A through-wall terminal connector and battery pack

Abstract

This utility model provides a through-wall terminal connector and a battery pack. The through-wall terminal connector is suitable for installation on a battery pack housing and is used to realize the electrical connection between the internal circuit of the battery pack and the external battery management module. It includes: a plug body, inserted into a mounting hole in the battery pack housing, having a mounting section, a conductive connection part, and a plug end; a sealing structure disposed near the outer surface of the housing on the plug body, forming a sealed fit between the plug body and the housing; and a fastening structure disposed along both sides of the plug body and fixing it to the housing. The battery pack includes a housing for accommodating multiple battery cell modules and the aforementioned through-wall terminal connector. This utility model solves the technical problems caused by externalizing the battery management system, such as destructive maintenance of the housing, poor sealing of the data acquisition harness, and poor insulation performance.

Description

Technical Field

[0001] This utility model relates to the field of battery connector technology, and in particular to a through-wall terminal connector and battery pack. Background Technology

[0002] Batteries are widely used in energy storage systems and new energy vehicles. Battery packs (modules) typically have a battery management system (BMS) slave module inside, which is used to collect operating parameters such as voltage and temperature of individual battery cells and communicate with the external master control module through the data acquisition harness.

[0003] In existing technologies, the slave control module is mostly installed internally, with the acquisition harness directly connected to the battery cell and extending out from the battery pack casing. However, this structure has significant shortcomings: First, module maintenance or replacement requires disassembling the battery pack casing, which disrupts its sealed and dry environment, easily leading to condensation and decreased insulation performance; second, the acquisition harness extending from the high-voltage side to the low-voltage casing poses a potential safety hazard, and the overall structure is complex and has low integration, which is not conducive to standardization and maintenance operations.

[0004] Therefore, the engineering proposal suggests placing the BMS slave module outside the battery pack. However, this layout presents new challenges: a stable connection must be achieved between the internal data acquisition harness of the battery pack and the external slave module, while ensuring electrical insulation and structural sealing performance. However, existing standard components such as FFC connectors and FPC board-to-board connectors are insufficient to meet the complex requirements of through-wall installation, sealed fixation, and compatibility with various cables / circuit boards.

[0005] Therefore, there is an urgent need to design a through-wall terminal connector that is compact, reliable, and has good sealing and insulation, as well as a battery pack using the connector, for efficient connection between the internal acquisition circuit of the battery pack and the external module, to meet the system requirements under the trend of BMS externalization. Utility Model Content

[0006] In order to overcome the shortcomings of the prior art, the purpose of this utility model is to provide a compact and reliable through-wall terminal connector and a battery pack using the connector.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: A through-wall terminal connector is suitable for installation on a battery pack housing to achieve electrical connection between the internal circuitry of the battery pack and an external battery management module. The connector includes a plug body, a sealing structure, and a fastening structure. The plug body is inserted into a mounting hole in the battery pack housing and includes a mounting section, a conductive connection portion, and a plug end. The mounting section is located within the mounting hole of the battery pack housing and is used to position the plug body and form a mating fit with the housing. The conductive connection portion is located on the inner side of the plug body and is used to connect to a flexible cable, flexible circuit board, or printed circuit board disposed inside the battery pack. The plug end is located on the outer side of the plug body and is used to connect to a socket of the battery management module. The sealing structure is disposed on the plug body near the outer surface of the battery pack housing, at least partially covering the outer periphery of the mounting section and fitting into the mounting hole of the battery pack housing, forming a sealed fit between the plug body and the battery pack housing. The fastening structure is disposed on both sides of the plug body along the length direction and connected to the plug body and the battery pack housing to fix the connector to the battery pack housing.

[0008] Furthermore, the conductive connection portion includes one or more rows of metal crimp terminals disposed inside the plug body. The metal crimp terminals have an open U-shaped groove structure and are embedded in the inner cavity groove of the plug body for inserting a flexible flat cable and forming a direct conductive connection between its conductor and the crimp terminals.

[0009] Furthermore, the conductive connection includes multiple metal pins, which are pin-shaped structures arranged along the inner bottom or sidewall of the plug body, and are used to connect to the conductive pads of the flexible printed circuit board or the printed circuit board by surface mount soldering or through-hole soldering, respectively.

[0010] Furthermore, the plug end has a slot structure for mating with the matching socket on the battery management module; along the length direction, the plug end has groove-shaped guides on both sides for guiding the plug end to be inserted into the matching socket.

[0011] Furthermore, the sealing structure includes a sealing panel disposed on the outside of the plug body and an annular sealing gasket disposed on the outer periphery of the mounting section. The sealing panel is attached to the outer surface of the battery pack housing and is used to provide insulation. The sealing gasket is sleeved on the outer periphery of the mounting section and sandwiched between the mounting section and the battery pack housing to achieve a circumferential sealing fit.

[0012] Furthermore, the fastening structure includes a fastening screw that passes through the mounting hole of the sealing panel and the mounting section and is screwed thereto, and also includes a hollow mounting post disposed inside the plug body and coaxially disposed with the mounting hole.

[0013] Furthermore, the plug body is made of insulating plastic that is resistant to high temperatures and electrical breakdown.

[0014] A battery pack includes: a battery pack and the aforementioned through-wall terminal connector; a battery pack housing for accommodating multiple battery cell modules; and a through-wall terminal connector mounted on the battery pack housing for realizing electrical connection between the internal circuitry of the battery pack and an external battery management module.

[0015] The aforementioned through-wall terminal connector addresses the maintenance difficulties, compromised housing seals, and safety hazards posed by protruding data acquisition harnesses caused by the built-in slave control modules in existing battery management systems. By incorporating a plug body, conductive connection section, insertion terminal, sealing structure, and fastening structure, it achieves a reliable connection between the internal data acquisition circuitry of the battery pack and the external control module. This connector boasts excellent sealing and insulation, is compatible with various flexible cables and circuit board structures, supports external deployment of slave control modules, and improves system maintenance convenience, electrical safety, and integration, meeting the practical needs of energy storage devices and new energy vehicles for highly reliable connection solutions. Using this through-wall terminal connector in the battery pack satisfies the technical requirements for electrical connection, sealing, and insulation, while also enhancing the system's modularity and maintainability. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the front side of the connector provided by this utility model; Figure 2 This is a rear view diagram of the first embodiment of the connector provided by this utility model; Figure 3 This is a rear view diagram of the second embodiment of the connector provided by this utility model; Figure 4 This is an installation diagram of the first and second embodiments of the connector provided by this utility model; Figure 5 This is a schematic diagram of the connector provided by this utility model on the assembly of a battery pack (module). Detailed Implementation

[0017] The technical solutions in the embodiments of this utility model will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0018] like Figures 1 to 3 As shown, this application provides a through-wall terminal connector suitable for installation on a battery pack housing to realize electrical connection between the internal circuit of the battery pack and an external battery management module, including: a plug body 1, a sealing structure 2, and a fastening structure 3.

[0019] Specifically, the plug body 1 is inserted into the mounting hole of the battery pack housing, and includes a mounting section 11, a conductive connection portion 12, and a plug end 13. The mounting section 11 is located within the mounting hole of the battery pack housing and is used to position the plug body 1 and form a mating connection with the housing. The conductive connection portion 12 is located on the inner side of the plug body 1 and is used to connect to a flexible cable, flexible circuit board, or printed circuit board disposed inside the battery pack. The plug end 13 is located on the outer side of the plug body 1 and is used to connect to the socket of the battery management module. The inner side of the plug body 1 refers to the side of the plug body 1 facing the inside of the battery pack, and the outer side refers to the side facing the outside of the battery pack.

[0020] The sealing structure 2 is located near the outer surface of the battery pack housing of the plug body 1, at least partially covering the outer periphery of the mounting section 11 and fitting into the mounting hole of the battery pack housing, forming a sealed fit by being clamped between the plug body 1 and the battery pack housing.

[0021] Fastening structure 3 is provided on both sides of plug body 1 along the length direction and is connected to plug body 1 and battery pack housing, used to fix connector to battery pack housing.

[0022] This embodiment achieves a through-wall connection by inserting the plug body 1 into the mounting hole of the battery pack housing. The mounting section 11 of the plug body 1 is inserted into the battery pack housing for stable positioning, while the conductive connection part 12 is located inside the housing, providing conductivity with the internal circuitry of the battery pack (such as flexible cables, FPCs, or PCBs). The plug end 13 is located outside the housing, connecting to the battery management module via a standard socket to form an electrical connection closed loop. The sealing structure 2 effectively prevents moisture or dust from entering the battery pack, thus ensuring insulation and sealing. The fastening structure 3 is arranged along both sides of the plug body 1, typically using screws or clips, in conjunction with threaded holes or reinforcing ribs on the housing, ensuring the connector is securely installed and has a certain vibration resistance, adapting to the usage requirements of applications such as new energy vehicles.

[0023] As one possible implementation method, such as Figure 2As shown, the conductive connection portion 12 includes one or more rows of metal crimp terminals disposed inside the plug body 1. The metal crimp terminals have an open U-shaped groove structure and are embedded in the inner cavity of the plug body 1, used to insert a flexible flat cable and establish a direct conductive connection between its conductor and the crimp terminals. In this embodiment, the metal crimp terminals adopt an open U-shaped groove design and are fixedly embedded in the groove structure inside the plug body 1 in rows. The flexible flat cable (e.g., FFC) used inside the battery pack is inserted through the insertion port of the conductive connection portion 12, passing through the corresponding U-shaped groove. The edge of the groove performs a piercing crimp on the cable conductor, achieving direct electrical contact between the exposed conductor and the metal terminal. To improve connection stability and insulation performance, UV adhesive can be injected into the contact area after crimping for curing, thereby enhancing shock resistance and preventing loosening of the connection. This method achieves a fast and reliable electrical connection between the internal signal acquisition cable and the internal terminals of the plug.

[0024] As another possible implementation, such as Figure 3 As shown, the conductive connection part 12 includes multiple metal pins. These metal pins are pin-shaped structures arranged along the inner bottom or sidewall of the plug body 1, and are used to connect to the conductive pads of a flexible printed circuit board (FPC) or a printed circuit board via surface mount soldering (THT) or through-hole soldering, respectively. This embodiment uses metal pins as the core structure of the conductive connection part 12, with the metal pins arranged at regular intervals along the inner bottom or sidewall of the plug body 1. The pins are connected to the conductive pads on the FPC (Flexible Printed Circuit Board) or PCB (Printed Circuit Board) via through-hole soldering (THT) or surface mount soldering (SMT) processes, respectively, forming a reliable electrical path. In a board-to-board structure, this connection method achieves electrical signal transmission through standardized pad contact with pins, and can be mated with an external socket via plug terminals to complete the entire signal path.

[0025] like Figure 4 As shown, it's important to understand that, depending on the actual battery pack requirements, they can be used in combination within the same battery pack or configured independently to meet various wiring and maintenance needs. When assembling the connectors, a sealing ring and a sealing cap can be used to provide overall sealing protection for the control module, further ensuring the safety of the electrical connection.

[0026] like Figure 1As shown, the plug end 13 is a slot structure used to mate with the matching socket on the battery management module. Along its length, the plug end 13 has groove-shaped guides on both sides to guide its insertion into the matching socket. The plug end 13 of the plug body 1 is designed as a slot structure, its shape matching the socket port on the battery management module. The plug end 13 achieves a mating positioning function through the groove-shaped guides on both sides, providing directional guidance and preventing misalignment during insertion. When the socket end and plug are inserted, the conductive components in the slot and the contact points in the socket achieve precise conductivity, forming an electrical connection path. This structure combines mechanical fixation and electrical connection, ensuring stability during connection and shock resistance during subsequent operation. It should be understood that the plug end 13 can not only be designed as a slot structure, but can also be transformed into a pin structure according to actual needs, i.e., the plug end is set as an exposed pin for insertion into an external socket hole to form a mating connection. This structure is suitable for through-hole sockets or socket structures with locking mechanisms, improving insertion and removal strength. In addition, the plug end can also integrate a snap-fit ​​structure, such as a flexible hook or a sliding lock, to provide a self-locking function after being inserted into the socket to prevent the connection from coming loose.

[0027] like Figures 1 to 3 As shown, the fastening structure 3 includes a fastening screw that passes through the mounting hole 31 of the sealing panel 21 and the mounting section 11 and is screwed thereto. It also includes a hollow mounting post 32 located inside the plug body 1 and coaxially arranged with the mounting hole 31. By providing the mounting hole 31 and the hollow mounting post 32, an axially symmetrical screw fastening channel is formed. This, combined with the fastening screw, achieves high-strength fixing of the connector, not only improving the structural stability between the connector and the housing but also significantly enhancing vibration and impact resistance. It is particularly suitable for use in high-dynamic environments such as new energy vehicles or energy storage equipment. When used in conjunction with the sealing structure 2, this fastening method can further compress the sealing panel 21 and the sealing gasket 22, improving sealing performance and overall reliability.

[0028] The plug body 1 is made of high-temperature resistant and electrical breakdown-resistant insulating plastic. As the core support structure of the connector, the plug body 1 is made of high-molecular insulating plastic with good insulation properties, and also has high-temperature resistance and electrical breakdown resistance. This insulating plastic is manufactured through injection molding and can withstand the effects of high temperature, high humidity, and strong electric fields in the internal and external operating environments of the battery pack. This ensures that the connector maintains stable mechanical support and electrical isolation performance under long-term operating conditions, thereby guaranteeing the safety of the electrical connection and the reliability of system operation.

[0029] like Figure 5As shown, this application also provides a battery pack, which includes a battery pack housing and the aforementioned through-wall terminal connector. The battery pack housing is used to accommodate multiple cell modules and is preferably made of metal or high-insulation engineering plastic material to meet the requirements of mechanical strength and electrical insulation. The through-wall terminal connector is installed on the battery pack housing to realize the electrical connection between the internal circuit of the battery pack and the external battery management module. Specifically, the plug body 1 of the through-wall terminal connector passes through the battery pack housing, and a sealing fit is formed between the plug body 1 and the housing through a sealing structure, and the connector is firmly installed on the battery pack housing by means of a fastening structure. Through the above structural design, the battery pack can realize the connection or replacement of the internal BMS slave control module without opening the battery pack housing, avoiding the damage to the battery pack's sealing and dry environment caused by opening the pack for maintenance, and improving the convenience of maintenance and system reliability. By integrating the above-mentioned through-wall terminal connector, it not only meets the technical requirements of electrical connection, sealing and insulation, but also improves the modularity and maintainability of the system, and is suitable for the application needs of new energy vehicles and energy storage battery systems.

[0030] The above description of embodiments of the present invention, through which those skilled in the art are able to implement or use the present invention, will be readily apparent to those skilled in the art. Various modifications to these embodiments will be readily apparent to those skilled in the art. The general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novelty disclosed herein.

Claims

1. A through-wall terminal connector, suitable for installation on a battery pack housing, for realizing electrical connection between the internal circuitry of the battery pack and an external battery management module, characterized in that, The connector includes: The plug body (1) is inserted into the mounting hole of the battery pack housing, and includes: The mounting section (11) is located in the mounting hole of the battery pack housing and is used to position the plug body (1) and form a fit with the housing; The conductive connection part (12) is located inside the plug body (1) and is used to connect with the flexible cable, flexible circuit board or printed circuit board disposed inside the battery pack. The plug end (13) is located on the outside of the plug body (1) and is used to connect to the socket of the battery management module; The sealing structure (2) is located on the plug body (1) near the outer surface of the battery pack housing, at least partially covering the outer periphery of the mounting section (11) and fitting into the mounting hole of the battery pack housing, forming a sealed fit by being clamped between the plug body (1) and the battery pack housing. Fastening structure (3) is provided on both sides of the plug body (1) along the length direction and connected to the plug body (1) and the battery pack housing, for fixing the connector to the battery pack housing.

2. The through-wall terminal connector according to claim 1, characterized in that, The conductive connection part (12) includes one or more rows of metal crimp terminals disposed inside the plug body (1). The metal crimp terminals have an open U-shaped groove structure and are embedded in the inner cavity groove of the plug body (1) for inserting a flexible flat cable and making its conductor form a direct conductive connection with the crimp terminals.

3. The through-wall terminal connector according to claim 1, characterized in that, The conductive connection part (12) includes multiple metal pins, which are pin-shaped structures arranged along the inner bottom or sidewall of the plug body (1) and used to connect to the conductive pads of the flexible printed circuit board or the printed circuit board by surface mount soldering or through-hole soldering respectively.

4. The through-wall terminal connector according to claim 1, characterized in that, The plug-in end (13) is a slot structure for plugging into the matching socket on the battery management module; along the length direction, the plug-in end (13) has groove-shaped guides on both sides for guiding the plug-in end (13) to be plugged into the matching socket.

5. The through-wall terminal connector according to claim 1, characterized in that, The sealing structure (2) includes a sealing panel (21) disposed on the outside of the plug body (1) and an annular sealing gasket (22) disposed on the outer periphery of the mounting section (11). The sealing panel (21) is attached to the outer surface of the battery pack housing and is used to provide insulation. The sealing gasket (22) is sleeved on the outer periphery of the mounting section (11) and sandwiched between the mounting section (11) and the battery pack housing to achieve a circumferential sealing fit.

6. The through-wall terminal connector according to claim 5, characterized in that, The fastening structure (3) includes a fastening screw that passes through the mounting hole (31) of the sealing panel (21) and the mounting section (11) and is screwed thereto, and also includes a hollow mounting post (32) disposed inside the plug body (1) and coaxially disposed with the mounting hole (31).

7. The through-wall terminal connector according to claim 1, characterized in that, The plug body (1) is made of insulating plastic that is resistant to high temperature and electrical breakdown.

8. A battery pack, characterized in that, include: A battery pack housing for accommodating multiple battery cell modules; The through-wall terminal connector as described in claim 1 is mounted on the battery pack housing and is used to realize the electrical connection between the internal circuit of the battery pack and the external battery management module.

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