Battery pack soft connection female end connector

Abstract

The utility model discloses a battery pack soft connection female end connector, male end assembly contains step post structure male end insulator shell and male end power, signal terminal, female end assembly contains protection shell, two female end insulator shell, female end power, signal terminal, elastic clamping piece structure external terminal, soft copper row, signal line, two female end insulator shell is firm in protection shell, and female end insulator shell is one with the sealed ring's plug structure, and soft copper row, signal line connects corresponding terminal respectively, and protection shell is equipped with window and can detachable fixed with battery pack shell body, and when assembling, female end insulator shell one inserts male end insulator shell, and corresponding terminal inserts. In the scheme, female end assembly can be independently disassembled and replaced, and the maintenance cost is reduced, and soft copper row anti -vibration prevents terminal loose, and double -layer sealing and elastic clamping piece guarantee the stable transmission of large current, and multiple screw fixation improves the assembly and connection reliability.

Description

Technical Field

[0001] This utility model relates to battery connection technology, specifically to a flexible female connector suitable for new energy battery packs, which is particularly suitable for electrical connections in high current transmission scenarios. Background Technology

[0002] With the rapid development of the new energy industry, battery packs have been widely used in various new energy devices, and their electrical connection with external devices relies on dedicated connectors. Currently, battery pack connectors on the market have the following prominent problems in practical applications:

[0003] High maintenance costs and complex operation: Existing connectors mostly adopt an integrated design or a structure where both male and female ends are fixedly installed. As a frequently plugged and unplugged component, the female end is prone to wear, oxidation, or damage after long-term use. In this case, it is necessary to replace the entire wiring harness or connector assembly, or even disassemble the internal structure of the battery pack, resulting in long maintenance cycles and high costs.

[0004] Insufficient vibration resistance: Battery pack applications often involve vibrating environments. The rigid connection method of traditional connectors is prone to stress concentration, leading to loose terminals, increased contact resistance, and in severe cases, arcing or connection failure. Although some solutions use flexible connections, they do not incorporate a quick-replacement structural design, failing to balance vibration mitigation and maintenance convenience.

[0005] Poor reliability of high-current connections: For high-current transmission scenarios of 40A and above, connection stability and low contact resistance are crucial. Existing pluggable connectors, after prolonged use, are prone to contact point pressure drops, and coupled with insufficient sealing performance, this can easily lead to poor contact and increased resistance, posing safety hazards.

[0006] Therefore, there is an urgent need for a battery pack connector solution that can solve the above problems while taking into account ease of maintenance, vibration resistance, and high-current connection reliability. Utility Model Content

[0007] To overcome the shortcomings of the prior art, the purpose of this utility model is to provide a battery pack electrical connection device with a reasonable structural design, so as to solve the technical pain points that existing battery pack connectors may have in practical applications, while improving the reliability of the connection, the convenience of maintenance and the vibration resistance.

[0008] To achieve the above and other related objectives, the technical solution provided by this utility model is: a flexible female connector for a battery pack, comprising:

[0009] A male terminal assembly includes a male insulating shell, a male power terminal, and a male signal terminal. The male insulating shell is fixed to the battery pack housing, and the male power terminal and the male signal terminal are fixed to the plug-in end of the male insulating shell.

[0010] The female terminal assembly includes a protective shell, a first female terminal insulating shell, a second female terminal insulating shell, a female terminal power terminal, a female terminal signal terminal, an external power supply terminal, an external signal terminal, a flexible copper busbar, and a signal line. The first and second female terminal insulating shells are both fixed inside the protective shell. The female terminal power terminal and the female terminal signal terminal are fixed to the plug-in end of the first female terminal insulating shell. The external power supply terminal and the external signal terminal are fixed to the plug-in end of the second female terminal insulating shell. The flexible copper busbar connects the female terminal power terminal and the external power supply terminal. The signal line connects the female terminal signal terminal and the external signal terminal.

[0011] In the assembled state, the female insulating shell is inserted into the male insulating shell, the female power terminal is plugged into the male power terminal, the female signal terminal is plugged into the male signal terminal, and the protective shell is detachably and fixedly installed with the battery pack shell.

[0012] A preferred technical solution is as follows: the periphery of the male end insulating shell is configured as a stepped column structure and includes a large diameter section, a small diameter section and a stepped surface. The battery pack housing is provided with an installation hole for the small diameter section to pass through. The main body of the male end insulating shell is located on the inner side of the battery pack housing. The small diameter section extends out of the mounting hole from the outer side of the battery pack housing. A sealing gasket is provided on the stepped surface, and the sealing gasket is sealed to the inner side of the battery pack housing.

[0013] The preferred technical solution is that the stepped surface and the battery pack housing are detachably and fixedly connected by screws.

[0014] The preferred technical solution is as follows: the male end insulating shell is configured as a slot structure, the female end insulating shell is configured as a plug structure, the outer periphery of the plug structure is provided with a sealing ring, and the sealing ring is sealed to the slot structure.

[0015] The preferred technical solution is as follows: the first female end insulating shell and the protective shell are detachably and fixedly connected by screws, and the second female end insulating shell and the protective shell are detachably and fixedly connected by screws.

[0016] The preferred technical solution is that the plug-in ends of the external power supply terminal and the external signal terminal are both configured as elastic clip structures.

[0017] The preferred technical solution is that the protective shell is provided with a window, and the plug-in end of the female end insulating shell is located in the window.

[0018] Due to the application of the above technical solution, the beneficial effects of this utility model are as follows:

[0019] Significantly improved maintenance convenience: The female terminal component is detachably connected to the battery pack housing through a protective shell. When the female terminal component is damaged, there is no need to disassemble the battery pack or replace the entire connector assembly. Only the protective shell needs to be removed to replace the female terminal independently, which greatly reduces maintenance costs and operational complexity.

[0020] Vibration resistance optimization: The female terminal uses a soft copper busbar to connect the power terminals. The soft copper busbar has good flexibility and can effectively absorb the stress generated by vibration, avoiding terminal loosening caused by rigid connection, and further improving the connection stability under vibration environment.

[0021] Enhanced reliability of high-current connections: The external power supply terminals and external signal terminals adopt a flexible clip structure, which can ensure stable contact pressure after long-term insertion and removal, and reduce contact resistance; the sealing gasket of the male terminal step surface and the sealing ring of the female terminal plug structure form a double seal to prevent moisture and impurities from entering, ensuring safety and stability during high-current transmission. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of the female connector involved in this utility model.

[0023] Figure 2 This is a schematic diagram of the structure of the public terminal component involved in this utility model.

[0024] Figure 3 This is a structural schematic diagram of the female end component involved in this utility model from one perspective after removing the protective shell.

[0025] Figure 4 This is a structural schematic diagram of the female end component involved in this utility model from another perspective after the protective shell has been removed. Detailed Implementation

[0026] The following specific embodiments illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification.

[0027] Please see Figures 1-4It should be noted that in the description of this utility model, the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the utility model product is in use. These terms are used only for the convenience of describing this utility model and for simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. Furthermore, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance. The terms "horizontal," "vertical," and "suspended," etc., do not indicate that the component must be absolutely horizontal or suspended, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0028] In the description of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" 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; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0029] Example:

[0030] like Figures 1 to 4 As shown, according to a general technical concept of this utility model, a battery pack flexible connection female connector is provided, comprising:

[0031] The male terminal assembly includes a male terminal insulating shell 11, a male terminal power terminal 12, and a male terminal signal terminal 13. The male terminal insulating shell 11 is fixed on the battery pack housing 100, and the male terminal power terminal 12 and the male terminal signal terminal 13 are fixed on the plug-in end of the male terminal insulating shell 11.

[0032] The female terminal assembly includes a protective shell 21, a first female terminal insulating shell 22, a second female terminal insulating shell 23, a female terminal power terminal 24, a female terminal signal terminal 25, an external power supply terminal 26, an external signal terminal 27, a flexible copper busbar 28, and a signal line 29. The first female terminal insulating shell 22 and the second female terminal insulating shell 23 are both fixed inside the protective shell 21. The female terminal power terminal 24 and the female terminal signal terminal 25 are fixed at the plug-in end of the first female terminal insulating shell 22. The external power supply terminal 26 and the external signal terminal 27 are fixed at the plug-in end of the second female terminal insulating shell 23. The flexible copper busbar 28 connects the female terminal power terminal 24 and the external power supply terminal 26. The signal line 29 connects the female terminal signal terminal 25 and the external signal terminal 27.

[0033] In the assembled state, the female end insulating shell 22 is inserted into the male end insulating shell 11, the female end power terminal 24 is inserted into the male end power terminal 12, the female end signal terminal 25 is inserted into the male end signal terminal 13, and the protective shell 21 is detachably and fixedly installed with the battery pack shell 100.

[0034] Installation and technical effect adaptation of public terminal components

[0035] First, the installation of the male terminal component is carried out: the male terminal insulating shell 11 adopts a stepped column structure design, which includes a large diameter section 111 located on the inside, a small diameter section 112 for extending out of the battery pack shell 100, and a stepped surface 113 connecting the two sections. The battery pack shell 100 has a mounting hole pre-drilled to fit the small diameter section 112. During installation, the sealing gasket 3 is first tightly fitted to the stepped surface 113. Then, the small-diameter section 112 of the male end insulating shell 11 is inserted into the mounting hole from the inside of the battery pack housing 100 and extends to the outside of the housing, leaving the large-diameter section 111 inside the battery pack housing 100. This stepped column structure can accurately achieve the axial positioning of the male end insulating shell 11, avoiding misalignment or offset during installation, ensuring the alignment accuracy when plugging in the female end component, and reducing terminal contact problems caused by positioning deviation. The sealing gasket 3, which is fitted to the stepped surface 113, will be in close contact with the inner wall of the battery pack housing 100, forming the first line of sealing defense, effectively blocking moisture, dust and other impurities in the external environment from entering the battery pack, preventing internal electrical components from getting damp or contaminated, and ensuring the overall sealing and safety of the battery pack.

[0036] Subsequently, galvanized anti-rust screws are used to detachably fix the stepped surface 113 to the inner side of the battery pack housing 100. The galvanized material can improve the corrosion resistance of the screws, adapt to complex application environments such as vehicles and outdoor equipment, and avoid the difficulty of disassembly caused by screw corrosion after long-term use. At the same time, the detachable screw connection method not only ensures the long-term stable installation of the male terminal component (avoiding loosening under vibration), but also provides convenience for the subsequent maintenance or replacement of the male terminal component without damaging the structure of the battery pack housing 100, reducing the complexity of maintenance operations.

[0037] After the male insulating shell 11 is fixed, the male power terminal 12 and the male signal terminal 13 are fixed to the insertion end of the male insulating shell 11 by injection molding insert process. The injection molding insert process can form a tight connection between the terminal and the insulating shell without gaps, avoid terminal displacement due to vibration, and ensure the alignment accuracy when plugging in the female terminal. Especially for high current transmission scenarios, the stable terminal position can effectively reduce contact resistance, prevent local overheating, ensure the reliability of power transmission, and avoid electrical faults caused by terminal displacement.

[0038] Synergy of assembly and technical effects of mother components

[0039] Next, the female terminal assembly is assembled: Take the protective shell 21 made of ABS flame-retardant material (the flame-retardant material can improve the fire safety of the connector and adapt to the high temperature environment that the battery pack may encounter), and fix the female terminal insulating shell 1 22 and female terminal insulating shell 23 to the inside of the protective shell 21 respectively by stainless steel screws. The stainless steel screws have both rust resistance and high strength, which can ensure that the two insulating shells are stably installed in the protective shell 21 for a long time, avoiding mutual interference or displacement due to vibration. At the same time, the detachable screw connection design allows that if a certain insulating shell or its internal terminals are damaged in the future, it can be disassembled and replaced separately without replacing the entire female terminal assembly, which greatly reduces maintenance costs and improves the economy of later use.

[0040] At the insertion end of the female insulating shell 22, the female power terminal 24 and the female signal terminal 25 are fixed by a crimping process. The female insulating shell 22 is designed as a plug structure, and a sealing ring 4 made of nitrile rubber is fitted on its outer peripheral wall. Correspondingly, the insertion end of the male insulating shell 11 is designed as a slot structure adapted to the plug structure. The matching design of the plug and slot can ensure accurate alignment when the male and female ends are inserted, avoid terminal collision damage, and improve assembly efficiency. After the plug is inserted into the slot, the nitrile rubber sealing ring 4 will fit tightly between the outer periphery of the plug and the inner wall of the slot, forming a second sealing line. Together with the sealing gasket 3 of the male end, it forms a double sealing structure, further improving the overall sealing level of the connector. Even in harsh environments with humidity and dust, it can effectively protect the contact area of ​​the male and female terminals, prevent terminal oxidation or short circuit, and ensure the stability of the electrical connection.

[0041] Subsequently, the external power terminal 26 and the external signal terminal 27 are fixed to the plug-in end of the female insulating shell 23. The plug-in ends of both the external power terminal 26 and the external signal terminal 27 are designed with a phosphor bronze elastic clip structure. A reasonable pre-tightening amount is reserved at the opening of the clip. Phosphor bronze has excellent elasticity and conductivity. The elastic clip structure combined with the pre-tightening amount design allows the clip to generate a stable clamping force through its own elasticity when the external wire harness plug is inserted. Even with long-term and frequent plugging and unplugging (such as connecting external equipment during maintenance), the elasticity of the clip is not easy to fail. It can always maintain a stable contact pressure, avoid the increase in contact resistance due to insufficient contact pressure, and prevent arcing or overheating during high current transmission, which significantly improves the reliability of external connection. At the same time, the structural design of the elastic clip also reduces the difficulty of plugging and unplugging operations and improves the convenience of operation.

[0042] After the terminals are fixed, a flexible copper busbar 28 made of T2 copper is used to connect the female power terminal 24 to the external power terminal 26. A signal line 29 with a tinned copper core and PVC insulation layer is used to connect the female signal terminal 25 to the external signal terminal 27. The flexible copper busbar 28 made of T2 copper combines high conductivity and flexibility. The high conductivity reduces power loss during high current transmission and is suitable for high current scenarios of 40A and above. The good flexibility can effectively absorb the stress generated by the battery pack in the vibration environment (such as vehicle bumps and equipment movement), avoid the breakage or loosening of the terminal welds caused by rigid connections, ensure the continuity of power transmission, and reduce connection failure problems caused by vibration. The tinned copper core of the signal line 29 can improve the anti-interference ability of signal transmission, avoid the interference of external electromagnetic signals on the battery pack voltage, temperature and other status signals, and the PVC insulation layer can prevent signal leakage, ensuring that the status signals can be accurately transmitted to external monitoring equipment, so that the staff can monitor the battery operating status in real time and detect abnormalities in time.

[0043] In addition, a rectangular window is provided on the protective shell 21 at the position corresponding to the plug-in end of the female end insulating shell 23. During assembly, the plug-in end of the female end insulating shell 23 is placed exactly in the window. The window not only provides physical protection for the plug-in end of the female end insulating shell 23, preventing damage to the plug-in end due to external collisions and extending the service life of the component, but also clearly indicates the plug-in position of the external wiring harness, making it convenient for operators to quickly align and plug in, improving the efficiency of assembly and maintenance. At the same time, the protective shell 21 completely encloses the soft copper busbar 28, signal line 29 and other components inside the female end assembly, preventing foreign objects from getting tangled or accidental contact by personnel, avoiding the risk of electrical short circuits, and ensuring the safety of the internal structure of the female end assembly.

[0044] Overall assembly and integrated effect of male and female components

[0045] Finally, the male and female components are assembled: the plug structure of the female insulating shell 22 is aligned with the slot structure of the male insulating shell 11 and inserted, so that the female power terminal 24 and the male power terminal 12 are precisely connected, and the female signal terminal 25 and the male signal terminal 13 are precisely connected. At this time, the sealing ring 3 on the outer periphery of the female insulating shell 22 is tightly fitted with the inner wall of the slot of the male insulating shell 11, completing the sealing and electrical connection of the male and female ends, ensuring stable transmission of current and signal; then, high-strength bolts are used to detachably fix the protective shell 21 to the battery pack shell 100. The high-strength bolts can form an integral fixation for the female component, preventing the female component from shifting when the vehicle is moving or the equipment is moved, ensuring that the male and female terminals always maintain stable contact, further improving the connection reliability; at the same time, the detachable bolt connection design means that when the female component is worn, oxidized or malfunctioning, the entire female component can be removed and replaced simply by removing the bolts, without disassembling the internal structure of the battery pack, which greatly shortens maintenance time, reduces maintenance costs, and significantly improves the convenience of the connector in later use.

[0046] This embodiment, through the synergistic cooperation of the above series of structural designs, deeply integrates various technical features with their corresponding technical effects, ultimately achieving a comprehensive effect of convenient connector maintenance, excellent vibration resistance, reliable high-current connection, and good sealing performance, fully adapting to the actual application needs of battery packs in complex environments.

[0047] The above embodiments are merely illustrative of the principles and effects of this utility model and are not intended to limit the scope of this utility model. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this utility model. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this utility model should still be covered by the claims of this utility model.

Claims

1. A flexible female connector for a battery pack, characterized in that, include: A male terminal assembly includes a male insulating shell, a male power terminal, and a male signal terminal. The male insulating shell is fixed to the battery pack housing, and the male power terminal and the male signal terminal are fixed to the plug-in end of the male insulating shell. The female terminal assembly includes a protective shell, a first female terminal insulating shell, a second female terminal insulating shell, a female terminal power terminal, a female terminal signal terminal, an external power supply terminal, an external signal terminal, a flexible copper busbar, and a signal line. The first and second female terminal insulating shells are both fixed inside the protective shell. The female terminal power terminal and the female terminal signal terminal are fixed to the plug-in end of the first female terminal insulating shell. The external power supply terminal and the external signal terminal are fixed to the plug-in end of the second female terminal insulating shell. The flexible copper busbar connects the female terminal power terminal and the external power supply terminal. The signal line connects the female terminal signal terminal and the external signal terminal. In the assembled state, the female insulating shell is inserted into the male insulating shell, the female power terminal is plugged into the male power terminal, the female signal terminal is plugged into the male signal terminal, and the protective shell is detachably and fixedly installed with the battery pack shell.

2. The battery pack flexible female connector according to claim 1, characterized in that: The periphery of the male end insulating shell is configured as a stepped column structure and includes a large diameter section, a small diameter section, and a stepped surface. The battery pack housing is provided with a mounting hole for the small diameter section to pass through. The main body of the male end insulating shell is located inside the battery pack housing. The small diameter section extends out of the mounting hole from the outside of the battery pack housing. A sealing gasket is provided on the stepped surface, and the sealing gasket is sealed to the inside of the battery pack housing.

3. The battery pack flexible female connector according to claim 2, characterized in that: The stepped surface is detachably fixed to the battery pack housing by screws.

4. The battery pack flexible female connector according to claim 1, characterized in that: The male end insulating shell is configured as a slot structure, and the female end insulating shell is configured as a plug structure. The outer periphery of the plug structure is provided with a sealing ring, and the sealing ring is sealed to the slot structure.

5. A battery pack flexible female connector according to claim 1, characterized in that: The first female end insulating shell is detachably and fixedly connected to the protective shell by screws, and the second female end insulating shell is detachably and fixedly connected to the protective shell by screws.

6. The battery pack flexible female connector according to claim 1, characterized in that: The plug-in ends of both the external power supply terminal and the external signal terminal are configured as elastic clip structures.

7. A battery pack flexible female connector according to claim 1, characterized in that: The protective shell is provided with a window, and the plug-in end of the second female insulating shell is located in the window.

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