Plug terminal ultrasonic heat fusion structure and charging gun

Abstract

The utility model relates to charging gun technical field, especially a plug terminal ultrasonic heat fusion structure and charging gun, including opposite plug fixing seat, power connection element, terminal subassembly and circuit board, the opposite plug fixing seat includes the plug connector, mounting panel and fixed platform who sets up in turn along opposite plug direction, the fixed platform recessed has the sunken groove to the mounting panel direction, the plug connector is provided with power socket and terminal jack, the circuit board sets up in the sunken groove, one end of power connection element passes through the circuit board, the other end extends to power socket, the terminal subassembly includes a plurality of plug-in terminals, one end of plug-in terminal is welded on the circuit board through ultrasonic heat fusion, the other end extends to terminal jack. Compared with traditional welding mode, the utility model does not need additional welding material in ultrasonic heat fusion, reduces production cost. Moreover, the welding process is fast, can improve production efficiency, is suitable for large-scale production.

Description

Technical Field

[0001] This utility model relates to the field of charging gun technology, and in particular to an ultrasonic heat-fusion structure for plug terminals and a charging gun. Background Technology

[0002] With the booming development of the electric vehicle industry, the charging gun, as a key component of the electric vehicle charging system, directly affects the charging efficiency and safety in terms of performance and reliability. While existing charging guns have made some progress in design and manufacturing, some problems still need to be addressed. Currently, the plug of the charging gun needs to be equipped with terminals for electrical connection to the electric vehicle charging interface to transmit electrical energy and signals. In existing technologies, there are two main ways to connect the terminals to the circuit board: one is through connecting wires, and the other is through riveting.

[0003] The most common connection method is riveting. While riveting provides a relatively strong mechanical connection, it has certain limitations in terms of electrical performance. If the riveting process is not properly controlled, the contact resistance at the riveted area can increase, leading to excessive heat generation during charging, affecting charging efficiency, and potentially damaging terminals and circuit boards. Furthermore, once riveting is completed, subsequent repair and replacement are more difficult, increasing usage costs and maintenance complexity.

[0004] The existing connection method between the charging gun terminals and the circuit board has significant shortcomings in terms of connection stability, and can no longer meet the high-performance and high-reliability requirements of the rapidly developing electric vehicle industry for charging guns. Therefore, there is an urgent need to develop a new connection method to improve the connection stability between the terminals and the circuit board, and ensure the safe and efficient operation of the charging gun. Utility Model Content

[0005] To address the aforementioned issues, this invention, compared to traditional welding methods, utilizes ultrasonic heat fusion welding, eliminating the need for additional welding materials and reducing production costs. Furthermore, the welding process is rapid, improving production efficiency and making it suitable for mass production of plug terminal ultrasonic heat fusion welding structures and charging guns.

[0006] The technical solution adopted by this utility model is: an ultrasonic heat-fusion welding structure for plug terminals, including a mating fixing base, a power connection element, a terminal assembly, and a circuit board. The mating fixing base includes a plug connector, a mounting panel, and a fixing platform arranged sequentially along the mating direction. The fixing platform is recessed in the direction of the mounting panel. The plug connector is provided with a power socket and a terminal socket. The circuit board is disposed in the recess. One end of the power connection element passes through the circuit board and the other end extends to the power socket. The terminal assembly includes multiple plug terminals. One end of each plug terminal is ultrasonically heat-fused onto the circuit board and the other end extends to the terminal socket.

[0007] A further improvement to the above solution is that a guide plane is provided on one side of the connector, and plug-in locking slots are provided on both sides of the guide plane.

[0008] A further improvement to the above solution is that the mounting panel is provided with a countersunk hole, and a sealing groove is provided on the side of the mounting panel near the fixing platform. A sealing element is provided in the sealing groove for sealing during the installation of the mounting panel.

[0009] A further improvement to the above solution is that a support column is provided on the settling tank, and a threaded hole is provided on the support column. A through hole is provided on the circuit board corresponding to the threaded hole. The circuit board is fixed to the support column by screws passing through the through hole and the threaded hole.

[0010] A further improvement to the above scheme is that the bottom surface of the sink is provided with a power supply fixing cavity and a terminal fixing cavity. The power supply fixing cavity is used to connect the sink to a power socket, and the terminal fixing cavity is used to connect the sink to a terminal socket.

[0011] A further improvement to the above scheme is that the bottom surface of the settling tank is provided with a pressure groove, and a pressure block is provided in the pressure groove. One end of the pressure block is used to fix the power connection element in the power fixing cavity.

[0012] A further improvement to the above solution is that the power connection element is a power terminal, the power connection element is provided with a power mating part, the power mating part is used to fix the power connection element in the power fixing cavity; the circuit board is provided with a through groove, one end of the power connection element is provided with a wiring part, one end of the wiring part passes through the through groove, and is used to connect a cable.

[0013] A further improvement to the above solution is that the plug-in terminal is provided with a terminal mating part, the terminal mating part is located in the terminal fixing cavity, one end of the plug-in terminal is provided with a plug-in pin, the plug-in pin is inserted into the circuit board and is ultrasonically thermofused.

[0014] A further improvement to the above solution is that the plug pin is provided with a welding spring, and the welding spring is connected to the circuit board by ultrasonic hot melt welding.

[0015] A charging gun includes the aforementioned plug terminal ultrasonic heat fusion structure.

[0016] The beneficial effects of this utility model are:

[0017] Compared to existing charging gun terminal structures, this invention offers a robust overall framework for the charging gun through the sequential arrangement of the plug, mounting panel, and fixing platform. The power socket and terminal socket at the plug can precisely interface with external devices, ensuring a stable connection during charging. The recessed design of the fixing platform provides a stable mounting space for the circuit board, preventing it from shaking or shifting during use and ensuring the stability of the internal structure of the charging gun. In terms of electrical connection, the power connection element passes through the circuit board at one end and extends to the power socket at the other, achieving reliable power transmission. Ultrasonic thermofusion welding technology is used to fix one end of the plug terminal to the circuit board, resulting in a strong connection that effectively reduces contact resistance. Low contact resistance means less heat is generated during charging, reducing energy loss and improving charging efficiency. Simultaneously, a good electrical connection reduces safety hazards caused by poor contact, such as overheating and arcing, significantly improving the safety of the charging gun. From a manufacturing perspective, ultrasonic thermofusion welding technology offers advantages such as high efficiency and environmental friendliness. Compared to traditional welding methods, ultrasonic thermofusion welding does not require additional welding materials, reducing production costs. Moreover, the welding process is fast, which can improve production efficiency and is suitable for large-scale production. Attached Figure Description

[0018] Figure 1 This is a three-dimensional schematic diagram of the ultrasonic heat-fusion structure of the plug terminal of this utility model;

[0019] Figure 2 for Figure 1 Explosion-proof diagram of the ultrasonic thermal fusion structure of the plug terminal;

[0020] Figure 3 for Figure 1 Another perspective of the exploded view of the ultrasonic thermal fusion structure of the plug terminal;

[0021] Figure 4 for Figure 1 Front view schematic diagram of the ultrasonic thermal fusion structure of the plug terminal;

[0022] Figure 5 for Figure 4 Sectional view of AA.

[0023] Explanation of reference numerals in the attached drawings: 1. Plug-in fixing base; 11. Plug-in connector; 111. Power socket; 112. Terminal socket; 113. Guide plane; 114. Plug-in locking groove; 12. Mounting panel; 121. Mounting countersunk hole; 122. Sealing groove; 123. Fixing platform; 13. Countersunk groove; 14. Support column; 141. Threaded hole; 142. Power fixing cavity; 143. Terminal fixing cavity; 144. Pressure groove; 145. Pressure block; 146. Power connection element; 2. Power mating part; 21. Wiring part; 22. Terminal assembly; 3. Plug-in terminal; 311. Terminal mating part; 312. Plug-in pin; 313. Welding spring; 4. Circuit board; 41. Through hole; 42. Through groove. Detailed Implementation

[0024] To facilitate understanding of this utility model, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of this utility model are shown in the drawings. However, this utility model can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of this utility model.

[0025] It should be noted that when a component is said to be "fixed to" another component, it can be directly attached to the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component.

[0026] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. Figures 1-5As shown, in one embodiment of this utility model, an ultrasonic heat-fusion welding structure for plug terminals is disclosed, including a mating fixing base 1, a power connection element 2, a terminal assembly 3, and a circuit board 4. The mating fixing base 1 includes a plug connector 11, a mounting panel 12, and a fixing platform 13 arranged sequentially along the mating direction. The fixing platform 13 has a recessed groove 14 facing the mounting panel 12. The plug connector 11 is provided with a power socket 111 and a terminal socket 112. The circuit board 4 is disposed in the recessed groove 14. One end of the power connection element 2 passes through the circuit board 4, and the other end extends to the power socket 111. The terminal assembly 3 includes a plurality of plug terminals 31. One end of each plug terminal 31 is ultrasonically heat-fused onto the circuit board 4, and the other end extends to the terminal socket 112. From the perspective of structural stability, the sequential arrangement of the plug connector 11, the mounting panel 12, and the fixing platform 13 in the mating fixing base 1 provides a robust overall structure for the charging gun. The power socket 111 and terminal socket 112 at the connector 11 can accurately interface with external devices, ensuring a stable connection during charging. The recessed groove 14 design of the mounting platform 13 provides a stable installation space for the circuit board 4, preventing it from shaking or shifting during use and ensuring the stability of the internal structure of the charging gun. In terms of electrical connection, one end of the power connection element 2 passes through the circuit board 4, and the other end extends to the power socket 111, achieving reliable power transmission. One end of the connector terminal 31 is fixed to the circuit board 4 using ultrasonic thermofusion welding technology. This connection method is not only robust but also effectively reduces contact resistance. Low contact resistance means less heat is generated during charging, reducing energy loss and improving charging efficiency. At the same time, a good electrical connection also reduces safety hazards caused by poor contact, such as overheating and arcing, greatly improving the safety of the charging gun. From a manufacturing perspective, ultrasonic thermofusion welding technology has advantages such as high efficiency and environmental friendliness. Compared to traditional welding methods, ultrasonic thermofusion welding does not require additional welding materials, reducing production costs. Moreover, the welding process is fast, improving production efficiency and making it suitable for large-scale production.

[0027] A guide plane 113 is provided on one side of the connector 11, and insertion locking slots 114 are provided on both sides of the guide plane 113. In this embodiment, the guide plane 113 provides clear guidance for the insertion process between the charging gun and the external device. In actual use, users can quickly and accurately connect the connector 11 of the charging gun to the corresponding interface of the external device according to the guide plane 113, avoiding time waste and possible damage caused by blind insertion, and improving the convenience and efficiency of charging operation. The insertion locking slots 114 play a key role. After the connector 11 is connected to the external device, the slot can cooperate with the corresponding locking structure on the external device to achieve a firm lock. This can effectively prevent the charging gun from accidentally separating from the external device due to external force pulling, vibration, or other factors during the charging process, ensuring the continuity and stability of the charging process.

[0028] The mounting panel 12 is provided with a countersunk hole 121, and a sealing groove 122 is provided on the side of the mounting panel 12 near the fixing platform 13. A sealing element 123 is provided in the sealing groove 122 for sealing during the installation of the mounting panel 12. In this embodiment, the countersunk hole 121 provides convenience and stability for the installation of the charging gun. The countersunk hole 121 can cooperate with corresponding bolts or other connecting parts on external equipment or mounting brackets, so that the mounting panel 12 can be firmly installed in the designated position. The combination of the sealing groove 122 and the sealing element 123 plays a key role in waterproofing, dustproofing, and moisture-proofing. The charging gun is used outdoors or in various complex environments, and is inevitably affected by water, dust, and moisture. The sealing element 123 is placed in the sealing groove 122. When the mounting panel 12 is installed, the sealing element 123 is subjected to a certain amount of compression, thereby forming a tight sealing layer between the mounting panel 12 and the mating surface.

[0029] A support column 141 is provided on the sink 14, and the support column 141 is provided with a threaded hole 142. The circuit board 4 is provided with a through hole 41 corresponding to the threaded hole 142. The circuit board 4 is fixed to the support column 141 by screws passing through the through hole 41 and the threaded hole 142. In this embodiment, the support column 141 provides reliable support for the circuit board 4. The support column 141 can firmly support the circuit board 4 in the sink 14, avoiding direct contact between the circuit board 4 and the bottom of the sink 14, reducing the impact of uneven bottom or vibration on the circuit board 4. Moreover, the connection between the circuit board 4 and the threaded hole 142 on the support column 141 by screws passing through the through hole 41 of the circuit board 4 further enhances the connection strength between the circuit board 4 and the mating fixing seat 1. The rigid connection method ensures that the circuit board 4 will not easily shake or shift during the use of the charging gun, ensuring the stability of the internal structure and providing a solid foundation for the normal operation of the charging gun. Stable installation of the circuit board 4 helps to maintain good electrical connection. Because the circuit board 4 is firmly fixed, the connection between the power connection element 2 and the plug terminal 31 and the circuit board 4 is also more stable.

[0030] The bottom surface of the recess 14 is provided with a power supply fixing cavity 143 and a terminal fixing cavity 144. The power supply fixing cavity 143 is used to connect the recess 14 to the power socket 111, and the terminal fixing cavity 144 is used to connect the recess 14 to the terminal socket 112. In this embodiment, the arrangement of the power supply fixing cavity 143 and the terminal fixing cavity 144 makes the internal structure of the charging gun more regular and orderly. The power supply fixing cavity 143 connects the recess 14 to the power socket 111, providing a clear and dedicated channel for the power connection element 2. This allows the power connection element 2 to extend smoothly from the circuit board 4 to the power socket 111, avoiding mutual interference in a cluttered space, reducing the crossing and tangling of connection lines, which is conducive to the rational use of the internal space of the charging gun and also facilitates the assembly operation in the production process. Similarly, the terminal fixing cavity 144 connects the recess 14 to the terminal socket 112, providing an independent extension path for multiple plug-in terminals 31, ensuring that each plug-in terminal 31 is neatly arranged, which helps to improve the stability and reliability of the overall structure. The power supply fixing cavity 143 provides a stable transmission channel for the power connection element 2, reducing interference from external factors on power transmission, lowering signal loss and energy consumption, and improving charging efficiency. Meanwhile, the terminal fixing cavity 144 ensures accurate connection between each plug-in terminal 31 and the circuit board 4 and terminal socket 112, enabling accurate signal transmission and guaranteeing the stability and accuracy of data communication during charging. For example, for charging guns with intelligent charging functions, it can better achieve information interaction with the charging equipment.

[0031] The bottom surface of the sink 14 is provided with a pressure groove 145, and a pressure block 146 is provided within the pressure groove 145. One end of the pressure block 146 is used to fix the power connection element 2 to the power fixing cavity 143. In this embodiment, the setting of the pressure block 146 greatly enhances the connection between the power connection element 2 and the power fixing cavity 143. In the actual use of the charging gun, it will face various complex environments and external forces, such as pulling during insertion and removal, and vibration during use. The pressure block 146 can firmly fix the power connection element 2 in the power fixing cavity 143, preventing it from loosening or shifting due to these external forces. A stable connection helps to improve the efficiency and quality of power transmission. When the power connection element 2 is firmly fixed, the contact resistance between it and the power fixing cavity 143 remains stable and at a low level. This allows electrical energy to be transmitted more smoothly, reduces energy loss, and improves charging efficiency.

[0032] The power connection element 2 is a power terminal. The power connection element 2 is provided with a power mating part 21, which is used to fix the power connection element 2 within the power fixing cavity 143. The circuit board 4 is provided with a through groove 42. One end of the power connection element 2 is provided with a wiring part 22, which passes through the through groove 42 for connecting a cable. In this embodiment, the power mating part 21 ensures that the power connection element 2 is securely fixed within the power fixing cavity 143. During the use of the charging gun, it is affected by external forces during insertion and removal, vibrations generated during equipment operation, etc. The tight fit between the power mating part 21 and the power fixing cavity 143 effectively resists these external forces, preventing the power connection element 2 from loosening or shifting, thus ensuring the stability of the power connection. This avoids poor contact problems caused by unstable connections, reduces safety hazards such as overheating and arcing, and improves the safety of the charging gun. A stable connection is the foundation for ensuring efficient power transmission. The power connector 2 is securely fixed, reducing contact resistance and allowing electrical energy to be smoothly transmitted from the cable through the power connector 2 to the internal circuitry of the charging gun. The through-slot 42 on the circuit board 4 provides a reasonable wiring path for the wiring portion 22 of the power connector 2. The wiring portion 22 passes through the through-slot 42 to connect with the cable, avoiding messy wiring and making the internal wiring of the charging gun more organized.

[0033] The plug-in terminal 31 is provided with a terminal mating part 311, which is disposed in the terminal fixing cavity 144. One end of the plug-in terminal 31 is provided with a plug-in pin 312, which is inserted into the circuit board 4 and welded by ultrasonic thermofusion. Specifically, a welding spring 313 is provided on the plug-in pin 312, which is connected to the circuit board 4 by ultrasonic thermofusion welding. In this embodiment, the terminal mating part 311 is disposed in the terminal fixing cavity 144, providing stable positioning and support for the plug-in terminal 31. This prevents the plug-in terminal 31 from easily shaking or shifting during the use of the charging gun, ensuring the reliability of its connection with the circuit board 4. The plug-in pin 312 is inserted into the circuit board 4, and the ultrasonic thermofusion welding further enhances the connection strength. In particular, the welding spring 313 can better and more tightly bond with the circuit board 4 during ultrasonic thermofusion welding, forming a strong connection. Even when the charging gun is subjected to external forces such as vibration and insertion / removal forces, the connection between the connector 31 and the circuit board 4 remains stable, preventing problems such as poor contact and signal interruption caused by loose connections, thus improving the stability and reliability of the charging gun. Through ultrasonic thermofusion welding, the contact resistance between the welding spring 313 and the circuit board 4 is low and stable. This helps reduce energy loss during power transmission and improves charging efficiency. Simultaneously, the stable electrical connection ensures the accuracy and stability of signal transmission. For charging guns with intelligent charging functions that require data interaction, this ensures accurate data transmission during charging, enabling precise control and monitoring of charging parameters.

[0034] The above solution is applied to the charging gun. In terms of structural design, the power fixing cavity 143 and terminal fixing cavity 144 on the bottom of the recess 14 make the internal layout of the charging gun more organized. The power fixing cavity 143 connects the recess 14 to the power socket 111, and the terminal fixing cavity 144 connects the recess 14 to the terminal socket 112, ensuring orderly installation of the power connection element 2 and the plug-in terminal 31, avoiding messy wiring, and facilitating production assembly. In terms of electrical performance, the stable connection design is significantly effective. The power fixing cavity 143 and the pressure block 146 ensure the stability of the power connection element 2, reduce contact resistance, reduce energy loss, and improve charging efficiency. The terminal mating part 311 of the plug-in terminal 31 is ultrasonically thermofused, ensuring a firm connection between the plug-in pin 312 and the circuit board 4, ensuring accurate signal transmission and achieving stable data communication. From a safety perspective, the independent design and stable connection of each chamber reduce the risk of short circuits and poor contact, ensuring the safety of the charging process. Furthermore, it facilitates later maintenance, allowing for quick location and repair in case of problems.

[0035] The above embodiments only illustrate several implementation methods of this utility model, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of this utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. An ultrasonic heat staking structure of a plug terminal, characterized by: The device includes a mating mounting base, a power connection element, a terminal assembly, and a circuit board. The mating mounting base includes a plug, a mounting panel, and a fixing platform arranged sequentially along the mating direction. The fixing platform has a recessed groove facing the mounting panel. The plug has a power socket and a terminal socket. The circuit board is disposed in the recessed groove. One end of the power connection element passes through the circuit board and the other end extends to the power socket. The terminal assembly includes multiple plug terminals. One end of each plug terminal is ultrasonically heat-welded onto the circuit board, and the other end extends to the terminal socket.

2. The plug terminal ultrasonic heat staking structure according to claim 1, characterized by: A guide plane is provided on one side of the connector, and a plug-in locking slot is provided on both sides of the guide plane.

3. The plug terminal ultrasonic heat staking structure according to claim 1, characterized by: The mounting panel is provided with mounting countersunk holes, and the side of the mounting panel near the fixing platform is provided with a sealing groove. A sealing element is provided in the sealing groove for sealing during the installation of the mounting panel.

4. The plug terminal ultrasonic heat staking structure of claim 1, wherein: The settling tank is provided with a support column, and the support column is provided with a threaded hole. The circuit board is provided with a through hole corresponding to the threaded hole. The circuit board is connected to the threaded hole by a screw passing through the through hole to fix it on the support column.

5. The plug terminal ultrasonic heat staking structure of claim 1, wherein: The bottom surface of the sink is provided with a power supply fixing cavity and a terminal fixing cavity. The power supply fixing cavity is used to connect the sink to a power socket, and the terminal fixing cavity is used to connect the sink to a terminal socket.

6. The plug terminal ultrasonic heat staking structure of claim 5, wherein: The bottom surface of the settling tank is provided with a pressure groove, and a pressure block is provided in the pressure groove. One end of the pressure block is used to fix the power connection element in the power fixing cavity.

7. The plug terminal ultrasonic heat staking structure of claim 5, wherein: The power connection element is a power terminal, and the power connection element is provided with a power mating part, which is used to fix the power connection element in the power fixing cavity; the circuit board is provided with a through groove, and one end of the power connection element is provided with a wiring part, which passes through the through groove for connecting a cable.

8. The plug terminal ultrasonic heat staking structure of claim 5, wherein: The plug-in terminal is provided with a terminal mating part, which is located in the terminal fixing cavity. One end of the plug-in terminal is provided with a plug-in pin, which is inserted into the circuit board and welded by ultrasonic thermofusion.

9. The plug terminal ultrasonic heat staking structure of claim 8, wherein: The plug pin is equipped with a welding spring, which is connected to the circuit board by ultrasonic hot melt welding.

10. A charging gun, characterized by: The plug terminal ultrasonic heat fusion structure includes any one of claims 1 to 9.

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