A soft connection structure between a battery pack and a fuse

Abstract

The utility model relates to battery pack connector technical field, specifically is a kind of soft connection structure between battery pack and fuse, including plug and socket two main parts, socket is fixedly installed on the positive and negative panel of battery pack by fixed bolt, plug is connected with fuse by soft copper row, the plug includes conductive male end, lock catch and rubber-coated part, the rubber-coated part is covered in the connecting part of soft copper row and conductive male end, provides insulation protection, the socket includes terminal, sealing washer and hanging table, the sealing washer is arranged between socket and battery pack panel. The utility model uses when, adopt the sheet type contact structure of optimization design, contact area is big, current-carrying capacity can reach above 500A, can satisfy the demand of high current application. Through reasonable structure design and material selection, under the same current-carrying capacity, compared with traditional circular connector, the volume is reduced by more than 30%.

Description

Technical Field

[0001] This utility model relates to the field of battery pack connector technology, specifically a soft connection structure between a battery pack and a fuse. Background Technology

[0002] With the rapid development of new energy technologies, high-capacity battery packs are increasingly widely used in various fields. The connection between the battery pack and the fuse needs to transmit a large current of hundreds of amperes, which places high demands on the performance of the connector. Traditional high-current connectors mainly adopt a circular mating structure, which has the following prominent problems: First, the limited contact area of ​​circular connectors typically limits their operation to a current range of 100-350A, making it difficult to meet higher current transmission requirements. When the current requirement exceeds 500A, the circular connector becomes extremely bulky and significantly heavier, occupying valuable installation space and increasing the overall system weight. Second, traditional connectors are difficult to assemble due to the insufficient flexibility of flexible components when the installation distance is short. Installers need to spend considerable time and effort to install and secure the connectors, greatly increasing installation and time costs. Third, existing connectors lack effective error-proofing designs, making it easy to reverse the positive and negative terminals. In battery pack systems, reversed positive and negative terminals can cause serious equipment damage or even safety accidents, posing a serious threat to system reliability.

[0003] Therefore, there is an urgent need for a new type of connection structure between the battery pack and the fuse, which can ensure high current transmission capacity while having advantages such as small size, light weight, low cost, easy installation and high reliability, to meet the needs of modern energy storage systems and electric vehicles. Utility Model Content

[0004] The purpose of this invention is to provide a flexible connection structure between a battery pack and a fuse, thereby solving at least the problems mentioned in the background art.

[0005] To achieve the above objectives, this utility model provides the following technical solution: A flexible connection structure between a battery pack and a fuse includes two main parts: a plug and a socket. The socket is fixedly installed on the positive and negative electrode panels of the battery pack by fixing bolts. The plug is connected to the fuse via a flexible copper busbar. The plug includes a conductive male terminal, a latch, and an insulated part. The insulated part covers the connection between the flexible copper busbar and the conductive male terminal to provide insulation protection. The socket includes a terminal, a sealing gasket, and a mounting bracket. The sealing gasket is disposed between the socket and the battery pack panel.

[0006] As a further embodiment of this utility model, the soft copper busbar has a J-shaped structure, with one end fixedly connected to the conductive male terminal by a rivet. The adapter copper busbar is provided with a nut and a fixing hole, and an annular sealing ring is provided on the rear side of the sealing gasket.

[0007] As a further embodiment of this utility model, the socket is provided with limiting ribs, and the plug is provided with corresponding connection ports.

[0008] As a further embodiment of this utility model, the soft copper busbar is provided with riveting holes, and is riveted and fixed to the conductive male terminal by rivets.

[0009] As a further improvement of this utility model, the latch is made of elastic material and has a certain deformation capacity. When the plug is inserted into the socket, the latch will undergo elastic deformation until it locks in place with the mounting bracket.

[0010] As a further improvement of this utility model, the overmolded part is made of flame-retardant engineering plastic and formed by injection molding.

[0011] As a further improvement of this utility model, the riveting hole is aligned with the corresponding hole on the conductive male terminal, and then riveted and fixed by a rivet.

[0012] Compared with the prior art, the beneficial effects of this utility model are: 1. When used, this utility model employs an optimized plate-type contact structure with a large contact area and a current-carrying capacity of over 500A, meeting the needs of high-current applications. Through reasonable structural design and material selection, it reduces the volume by more than 30% compared to traditional circular connectors while maintaining the same current-carrying capacity.

[0013] 2. This utility model adopts a plug-in connection method, and the insertion and extraction force has been optimized, making operation labor-saving and convenient. It features an error-proof design; through the cooperation of the limiting ribs and the connection port, the correct connection direction is ensured, greatly improving installation efficiency and accuracy.

[0014] 3. This utility model features a good locking function, preventing the connector from accidentally loosening under vibration through the cooperation of the latch and the mounting plate. The sealing gasket provides a reliable seal, resisting the effects of harsh environments and ensuring the stability and safety of the connection. Attached Figure Description

[0015] Figure 1 This is a three-dimensional structural diagram of a flexible connection structure between a battery pack and a fuse.

[0016] Figure 2 This is a schematic diagram of the unconnected state of a soft connection structure between a battery pack and a fuse.

[0017] Figure 3This is an exploded structural diagram of the plug end of a flexible connection structure between a battery pack and a fuse.

[0018] Figure 4 This is an exploded structural diagram of a socket end of a flexible connection structure between a battery pack and a fuse.

[0019] In the diagram: 1. Plug; 101. Lock; 102. Conductive male terminal; 103. Rivet; 2. Socket; 21. Mounting stand; 22. Limiting rib; 23. Connection port; 3. Flexible copper busbar; 31. Riveting hole; 4. Rubber-coated part; 5. Fixing bolt; 6. Terminal; 7. Sealing gasket; 71. Annular sealing ring; 8. Adapter copper busbar; 81. Nut; 82. Fixing hole. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present utility model.

[0021] Please see Figure 1-4 This utility model provides a flexible connection structure between a battery pack and a fuse, including two main parts: a plug 1 and a socket 2. The socket 2 is fixedly installed on the positive and negative electrode panels of the battery pack by fixing bolts 5. The plug 1 is connected to the fuse through a flexible copper busbar 3. The plug 1 includes a conductive male terminal 102, a latch 101, and an insulated part 4. The insulated part 4 covers the connection part between the flexible copper busbar 3 and the conductive male terminal 102, providing insulation protection. The socket 2 includes a terminal 6, a sealing gasket 7, and a mounting base 21. The sealing gasket 7 is disposed between the socket 2 and the battery pack panel.

[0022] The plug 1 and socket 2 are connected by a plug-in method. When the plug 1 and socket 2 are connected, the latch 101 and the mounting plate 21 cooperate to achieve the locking function. The sealing gasket 7 is set between the socket 2 and the battery pack panel. It is made of elastic sealing material to provide a reliable sealing effect and prevent moisture, dust and other contaminants from entering the connector. The terminal 6, as a key component for current transmission, is made of highly conductive material to ensure good electrical performance. The mounting plate 21 is set on the outer shell of the socket 2 and cooperates with the latch 101 on the plug 1 to achieve the mechanical locking function.

[0023] The latch 101 is made of elastic material and has a certain deformation capacity. When the plug 1 is inserted into the socket 2, the latch 101 will undergo elastic deformation until it locks in place with the mounting bracket 21.

[0024] The coated component 4 is made of flame-retardant engineering plastic through injection molding. The coated component 4 not only provides insulation protection to prevent accidental electric shock, but also protects metal components from corrosion and mechanical damage, extending their service life. The coated component 4, together with the soft copper busbar 3 and the conductive male terminal 102, forms an integral structure, improving the mechanical strength of the connection.

[0025] In some embodiments, the soft copper busbar 3 has a J-shaped structure, with one end fixedly connected to the conductive male terminal 102 by a rivet 103. The adapter copper busbar 8 is provided with a nut 81 and a fixing hole 82, and an annular sealing ring is provided on the rear side of the sealing gasket.

[0026] The sealing gasket 7 is used to seal between the positive and negative terminal connector (2) and the device panel, and the annular sealing ring 71 is used to seal between the connector (1) and the positive and negative terminal connector (2).

[0027] The design employs a J-shaped bend. This design gives the soft copper busbar 3 excellent flexibility, enabling it to adapt to different installation spaces and location requirements. At the same time, it can absorb stress caused by vibration and thermal expansion and contraction during equipment operation, improving the reliability of the connection.

[0028] The adapter copper busbar 8 is fixedly connected to the fuse via a nut 81 and a fixing hole 82.

[0029] The socket 2 is provided with a limiting rib 22, and the plug 1 is provided with a corresponding connection port 23. The limiting rib 22 and the connection port 23 cooperate to prevent misinsertion.

[0030] These ribs are arranged along the insertion direction and cooperate with the connection port 23 on the plug 1 to prevent misinsertion. The arrangement of the limiting ribs 22 ensures that the plug 1 can only be inserted into the socket 2 in the correct direction, effectively preventing the problem of reversed positive and negative terminals due to misinsertion.

[0031] In some embodiments, the soft copper busbar 3 is provided with a riveting hole 31, which is riveted and fixed to the conductive male terminal 102 by a rivet 103.

[0032] The riveting hole 31 is aligned with the corresponding hole on the conductive male terminal 102, and then riveted and fixed by the rivet 103. Riveting connections have advantages such as reliable connection, low resistance, and vibration resistance, making them very suitable for high-current connection applications. The working principle of this utility model is as follows: The installation process for socket 2 is as follows: First, align socket 2 with the mounting holes on the battery pack panel, ensuring that the sealing gasket 7 is in full contact with the panel surface. The sealing gasket 7 is made of silicone rubber, which has good elasticity and sealing performance. Then, pass the fixing bolts through the mounting holes of socket 2 and the corresponding holes on the battery pack panel, and use a tool to tighten the nuts to ensure that socket 2 is firmly fixed to the battery pack panel. The terminals 6 on socket 2 are connected to the positive and negative terminals of the battery pack through internal connections.

[0033] The socket 2 housing is equipped with limiting ribs 22. These ribs are arranged along the insertion direction, and their height and width are precisely calculated to ensure that the plug 1 can only be inserted in the correct direction. The top of the limiting ribs 22 is rounded to facilitate guidance during insertion. The socket 2 also has mounting brackets 21 on both sides. The tilt angle of the mounting brackets 21 is optimized to provide sufficient locking force without causing excessive insertion and extraction force.

[0034] The assembly process of plug 1 is as follows: First, align the soft copper busbar 3 with the conductive male terminal 102, ensuring that the riveting hole 31 on the soft copper busbar 3 is aligned with the hole on the conductive male terminal 102. Then, use a rivet 103 to pass through the aligned hole and use a riveting process to firmly connect the two. During the riveting process, the riveting pressure should be controlled to ensure a reliable connection without damaging the materials.

[0035] Next, the overmolding process is performed: the assembled soft copper busbar 3 and conductive male terminal 102 are placed into the injection mold and injection molded using flame-retardant PA66 material. During the injection molding process, parameters such as temperature, pressure, and time must be carefully controlled to ensure that the overmolded part 4 is firmly bonded to the metal part, without defects such as bubbles or insufficient material. The overmolded part 4 completely covers the connection area between the soft copper busbar 3 and the conductive male terminal 102, providing insulation and mechanical protection.

[0036] The other end of the flexible copper busbar 3 is connected to the adapter copper busbar 8: First, align the connecting hole at the end of the flexible copper busbar 3 with the fixing hole 82 on the adapter copper busbar 8, then insert the fixing bolt 5 and tighten the nut 81 using a tool. The nut 81 has an anti-loosening design and an internal nylon ring to prevent loosening under vibration. The other end of the adapter copper busbar 8 is connected to the fuse terminal in the same way.

[0037] The connection process between plug 1 and socket 2 is as follows: First, align plug 1 with socket 2, ensuring that the connector 23 on plug 1 is aligned with the limiting rib 22 on socket 2. Then, apply appropriate force along the insertion direction to insert plug 1 into socket 2. During insertion, the latch 101 on plug 1 will contact the mounting bracket 21 on socket 2 and undergo elastic deformation. When plug 1 is fully inserted, the latch 101 will spring back to its original position and lock with the mounting bracket 21. A clear "click" sound can be heard at this time, indicating that the connection is complete.

[0038] After connection, the conductive male terminal 102 and terminal 6 form good electrical contact, and current can be transmitted between the battery pack and the fuse through this path. The J-shaped design of the soft copper busbar 3 allows for a certain degree of displacement and deformation, which can absorb the vibration and thermal stress generated during equipment operation and ensure the reliability of the connection.

[0039] When this invention is in use, the electrical energy of the battery pack is transmitted through the following path: Battery pack positive and negative terminals → Terminal 6 of socket 2 → Conductive male terminal 102 of plug 1 → Soft copper busbar 3 → Adapter copper busbar 8 → Fuse → Electrical equipment.

[0040] When plug 1 is inserted into socket 2, the conductive male terminal 102 forms multiple contact points with terminal 6. These contact points employ a graded contact design to ensure uniform wear during insertion and removal, thus extending service life. The materials and surface treatments of the contact points are optimized, resulting in low contact resistance and low heat generation.

[0041] The J-shaped design of the soft copper busbar 3 plays a key role. First, it provides the necessary flexibility, allowing a certain degree of relative displacement between the plug 1 and the socket 2. Second, the J-shaped structure can absorb the stress generated by these displacements, preventing stress from being directly transmitted to the connection interface and ensuring the reliability of the connection.

[0042] When plug 1 is inserted into socket 2, latch 101 slides along the inclined surface of mounting base 21 and undergoes elastic deformation. When plug 1 is fully inserted, latch 101 springs back to its original position, and its locking hook part engages with the locking surface of mounting base 21 to form a mechanical lock. At this time, the limiting rib 22 on socket 2 and the connection port 23 on plug 1 form a mating relationship. Since the arrangement of the limiting rib 22 is asymmetrical, the limiting rib 22 can only enter the connection port 23 when plug 1 is aligned in the correct direction.

[0043] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A flexible connection structure between a battery pack and a fuse, characterized in that, It includes two main parts: a plug (1) and a socket (2). The socket (2) is fixedly installed on the positive and negative pole panels of the battery pack by fixing bolts (5). The plug (1) is connected to the fuse through a soft copper busbar (3). The plug (1) includes a conductive male terminal (102), a latch (101) and an insulated part (4). The insulated part (4) covers the connection between the soft copper busbar (3) and the conductive male terminal (102) to provide insulation protection. The socket (2) includes a terminal (6), a sealing gasket (7) and a mounting plate (21). The sealing gasket (7) is set between the socket (2) and the battery pack panel. The other end of the soft copper busbar (3) is connected to the adapter copper busbar (8).

2. The flexible connection structure between the battery pack and the fuse according to claim 1, characterized in that, The soft copper busbar (3) has a J-shaped structure, and one end is fixedly connected to the conductive male terminal (102) by a rivet (103). The adapter copper busbar (8) is provided with a nut (81) and a fixing hole (82). The rear side of the sealing gasket (7) is provided with an annular sealing ring (71).

3. The flexible connection structure between the battery pack and the fuse according to claim 1, characterized in that, The socket (2) is provided with a limiting rib (22), and the plug (1) is provided with a corresponding connection port (23).

4. The flexible connection structure between the battery pack and the fuse according to claim 2, characterized in that, The soft copper busbar (3) is provided with a riveting hole (31) and is riveted and fixed to the conductive male terminal (102) by a rivet (103).

5. The flexible connection structure between the battery pack and the fuse according to claim 1, characterized in that, The latch (101) is made of elastic material.

6. The flexible connection structure between the battery pack and the fuse according to claim 1, characterized in that, The coated parts (4) are made of flame-retardant engineering plastics through injection molding.

7. The flexible connection structure between the battery pack and the fuse according to claim 4, characterized in that, The rivet hole (31) is aligned with the corresponding hole on the conductive male terminal (102) and fixed by riveting with rivets (103).

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