High-power connecting switch pin for new energy vehicle
Patent Information
- Application Number
- CN202522543302.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-01
- Publication Date
- 2026-10-27
- Estimated Expiration
- 2035-12-01
AI Technical Summary
[0004]本实用新型的目的在于：解决当前新能源汽车高功率连接开关插针在实际应用中难以兼顾高导电性、耐高温性和机械强度的问题，同时避免因镀层剥落或接触电阻增大而导致的性能下降
通过设置的导电芯体和外部包覆层，利用高纯度铜基材料和银基导电涂层的组合，提升了插针的导电性能，同时通过散热补偿结构中的蜂窝状散热通道和石墨烯导热片，有效降低了插针在高功率工作状态下的温升，延长了使用寿命。抗振增强结构中的弹性支撑件通过弧形设计提供了良好的抗振性能，避免了高频振动环境下镀层剥落的风险。此外，柔性绝缘层和刚性保护层的双重防护设计，进一步增强了插针的机械强度和耐腐蚀性，解决了现有技术中插针在长期使用过程中因接触电阻增大或材料老化而导致性能下降的问题。
Smart Images
Figure CN224908529U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of high-voltage electrical connection technology for new energy vehicles, specifically a high-power connection switch pin for new energy vehicles. Background Technology
[0002] In the electrical systems of new energy vehicles, high-power connection switch pins are one of the key components for achieving efficient circuit connection and stable transmission. Currently, some connection pins based on metal materials and conductive coating technology have appeared on the market, but these products often struggle to simultaneously meet the performance requirements of high conductivity, high temperature resistance, and mechanical strength in practical applications. Furthermore, these pins are prone to performance degradation during long-term use due to increased contact resistance or material aging, thus affecting the reliability of the entire vehicle's electrical system.
[0003] Therefore, we have made improvements and proposed a high-power connection switch pin for new energy vehicles. Utility Model Content
[0004] The purpose of this invention is to solve the problem that the high-power connection switch pins for new energy vehicles are difficult to balance in practical applications, while avoiding performance degradation due to plating peeling or increased contact resistance.
[0005] To achieve the aforementioned objectives and address the problems, this utility model provides a high-power connection switch pin for new energy vehicles, comprising a conductive main body structure, a heat dissipation compensation structure, and a vibration-resistant reinforcement structure. The conductive main body structure includes a conductive core and an outer covering layer. The heat dissipation compensation structure is disposed inside the conductive core, and the vibration-resistant reinforcement structure is nested outside the conductive core and fixedly connected to the outer covering layer. Through the synergistic effect of the conductive main body structure, the heat dissipation compensation structure, and the vibration-resistant reinforcement structure, the overall performance of the pin is improved.
[0006] The conductive core is composed of multiple layers of composite material. The inner layer is a high-purity copper-based material, and the outer layer is a silver-based conductive coating. The silver-based conductive coating is uniformly applied to the surface of the copper-based material through an electroplating process, and its thickness is between 0.1 mm and 0.2 mm. The heat dissipation compensation structure includes several heat dissipation channels distributed along the axial direction of the conductive core. The cross-section of the heat dissipation channels is honeycomb-shaped, and adjacent heat dissipation channels are connected by heat-conducting sheets. The heat-conducting sheets are made of graphene material, and their thickness is between 0.05 mm and 0.1 mm.
[0007] As a preferred technical solution of this application, the outer covering layer includes a flexible insulating layer and a rigid protective layer. The flexible insulating layer is directly wrapped around the outside of the conductive core, and the rigid protective layer is fixed to the outside of the flexible insulating layer by injection molding. The flexible insulating layer is made of silicone rubber material with a thickness between 0.3 mm and 0.5 mm, and the rigid protective layer is made of polyamide material with a thickness between 0.6 mm and 0.8 mm.
[0008] As a preferred technical solution of this application, the vibration-resistant reinforcement structure includes a plurality of elastic support members arranged radially along the conductive core. One end of each elastic support member is welded and fixed to the outer wall of the conductive core, and the other end is snapped and fixed to the inner wall of the rigid protective layer. The elastic support member is made of stainless steel spring steel, and its cross-section is arc-shaped, with the arc-shaped protrusion facing the central axis of the conductive core.
[0009] As a preferred technical solution of this application, the conductive core is provided with connecting ends at both ends, the outer side of the connecting ends is provided with a threaded structure, the pitch of the threaded structure is between 1.5mm and 2.0mm, and the inner side of the connecting ends is provided with a tapered conductive contact surface, the cone angle of the tapered conductive contact surface is between 30° and 45°.
[0010] As a preferred technical solution of this application, the inner wall of the heat dissipation channel is provided with a microporous structure, the diameter of the microporous structure is between 0.02mm and 0.05mm, the microporous structure is uniformly distributed along the axial direction of the heat dissipation channel, and the spacing between adjacent micropores is between 0.1mm and 0.2mm.
[0011] As a preferred embodiment of this application, the outer surface of the flexible insulating layer is provided with a plurality of annular grooves, which are uniformly distributed along the axial direction of the flexible insulating layer, and the spacing between adjacent annular grooves is between 2 mm and 3 mm. The depth of the annular grooves is between 0.2 mm and 0.3 mm, and the width is between 1 mm and 1.5 mm.
[0012] As a preferred technical solution of this application, the outer surface of the rigid protective layer is provided with anti-slip texture. The depth of the anti-slip texture is between 0.1 mm and 0.2 mm, and the width is between 0.5 mm and 1 mm. The anti-slip texture is distributed alternately along the axial and circumferential directions of the rigid protective layer.
[0013] Compared with the prior art, the beneficial effects of this utility model are as follows: By employing a conductive core and external coating, and utilizing a combination of high-purity copper-based materials and silver-based conductive coatings, the conductivity of the pins is enhanced. Simultaneously, the honeycomb heat dissipation channels and graphene heat-conducting sheets in the heat dissipation compensation structure effectively reduce the temperature rise of the pins under high-power operation, extending their service life. The elastic support component in the vibration-resistant reinforcement structure provides excellent vibration resistance through its arc-shaped design, avoiding the risk of plating peeling under high-frequency vibration environments. Furthermore, the dual protection design of a flexible insulation layer and a rigid protective layer further enhances the mechanical strength and corrosion resistance of the pins, solving the problem of performance degradation caused by increased contact resistance or material aging during long-term use in existing technologies. Attached Figure Description
[0014] Figure 1 This is a schematic diagram of the overall structure of this utility model.
[0015] Figure 2 This is a schematic diagram of the heat dissipation channel structure of this utility model. Figure 3 This is a schematic diagram of the connection end structure of this utility model.
[0016] Figure 4 This is a schematic diagram of the external coating layer structure of this utility model.
[0017] Figure 5 This is a schematic diagram of the elastic support structure of this utility model.
[0018] The attached figures are labeled as follows: 1. Conductive core; 2. Silver-based conductive coating; 3. Heat dissipation channel; 4. Graphene thermal conductive sheet; 5. Flexible insulating layer; 6. Rigid protective layer; 7. Elastic support; 8. Connecting end; 9. Threaded structure; 10. Conical conductive contact surface; 11. Microporous structure; 12. Annular groove; 13. Anti-slip texture. Detailed Implementation
[0019] This utility model provides a high-power connection switch pin for new energy vehicles, the overall structure of which is as follows: Figure 1 As shown, it includes a conductive core 1, an outer covering layer, a heat dissipation compensation structure, and a vibration-resistant reinforcement structure. The conductive core 1 is the core component of the pin, and a flexible insulating layer 5 and a rigid protective layer 6 are sequentially arranged on its outer side to form an outer covering layer; the heat dissipation compensation structure is embedded inside the conductive core 1, and the vibration-resistant reinforcement structure is located between the conductive core 1 and the rigid protective layer 6, and is fixedly connected by welding or snap-fitting.
[0020] The conductive core 1 consists of an inner layer of high-purity copper-based material and an outer layer of silver-based conductive coating 2, such as... Figure 3As shown, a silver-based conductive coating 2 is uniformly applied to the surface of the copper-based material through an electroplating process, with a thickness between 0.1 mm and 0.2 mm. The high-purity copper-based material, as the main conductive component of the conductive core 1, possesses excellent conductivity, while the silver-based conductive coating 2 further enhances the surface conductivity of the conductive core 1 and also provides some oxidation resistance. Connecting ends 8 are provided at both ends of the conductive core 1. The outer side of the connecting ends 8 is machined with a threaded structure 9, with a pitch between 1.5 mm and 2.0 mm, for mechanical connection with other components. The inner side of the connecting ends 8 is designed as a tapered conductive contact surface 10, with a cone angle between 30° and 45°, to ensure a stable current path is formed when in contact with other conductive components.
[0021] The heat dissipation compensation structure includes several heat dissipation channels 3 distributed along the axial direction of the conductive core 1. The cross-section of the heat dissipation channel 3 is honeycomb-shaped, such as... Figure 2 As shown. Adjacent heat dissipation channels 3 are connected by graphene thermal conductive sheets 4, the thickness of which is between 0.05 mm and 0.1 mm. The inner wall of the heat dissipation channel 3 is provided with microporous structures 11, the diameter of which is between 0.02 mm and 0.05 mm, and they are uniformly distributed along the axial direction of the heat dissipation channel 3. The spacing between adjacent micropores is between 0.1 mm and 0.2 mm. Figure 3 As shown. This design not only increases the surface area of the heat dissipation channel 3, but also improves the heat conduction efficiency by utilizing the capillary effect of the microporous structure 11. The graphene thermal conductive sheet 4 connects adjacent heat dissipation channels 3 to form a heat conduction path, which can quickly transfer the heat generated inside the conductive core 1 to the external environment.
[0022] The vibration-resistant reinforcement structure includes multiple elastic support members 7 arranged radially along the conductive core 1, such as... Figure 5 As shown, one end of the elastic support 7 is welded and fixed to the outer wall of the conductive core 1, and the other end is fixed to the inner wall of the rigid protective layer 6 by a snap-fit method. The elastic support 7 is made of stainless steel spring steel, and its cross-section is arc-shaped, with the arc protrusion facing the central axis of the conductive core 1. This design allows the elastic support 7 to undergo elastic deformation when subjected to vibration or impact, thereby absorbing external vibration energy and preventing the conductive core 1 from peeling off the plating or mechanical damage due to long-term high-frequency vibration. In addition, the arc-shaped design of the elastic support 7 can also disperse stress to a certain extent and improve the overall mechanical strength of the pin.
[0023] The outer covering layer includes a flexible insulating layer 5 and a rigid protective layer 6, such as Figure 4As shown. The flexible insulating layer 5 is directly wrapped around the outside of the conductive core 1, made of silicone rubber, with a thickness between 0.3 mm and 0.5 mm. Multiple annular grooves 12 are provided on the outer surface of the flexible insulating layer 5. The annular grooves 12 are evenly distributed along the axial direction of the flexible insulating layer 5, with a spacing of 2 mm to 3 mm between adjacent annular grooves 12, a depth of 0.2 mm to 0.3 mm, and a width of 1 mm to 1.5 mm. The design of the annular grooves 12 not only reduces the weight of the flexible insulating layer 5 but also improves its flexibility, allowing it to better adapt to the shape changes of the conductive core 1. The rigid protective layer 6 is fixed to the outside of the flexible insulating layer 5 by injection molding, made of polyamide, with a thickness between 0.6 mm and 0.8 mm. The outer surface of the rigid protective layer 6 is provided with anti-slip textures 13, with a depth of 0.1 mm to 0.2 mm and a width of 0.5 mm to 1 mm, which are staggered along the axial and circumferential directions of the rigid protective layer 6. The anti-slip texture 13 design enhances the grip of the pins, making installation and removal easier.
[0024] In practical applications, the pin of this invention achieves mechanical connection with other electrical components through the threaded structure 9 on the connecting end 8, while the tapered conductive contact surface 10 ensures the stability of current transmission. When the pin is in a high-power operating state, the heat generated inside the conductive core 1 is quickly transferred to the external environment through the heat dissipation channel 3 and the graphene heat-conducting sheet 4, avoiding the impact of excessive temperature rise on conductivity. The elastic support 7 absorbs vibration energy during vehicle operation, preventing mechanical damage or plating peeling of the conductive core 1 due to long-term vibration. The dual protection design of the flexible insulating layer 5 and the rigid protective layer 6 ensures the mechanical strength and corrosion resistance of the pin under complex working conditions.
[0025] All components in the above structure are connected through precision manufacturing and assembly processes. For example, the encapsulation relationship between the conductive core 1 and the outer covering layer is achieved through injection molding, while the snap-fit fixing between the elastic support 7 and the rigid protective layer 6 is achieved through mold pressing. In addition, the annular groove 12 on the flexible insulating layer 5 and the anti-slip texture 13 on the outer surface of the rigid protective layer 6 are both formed in one step during the injection molding process, which simplifies the manufacturing process and ensures the consistency of the finished product quality.
[0026] The pin of this invention is suitable for high-power electrical connection scenarios in new energy vehicles, such as battery management systems, motor controllers, and charging interfaces. In these applications, the pin needs to withstand large current loads and frequent mechanical vibrations, while also possessing good high-temperature resistance and corrosion resistance. This invention successfully solves the problems existing in the prior art by optimizing the material combination of the conductive core 1, designing an efficient heat dissipation compensation structure, and enhancing vibration resistance, thus meeting the stringent requirements of new energy vehicles for high-power connection switch pins.
[0027] To enable those skilled in the art to fully understand and implement this utility model, the following supplementary explanation of the implementation principle of this utility model is provided in conjunction with specific application scenarios.
[0028] In the battery management system of new energy vehicles, high-power connection switch pins are widely used for connecting and disconnecting high-voltage circuits. When the pins are installed in the high-voltage interface of the battery management system, they are first mechanically fixed to other electrical components through the threaded structure 9 on the connection end 8, ensuring a tight connection between the pins and the mating parts. The design of the tapered conductive contact surface 10 allows the pins to form a stable current path when inserted into the mating parts. Its tapered angle ranges from 30° to 45°, which maximizes the contact area while reducing contact resistance, thereby improving the stability of current transmission.
[0029] When the pin is operating at high power, heat is generated inside the conductive core 1 due to the current flowing through it. At this time, the heat dissipation channel 3 and the graphene thermal conductive sheet 4 work together to achieve efficient heat dissipation. Specifically, the heat inside the conductive core 1 is conducted outward through the honeycomb-shaped heat dissipation channel 3, and the microporous structure 11 on the inner wall of the heat dissipation channel 3 further enhances the heat diffusion efficiency through capillary action. Adjacent heat dissipation channels 3 are connected by graphene thermal conductive sheets 4 with a thickness of 0.05 mm to 0.1 mm, forming an efficient heat conduction path that quickly transfers heat to the external environment, preventing a decrease in conductivity due to excessive temperature rise. This design significantly improves the reliability of the pin under high-temperature conditions.
[0030] Meanwhile, during vehicle operation, the pins are inevitably subjected to high-frequency vibrations. The elastic support 7 in the vibration-resistant reinforcement structure absorbs vibration energy through its arc-shaped cross-section design, preventing mechanical damage or plating peeling of the conductive core 1 due to long-term vibration. One end of the elastic support 7 is welded and fixed to the outer wall of the conductive core 1, and the other end is fixed to the inner wall of the rigid protective layer 6 by a snap-fit method. This double fixing method ensures the stability of the elastic support 7 in the vibration environment. In addition, the arc-shaped design can also disperse stress to a certain extent, further improving the overall mechanical strength of the pins.
[0031] The dual protection design of the flexible insulating layer 5 and the rigid protective layer 6 provides additional protection for the pin. The flexible insulating layer 5 is made of silicone rubber, and the annular grooves 12 on its outer surface not only reduce the overall weight but also improve flexibility, allowing it to better adapt to the shape changes of the conductive core 1. The rigid protective layer 6 is fixed to the outside of the flexible insulating layer 5 through injection molding, and the anti-slip textures 13 on its outer surface enhance the grip of the pin, facilitating installation and removal. This dual protection design effectively improves the corrosion resistance and mechanical strength of the pin under complex working conditions.
[0032] In the actual assembly process, the encapsulation relationship between the conductive core 1 and the outer covering layer is achieved through injection molding, ensuring a tight connection between the components. The snap-fit fixing between the elastic support 7 and the rigid protective layer 6 is achieved through mold pressing, which simplifies the manufacturing process and ensures the consistency of the finished product quality. The annular groove 12 on the flexible insulating layer 5 and the anti-slip texture 13 on the outer surface of the rigid protective layer 6 are both formed in one step during injection molding, further improving production efficiency.
[0033] In summary, the high-power connection switch pin of this invention successfully solves the problems existing in the prior art by optimizing the material combination of the conductive core 1, designing an efficient heat dissipation compensation structure, and enhancing vibration resistance, thus meeting the stringent requirements of new energy vehicles for high-power connection switch pins. The combination of the above specific implementation steps and principles enables those skilled in the art to clearly understand and implement the technical solution of this invention.
Claims
1. A high-power connection switch pin for new energy vehicles, characterized in that, The system includes a conductive core (1), an outer covering layer, a heat dissipation compensation structure, and a vibration-resistant reinforcement structure. The conductive core (1) is composed of an inner layer of high-purity copper-based material and an outer layer of silver-based conductive coating (2). The silver-based conductive coating (2) is uniformly covered on the surface of the high-purity copper-based material by electroplating. The heat dissipation compensation structure includes several heat dissipation channels (3) distributed along the axial direction of the conductive core (1). Adjacent heat dissipation channels (3) are connected by graphene heat-conducting sheets (4). The vibration-resistant reinforcement structure includes several elastic support members (7) arranged radially along the conductive core (1). One end of the elastic support member (7) is welded and fixed to the outer wall of the conductive core (1), and the other end is snapped and fixed to the inner wall of the rigid protective layer (6). The outer covering layer includes a flexible insulating layer (5) and a rigid protective layer (6). The flexible insulating layer (5) is directly wrapped around the outside of the conductive core (1), and the rigid protective layer (6) is fixed to the outside of the flexible insulating layer (5) by injection molding.
2. The high-power connection switch pin for new energy vehicles according to claim 1, characterized in that, The thickness of the silver-based conductive coating (2) is between 0.1 mm and 0.2 mm.
3. A high-power connection switch pin for new energy vehicles according to claim 1, characterized in that, The heat dissipation channel (3) has a honeycomb cross-section and the inner wall of the heat dissipation channel (3) is provided with a microporous structure (11). The diameter of the microporous structure (11) is between 0.02 mm and 0.05 mm, and the spacing between adjacent micropores is between 0.1 mm and 0.2 mm.
4. A high-power connection switch pin for new energy vehicles according to claim 1, characterized in that, The thickness of the graphene thermal conductive sheet (4) is between 0.05 mm and 0.1 mm.
5. A high-power connection switch pin for new energy vehicles according to claim 1, characterized in that, The flexible insulating layer (5) is made of silicone rubber material with a thickness of 0.3 mm to 0.5 mm. The outer surface of the flexible insulating layer (5) is provided with a plurality of annular grooves (12). The spacing between adjacent annular grooves (12) is 2 mm to 3 mm. The depth of the annular grooves (12) is 0.2 mm to 0.3 mm and the width is 1 mm to 1.5 mm.
6. A high-power connection switch pin for new energy vehicles according to claim 1, characterized in that, The rigid protective layer (6) is made of polyamide material with a thickness of 0.6 mm to 0.8 mm. The outer surface of the rigid protective layer (6) is provided with anti-slip texture (13), the depth of which is between 0.1 mm and 0.2 mm and the width of which is between 0.5 mm and 1 mm.
7. A high-power connection switch pin for new energy vehicles according to claim 1, characterized in that, The elastic support (7) is made of stainless steel spring steel, and its cross section is arc-shaped with the arc protrusion facing the central axis of the conductive core (1).
8. A high-power connection switch pin for new energy vehicles according to claim 1, characterized in that, The conductive core (1) has a connecting end (8) at each end. The outer side of the connecting end (8) is provided with a thread structure (9). The pitch of the thread structure (9) is between 1.5 mm and 2.0 mm. The inner side of the connecting end (8) is provided with a conical conductive contact surface (10). The cone angle of the conical conductive contact surface (10) is between 30 degrees and 45 degrees.