Electrical connectors and battery packs

Abstract

This utility model relates to the field of battery application connections, and more particularly to an electrical connector and a battery pack. An electrical connector for charging and discharging connections of a battery pack includes: an insulating base; at least two power transmission terminals fixed to the insulating base for electrical connection with the battery pack's total positive electrode terminal and total negative electrode terminal, serving as a power interface for charging or discharging; at least one voltage sampling terminal fixed to the insulating base for voltage sampling of individual cells within the battery pack; and at least one communication signal transmission terminal fixed to the insulating base for a communication protocol interface between the battery management system and external systems.

Description

Technical Field

[0001] This utility model relates to the field of external connection technology for battery packs, specifically to a multifunctional, compact electrical connector for a lithium-ion battery pack charging, discharging and management system, and a battery pack including the electrical connector. Background Technology

[0002] With the rapid development of lithium-ion battery technology, its application in consumer electronics, power tools, drones, energy storage systems, and other fields is becoming increasingly widespread. The requirements for supporting battery packs are also trending towards higher energy density, higher safety, and intelligent management. Against this backdrop, battery packs not only need to provide power interfaces for charging and discharging, but also sampling interfaces for monitoring the voltage of individual cells, as well as communication interfaces for data exchange with external devices (such as smart chargers and main unit devices).

[0003] Existing technologies employ a multi-connector approach, where separate connectors are used for power transmission, voltage sampling, and communication functions. The drawbacks of this approach are obvious: it results in a bulky battery pack interface, occupies a large amount of space, involves complex wiring, and is costly, failing to meet the current design trend towards miniaturization and compactness in devices. Summary of the Invention

[0004] One of the objectives of this utility model is to provide a novel electrical connector that integrates charging / discharging, voltage sampling, and communication functions. When applied to battery packs, it improves the charging / discharging safety and controllability of the battery packs, thereby enhancing their market competitiveness.

[0005] In a first aspect, the present invention provides an electrical connector for charging and discharging connection of a battery pack, comprising: Insulating base; At least two power transmission terminals are fixed on the insulating base for electrical connection with the total positive electrode terminal and the total negative electrode terminal of the battery pack, serving as power interfaces for charging or discharging. At least one voltage sampling terminal is fixed to the insulating base and serves as a voltage sampling interface for individual cells within the battery pack. At least one communication signal transmission terminal is fixed on the insulating base and is used as a communication protocol interface between the battery management system and the outside.

[0006] Optionally, the insulating base is a male component adhesive base. Each of the power transmission terminals, voltage sampling terminals, and communication signal transmission terminals is a female terminal. The front end of each female terminal is embedded in the male component socket, the front end of which is located in the front end of the male component socket, and the rear end extends out of the rear end of the male component socket.

[0007] Optionally, the insulating base is a female plastic shell with the shell opening located at the front end. Each of the power transmission terminals, each of the voltage sampling terminals, and each of the communication signal transmission terminals are common component terminals. Each of the male component terminals is disposed from back to front within the cavity of the female component housing, with its end located within the housing opening.

[0008] Optionally, each of the aforementioned male component terminals is provided with an elastic portion capable of radial elastic deformation.

[0009] Optionally, each of the power transmission terminals, each of the voltage sampling terminals, each of the communication signal transmission terminals, and the insulating base are integrated into the insulating base by injection molding.

[0010] Optionally, the outer periphery of the insulating base is provided with an inwardly recessed or outwardly protruding plug handle position.

[0011] Optionally, at least one outer corner of the insulating base has a different shape from at least another corner.

[0012] Optionally, the rear end face of the base is provided with a terminal marking section.

[0013] Secondly, an embodiment of the present invention provides a battery pack comprising: The battery pack body includes at least two individual cells connected in series; A battery management system is installed on the battery pack body and electrically connected to each of the individual batteries, used to control the charging, discharging and status monitoring of the battery pack body; Any of the electrical connectors described above; The power transmission terminal of the electrical connector is electrically connected to the total positive and total negative terminals of the battery pack body. The voltage sampling terminals of the electrical connector are electrically connected to the voltage sampling nodes of the corresponding individual cells in the battery pack body. The communication signal transmission terminal of the electrical connector is electrically connected to the communication port of the battery management system.

[0014] Optionally, the electrical connector is embedded in the outer shell of the battery pack body and serves as the battery pack's only external charging, discharging, and communication interface.

[0015] As can be seen from the above, by adopting the technical solution of this embodiment, the user can simultaneously establish a power transmission circuit and a signal sampling circuit through a single plug-in / plug-out operation. Furthermore, each terminal is fixed to the insulating base at intervals, maintaining a safe distance and eliminating the risk of displacement and short circuits, thus preventing short circuit risks. In addition, the integrated design reduces the number of components, improves product reliability, and reduces production costs. Attached Figure Description

[0016] The accompanying drawings, which are provided to further illustrate the present invention and form part of this application, do not constitute an undue limitation of the present invention.

[0017] Figure 1 , 2 A three-dimensional structural schematic diagram of an electrical connector using male rubber base and female terminal provided for Embodiment 1 of this utility model; Figure 3 An exploded view of the electrical connector provided in Embodiment 1 of this utility model; Figure 4 , 5 A three-dimensional structural diagram of an electrical connector using a female housing and male terminals, provided for Embodiment 2 of this utility model; Figure 6 This is an exploded structural diagram of the electrical connector provided in Embodiment 2 of this utility model; Figure 7 This is an exploded structural diagram of the electrical connectors provided in Embodiments 1 and 2 of this utility model (one of which is connected to the battery pack, and the other is connected to the electrical device or charger). Figure 8 , 9 This is a three-dimensional structural diagram of the electrical connectors provided in Embodiments 1 and 2 of this utility model when they are connected. Figure 10 This is a front view schematic diagram of the electrical connectors provided in Embodiments 1 and 2 of this utility model when they are connected. Figure 11 for Figure 10 AA section view; Figure 12 for Figure 10 BB cross-sectional view; Figure 13 This is a schematic diagram illustrating the working principle of the battery pack provided in Embodiment 3 of this utility model.

[0018] Explanation of reference numerals in the attached figures: 11: Male component plastic base; 12: Female component plastic housing; 2: Power transmission terminal; 3: Voltage sampling terminal; 4: Communication signal transmission terminal; 5: Plug-in / unplug handle position; 6: Anti-reverse installation chamfer; 7: Battery pack body; 8: Battery Management System (BMS) Detailed Implementation

[0019] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. The illustrative embodiments and descriptions of the present invention are used to explain the present invention, but are not intended to limit the present invention.

[0020] Examples of embodiments of the present invention are shown in the accompanying drawings in a detailed description below, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout.

[0021] The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention. In the description of the present invention, it should be understood that terms such as "length," "width," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the drawings and are only for the convenience of describing the present invention and simplifying the description, and do not 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 limiting the present invention.

[0022] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0023] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; 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 utility model according to the specific circumstances.

[0024] The core of this invention is to provide a highly integrated electrical connector, the overall structure of which is as follows: Figures 1-6 As shown, it is designed to provide a compact, safe, reliable, and multifunctional external interface for lithium-ion battery packs.

[0025] The basic structure of this electrical connector includes an insulating base (male housing 11 in Embodiment 1, and female housing 12 in Embodiment 2) and three types of functional terminals fixed thereon. These terminals include: At least two power transmission terminals 2 are used to carry large currents for charging and discharging; At least one voltage sampling terminal 3 is used to accurately monitor the voltage of each individual cell in the battery pack; And at least one communication signal transmission terminal 4 for digital communication between the battery management system (BMS 8) and external devices (such as smart chargers).

[0026] like Figures 7 to 12 As shown, one of the electrical connectors in Embodiments 1 and 2 is installed on the battery pack end, and the other is installed on the electrical device or charger end. The two electrical connectors are plugged into each other to form a complete electrical path.

[0027] This connector integrates what traditionally requires multiple independent connectors into a tiny, insulated base space. Power transmission terminal 2 directly connects to the battery's positive and negative terminals; each voltage sampling terminal 3 connects to each individual battery node. The obtained voltage sampling signals are transmitted to the BMS 8 within the battery pack for charging and discharging management and monitoring, and are further transmitted externally for the control system at the device or charger end to further monitor the battery pack's discharge and charging. This design improves the safety and reliability of the battery pack by moving beyond reliance on the BMS 8 within the battery pack. Communication signal transmission terminal 4 serves as the digital channel for communication between the BMS 8 and external devices or chargers. This design makes the connector of this invention simultaneously a power transmission channel, a status monitoring channel, and a smart communication hub for the battery.

[0028] The beneficial effect of this utility model is that by integrating a power interface, a voltage sampling interface, and a communication transmission interface into the electrical connector, the market competitiveness of the battery pack terminal product is enhanced.

[0029] The following embodiments and features are all specific implementations and optimizations of this overall solution. Example 1: Configuration of male component socket 11 and female component terminal.

[0030] like Figures 1-3 As shown, this embodiment provides an electrical connector, whose insulating base is a male plastic base 11.

[0031] Each of the power transmission terminals 2, voltage sampling terminals 3, and communication signal transmission terminals 4 are female terminals. The front ends of these female terminals are embedded and fixed in the male connector base 11, with their front insertion ports exposed in the insertion holes at the front end of the male connector base 11 for insertion with the male terminals. The rear ends of the female terminals extend out from the rear end of the male connector base 11 for electrical connection with the battery pack or internal circuitry of the device through soldering or other methods.

[0032] In this embodiment, the conductive metal contacts (female terminals) are concealed inside the sockets of the male connector housing 11, forming a female interface. This effectively prevents accidental external contact and improves the electrical safety of the connector during use. Simultaneously, this structure facilitates mating with the female housing 12 of Embodiment Two.

[0033] Example 2: Configuration of female housing 12 and male terminal.

[0034] like Figures 4 to 6 As shown, this embodiment provides another type of electrical connector, whose insulating base is a female plastic shell 12 with the shell opening located at the front end.

[0035] Each of the power transmission terminals 2, voltage sampling terminals 3, and communication signal transmission terminals 4 are male terminals. Each male terminal is arranged from back to front in the cavity of the female housing 12, and the end of each male terminal is located inside the housing opening, extending into the socket of the female terminal of the mating electrical connector during insertion.

[0036] like Figure 7 As shown, in practical applications, one of the electrical connectors in Embodiment 1 and Embodiment 2 can be connected to the battery pack, and the other can be connected to the electrical device or charger, with the two plugged into each other (e.g., Figures 8 to 10 As shown in the figure, together they form a complete charging and discharging path as well as a signal transmission path. This male-female mating structure ensures the reliability and interchangeability of the connection.

[0037] As an illustration of this embodiment, such as Figure 11 and Figure 12 As shown in the cross-sectional view, each component terminal in Embodiment 2 is provided with an elastic part capable of radial elastic deformation.

[0038] This elastic portion can be formed by creating a slot (i.e., a groove) on the front end section of the male terminal for insertion, thus forming an elastic fabric (leaf or other spring sheet) capable of radial elastic deformation on the front end section of the male terminal. When the male terminal is inserted into the corresponding female terminal, the elastic portion is compressed and undergoes radial elastic deformation, continuously applying a reverse contact pressure to the inner wall of the female terminal. This structure ensures a tight and reliable electrical contact between the male and female terminals, effectively reducing contact resistance. Simultaneously, the elastic deformation of the elastic portion can compensate for tolerance wear of the connector, significantly improving the connector's mating and extraction life and the stability of the electrical connection.

[0039] As an illustration of this embodiment, in Embodiments 1 and 2, each terminal is bonded to the insulating base via injection molding. During manufacturing, the metal terminal is first positioned in a mold, then molten high-temperature resistant engineering plastic is injected into the mold, encasing a specific portion of the terminal (e.g., the front section) and cooled to solidify. Figure 3 and Figure 6As shown, there is no assembly gap between the terminals and the housing, forming an integrated electrical connector. The integrated injection molding method effectively avoids the risk of terminals loosening due to subsequent vibration or insertion / removal. This helps ensure the positional accuracy and consistency of all terminals within the housing, improving the product's mechanical strength, stability, and production consistency. Furthermore, because the injection-molded housing is heat-resistant, it will not melt or deform during subsequent wire bonding processes, ensuring welding quality.

[0040] As an illustration of this embodiment, an inwardly recessed or outwardly protruding insertion / removal handle 5 is provided on the outer periphery of the insulating base. For example, in Embodiment 1, at least one outwardly protruding protrusion is provided on the outer periphery of the male component housing 11 as an insertion / removal handle 5; in Embodiment 2, two opposite inwardly recessed recesses are provided on the outer periphery of the female component housing 12 as insertion / removal handles 5. This handle provides a clear point of force application for the user's fingers. During insertion and removal operations, the user can apply pushing or pulling force more effortlessly and accurately through the handle, greatly improving the user experience and preventing damage to the connector or cable that may be caused by improper force application.

[0041] As an illustration of this embodiment, at least one outer corner of the insulating base has a different shape from at least another corner, serving as an anti-reverse installation chamfer 6. For example... Figure 1 , Figure 4 , Figure 8 and Figure 9 As shown, at least one corner of the male connector housing 11 and the female connector housing 12 is designed with an asymmetrical shape (e.g., one side is a right angle, and the other side is a rounded or chamfered corner). This structure ensures that the connector can only be inserted in one correct orientation. This fundamentally eliminates serious safety accidents such as short circuits, terminal damage, or even equipment failure caused by reverse installation or incorrect insertion, significantly improving safety performance.

[0042] As an illustration of this embodiment, a terminal marking portion is provided on the rear end face of the insulating base. For example... Figure 3 and Figure 6 As shown, near each terminal outlet hole on the rear face of the housing, the function of each terminal is clearly marked using embossing, color, or symbols (such as +, -, S1, S2, COM, etc.). During the production or maintenance process of soldering wires to the rear of the terminals, operators can quickly and accurately distinguish between positive and negative poles, voltage sampling points, and communication terminals according to the markings, effectively preventing functional failures or safety hazards caused by incorrect soldering, and improving production efficiency and product yield.

[0043] Example 3: Battery pack system.

[0044] like Figure 13As illustrated, this embodiment provides a battery pack, which includes a battery pack body 7, a battery management system (BMS 8), and an electrical connector as in Embodiment 1 or Embodiment 2.

[0045] Among them, the power transmission terminal 2 of the electrical connector is electrically connected to the total positive and total negative terminals of the battery pack body 7, and is responsible for charging and discharging with high current.

[0046] The voltage sampling terminals 3 are electrically connected to the voltage sampling nodes of the corresponding individual cells in the battery pack body 7, and transmit the voltage sampling signals of each individual cell to the BMS 8, and to each voltage sampling terminal 3 of this electrical connector, so as to output to the external electrical equipment or charger side.

[0047] The communication signal transmission terminal 4 is electrically connected to the communication port of the BMS 8, enabling the BMS 8 to exchange data with an external smart charger or electrical device (such as reporting battery status or receiving control commands) through this terminal.

[0048] The electrical connector of this invention serves as the sole external interface of the battery pack, achieving a high degree of integration of power, sampling, and communication signals within a very small space. Battery packs using this connector offer advantages such as compact interface, comprehensive functionality, secure and reliable connection, and ease of production and maintenance, significantly enhancing the overall competitiveness of battery pack products.

[0049] In application, the electrical connector shown in Embodiment 1 can be installed on the battery pack casing, and the electrical connector shown in Embodiment 2 can be installed on the electrical device or charger. By connecting the two electrical connectors in Embodiments 1 and 2, the connection between the battery pack and the electrical device or charger can be realized, making the external connection of the battery pack more convenient and efficient.

[0050] It should be noted that, Figures 1-12 Taking an electrical connector suitable for a battery pack consisting of two individual cells connected in series as an example, a voltage sampling terminal 3 is electrically connected to the series connection point between the two individual cells to sample their voltage. The BMS 8 inside the battery pack and the control system outside the battery pack can determine the voltage values ​​of the two individual cells in the battery pack based on the sampled voltage of the voltage sampling terminal 3 and the voltage of the power transmission terminal 2, thereby realizing the status monitoring of each individual cell and achieving balanced discharge and balanced charging of the battery.

[0051] See Figure 13As shown, the battery pack consists of 3 individual cells. Two voltage sampling terminals 3 can be set up to be electrically connected to the series connection point between individual cells S1 and S2, and the series connection point between individual cells S2 and S3, respectively. By using their voltages, similarly, the sampling voltage of the BMS 8 inside the battery pack and the voltage of the control system voltage sampling terminal 3 outside the battery pack, as well as the voltage of the power transmission terminal 2, can determine the voltage value of the three individual cells in the battery pack, realize the status monitoring of each individual cell, and realize the balanced discharge and balanced charging of the battery.

[0052] The above embodiments do not constitute a limitation on the scope of protection of this technical solution. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the above embodiments should be included within the scope of protection of this technical solution.

Claims

1. An electrical connector for charging and discharging connection of a battery pack, characterized in that, include: Insulating base; At least two power transmission terminals are fixed on the insulating base for electrical connection with the total positive electrode terminal and the total negative electrode terminal of the battery pack, serving as power interfaces for charging or discharging. At least one voltage sampling terminal is fixed to the insulating base and serves as a voltage sampling interface for individual cells within the battery pack. At least one communication signal transmission terminal is fixed on the insulating base and is used as a communication protocol interface between the battery management system and the outside.

2. The electrical connector according to claim 1, characterized in that, The insulating base is a male component adhesive base. Each of the power transmission terminals, voltage sampling terminals, and communication signal transmission terminals is a female terminal. The front end of each female terminal is embedded in the male component socket, the front end of which is located in the front end of the male component socket, and the rear end extends out of the rear end of the male component socket.

3. The electrical connector according to claim 1, characterized in that, The insulating base is a female plastic shell with the shell opening located at the front end. Each of the power transmission terminals, each of the voltage sampling terminals, and each of the communication signal transmission terminals are common component terminals. Each of the male component terminals is disposed from back to front within the cavity of the female component housing, with its end located within the housing opening.

4. The electrical connector according to claim 3, characterized in that, Each of the aforementioned component terminals is provided with an elastic portion capable of radial elastic deformation.

5. The electrical connector according to any one of claims 1 to 4, characterized in that, Each of the power transmission terminals, each of the voltage sampling terminals, each of the communication signal transmission terminals, and the insulating base are bonded to the insulating base by injection molding.

6. The electrical connector according to any one of claims 1 to 4, characterized in that, The outer periphery of the insulating base is provided with a plug-in handle that is recessed inward or protruded outward.

7. The electrical connector according to any one of claims 1 to 4, characterized in that, At least one outer corner of the insulating base has a different shape from at least another corner.

8. The electrical connector according to any one of claims 1 to 4, characterized in that, A terminal marking section is provided on the rear end face of the insulating base.

9. A battery pack, characterized in that, The battery pack body includes at least two individual cells connected in series; A battery management system is installed on the battery pack body and electrically connected to each of the individual batteries, used to control the charging, discharging and status monitoring of the battery pack body; The electrical connector according to any one of claims 1 to 8; The power transmission terminal of the electrical connector is electrically connected to the total positive and total negative terminals of the battery pack body. The voltage sampling terminals of the electrical connector are electrically connected to the voltage sampling nodes of the corresponding individual cells in the battery pack body. The communication signal transmission terminal of the electrical connector is electrically connected to the communication port of the battery management system.

10. The battery pack according to claim 9, characterized in that, The electrical connector is embedded in the outer shell of the battery pack body and serves as the battery pack's only external charging, discharging, and communication interface.

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