New energy direct current charging plug-in module and charging socket thereof

Abstract

The utility model discloses a new energy direct current charging plug module and charging socket thereof, and the module comprises a direct current connector, a direct current cable and an injection molding package, the package is integrated with the cable joint part through one-piece injection molding cladding terminal, forms the integrated structure of sealed fixed connection, the temperature monitoring PCB assembly integrated in the package is built -in sensor, and the joint part is directly pasted and monitors temperature, and the cable end cover is connected with the package tail end lock catch. In the charging socket, the positive / negative plug module is respectively connected with the independent first / second wire harness installation cavity to form the wire harness positive / negative sealed unit, and the low -voltage signal terminal assembly monopolizes the terminal sealed unit, and three units realize physical isolation and electrical independence. The utility model discloses through injection molding integrated package isolation metal welding area oxidation, and sensor monitoring heating core, realizes the early warning fast, and simultaneously three unit independent sealed framework will be failure strictly limited in the failure unit, and prevents the cascade accident.

Description

Technical Field

[0001] This utility model relates to the field of automotive parts technology, and in particular to a new energy DC charging plug module and its charging socket. Background Technology

[0002] In the field of DC charging technology for new energy vehicles, the DC charging connector module is a key component for energy transfer between the vehicle and the charging equipment. With the increasing use of aluminum wires in vehicles due to weight reduction and cost considerations, the dissimilar metal joint formed by welding aluminum wires to copper terminals is exposed to air, posing a risk of oxidation. This can negatively impact the reliability and durability of the electrical connection in the long term, becoming a potential safety hazard. In traditional modular structures, sealing this critical welding area is typically achieved through separately assembled sealing or structural components. This method is not only cumbersome and inefficient, but also involves multiple sealing interfaces, increasing the risk of seal failure over long-term use. Furthermore, with the widespread adoption of high-power liquid-cooled charging technology, liquid-cooling structures have been introduced into the charging gun / socket, causing changes in temperature distribution during charging. The highest temperature points often appear at weak points or high-resistance points along the current flow path, such as the aforementioned aluminum-copper welded joint area. However, traditional temperature monitoring solutions typically place sensors near the plug-in terminal body or front contact point, which is significantly off-center from the actual heat-generating hotspot (i.e., the welded joint). This results in delayed or even failed temperature monitoring, failing to accurately and timely reflect the true overheating risk inside the module and making it difficult to effectively warn of potential overheating faults, thus posing a threat to charging safety. Summary of the Invention

[0003] This application provides a new energy DC charging plug-in module and its charging socket, which overcomes the safety hazards of new energy DC charging by combining injection molding integrated sealing and targeted temperature monitoring.

[0004] To achieve the above objectives, this utility model provides the following technical solution: a new energy DC charging plug-in module, comprising:

[0005] DC connector terminals are used to connect and mate with a DC charging socket to establish an electrical connection;

[0006] A DC cable, connected to the tail end of a DC connector terminal;

[0007] The injection-molded package is formed by injection molding and covering the outer peripheral wall of the DC connector terminal and the DC cable joint, forming an integrated structure that seals and fixes the DC connector terminal and the DC cable into one piece.

[0008] A temperature monitoring PCB assembly is mounted on an injection-molded package. The PCB assembly integrates a temperature sensor for monitoring the temperature of the DC connector terminal and the DC cable junction.

[0009] The cable end cap is installed at the tail end of the DC cable and locked to the tail end of the injection-molded package.

[0010] Compared with the prior art, the advantages of this utility model are:

[0011] This new energy DC charging plug-in module employs a modular integrated design, using injection molding to solidify the DC connector terminals, DC cable joints, and temperature monitoring PCB assembly into a single sealed structure, completely isolating the oxidation risk at the aluminum-copper dissimilar metal welding area. Simultaneously, the temperature sensor integrated into the injection-molded body is directly attached to the actual heat-generating hotspots—the DC connector terminals and DC cable joints—precisely detecting localized overheating that is difficult to monitor in traditional liquid-cooled high-power charging, providing early warning. Its modular architecture not only simplifies the assembly process and improves structural stress resistance but also supports rapid disassembly and maintenance through standardized cable end cap locking connections, significantly reducing replacement costs. This highly integrated modular setup, while ensuring long-term reliable electrical connections and zero-deviation temperature monitoring, further optimizes production efficiency and ease of maintenance, providing a standardized and highly compatible solution for the lightweighting of new energy vehicles, the application of aluminum conductors, and the safe evolution of high-power fast charging technology.

[0012] As an improvement, the DC cable and DC connector are coaxially extended to form an axially collinear layout. The injection-molded package is a one-piece cylindrical injection-molded package. The outer wall of the first end of the cylindrical injection-molded package has a first temperature control mounting groove protruding at the connection between the DC connector and the DC cable to support the temperature monitoring PCB assembly. This new energy DC charging plug-in module, through the coaxial extension line and axially collinear layout design, ensures that the DC cable and DC connector are aligned in a straight line. At the same time, the one-piece cylindrical injection-molded package has a first temperature control mounting groove precisely protruding on its outer wall, directly supporting the temperature monitoring PCB assembly and ensuring that the sensor is in zero-distance contact with the DC connector and cable joint, i.e., the core heat point, completely eliminating the positional deviation problem of traditional monitoring. The cylindrical structure not only achieves 360° uniform sealing protection of the dissimilar metal welding area, eliminating the risk of oxidation, but its axially collinear design also optimizes the internal current transmission efficiency and reduces eddy current loss. The integrated temperature control mounting groove ensures accurate temperature measurement while avoiding the risk of sealing failure of external additional assembly.

[0013] As an improvement, the DC cable and DC connector are orthogonally arranged to form a radially orthogonal layout. The injection-molded package includes an axially extending terminal package for covering the DC connector, and a radially extending cable package that is orthogonally connected to the terminal package for covering the DC cable. The plug-in module also includes an anti-rotation structure composed of DC locking pins to restrict the rotation of the DC connector. The radially orthogonal layout design of this new energy DC charging plug-in module forms a compact L-shaped structure by arranging the DC cable and DC connector at 90° perpendicularly, which perfectly adapts to installation scenarios where the lateral space inside the charging gun / socket is limited. The L-shaped integrated injection-molded package is seamlessly orthogonally connected by the axially extending terminal package and the radially extending cable package, forming a continuous sealing barrier without dead angles at the dissimilar metal joint, completely blocking the oxidation path. At the same time, the DC locking pin anti-rotation structure integrated in the cable package mechanically locks the DC connector, eliminating the risk of shear damage to the aluminum-copper welding area caused by torsional stress during the insertion and removal process, and ensuring the stability of the long-term electrical connection.

[0014] As an improvement, a second temperature-controlled mounting groove is provided at the connection between the terminal encapsulation part and the cable encapsulation part to support the temperature monitoring PCB assembly and then seal it with temperature-controlled potting compound. The anti-rotation structure also includes a first limiting block extending radially from the tail end of the cable encapsulation part. The second temperature-controlled mounting groove at the connection between the two directly supports the temperature monitoring PCB assembly and is sealed with high thermal conductivity and insulation temperature-controlled potting compound, realizing zero-distance mounting of the sensor and the heat-generating core area. At the same time, the potting compound filling eliminates air gap thermal resistance, ensuring rapid temperature data response in liquid-cooled environments. The first limiting block extending radially from the tail end of the cable encapsulation part of the anti-rotation structure forms a rigid engagement with the equipment mounting groove, preventing the DC cable from swinging circumferentially.

[0015] As an improvement, the plug-in module also includes a terminal bracket that fits onto the first end of the DC plug terminal and abuts against the front face of the terminal package to form an axial sealing limit; a cable bracket that fits onto the tail end of the DC cable and abuts against the lower end face of the cable package to form a radial sealing limit; and a mounting base located at the connection between the terminal package and the cable package for plugging in and installing the temperature monitoring PCB assembly. The lower end of the mounting base is fixedly connected to the upper end of the injection-molded package. The anti-rotation structure also includes a second limiting block extending radially from the cable bracket. The terminal bracket fits onto the first end of the DC plug terminal and rigidly abuts against the front face of the terminal package to form an axial dynamic sealing barrier, preventing separation of the sealing interface caused by plugging and unplugging impacts. The cable bracket fits onto the tail end of the DC cable and elastically presses against the lower end face of the cable package to construct a radial self-compensating seal, effectively absorbing cable swing deformation. The two brackets work together to lock the dissimilar metal welding area in a completely airtight environment. A dedicated mounting base is provided at the connection between the terminal package and the cable package for inserting the temperature monitoring PCB assembly and sealing it with high thermal conductivity potting compound, which greatly shortens the heat conduction path between the sensor and the aluminum-copper welding area.

[0016] According to any of the above-mentioned new energy DC charging plug-in modules, the charging socket includes a socket panel and a low-voltage signal terminal assembly, and has a partitioned cavity structure inside. Two plug-in modules, as the positive and negative terminals for DC charging, are detachably installed on both sides of the cavity structure. The low-voltage signal terminal assembly is fixedly installed in the cavity structure between the positive plug-in module and the negative plug-in module. The positive plug-in module and the corresponding first wire harness mounting cavity in the cavity structure form an independent wire harness positive terminal sealing unit, and the negative plug-in module and the corresponding second wire harness mounting cavity in the cavity structure form an independent wire harness negative terminal sealing unit. The low-voltage signal terminal assembly and the cavity structure... The corresponding terminal mounting cavities form independent terminal sealing units, ensuring that the wire harness positive sealing unit, wire harness negative sealing unit, and terminal sealing unit are physically isolated and electrically independent. The sealing failure or circuit fault of any unit will not be transmitted to the other units. The positive plug-in module and the first wire harness mounting cavity form the wire harness positive sealing unit, the negative plug-in module and the second wire harness mounting cavity form the wire harness negative sealing unit, and the low-voltage signal terminal assembly occupies the terminal sealing unit exclusively. The three units are completely blocked by a rigid isolation wall to block the gas / liquid passage, ensuring that in the event of single-pole sealing failure, coolant leakage, or circuit short circuit, the risk is strictly controlled within the faulty unit, completely eliminating cascading accidents.

[0017] As an improvement, the plug-in module also includes a retaining ring clamped to the outer wall of the DC plug terminal head and locked to the inner wall of the first and second wire harness mounting cavities to restrict the axial movement of the positive and negative DC plug terminal wire harness assemblies in the first and second wire harness mounting cavities; a toothed sealing ring set at the connection between the DC plug terminal and the first and second wire harness mounting cavities, and at the connection between the injection-molded package and the cable end cap; and a metal retaining ring clamped to the head of the DC plug terminal and rigidly locked to the inner wall of the wire harness mounting cavity, strictly limiting the axial displacement of the positive / negative plug-in module, eliminating the risk of terminal retraction caused by high-current insertion and extraction impact, and improving the stability of the aluminum-copper welding area; and multi-level toothed sealing rings are arranged at two nodes at the interface between the DC plug terminal and the mounting cavity, and at the connection between the injection-molded package and the cable end cap. The sawtooth structure generates radial elastic deformation under pressure, improving the sealing performance of the plug-in module when inserted into the first and second wire harness mounting cavities.

[0018] As an improvement, the first end of the cylindrical injection-molded package in the axially collinear layout is inserted into the first wire harness mounting cavity and the second wire harness mounting cavity respectively and is fixedly connected to the first wire harness mounting cavity and the second wire harness mounting cavity, so that the first end of the cylindrical injection-molded package forms an axial sealing limit with the first wire harness mounting cavity and the second wire harness mounting cavity. The first end of the cylindrical injection-molded package is directly inserted into the wire harness mounting cavity and rigidly fixed to form an axial sealing interface.

[0019] As an improvement, the first end of the DC connector in the radially orthogonal layout is inserted into the first and second wiring harness mounting cavities respectively, forming a circumferential rotational fit with the first and second wiring harness mounting cavities. The front end face of the terminal package forms an axial sealing limit with the rear end face of the first and second wiring harness mounting cavities. The circumferential rotational fit between the first end of the DC connector and the wiring harness mounting cavity is used to adjust the exit angle of the DC cable, improving the adaptability of the charging plug module. The front end face of the terminal package and the rear end face of the wiring harness mounting cavity form a sealing interface through high-precision planar pressing, improving the sealing performance between the charging plug module and the wiring harness mounting cavity.

[0020] As an improvement, the anti-rotation structure also includes a limiting groove provided on the socket panel corresponding to the first limiting block or the second limiting block for embedding the first limiting block or the second limiting block and being pinned by a DC locking pin. The socket panel is provided with a limiting groove to form an engagement with the first limiting block and the second limiting block of the plug-in module, and is then radially pinned by a DC locking pin to construct a double locking mechanism. Attached Figure Description

[0021] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments:

[0022] Figure 1 An exploded view of an injection-molded structure with a radially orthogonal layout for a new energy DC charging plug-in module.

[0023] Figure 2 A schematic diagram of a radially orthogonal layout of a new energy DC charging plug-in module and its structure in conjunction with a charging socket;

[0024] Figure 3 An exploded view of a radially orthogonal layout of a new energy DC charging plug-in module and its matching with a charging socket;

[0025] Figure 4 A schematic diagram of a radially orthogonally arranged limiting block and limiting groove pin connection structure for a new energy DC charging plug module;

[0026] Figure 5 A schematic diagram of a radially orthogonal layout socket panel structure for a new energy DC charging socket;

[0027] Figure 6 An exploded view of a low-pressure injection molded structure with a radially orthogonal layout for a new energy DC charging plug-in module.

[0028] Figure 7 An exploded view of an injection-molded structure with an axially collinear layout for a new energy DC charging plug-in module.

[0029] Figure 8 A schematic diagram of the axially collinear layout of a new energy DC charging plug-in module and its structure in conjunction with a charging socket.

[0030] Figure 9 This is a schematic diagram of the axially collinear layout of a new energy DC charging socket panel.

[0031] The markings in the above figures are as follows: 1. Socket panel; 1.1. First wire harness mounting cavity; 1.2. Second wire harness mounting cavity; 1.3. Terminal mounting cavity; 1.4. Limiting groove; 2. Plug-in module; 2.1. DC connector terminal; 2.2. DC cable; 2.3. Snap ring; 2.4. Cable end cap; 2.5. Toothed sealing ring; 2.6. Temperature monitoring PCB assembly; 2.7. Cylindrical injection molded package; 2.8. First temperature control mounting groove. 2.9 Terminal encapsulation part; 2.10 Cable encapsulation part; 2.11 DC locking pin; 2.12 First limit block; 2.13 Second temperature control mounting slot; 2.14 Second limit block; 2.15 Mounting base; 2.16 Terminal bracket; 2.17 Cable bracket; 2.18 Temperature control potting compound; 3. Low voltage signal terminal assembly; 4. Waterproof gasket; 5. DC circuit board; 6. PE terminal; 7. Signal terminal potting compound. Detailed Implementation

[0032] In this utility model, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "planar direction", "circumferential", etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0033] Example 1

[0034] like Figures 1 to 5As shown, a new energy DC charging plug-in module includes a DC connector terminal 2.1, a DC cable 2.2, an injection-molded package, a temperature monitoring PCB assembly 2.6, and a cable end cap 2.4. The DC connector terminal 2.1 is used to plug into an external charging device or a vehicle's DC charging socket to establish an electrical connection. The DC cable 2.2 is connected to the tail end of the DC connector terminal 2.1. The injection-molded package is formed by injection molding and covers the outer peripheral wall of the joint between the DC connector terminal 2.1 and the DC cable 2.2, forming an integrated structure that seals and fixes the DC connector terminal 2.1 and the DC cable 2.2 into one unit. The temperature monitoring PCB assembly 2.6 is disposed on the injection-molded package and has an integrated temperature sensor for monitoring the temperature of the joint between the DC connector terminal 2.1 and the DC cable 2.2. The cable end cap 2.4 is disposed at the tail end of the DC cable 2.2 and is locked to the tail end of the injection-molded package.

[0035] The DC cable 2.2 and the DC connector 2.1 are orthogonally arranged to form a radially orthogonal layout. The injection-molded package includes a terminal package 2.9 that extends axially to cover the DC connector 2.1 and a cable package 2.10 that extends radially and is orthogonally connected to the terminal package 2.9 to cover the DC cable 2.2. The plug module 2 also includes an anti-rotation structure consisting of a DC locking pin 2.11 for limiting the rotation of the DC connector 2.1.

[0036] The connection between the terminal encapsulation part 2.9 and the cable encapsulation part 2.10 is provided with a second temperature control mounting groove 2.13 for carrying the temperature monitoring PCB assembly 2.6 and then sealing it with temperature control potting compound 2.18. The anti-rotation structure also includes a first limiting block 2.12 that extends radially from the tail end of the cable encapsulation part 2.10.

[0037] A charging socket for a new energy DC charging plug-in module includes a socket panel 1 and a low-voltage signal terminal assembly 3. The socket has an internally separated chamber structure. Two plug-in modules 2, serving as positive and negative terminals for DC charging, are detachably installed on opposite sides of the chamber structure. The low-voltage signal terminal assembly 3 is fixedly installed within the chamber structure between the positive and negative plug-in modules 2. The positive plug-in module 2 and a corresponding first wire harness mounting cavity 1.1 within the chamber structure form an independent positive wire harness sealing unit. The negative plug-in module 2 and a corresponding second wire harness mounting cavity 1.2 within the chamber structure form an independent negative wire harness sealing unit. The low-voltage signal terminal assembly 3 and a corresponding terminal mounting cavity 1.3 within the chamber structure form an independent terminal sealing unit. This ensures that the positive wire harness sealing unit, the negative wire harness sealing unit, and the terminal sealing unit are physically isolated and electrically independent, preventing any sealing failure or circuit fault in any unit from being transmitted to the other units.

[0038] The plug-in module 2 also includes a retaining ring 2.3 that is clamped to the outer wall of the first end of the DC plug terminal 2.1 and locked to the inner wall of the first wire harness mounting cavity 1.1 and the second wire harness mounting cavity 1.2 to restrict the axial movement of the wire harness assembly of the positive DC plug terminal 2.1 and the wire harness assembly of the negative DC plug terminal 2.1 on the first wire harness mounting cavity 1.1 and the second wire harness mounting cavity 1.2, and a toothed sealing ring 2.5 that is disposed at the connection between the DC plug terminal 2.1 and the first wire harness mounting cavity 1.1 and the second wire harness mounting cavity 1.2 and at the connection between the injection molded package and the cable end cap 2.4.

[0039] In the radially orthogonal layout, the first end of the DC connector 2.1 is inserted into the first wire harness mounting cavity 1.1 and the second wire harness mounting cavity 1.2 respectively, forming a circumferential rotational fit with the first wire harness mounting cavity 1.1 and the second wire harness mounting cavity 1.2, and the front end face of the terminal encapsulation part 2.9 forms an axial sealing limit with the rear end face of the first wire harness mounting cavity 1.1 and the second wire harness mounting cavity 1.2.

[0040] The anti-rotation structure also includes a limiting groove 1.4 provided on the socket panel 1 corresponding to the first limiting block 2.12 for embedding the first limiting block 2.12 and being pinned by the DC lock pin 2.11.

[0041] The DC charging socket also includes a waterproof gasket 4, a DC circuit board 5, and a PE terminal 6 that is sequentially sleeved on the outer wall of the low-voltage signal terminal assembly 3 and encapsulated with signal terminal potting compound 7, which are connected to the DC circuit board 5.

[0042] The DC cable 2.2 is vertically soldered to the end of the DC connector terminal 2.1, forming an orthogonal arrangement to create a radially orthogonal layout. The soldering area is then completely encapsulated with plastic using injection molding, forming an integrated terminal encapsulation part 2.9 (axially extending) and a cable encapsulation part 2.10 (radially extending), thoroughly sealing the solder joint. The temperature monitoring PCB assembly 2.6 is installed in the pre-set second temperature control mounting slot 2.13, and then sealed and fixed with temperature control potting compound 2.18. A retaining ring 2.3 (for subsequent axial positioning) is inserted into the first end of the DC connector terminal 2.1. A cable end cap 2.4 is snapped into the end of the injection-molded encapsulation layer, and a toothed sealing ring 2.5 is provided at the connection point. The first limiting block 2.12 is then fixed to... At the tail end of the cable encapsulation part 2.10, the head end of the DC connector terminal 2.1 is inserted into the first wire harness mounting cavity 1.1 (positive) and the second wire harness mounting cavity 1.2 (negative) of the cavity structure, so that the front end face of the terminal encapsulation part 2.9 fits against the rear end face of the first wire harness mounting cavity 1.1 (positive) and the second wire harness mounting cavity 1.2 (negative), forming an axial sealing limit. After rotating circumferentially to a specified angle, the first limiting block 2.12 is embedded into the first limiting groove 1.4 corresponding to the socket panel 1. The DC locking pin 2.11 is inserted through the limiting block and the panel to lock the rotational freedom and prevent loosening. The low-voltage signal terminal assembly 3 is inserted into the terminal mounting cavity 1.3 between the positive and negative poles. The waterproof gasket 4 and the DC circuit board 5 are then sequentially fitted in. The PE terminal 6 is inserted into the DC circuit board 5 and sealed as a whole by the signal terminal potting compound 7 to form an independent low-voltage sealing module.

[0043] Example 2

[0044] like Figures 1 to 4 , Figure 6 As shown, a new energy DC charging plug-in module includes a DC connector terminal 2.1, a DC cable 2.2, an injection-molded package, a temperature monitoring PCB assembly 2.6, and a cable end cap 2.4. The DC connector terminal 2.1 is used to plug into an external charging device or a vehicle's DC charging socket to establish an electrical connection. The DC cable 2.2 is connected to the tail end of the DC connector terminal 2.1. The injection-molded package is formed by injection molding and covers the outer peripheral wall of the joint between the DC connector terminal 2.1 and the DC cable 2.2, forming an integrated structure that seals and fixes the DC connector terminal 2.1 and the DC cable 2.2 into one unit. The temperature monitoring PCB assembly 2.6 is disposed on the injection-molded package and has an integrated temperature sensor for monitoring the temperature of the joint between the DC connector terminal 2.1 and the DC cable 2.2. The cable end cap 2.4 is disposed at the tail end of the DC cable 2.2 and is locked to the tail end of the injection-molded package.

[0045] The DC cable 2.2 and the DC connector 2.1 are orthogonally arranged to form a radially orthogonal layout. The injection-molded package includes a terminal package 2.9 that extends axially to cover the DC connector 2.1 and a cable package 2.10 that extends radially and is orthogonally connected to the terminal package 2.9 to cover the DC cable 2.2. The plug module 2 also includes an anti-rotation structure consisting of a DC locking pin 2.11 for limiting the rotation of the DC connector 2.1.

[0046] The plug-in module 2 also includes a terminal bracket 2.16 that is sleeved on the first end of the DC plug terminal 2.1 and abuts against the front end face of the terminal encapsulation part 2.9 to form an axial sealing limit; a cable bracket 2.17 that is sleeved on the tail end of the DC cable 2.2 and abuts against the lower end face of the cable encapsulation part 2.10 to form a radial sealing limit; and a mounting base 2.15 disposed at the connection between the terminal encapsulation part 2.9 and the cable encapsulation part 2.10 for plugging and installing the temperature monitoring PCB assembly 2.6. The lower end of the mounting base 2.15 is fixedly connected to the upper end of the injection molded encapsulation body. The anti-rotation structure also includes a second limiting block 2.14 that extends radially from the cable bracket 2.17.

[0047] A charging socket for a new energy DC charging plug-in module includes a socket panel 1 and a low-voltage signal terminal assembly 3. The socket has an internally separated chamber structure. Two plug-in modules 2, serving as positive and negative terminals for DC charging, are detachably installed on opposite sides of the chamber structure. The low-voltage signal terminal assembly 3 is fixedly installed within the chamber structure between the positive and negative plug-in modules 2. The positive plug-in module 2 and a corresponding first wire harness mounting cavity 1.1 within the chamber structure form an independent positive wire harness sealing unit. The negative plug-in module 2 and a corresponding second wire harness mounting cavity 1.2 within the chamber structure form an independent negative wire harness sealing unit. The low-voltage signal terminal assembly 3 and a corresponding terminal mounting cavity 1.3 within the chamber structure form an independent terminal sealing unit. This ensures that the positive wire harness sealing unit, the negative wire harness sealing unit, and the terminal sealing unit are physically isolated and electrically independent, preventing any sealing failure or circuit fault in any unit from being transmitted to the other units.

[0048] The plug-in module 2 also includes a retaining ring 2.3 that is clamped to the outer wall of the first end of the DC plug terminal 2.1 and locked to the inner wall of the first wire harness mounting cavity 1.1 and the second wire harness mounting cavity 1.2 to restrict the axial movement of the wire harness assembly of the positive DC plug terminal 2.1 and the wire harness assembly of the negative DC plug terminal 2.1 on the first wire harness mounting cavity 1.1 and the second wire harness mounting cavity 1.2, and a toothed sealing ring 2.5 that is disposed at the connection between the DC plug terminal 2.1 and the first wire harness mounting cavity 1.1 and the second wire harness mounting cavity 1.2 and at the connection between the injection molded package and the cable end cap 2.4.

[0049] In the radially orthogonal layout, the first end of the DC connector 2.1 is inserted into the first wire harness mounting cavity 1.1 and the second wire harness mounting cavity 1.2 respectively, forming a circumferential rotational fit with the first wire harness mounting cavity 1.1 and the second wire harness mounting cavity 1.2, and the front end face of the terminal encapsulation part 2.9 forms an axial sealing limit with the rear end face of the first wire harness mounting cavity 1.1 and the second wire harness mounting cavity 1.2.

[0050] The anti-rotation structure also includes a limiting groove 1.4 provided on the socket panel 1 corresponding to the second limiting block 2.14 for embedding the second limiting block 2.14 and being pinned by the DC lock pin 2.11.

[0051] The DC charging socket also includes a waterproof gasket 4, a DC circuit board 5, and a PE terminal 6 that is sequentially sleeved on the outer wall of the low-voltage signal terminal assembly 3 and encapsulated with signal terminal potting compound 7, which are connected to the DC circuit board 5.

[0052] The DC cable 2.2 is vertically soldered to the tail end of the DC connector terminal 2.1, forming an orthogonal arrangement to create a radially orthogonal layout. The soldering area is then completely encapsulated in plastic using injection molding, forming an integrated terminal encapsulation part 2.9 (axially extending) and a cable encapsulation part 2.10 (radially extending), thoroughly sealing the solder joint. The lower end of the mounting base 2.15 is fixedly connected to the upper end of the connection between the terminal encapsulation part 2.9 and the cable encapsulation part 2.10. The temperature monitoring PCB assembly 2.6 is inserted and installed within the mounting base 2.15. A retaining ring 2.3 (for subsequent axial positioning) is fitted onto the head end of the DC connector terminal 2.1. A cable end cap 2.4 is snapped onto the tail end of the injection-molded coating, and a toothed sealing ring 2.5 is provided at the connection point. The second limiting block 2.14 is then... The terminal bracket 2.16 is fixed to the radially extending structure at the tail end of the DC cable 2.2, and is inserted into the terminal bracket 2.16 to the head end of the DC connector terminal 2.1, abutting against the front end face of the terminal encapsulation part 2.9. The cable bracket 2.17 is inserted into the tail end of the DC cable 2.2, abutting against the lower end face of the cable encapsulation part 2.10. The head end of the DC connector terminal 2.1 is inserted into the first wire harness mounting cavity 1.1 (positive) and the second wire harness mounting cavity 1.2 (negative) of the cavity structure, so that the front end face of the terminal encapsulation part 2.9 is in contact with the first wire harness mounting cavity 1.1 (positive) and the second wire harness mounting cavity 1.2. 2. The rear end face of the negative electrode is attached to form an axial sealing limit. After rotating circumferentially to a specified angle, the second limiting block 2.14 is embedded into the second limiting groove 1.5 corresponding to the socket panel 1. The DC locking pin 2.11 is inserted through the limiting block and the panel to lock the rotational freedom and prevent loosening. The low-voltage signal terminal assembly 3 is inserted into the terminal mounting cavity 1.3 between the positive and negative electrodes. The waterproof gasket 4 and the DC circuit board 5 are then inserted in sequence. The PE terminal 6 is plugged into the DC circuit board 5 and sealed as a whole with the signal terminal potting compound 7 to form an independent low-voltage sealing module.

[0053] Example 3

[0054] like Figures 7 to 9 As shown, a new energy DC charging plug-in module includes a DC connector terminal 2.1, a DC cable 2.2, an injection-molded package, a temperature monitoring PCB assembly 2.6, and a cable end cap 2.4. The DC connector terminal 2.1 is used to plug into an external charging device or a vehicle's DC charging socket to establish an electrical connection. The DC cable 2.2 is connected to the tail end of the DC connector terminal 2.1. The injection-molded package is formed by injection molding and covers the outer peripheral wall of the joint between the DC connector terminal 2.1 and the DC cable 2.2, forming an integrated structure that seals and fixes the DC connector terminal 2.1 and the DC cable 2.2 into one unit. The temperature monitoring PCB assembly 2.6 is disposed on the injection-molded package and has an integrated temperature sensor for monitoring the temperature of the joint between the DC connector terminal 2.1 and the DC cable 2.2. The cable end cap 2.4 is disposed at the tail end of the DC cable 2.2 and is locked to the tail end of the injection-molded package.

[0055] The DC cable 2.2 and the DC connector 2.1 are coaxially extended to form an axially collinear layout. The injection molded package is an integrally formed cylindrical injection molded package 2.7. The outer wall of the first end of the cylindrical injection molded package 2.7 is provided with a first temperature control mounting groove 2.8 for supporting the temperature monitoring PCB assembly 2.6 at the connection between the DC connector 2.1 and the DC cable 2.2.

[0056] A charging socket for a new energy DC charging plug-in module includes a socket panel 1 and a low-voltage signal terminal assembly 3. The socket has an internally separated chamber structure. Two plug-in modules 2, serving as positive and negative terminals for DC charging, are detachably installed on opposite sides of the chamber structure. The low-voltage signal terminal assembly 3 is fixedly installed within the chamber structure between the positive and negative plug-in modules 2. The positive plug-in module 2 and a corresponding first wire harness mounting cavity 1.1 within the chamber structure form an independent positive wire harness sealing unit. The negative plug-in module 2 and a corresponding second wire harness mounting cavity 1.2 within the chamber structure form an independent negative wire harness sealing unit. The low-voltage signal terminal assembly 3 and a corresponding terminal mounting cavity 1.3 within the chamber structure form an independent terminal sealing unit. This ensures that the positive wire harness sealing unit, the negative wire harness sealing unit, and the terminal sealing unit are physically isolated and electrically independent, preventing any sealing failure or circuit fault in any unit from being transmitted to the other units.

[0057] The plug-in module 2 also includes a retaining ring 2.3 that is clamped to the outer wall of the first end of the DC plug terminal 2.1 and locked to the inner wall of the first wire harness mounting cavity 1.1 and the second wire harness mounting cavity 1.2 to restrict the axial movement of the wire harness assembly of the positive DC plug terminal 2.1 and the wire harness assembly of the negative DC plug terminal 2.1 on the first wire harness mounting cavity 1.1 and the second wire harness mounting cavity 1.2, and a toothed sealing ring 2.5 that is disposed at the connection between the DC plug terminal 2.1 and the first wire harness mounting cavity 1.1 and the second wire harness mounting cavity 1.2 and at the connection between the injection molded package and the cable end cap 2.4.

[0058] The first end of the cylindrical injection molded package 2.7 in the axially collinear layout is inserted into the first wire harness mounting cavity 1.1 and the second wire harness mounting cavity 1.2 respectively and is fixedly connected to the first wire harness mounting cavity 1.1 and the second wire harness mounting cavity 1.2, so that the first end of the cylindrical injection molded package 2.7 forms an axial sealing limit with the first wire harness mounting cavity 1.1 and the second wire harness mounting cavity 1.2.

[0059] The DC charging socket also includes a waterproof gasket 4, a DC circuit board 5, and a PE terminal 6 that is sequentially sleeved on the outer wall of the low-voltage signal terminal assembly 3 and encapsulated with signal terminal potting compound 7, which are connected to the DC circuit board 5.

[0060] The DC cable 2.2 is coaxially soldered to the end of the DC connector 2.1 to form a straight connection. The soldering area is then completely encapsulated in plastic via injection molding to form an integrated cylindrical injection-molded package 2.7, thoroughly sealing the solder joint and connection area. The temperature monitoring PCB assembly 2.6 is embedded into the first temperature control mounting groove 2.8 on the outer wall of the cylindrical injection-molded package 2.7, with the groove directly opposite the solder joint to ensure the temperature sensing element is waterproof and close to the heat source. A retaining ring 2.3 is inserted into the end of the DC connector 2.1 for subsequent axial positioning. A cable end cap 2.4 is attached to the end of the DC cable 2.2, and a toothed connection is provided at the joint. The sealing ring 2.5 is used to insert the first end of the cylindrical injection molded package 2.7 axially into the positive terminal of the first wire harness mounting cavity 1.1 and the negative terminal of the second wire harness mounting cavity 1.2. It is pushed in until the first end of the cylindrical injection molded package 2.7 fits tightly against the inner wall of the cavity to form an axial sealing limit. The retaining ring 2.3 automatically engages with the retaining groove on the inner wall of the cavity to limit the axial displacement of the wire harness assembly. The low-voltage signal terminal assembly 3 is inserted into the terminal mounting cavity 1.3 between the positive and negative terminals. The waterproof gasket 4 and the DC circuit board 5 are then inserted in sequence. The PE terminal 6 is plugged into the DC circuit board 5 and sealed as a whole by the signal terminal potting compound 7 to form an independent low-voltage sealing module.

[0061] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the technical solution of the present invention, or the direct application of the concept and technical solution of the present invention to other occasions without modification, are all within the protection scope of the present invention.

Claims

1. A new energy DC charging plug-in module, characterized in that, include: DC connector terminals are used to connect and mate with external charging devices or vehicle DC charging sockets to establish an electrical connection. A DC cable is connected to the tail end of the DC connector terminal. The injection-molded package is formed by injection molding and covering the outer peripheral wall of the DC connector terminal and the DC cable joint, thus forming an integrated structure that seals and fixes the DC connector terminal and the DC cable into one unit. A temperature monitoring PCB assembly is disposed on the injection molded package, and a temperature sensor is integrated on the PCB assembly to monitor the temperature of the DC connector terminal and the DC cable junction. The cable end cap is installed at the tail end of the DC cable and locked to the tail end of the injection-molded package.

2. The new energy DC charging plug-in module according to claim 1, characterized in that: The DC cable and the DC connector are coaxially extended to form an axially collinear layout. The injection molded package is an integrally formed cylindrical injection molded package. The outer wall of the first end of the cylindrical injection molded package has a first temperature control mounting groove for supporting the temperature monitoring PCB assembly, which protrudes from the DC connector and the DC cable connection.

3. The new energy DC charging plug-in module according to claim 1, characterized in that: The DC cable and DC connector are orthogonally arranged to form a radially orthogonal layout. The injection-molded package includes an axially extending terminal package for covering the DC connector, and a radially extending cable package that is orthogonally connected to the terminal package for covering the DC cable. The plug module also includes an anti-rotation structure consisting of a DC locking pin for limiting the rotation of the DC connector.

4. A new energy DC charging plug-in module according to claim 3, characterized in that: The connection between the terminal encapsulation part and the cable encapsulation part is provided with a second temperature control mounting groove for carrying the temperature monitoring PCB assembly and then sealing it with temperature control potting compound. The anti-rotation structure also includes a first limiting block that extends radially from the tail end of the cable encapsulation part.

5. A new energy DC charging plug-in module according to claim 3, characterized in that: The plug-in module further includes a terminal bracket sleeved on the first end of the DC plug terminal and abutting against the front end face of the terminal package to form an axial sealing limit; a cable bracket sleeved on the tail end of the DC cable and abutting against the lower end face of the cable package to form a radial sealing limit; and a mounting base disposed at the connection between the terminal package and the cable package for plugging in and installing a temperature monitoring PCB assembly. The lower end of the mounting base is fixedly connected to the upper end of the injection molded package. The anti-rotation structure also includes a second limiting block that extends radially from the cable bracket.

6. A charging socket, employing a new energy DC charging plug-in module as described in any one of claims 1-5, characterized in that: The charging socket includes a socket panel and a low-voltage signal terminal assembly, which has a partitioned chamber structure inside. The two plug-in modules, serving as the positive and negative terminals for DC charging, are detachably installed on both sides of the chamber structure. The low-voltage signal terminal assembly is fixedly installed in the chamber structure between the positive plug-in module and the negative plug-in module. The positive plug-in module and the corresponding first wire harness mounting cavity in the chamber structure form an independent wire harness positive terminal sealing unit. The negative plug-in module and the corresponding second wire harness mounting cavity in the chamber structure form an independent wire harness negative terminal sealing unit. The low-voltage signal terminal assembly and the corresponding terminal mounting cavity in the chamber structure form an independent terminal sealing unit. This ensures that the wire harness positive terminal sealing unit, the wire harness negative terminal sealing unit, and the terminal sealing unit are physically isolated and electrically independent, and that a sealing failure or circuit fault in any one unit will not be transmitted to the other units.

7. A charging socket according to claim 6, characterized in that: The plug-in module also includes a retaining ring that is clamped to the outer wall of the first end of the DC plug terminal and locked to the inner wall of the first wire harness mounting cavity and the second wire harness mounting cavity to restrict the axial movement of the positive DC plug terminal wire harness assembly and the negative DC plug terminal wire harness assembly in the first wire harness mounting cavity and the second wire harness mounting cavity, and a toothed sealing ring disposed at the connection between the DC plug terminal and the first wire harness mounting cavity and the second wire harness mounting cavity, and at the connection between the injection molded package and the cable end cap.

8. A charging socket according to claim 6, characterized in that: In an axially collinear layout, the first end of the cylindrical injection-molded package is inserted into the first wire harness mounting cavity and the second wire harness mounting cavity respectively, and is fixedly connected to the first wire harness mounting cavity and the second wire harness mounting cavity, so that the first end of the cylindrical injection-molded package forms an axial sealing limit with the first wire harness mounting cavity and the second wire harness mounting cavity.

9. A charging socket according to claim 6, characterized in that: In the radially orthogonal layout, the first end of the DC connector is inserted into the first wire harness mounting cavity and the second wire harness mounting cavity respectively, forming a circumferential rotational fit with the first wire harness mounting cavity and the second wire harness mounting cavity, and the front end face of the terminal package forms an axial sealing limit with the rear end face of the first wire harness mounting cavity and the second wire harness mounting cavity.

10. A charging socket according to claim 9, characterized in that: The anti-rotation structure also includes a limiting groove provided on the socket panel corresponding to the first limiting block or the second limiting block for embedding the first limiting block or the second limiting block and being pinned by a DC locking pin.

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