A high thermal conductivity charging gun

Abstract

This utility model relates to a high thermal conductivity charging gun, belonging to the technical field of charging guns. It includes a gun head, a terminal fixing plate, terminals, cables, a push rod, an electronic lock assembly, and a gun housing. The terminals are fixed to the terminal fixing plate, which is then fixed to the gun head by fasteners. The gun head and gun housing are fixedly connected. The terminals and cables are ultrasonically welded. The terminal fixing plate has a groove structure filled with a thermally conductive material. By filling the groove structure of the terminal fixing plate with a high thermal conductivity material, and ensuring the material submerges the welded joint between the terminals and cables, the heat generated during charging can be quickly transferred to the gun housing, increasing the heat dissipation area, improving heat dissipation efficiency, and reducing the risk of high-temperature alarms. Due to the improved heat dissipation performance, the amount of copper wire used in the cable can be reduced by more than 15%, reducing the cable cross-sectional area, thereby reducing the size and weight of the charging gun and improving user experience and portability.

Description

Technical Field

[0001] This utility model relates to the field of charging gun technology, specifically to a high thermal conductivity charging gun. Background Technology

[0002] With the miniaturization and increasing power of electronic devices, as well as the development of fast charging technology for new energy vehicles, thermal management has become a key challenge. For every 2°C increase in the temperature of electronic components, their reliability decreases by 10%. Currently, battery capacities are gradually increasing, and the requirements for charging rates are also becoming more stringent. As a crucial component of the charging system, the heat dissipation performance of the charging gun directly affects charging efficiency and safety.

[0003] Existing charging guns are mainly divided into air-cooled charging guns and liquid-cooled charging guns. Conventional air-cooled charging guns rely on air convection for heat dissipation. However, air has an extremely low thermal conductivity (only about 0.024 W / m·K), making it difficult to quickly dissipate the Joule heat generated by the high current (such as above 250A) inside the charging gun. This leads to excessive temperature rise at the gun head, triggering charging speed reduction or shutdown protection. Furthermore, to improve current carrying capacity and heat dissipation, the cross-sectional area of ​​the cable needs to be increased, resulting in a larger and heavier charging gun, affecting user experience and portability. While liquid-cooled charging guns offer better heat dissipation, they require the integration of components such as an electronic pump, coolant piping, a reservoir, and a heat sink, increasing the overall cost by 30%-50% compared to air-cooled solutions. Moreover, after long-term use, pipe joints or seals may leak due to aging or vibration, leading to insulation failure or short circuits.

[0004] Therefore, there is an urgent need for a charging gun with excellent heat dissipation performance, moderate cost, and lightweight structure. Utility Model Content

[0005] The present invention aims to solve the problems of poor heat dissipation, high cost and bulky structure of existing charging guns, and to provide a charging gun with high thermal conductivity.

[0006] To solve the above-mentioned technical problems, the technical solution provided by this utility model is as follows: A high thermal conductivity charging gun includes a gun head, a terminal fixing plate, terminals, cables, a push rod, an electronic lock assembly, and a gun housing; the terminals are fixed to the terminal fixing plate, the terminal fixing plate is fixed to the gun head by fasteners, and the gun head is fixedly connected to the gun housing; The terminal and the cable are ultrasonically welded. The terminal fixing plate has a groove structure, which is filled with thermally conductive material and the thermally conductive material is immersed in the welded joint between the terminal and the cable.

[0007] Preferably, the groove structure includes connecting ribs and a recessed platform, wherein the connecting ribs are used to enhance the overall strength of the terminal fixing plate, and the recessed platform is used to accommodate thermally conductive material.

[0008] Preferably, both the push rod and the electronic lock assembly are mounted on the gun casing.

[0009] Preferably, the electronic lock assembly includes a micro switch, a motor housing, a motor inside the motor housing, and a motor stop block used in conjunction with the motor, wherein the micro switch is electrically connected to the motor.

[0010] Preferably, a cable sealing ring is fitted on the outer side of the cable, and the cable sealing ring is fixed to the gun housing by a cable clamp.

[0011] Preferably, the connection point between the terminal and the cable is located in the hollow region, and the hollow region is filled with thermally conductive material.

[0012] Preferably, the gun head and the gun shell, and the fixing plate and the gun head are all fixedly connected by screws.

[0013] With the above structure, this utility model has the following advantages: 1. Excellent heat dissipation performance: By filling the groove structure of the terminal fixing plate with high thermal conductivity material, and immersing the thermal conductivity material in the welding joint between the terminal and the cable, the heat generated during charging can be quickly transferred to the gun shell through the thermal conductivity material, increasing the heat dissipation area, improving heat dissipation efficiency, and reducing the risk of high temperature alarm.

[0014] 2. Lightweight structure: Due to improved heat dissipation performance, the amount of copper wire used in the cable can be reduced by more than 15%, and the cross-sectional area of ​​the cable can be reduced, thereby reducing the size and weight of the charging gun, improving user experience and portability.

[0015] 3. Lower cost: Unlike liquid-cooled charging guns, it does not require a complex liquid cooling system, which reduces costs. At the same time, reducing the amount of copper wire used further reduces costs.

[0016] 4. High reliability: It adopts A / B two-component thermally conductive materials, which are mixed and cured to form a solid connection with the internal structure of the gun, eliminating the risk of leakage. In addition, ultrasonic welding ensures the reliability and durability of the connection between the terminal and the cable.

[0017] 5. Wide applicability: It can be used simultaneously in 250A / 300A / 350A / 400A air-cooled and liquid-cooled solutions, achieving increased current carrying capacity and reduced copper wire usage for the same specifications.

[0018] The above overview is for illustrative purposes only and is not intended to be limiting in any way. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features of the present invention will become readily apparent from the accompanying drawings and the following detailed description. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 This is a schematic diagram of the connection of the terminals of this utility model; Figure 3 This is a schematic diagram of the terminal fixing plate of this utility model; Figure 4 This is a structural schematic diagram of the electronic lock assembly of this utility model; Figure 5 This is a schematic diagram of the temperature rise test results of a 4*35 unfilled 300A current-carrying device of this utility model; Figure 6 This is a schematic diagram of the 300A current-carrying temperature rise test results of the 4*35 potting filler of this utility model; Figure 7 This is a schematic diagram of the temperature rise test results of a 4*45 unfilled 300A current-carrying device of this utility model.

[0021] As shown in the figure: 1. Gun head; 2. Terminal fixing plate; 2-1. Connecting rib; 2-2. Recessed platform; 3. Terminal; 4. Cable; 5. Screw; 6. Button; 7. Electronic lock assembly; 7-1. Micro switch; 7-2. Motor housing; 7-3. Motor stop; 8. Gun housing; 9. Cable sealing ring; 10. Wire clamp. Detailed Implementation

[0022] The embodiments of this application are described in detail below. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application.

[0023] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "joining" 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; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0024] The present invention will now be described in further detail in conjunction with the full text.

[0025] Combined with appendix Figures 1-4 A high thermal conductivity charging gun includes a gun head 1, a terminal fixing plate 2, a terminal 3, a cable 4, a push rod 6, an electronic lock assembly 7, and a gun shell 8. The terminal 3 is fixed on the terminal fixing plate 2, and the terminal fixing plate 2 is fixed in the gun head 1 by fasteners. The gun head 1 and the gun shell 8 are fixedly connected. The charging gun terminal 3 and the cable 4 are ultrasonically welded to ensure the reliability of the connection and long-term durability. The terminal fixing plate 3 is designed with an irregular groove structure to ensure strength while reducing shrinkage and to facilitate glue filling.

[0026] In specific implementation of this utility model, such as Figures 1-3 As shown. The connection point between terminal 3 and cable 4 is located in the hollow area, which is filled with thermally conductive material. The gun head 1 and gun housing 8, and the fixing plate 2 and gun head 1 are all fixedly connected by screws 5. Terminal 3 and cable 4 are ultrasonically welded. The terminal fixing plate 2 has a groove structure filled with thermally conductive material. The heat generated by the current is transferred to the gun housing through the thermally conductive material, allowing it to contact the external environment and achieve rapid heat dissipation. The thermally conductive material submerges the weld joint between terminal 3 and cable 4. The thermally conductive material is an A / B two-component silicone paste-like gap filler. After mixing, the A / B components can react and cure under normal or high temperature conditions. Before curing, it is a paste-like fluid; after curing, it forms a solid thermally conductive structure.

[0027] The parameters of the thermally conductive material are shown in the table below: Density Specific Gravity g / cm3 2.5~3 Mixing ratio / 1:1 Viscosity cps 2500~3500 Thermal conductivity W / mk 1~3 Hardness after curing ShoreA 40~75 Volume Resistivity Ω.cm 1012 Dielectric strength KV ≥10 Flammability class / V0 Application temperature ℃ -50~200 Operational time @ 25°C min <30 Curing time @ 25°C h 18~28 Curing time @ 100℃ min 18~24 In specific implementation of this utility model, such as Figure 3 As shown. The trench structure includes a connecting rib 2-1 and a recessed platform 2-2. The connecting rib 2-1 is used to enhance the overall strength of the terminal fixing plate 2, and the recessed platform 2-2 is used to accommodate the thermally conductive material. Specifically, the recessed platform 2-2 has an irregular design. 1. The terminal fixing plate 2 is designed as an irregular recessed platform 2-2, which facilitates the filling of thermal conductive material; the terminal and cable connection is designed in a hollow position, which can be immersed in liquid thermal conductive material and dissipate heat quickly after solidification.

[0028] 2. The thermally conductive material consists of two components, A and B, and is filled in paste form for easy assembly and use. After solidification in 1-24 hours, it is firmly connected to the internal structure of the gun, ensuring reliable operation.

[0029] 3. Through the use of ultrasonic technology and thermally conductive materials, the 300A charging gun can reduce the DC cable from 100mm² to 70mm².

[0030] Both the lever 6 and the electronic lock assembly 7 are mounted on the gun housing 8. This utility model provides a 300A high thermal conductivity standard DC charging gun with terminals. It uses a heat-conducting silicone paste-like material (thermal conductivity 1~3W / mk) with good heat dissipation to fill the gaps. The A / B single-component paste is stable at room temperature for a long time, while the two-component mixture can react and solidify under room temperature or high temperature conditions. The gun head terminal 3 and cable 4 are ultrasonically welded. The terminal fixing plate 2 is designed as a groove, and the heat-conducting material is filled into the terminal fixing plate, fully filling the complex structural surface and immersing the welded joint of the terminal 3. During the charging process, the heat generated is transferred to the gun shell through the heat-conducting material, increasing the heat dissipation area, enabling rapid heat dissipation, reducing the risk of high temperature alarms, and reducing the amount of copper wire used in the cable by more than 15%. This solution can also be used simultaneously in 250A / 350A / 400A air-cooled and liquid-cooled solutions, achieving increased current carrying capacity and reduced copper wire usage for the same specifications.

[0031] The electronic lock assembly 7 includes a micro switch 7-1, a motor housing 7-2, a motor inside the motor housing 7-2, and a motor stop 7-3 used in conjunction with the motor. The micro switch 7-1 is electrically connected to the motor.

[0032] A cable sealing ring 9 is fitted on the outside of the cable 4, and the cable sealing ring 9 is fixed to the gun shell 8 by a cable clamp 10.

[0033] The charging gun is suitable for air-cooled or liquid-cooled solutions with current carrying capacities of 250A, 300A, 350A, and 400A.

[0034] I. Testing Standard Requirements (GB / T20234.1-2023) Test requirements Acceptance Criteria 1. The maximum permissible temperature for the gripping area of ​​the charging gun is: Metal parts at 50℃: Non-metallic components 60℃: The maximum allowable temperature for charging cables can be relaxed to 70℃, but a high-temperature warning label must be provided. 2. The permissible temperature of the non-gripable parts of the charging gun that can be touched must not exceed: Metal parts 60℃: Non-metallic components at 85℃: 3. The temperature rise of the terminals (DC power supply contacts, charging communication contacts, charging connection confirmation contacts, and low-voltage auxiliary power supply contacts) shall not exceed 50K. Example

[0035] This invention uses a 4*35 cable, and then assembles a charging gun according to the installation and potting method of this invention. The gun head 1 and the gun shell 8, and the fixing plate 2 and the gun head 1 are all fixedly connected by screws 5. The terminal 3 and the cable 4 are ultrasonically welded. The terminal fixing plate 2 has a groove structure, and the groove structure is filled with thermally conductive material. The heat generated by the current carrying is transferred to the gun shell through the thermally conductive material, and then contacts the external environment to achieve rapid heat dissipation. The thermally conductive material is immersed in the welded joint of the terminal 3 and the cable 4. The thermally conductive material is an A / B two-component organosilicon paste-like gap filler material. The recessed platform 2-2 is used to accommodate the thermally conductive material. The charging gun is tested for temperature rise under a 300A current carrying capacity.

[0036] Comparative Example 1 and Comparative Example 2: The charging gun is assembled using 4*35 / 4*45 cables and the installation and potting method of this utility model. It adopts conventional air cooling. The difference from Example 1 is that Comparative Example 1 and Comparative Example 2 adopt conventional air cooling and do not potting. The charging gun is tested for temperature rise at 300A current. like Figures 5-7 As shown, in this embodiment, the high thermal conductivity charging gun, compared to a conventional air-cooled charging gun, exhibits a 15K reduction in terminal temperature rise and an 8K increase in gun casing temperature rise after filling with thermally conductive material during a 300A current-carrying temperature rise test. This indicates that heat inside the gun is rapidly transferred to the gun casing via the thermally conductive material, and then quickly dissipated to the external environment. Both the 4*35 potting compound and the 4*45 cable solutions can meet the 300A current-carrying temperature rise test requirements, achieving a 40mm² reduction in cable cross-section and significantly reducing costs.

[0037] The high thermal conductivity charging gun of this invention is applicable to air-cooled or liquid-cooled solutions with current carrying capacity of 250A, 300A, 350A, and 400A, achieving increased current carrying capacity and reduced copper wire usage for the same current carrying capacity.

[0038] The present invention and its embodiments have been described above. This description is not restrictive, and the embodiments shown throughout the text are only one of the embodiments of the present invention. The actual structure is not limited to this. In conclusion, if a person skilled in the art is inspired by this description and designs a similar structure and embodiment without departing from the inventive spirit of the present invention, such design should fall within the protection scope of the present invention.

Claims

1. A high thermal conductivity charging gun, characterized in that, It includes a gun head (1), a terminal fixing plate (2), a terminal (3), a cable (4), a push rod (6), an electronic lock assembly (7), and a gun shell (8); the terminal (3) is fixed on the terminal fixing plate (2), the terminal fixing plate (2) is fixed in the gun head (1) by fasteners, and the gun head (1) is fixedly connected to the gun shell (8); The terminal (3) and the cable (4) are ultrasonically welded. The terminal fixing plate (2) is provided with a groove structure. The groove structure is filled with a heat-conducting material, and the heat-conducting material is immersed in the weld between the terminal (3) and the cable (4).

2. The high thermal conductivity charging gun according to claim 1, characterized in that: The groove structure includes a connecting rib (2-1) and a recessed platform (2-2). The connecting rib (2-1) is used to enhance the overall strength of the terminal fixing plate (2), and the recessed platform (2-2) is used to accommodate the heat-conducting material.

3. The high thermal conductivity charging gun according to claim 1, characterized in that: Both the push rod (6) and the electronic lock assembly (7) are mounted on the gun shell (8).

4. The high thermal conductivity charging gun according to claim 3, characterized in that: The electronic lock assembly (7) includes a micro switch (7-1), a motor housing (7-2), a motor inside the motor housing (7-2), and a motor stop (7-3) used in conjunction with the motor. The micro switch (7-1) is electrically connected to the motor.

5. The high thermal conductivity charging gun according to claim 1, characterized in that: The cable (4) is fitted with a cable sealing ring (9) on its outer side, and the cable sealing ring (9) is fixed to the gun shell (8) by a wire clamp (10).

6. The high thermal conductivity charging gun according to claim 1, characterized in that: The connection point between the terminal (3) and the cable (4) is located in the hollow area, and the hollow area is filled with thermally conductive material.

7. The high thermal conductivity charging gun according to claim 1, characterized in that: The gun head (1) and the gun shell (8), and the terminal fixing plate (2) and the gun head (1) are all fixedly connected by screws (5).

Images