this application has the following beneficial effects:

[0035] The high-voltage box provided in this application, which supports high-current fast charging with a single gun, increases the contact area between the terminal components and the copper busbar of the charging circuit, enabling the connection between the copper busbar of the charging circuit and the charging cable to withstand a larger current. This allows the high-voltage box of this application to fast charge electric vehicles with large battery capacities, significantly improving charging efficiency.

[0036] The specific embodiments of this utility model will be described in further detail below with reference to the accompanying drawings. Attached Figure Description

[0037] The accompanying drawings, which form part of this application, are used to provide a further understanding of the present invention. The illustrative embodiments and descriptions of the present invention are used to explain the present invention, but do not constitute an undue limitation of the present invention. Obviously, the drawings described below are merely some embodiments; those skilled in the art can obtain other drawings based on these drawings without creative effort. In the drawings:

[0038] Figure 1 This illustration shows a schematic diagram of a high-voltage box structure that supports single-gun high-current fast charging, provided in an embodiment of this application.

[0039] Figure 2 This illustration shows a schematic diagram of a partial explosion structure of a high-voltage box that supports single-gun high-current fast charging, provided in an embodiment of this application.

[0040] Figure 3 This shows a schematic diagram of the high-voltage box, which supports single-gun high-current fast charging, after the cover is removed, according to an embodiment of this application.

[0041] Figure 4 This illustration shows a partial enlarged structural diagram of the small box of the high-voltage box that supports single-gun high-current fast charging, according to an embodiment of this application.

[0042] Figure 5 This illustration shows a partial enlarged schematic diagram of the joint structure of the copper busbar and terminal components of the high-voltage box charging circuit, which supports single-gun high-current fast charging, according to an embodiment of this application.

[0043] Figure 6 This illustration shows a partially exploded structural diagram of a high-voltage box with an opening on the top wall that supports single-gun high-current fast charging, according to an embodiment of this application.

[0044] Figure 7 This illustration shows a partial enlarged structural diagram of the mating part of the cylindrical body and the movable body of the high-voltage box fixing body that can support single-gun high-current fast charging, provided in an embodiment of this application.

[0045] Figure 8 This paper shows a partial enlarged cross-sectional view of the joint between the cylindrical body and the movable body of the high-voltage box fixing body that supports single-gun high-current fast charging, provided in an embodiment of this application.

[0046] Figure 9 A schematic diagram of the structure of the high-voltage box movable body that supports single-gun high-current fast charging provided in an embodiment of this application is shown.

[0047] In the diagram: 1. Main box; 11. Large box; 111. Lug; 12. Small box; 2. Charging cable; 3. Terminal piece; 31. Fitting part; 32. Sleeve; 4. Charging circuit copper busbar; 51. Flanged plate; 52. Fixing body; 53. Cylinder; 54. Card holder; 55. Movable body; 56. Claw; 57. Sealing ring; 6. Metal connector; 7. Cover.

[0048] It should be noted that these accompanying drawings and textual descriptions are not intended to limit the scope of the present invention in any way, but rather to illustrate the concept of the present invention to those skilled in the art by referring to specific embodiments. Detailed Implementation

[0049] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions in the embodiments will be clearly and completely described below with reference to the accompanying drawings. The following embodiments are used to illustrate this utility model, but are not intended to limit the scope of this utility model.

[0050] In the description of this utility model, it should be noted that the terms "upper", "lower", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0051] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0052] See Figure 1 to Figure 9 As shown in the illustration, this application provides a high-voltage box that supports single-gun high-current fast charging, including a high-voltage box body, a charging cable 2, and a metal connector 6. A charging circuit copper busbar 4 is disposed inside the high-voltage box body. The charging cable 2 is connected to a terminal piece 3, which has a through hole. The terminal piece 3 is located inside the high-voltage box body and is in close contact with the charging circuit copper busbar 4. One end of the metal connector 6 passes through the through hole and is connected to the charging circuit copper busbar 4. The other end of the metal connector 6 has a cap, which presses against the terminal piece 3, ensuring a tight fit between the terminal piece 3 and the charging circuit copper busbar 4.

[0053] The terminal 3 on the charging cable 2 of the high-voltage box provided in this application is directly attached to the charging circuit copper busbar 4 inside the high-voltage box body. This arrangement increases the contact area between the charging cable 2 and the charging circuit copper busbar 4, effectively reducing the heat generated when current flows between them. A metal connector 6 is used at the electrical connection point between the charging cable 2 and the charging circuit copper busbar 4. The metal connector 6 has good conductivity, further increasing the contact area between the charging cable 2 and the charging circuit copper busbar 4. Furthermore, the metal connector 6 has good heat dissipation properties, eliminating the need to wrap around the connection point and further improving heat dissipation. Therefore, the connection point between the charging cable 2 and the charging circuit copper busbar 4 can withstand a larger current, enabling the high-voltage box, which can support single-gun high-current fast charging, to achieve fast charging for electric vehicles with larger battery capacities, thus improving charging efficiency.

[0054] In some possible implementations, the terminal 3 has a connecting portion and a fitting portion 31. The connecting portion is used to connect with the charging cable 2, and the fitting portion is sheet-shaped and fits onto the charging circuit copper busbar 4. The fitting portion has the through hole, and the cap is pressed onto the fitting portion. The fitting portion 31 is sheet-shaped, which effectively increases the contact area between the charging circuit copper busbar 4 and the fitting portion 31, reduces the heat generation between the charging circuit copper busbar 4 and the fitting portion 31, increases the heat dissipation area, and further improves the overcurrent capability between the charging circuit copper busbar 4 and the fitting portion 31.

[0055] Furthermore, the charging circuit copper busbar 4 is also sheet-shaped. The sheet-shaped bodies of the charging circuit copper busbar 4 and the bonding part 31 copper busbar are bonded together, which effectively increases the contact area and reduces the heat generated when the current passes through. This arrangement can not only increase the heat dissipation area of ​​the charging circuit copper busbar 4 and the bonding part 31, but also further increase the current carried at the connection between the charging circuit copper busbar 4 and the bonding part 31.

[0056] Furthermore, the metal connector 6 can be a bolt, rivet, etc. The rod of the metal connector 6 passes through the through hole of the fitting part 31 and is fixed by threading or riveting to the charging circuit copper busbar 4. Preferably, the metal connector 6 is a bolt. Bolts not only ensure the structural stability of the connection, but also facilitate disassembly. They also facilitate the later maintenance of the high-voltage box that supports single-gun high-current fast charging, or make the operation more convenient when changing the mating relationship between the charging circuit copper busbar 4 and the terminal 3.

[0057] Furthermore, the charging circuit copper busbar 4 is provided with mounting holes, which can be threaded holes or through holes. If the mounting hole is a through hole, the bolt nut is limited to the side of the mating part 31 away from the charging circuit copper busbar 4, and the bolt stud passes through the mounting hole of the charging circuit copper busbar 4 and the through hole of the mating part 31 to be threadedly connected to the nut. Compared with the setting of threaded holes for mounting holes, the parts are easier to process and the cost is lower. If the mounting hole is a threaded hole, the bolt nut is limited to the side of the mating part 31 away from the charging circuit copper busbar 4, and the bolt stud passes through the through hole of the mating part 31 to be threadedly connected to the threaded hole of the charging circuit copper busbar 4. Compared with the setting of through holes for mounting holes, the space utilization is small, operation is convenient, and maintenance is time-saving and labor-saving.

[0058] In some possible implementations, the connection between the connector and the charging cable can be varied. This embodiment mainly discloses the following two:

[0059] The first type is, such as Figure 5 As shown, the connecting part includes a sleeve 32, and each conductive wire of the charging cable 2 is inserted into the sleeve 32. The sleeve 32 is compressed and deformed to fix the charging cable 2. Compared with the second connection method, this connection method is simple, has a high connection speed, and has no technical requirements, requiring no professional personnel to operate.

[0060] The second type involves a sheet-like connecting portion, where the conductive wires of the charging cable 2 are laid flat on one side of the connecting portion along its thickness direction and soldered to it. This connection method is not shown in the figure. Compared to the first method, this connection method offers stronger connection stability and better conductivity.

[0061] In some possible implementations, the high-voltage box body has a main box body 1 and a cover 7. The main box body 1 has a cavity and an opening communicating with the cavity. The charging circuit copper busbar 4 is located inside the cavity and exposed through the opening. The cover 7 is detachably connected to the main box body 1 and covers the opening. The opening allows the charging circuit copper busbar 4 to be led out and connected to the charging cable 2. The cover 7, detachably connected to the main box body 1, prevents water, dust, etc., from entering the cavity, as all connections within the cavity are electrical connections, and also prevents pressure on the internal connections, thus protecting the internal connections. When connection or maintenance is required, the detachable cover 7 exposes the opening and the connection point between the charging circuit copper busbar 4 and the charging cable 2.

[0062] Furthermore, the main box 1 includes a top wall, a bottom wall, and side walls, and the opening can be located on the top wall or on the side wall. Different opening positions can be selected depending on the usage environment.

[0063] Furthermore, the main housing 1 is provided with mounting feet for fixing to the battery system frame or vehicle frame by fasteners. For example, the mounting feet may include lugs 111 provided on the four corners of the side wall of the main housing 1. The lugs 111 are provided with through holes. The fasteners may be bolts. The studs of the bolts pass through the through holes on the lugs 111 and are connected to the battery system frame or vehicle frame. The bolt caps are confined on the lugs 111, thereby assembling and fixing the main housing 1.

[0064] In some possible implementations, the main housing includes a large housing 11 and a small housing 12. The large housing 11 and the small housing 12 are connected. The cavity includes a large cavity disposed within the large housing 11 and a small cavity disposed within the small housing 12. The charging circuit copper busbar 4 is at least partially located within the small cavity, and the opening is provided on the small housing 12. The small housing 12 extends out of the large housing 11, the charging circuit copper busbar 4 extends out of the large housing 11 and is disposed within the small housing 12, and the external port of the charging cable 2 is disposed within the small housing 12. When maintenance is required at the connection between the charging circuit copper busbar 4 and the charging cable 2, only the flange 51 at the opening of the small housing 12 needs to be removed, without exposing the connection structure inside the large housing 11. This prevents other foreign objects from entering the cavity of the large housing 11 and minimizes the risk of damaging the internal structure of the large housing 11 cavity. Furthermore, all the external ports of the charging cable 2 are located on the small box 12, which reduces changes to the overall structure of the large box 11 and facilitates the extension and arrangement of the charging cable 2.

[0065] Furthermore, the connection between the opening on one side of the small box 12 and the side of the large box 11 can be welded, which can ensure the connection strength at the connection point between the small box 12 and the large box 11.

[0066] In some possible implementations, the small box 12 has peripheral sidewalls that enclose two openings. One opening connects to the large box 11, and the edge of the other opening is provided with a flange 51 that connects to the peripheral sidewall. The cover 7 is detachably connected to the flange 51. The connection between the cover 7 and the small box 12 reduces the number of through-hole-like connection structures in the large box 11, better ensuring the airtightness of the large box 11 and reducing the possibility of water and dust entering the large cavity. The flange 51 increases the connection area at the connection between the cover 7 and the flange 51, ensuring a stable connection of the cover 7.

[0067] In some possible implementations, the flange plate 51 is provided with a plurality of connecting holes. A plurality of fasteners, each having one end passing through the cover 7 and connected to a connecting hole, have their other end confined within the cover 7. A plurality of rivet nuts are spaced apart along the edge of the flange plate 51. The connecting holes are located on the rivet nuts.

[0068] The fasteners can be bolts, rivets, etc. Preferably, bolted connections are used, as they are stable and easy to assemble and disassemble. When bolted connections are used, the bolt nuts are located on the side of the cover 7 away from the flange plate 51, and the studs penetrate the cover 7 and are threadedly connected to the rivet nuts on the flange plate 51.

[0069] Furthermore, a sealing gasket can be provided between the flange plate 51 and the cover 7. The sealing gasket can ensure the airtightness between the flange plate 51 and the cover 7, and at the same time prevent water, dust and other substances from entering the inner cavity of the small box 12, protecting the electrical connection structure in the inner cavity. The sealing gasket can be made of insulating and heat-resistant materials with sealing properties such as rubber and PVC.

[0070] In some possible implementations, the peripheral sidewall is provided with a through hole and a fixing member. The charging cable 2 passes through the through hole, and the fixing member secures the charging cable 2. The fixing member can restrict the charging cable 2, prevent the charging cable 2 from moving in the direction of its extension, eliminate the tension between the terminal piece 3 and the charging cable 2, and extend its service life and maintenance cycle.

[0071] In some possible implementations, the fixing member includes a fixed body 52 and a movable body 55. The fixed body 52 is fixed to the peripheral sidewall and has a cylindrical body 53 communicating with the wire hole, and the cylindrical body 53 has a retainer 54. The movable body 55 is sleeved on the charging cable 2, and the movable body 55 has a claw 56. The movable body 55 can be sleeved on the cylindrical body 53, and the claw 56 can be engaged with the retainer 54. After the charging cable 2 passes through the cylindrical body 53 of the movable body 55 and the fixed body 52, the claw 56 on the movable body 55 and the retainer 54 on the fixed body 52 cooperate to limit the movement of the charging cable 2.

[0072] Furthermore, a sealing ring 57 is provided between the movable body 55 and the cylindrical body 53 of the fixed body 52 to seal the gap between the cylindrical body 53 of the fixed body 52 and the wire hole of the movable body 55. The sealing ring 57, located between the cylindrical body 53 and the movable body 55, seals the wire hole, further enhancing the waterproof and dustproof performance of the small box 5. The sealing ring 57 can be made of a sealing material such as rubber or PVC.

[0073] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model in any way. Although the present utility model has been disclosed above with reference to a preferred embodiment, it is not intended to limit the present utility model. Any person skilled in the art can make some modifications or alterations to the above-described technical content to create equivalent embodiments without departing from the scope of the present utility model. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present utility model without departing from the scope of the present utility model shall still fall within the scope of the present utility model.

Claims

1. A high-voltage box capable of supporting single-gun high-current fast charging, characterized in that, include: The high-voltage box body has a charging circuit copper busbar inside. A charging cable is connected to a terminal piece, the terminal piece having a through hole, the terminal piece being located inside the high-voltage box body, and the terminal piece being in contact with the copper busbar of the charging circuit; A metal connector, one end of which passes through the through hole and is connected to the charging circuit copper busbar, and the other end of which has a cap that presses against the terminal piece, so that the terminal piece and the charging circuit copper busbar fit tightly together.

2. The high-voltage box supporting single-gun high-current fast charging according to claim 1, characterized in that, The terminal component has a connecting portion and a fitting portion; The connecting part is used to connect with the charging cable, the bonding part is sheet-shaped, the bonding part is bonded to the copper busbar of the charging circuit, and the bonding part has the through hole; The cap body is pressed against the fitting part.

3. The high-voltage box supporting single-gun high-current fast charging according to claim 2, characterized in that, The connecting part includes a sleeve; Each conductive wire of the charging cable is inserted into the sleeve; The sleeve is deformed by extrusion and pressed to fix the charging cable.

4. The high-voltage box supporting single-gun high-current fast charging according to claim 2, characterized in that, The connecting part is sheet-shaped, and each conductive wire of the charging cable is laid flat on one side surface of the connecting part along the thickness direction and welded to the connecting part.

5. The high-voltage box supporting single-gun high-current fast charging according to claim 2, characterized in that, The high-voltage box body has a main box body and a cover body; The main housing has a cavity and an opening communicating with the cavity, and the charging circuit copper busbar is located inside the cavity and exposed to the opening; The cover is detachably connected to the main box and covers the opening.

6. The high-voltage box supporting single-gun high-current fast charging according to claim 5, characterized in that, The main box body includes a large box body and a small box body; The large box and the small box are connected; The cavity includes a large cavity disposed within the large box and a small cavity disposed within the small box; The charging circuit copper busbar is at least partially located within the small cavity; The opening is provided on the small box.

7. The high-voltage box supporting single-gun high-current fast charging according to claim 6, characterized in that, The small box has a peripheral sidewall, which encloses two openings. One opening is connected to the large box, and the edge of the other opening is provided with a flange that connects to the peripheral sidewall. The cover is detachably connected to the flange.

8. The high-voltage box supporting single-gun high-current fast charging according to claim 7, characterized in that, The flange plate is provided with multiple connection holes; Multiple fasteners have one end passing through the cover and connected to the connection hole, while the other end of each fastener is confined to the cover.

9. The high-voltage box supporting single-gun high-current fast charging according to claim 7, characterized in that, The peripheral sidewall is provided with a wire hole and a fixing component; The charging cable passes through the through hole, and the fastener secures the charging cable.

10. The high-voltage box supporting single-gun high-current fast charging according to claim 9, characterized in that, The fastener includes a fixed body and a movable body; The fixing body is fixed to the peripheral side wall, and the fixing body has a cylindrical body communicating with the wire hole, and the cylindrical body has a retainer; The movable body is sleeved on the charging cable, and the movable body has a claw; The movable body can be fitted onto the cylinder, and the claw can be engaged with the card seat.

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