Aluminum battery charging connection assembly
Patent Information
- Application Number
- CN202522516838.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-27
- Publication Date
- 2026-11-03
- Estimated Expiration
- 2035-11-27
AI Technical Summary
Traditional charging cables have poor rigidity, take up a lot of space, have high impedance due to welding, are time-consuming and labor-intensive to assemble, and have high material costs.
The aluminum busbar assembly includes an aluminum busbar group, an aluminum busbar socket, an aluminum busbar high-voltage connector, and a mounting bracket. The aluminum busbar group has a flat structure and is fixed to the inside of the car body by bending and mounting bracket. A copper ring transition layer and an insulation layer are used to avoid welding and ensure stable contact.
It improves charging efficiency, saves assembly time and material costs, reduces space occupation, lowers weight and impedance, and enhances stability and reliability.
Smart Images
Figure CN224935153U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of current transmission, and in particular to an aluminum busbar charging connection component. Background Technology
[0002] As the battery capacity and charging efficiency of new energy vehicles continue to improve, the requirements for the connection cables between the charging plug and the battery inside the vehicle are also becoming increasingly stringent. Traditional cables consist of multiple copper and aluminum wires bundled into a cylindrical bundle. When it is necessary to improve charging efficiency, the cross-sectional diameter of the cable will also be increased accordingly, making the entire cable thicker and heavier.
[0003] The charging cable is approximately 1.5-2 meters long. It has a flexible structure and poor rigidity. If it is fixed to the inside of the vehicle body, a fixing bracket needs to be installed every 100mm or so, making the assembly work time-consuming and labor-intensive. Furthermore, because the thicker cable requires a larger bending angle when bent, it is difficult to run the cable close to the inner wall of the car body, thus taking up considerable space.
[0004] On the other hand, copper wire cables need to be soldered to the terminals of the socket and the terminals of the high-voltage connector to achieve stable contact, and the impedance at the solder joint is relatively high. Utility Model Content
[0005] This utility model proposes an aluminum busbar charging connection assembly for connecting the battery of an electric vehicle to an external power source. It is characterized by comprising: an aluminum busbar assembly, an aluminum busbar socket, an aluminum busbar high-voltage connector, and a fixing frame; one end of the aluminum busbar assembly is connected to the aluminum busbar socket, and the other end is connected to the aluminum busbar high-voltage connector; the fixing frame fixes the aluminum busbar assembly along the inner sidewall of the electric vehicle's outer shell; the aluminum busbar assembly includes multiple bends, and the fixing frame located at the bends is coated with adhesive; the aluminum busbar assembly includes a positive aluminum busbar and a negative aluminum busbar, with the middle portions of the positive and negative aluminum busbars overlapping and connecting to form the aluminum busbar junction portion of the assembly.
[0006] Furthermore, in the aluminum busbar charging connection assembly described above, the two ends of the positive aluminum busbar are respectively provided with a positive plug-in terminal and a positive high-voltage terminal, and the positive plug-in terminal and the positive high-voltage terminal are connected through the middle of the positive aluminum busbar; the two ends of the negative aluminum busbar are respectively provided with a negative plug-in terminal and a negative high-voltage terminal, and the negative plug-in terminal and the negative high-voltage terminal are connected through the middle of the negative aluminum busbar.
[0007] Furthermore, in the aluminum busbar charging connection assembly described above, the positive terminal and the negative terminal are plugged into the aluminum busbar socket.
[0008] Furthermore, in the aluminum busbar charging connection assembly described above, the positive high-voltage terminal and the negative high-voltage terminal are plugged into the aluminum busbar high-voltage connector.
[0009] Furthermore, in the aluminum busbar charging connection assembly described above, the positive terminal and the negative terminal are respectively provided with straight bends.
[0010] Furthermore, in the aluminum busbar charging connection assembly described above, the positive terminal, the positive high-voltage terminal, the negative terminal, and the negative high-voltage terminal are all welded with a copper ring transition layer.
[0011] Furthermore, in the aluminum busbar charging connection assembly described above, the plurality of bends are flat bends, vertical bends, torsional bends, or combinations thereof.
[0012] Furthermore, in the aluminum busbar charging connection assembly described above, the length of the torsional bend is greater than 40 mm.
[0013] Furthermore, in the aluminum busbar charging connection assembly described above, an elastic pad is provided between the middle of the positive aluminum busbar and the middle of the negative aluminum busbar located at the fixing frame.
[0014] Furthermore, in the aluminum busbar charging connection assembly described above, the gap between the aluminum busbar wire assembly and the inner side of the housing is greater than or equal to 3 mm.
[0015] The advantages of this utility model are:
[0016] 1. The aluminum busbars used as conductors have a certain rigidity and can be fixed to the inside of the car body with a small number of brackets, saving assembly time and improving work efficiency.
[0017] 2. The aluminum busbar is a flat cuboid structure. Even if it is necessary to improve the charging efficiency, the aluminum busbar 1 can keep the thickness unchanged and increase its cross-sectional area by increasing its width. Compared with cylindrical cables, the aluminum busbar 1 saves more space in the thickness direction.
[0018] 3. Since the aluminum busbar assembly has a certain rigidity, the AC cable of the vehicle body can also be fixed on the aluminum busbar assembly 1 to save space.
[0019] 4. The aluminum busbar of this utility model is made of 6101 T64 magnesium-silicon aluminum alloy, which is lighter than copper, achieving a weight reduction of 40% and a cost reduction of 30%. Attached Figure Description
[0020] Figure 1 This is a reference figure for the present invention.
[0021] Figure 2 This is a schematic diagram of multiple bends in the aluminum strip joint of this utility model. Detailed Implementation
[0022] 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, 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.
[0023] In the description of this utility model, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "one side," "one end," and "one side," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, in the description of this utility model, unless otherwise stated, "a plurality of" means two or more.
[0024] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" 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.
[0025] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the scope of the invention. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.
[0026] It should also be further understood that the term "and / or" as used in this specification and the appended claims refers to any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.
[0027] The accompanying drawings show various structural schematic diagrams according to embodiments of the present invention. These drawings are not to scale, and some details have been enlarged and may have been omitted for clarity. The shapes of the various regions and layers shown in the drawings, as well as their relative sizes and positional relationships, are merely exemplary and may deviate from reality due to manufacturing tolerances or technical limitations. Furthermore, those skilled in the art can design regions / layers with different shapes, sizes, and relative positions as needed.
[0028] This utility model provides an aluminum busbar charging connection assembly, which is installed in a new energy vehicle to connect the battery pack and an external power source for charging the electric vehicle.
[0029] like Figure 1 As shown, the aluminum busbar charging connection assembly of this utility model includes an aluminum busbar assembly 1, an aluminum busbar socket 2, an aluminum busbar high-voltage connector 3, and a fixing bracket 4. One end of the aluminum busbar assembly 1 is connected to the aluminum busbar socket 2, and the other end is connected to the aluminum busbar high-voltage connector 3. The aluminum busbar socket 2 is used to connect to an external power source, and the aluminum busbar high-voltage connector 3 is used to connect to the battery pack of the electric vehicle. The fixing bracket 4 is connected to the inside of the electric vehicle's outer shell, fixing the aluminum busbar assembly 1 along the inner wall of the electric vehicle's outer shell, with a gap of at least 3mm maintained between the aluminum busbar assembly 1 and the inner wall of the electric vehicle's outer shell.
[0030] The aluminum busbar assembly 1 includes a positive aluminum busbar 11 and a negative aluminum busbar 12. The middle portion of the positive aluminum busbar 11 (not shown in the figure) and the middle portion of the negative aluminum busbar 12 (not shown in the figure) are superimposed and connected to each other to form the aluminum busbar joint 13 of the aluminum busbar assembly. The fixing frame 4 fixes the aluminum busbar joint 13. The aluminum busbar includes multiple bends, and the fixing frame 4 located at the bends is coated with adhesive (not shown in the figure).
[0031] Preferably, an elastic pad (not shown in the figure) is provided between the middle of the positive aluminum busbar and the middle of the negative aluminum busbar at the fixing frame 4, as an insulating support, which can effectively buffer vibration and shock and prevent short circuit between electrodes.
[0032] The positive aluminum busbar 11, the negative aluminum busbar 12, and the aluminum busbar joint 13 are all flat cuboids. The side edges of the aluminum busbar joint 13 adopt a fully rounded corner optimized design, which can form a tight and uniform compression fit with the waterproof sealing plug of the aluminum busbar socket 2 and the aluminum busbar high voltage connector 3.
[0033] Combination Figure 2As shown, the plurality of bending portions include a flat bend 131, a vertical bend 132, a torsional bend 133, or a combination thereof. Specifically: the rectangular aluminum busbar joint 13 is bent toward the wider side to form a flat bend 131, the aluminum busbar joint 13 is bent toward the narrower side to form a vertical bend 132, and the aluminum busbar joint 13 is twisted as a whole to form a torsional bend 133. The length of the torsional bend 133 is at least 40 mm.
[0034] The positive aluminum busbar 11 has a positive plug-in terminal 111 and a positive high-voltage terminal 112 at its two ends, which are connected through the middle of the positive aluminum busbar. The negative aluminum busbar 12 has a negative plug-in terminal 121 and a negative high-voltage terminal 122 at its two ends, which are connected through the middle of the negative aluminum busbar.
[0035] The positive terminal 111 and the negative terminal 121 are connected to the aluminum busbar socket 2, and the positive high-voltage terminal 112 and the negative high-voltage terminal 122 are connected to the aluminum busbar high-voltage connector 3. The positive terminal 111 and the negative terminal 121 are each provided with a straight bend (113, 123), with a bending angle of approximately 90°. This minimizes the space occupied at the connection between the aluminum busbar assembly 1 and the aluminum busbar socket 2.
[0036] Preferably, a copper ring transition layer (not shown in the figure) is welded to the surfaces of the positive electrode plug-in terminal 111, the negative electrode plug-in terminal 121, the positive high voltage terminal 112, and the negative high voltage terminal 122.
[0037] Preferably, the sidewalls of both the positive electrode aluminum busbar 11 and the negative electrode aluminum busbar 12 are covered with an insulating layer. This insulating layer is made of EMS10991 PA12 special engineering plastic, which has ceramic-like wear resistance and molecular-level adhesion, a waterproof rating of IP67 or higher, and excellent resistance to chemical corrosion and mechanical stress. This insulation system supports direct exposed installation without additional protection, reducing material and labor costs while improving system reliability.
[0038] In a preferred embodiment of this utility model, the aluminum strip assembly can be attached and fixed to the inner side of the electric vehicle wheel cover by three fixing brackets 4.
[0039] The aluminum busbar socket 2 and high-voltage connector 3 of this utility model are both provided with positive aluminum busbar slots (21, 31) and negative aluminum busbar slots (22, 32), and copper terminals are provided in both the positive aluminum busbar slots (21, 31) and the negative aluminum busbar slots (22, 32). The positive plug-in end 111 and the positive high-voltage end 112 are respectively inserted into the positive aluminum busbar slots (21, 31) of the aluminum busbar socket 2 and the high-voltage connector 3, and are in contact with the copper terminals; the negative plug-in end 121 and the negative high-voltage end 122 are respectively inserted into the negative aluminum busbar slots (22, 32) of the aluminum busbar socket 2 and the high-voltage connector 3, and are in contact with the copper terminals.
[0040] In a preferred embodiment of this utility model, both the positive electrode aluminum busbar slots (21, 31) and the negative electrode aluminum busbar slots (22, 32) are provided with torque bolt locking mechanisms (but not limited thereto). The torque bolts of the torque bolt locking mechanisms pass through the two side walls of the aluminum busbar slots. By rotating the bolts, the distance between the two side walls of the aluminum busbar slots is changed, thereby pressing and fixing the two ends of the positive electrode aluminum busbar 11 and the negative electrode aluminum busbar 12 into the positive electrode aluminum busbar slots (21, 31) and the negative electrode aluminum busbar slots (22, 32), so that they are in stable contact with the copper terminals.
[0041] In a preferred embodiment of this invention, the aluminum busbar socket 2 uses a dedicated TE aluminum busbar socket, and the high-voltage connector 3 integrates a TE BCON series connector. Both support pre-embedded terminals and high-precision torque bolt connections, with a contact resistance of <5μΩ. The installation process requires no special tools, significantly improving assembly efficiency and first-pass yield.
[0042] In the assembly process of this utility model, the aluminum busbar socket 2 is first installed in place, and then a fixing bracket 4 is pre-installed on the inner side of the electric vehicle shell near the aluminum busbar socket. Then, the aluminum busbar assembly 1 is passed through the pre-installed fixing bracket 4 and connected to the aluminum busbar socket 2. The aluminum busbar assembly 1 is fixed with another fixing bracket 4. Then, the high-voltage connector 3 is installed, fixed and connected to the aluminum busbar assembly 1. Finally, the aluminum busbar assembly 1 is fixed with the fixing bracket 4 that has been coated with rubber.
[0043] The advantages of this utility model are:
[0044] 1. The aluminum busbar 1, which serves as the conductor, has a certain rigidity and can be fixed to the inside of the car body with a small number of fixing brackets, saving assembly time and improving work efficiency.
[0045] 2. The aluminum busbar 1 has a flat cuboid structure. Even if it is necessary to improve the charging efficiency, the aluminum busbar 1 can keep the thickness unchanged and increase its cross-sectional area by increasing its width. Compared with cylindrical cables, the aluminum busbar 1 saves more space in the thickness direction.
[0046] 3. Since the aluminum busbar assembly 1 has a certain rigidity, the AC cable of the vehicle body can also be fixed on the aluminum busbar assembly 1 to save space.
[0047] 4. The aluminum busbar of this utility model is made of 6101 T64 magnesium-silicon aluminum alloy, which is lighter than copper, achieving a weight reduction of 40% and a cost reduction of 30%.
[0048] 5. This utility model ensures stable contact between the positive electrode insertion terminal 111, the negative electrode insertion terminal 121, the positive high-voltage terminal 112, and the negative high-voltage terminal 122 and the copper terminal through the positive electrode aluminum busbar slots (21, 31) and negative electrode aluminum busbar slots (22, 32), without the need for welding fixation, thus reducing the impedance at the contact point. Simultaneously, welding a copper ring transition layer to the outer surface of the positive electrode insertion terminal 111, the negative electrode insertion terminal 121, the positive high-voltage terminal 112, and the negative high-voltage terminal 122 effectively prevents electrochemical corrosion caused by the material difference between the aluminum busbar and the copper terminal, thereby improving the product's service life.
[0049] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model in any way. Although the present utility model has been disclosed above with reference to preferred embodiments, it is not intended to limit the present utility model. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present utility model's technical solution. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present utility model without departing from the content of the present utility model's technical solution shall still fall within the scope of the present utility model's technical solution.
Claims
1. An aluminum busbar charging connection assembly for connecting the battery of an electric vehicle to an external power source, characterized in that, include: Aluminum busbar assemblies, aluminum busbar sockets, aluminum busbar high-voltage connectors, and mounting brackets; One end of the aluminum busbar assembly is connected to an aluminum busbar socket, and the other end is connected to an aluminum busbar high-voltage connector. The fixing bracket fixes the aluminum busbar assembly along the inner side wall of the electric vehicle's outer shell. The aluminum busbar assembly includes multiple bends, and the fixing bracket located at the bends is coated with rubber. The aluminum busbar assembly includes a positive aluminum busbar and a negative aluminum busbar. The middle part of the positive aluminum busbar and the middle part of the negative aluminum busbar are superimposed and connected to each other to form the aluminum busbar joint of the aluminum busbar assembly.
2. The aluminum busbar charging connection assembly as described in claim 1, characterized in that, The positive electrode aluminum busbar is provided with a positive electrode plug-in terminal and a positive electrode high voltage terminal at both ends, and the positive electrode plug-in terminal and the positive electrode high voltage terminal are connected through the middle of the positive electrode aluminum busbar. The negative electrode aluminum busbar is provided with a negative electrode plug-in terminal and a negative electrode high voltage terminal at both ends, and the negative electrode plug-in terminal and the negative electrode high voltage terminal are connected through the middle of the negative electrode aluminum busbar.
3. The aluminum busbar charging connection assembly as described in claim 2, characterized in that, The positive terminal and the negative terminal are connected to the aluminum busbar socket.
4. The aluminum busbar charging connection assembly as described in claim 3, characterized in that, The positive high-voltage terminal and the negative high-voltage terminal are plugged into the aluminum busbar high-voltage connector.
5. The aluminum busbar charging connection assembly as described in any one of claims 2 to 4, characterized in that, The positive terminal and the negative terminal are respectively provided with straight bends.
6. The aluminum busbar charging connection assembly as described in any one of claims 2 to 4, characterized in that, The positive terminal, positive high-voltage terminal, negative terminal, and negative high-voltage terminal are all welded with a copper ring transition layer.
7. The aluminum busbar charging connection assembly as described in any one of claims 1 to 4, characterized in that, The multiple bends are horizontal bends, vertical bends, torsional bends, or combinations thereof.
8. The aluminum busbar charging connection assembly as described in claim 7, characterized in that, The length of the torsional bend is greater than 40mm.
9. The aluminum busbar charging connection assembly as described in any one of claims 1 to 4, characterized in that, An elastic gasket is provided between the middle of the positive aluminum busbar and the middle of the negative aluminum busbar at the fixed frame.
10. The aluminum busbar charging connection assembly as described in any one of claims 1 to 4, characterized in that, The gap between the aluminum busbar and the inner side of the housing is greater than or equal to 3mm.