Aluminum busbar connection assembly and charging socket with aluminum busbar connection assembly

Abstract

We propose a charging socket that connects to an aluminum busbar and is secured by tightening conductive bolts. [Solution] The system comprises an aluminum busbar joint with a first through-hole and an aluminum busbar housing configured to surround the aluminum busbar joint, wherein the aluminum busbar of the aluminum busbar joint extends from the aluminum busbar housing, and the aluminum busbar housing includes first and second openings provided on each side of the aluminum busbar joint and aligned with the first through-hole. The charging socket connected to the aluminum busbar is divided into two parts, including an aluminum busbar connection assembly and a terminal connection assembly, and is connected by conductive bolts. During installation, the two parts are connected to each other by an insertion operation, and the installation is completed by tightening the bolts.

Description

Technical Field

[0003] , , ,

[0004]

[0001] The present disclosure generally relates to the technical field of aluminum busbar connections for charging sockets of electric vehicles, and in particular, to an aluminum busbar connection assembly and a charging socket comprising the aluminum busbar connection assembly.

Background Art

[0002] With the development of the new energy vehicle market, more and more equipment manufacturers are competing not only in terms of product performance but also in terms of price. For products of the same quality, lower costs are required. In the application of DC charging sockets for electric vehicles, with the demand for supplying high instantaneous currents, lower-cost aluminum busbar connection methods are becoming increasingly preferred by equipment manufacturers. However, due to the inherent shape of the aluminum busbar connection part, the aluminum busbar connection part has higher rigidity and lower connection flexibility compared to conventional wire harnesses. In the limited space inside the vehicle, the aluminum busbar connection part may interfere with other components, making installation difficult.

Summary of the Invention

Problems to be Solved by the Invention

[0003] To overcome at least one of the above or other drawbacks in the prior art, the present disclosure proposes a charging socket connected to an aluminum busbar and divided into two parts. The two parts are connected by conductive bolts, and the installation work can be completed simply by tightening the bolts.

Means for Solving the Problems

[0004] According to an embodiment of one aspect of the present disclosure, an aluminum busbar connection assembly is provided, comprising an aluminum busbar joint and an aluminum busbar housing, wherein the aluminum busbar joint is provided with a first through hole, the aluminum busbar housing is configured to surround the aluminum busbar joint, the aluminum busbars of the aluminum busbar joint extend from the aluminum busbar housing, the aluminum busbar housing includes a first opening and a second opening, each of which is provided on each side of the aluminum busbar joint and is aligned with the first through hole.

[0005] In one embodiment, the aluminum busbar connection assembly further comprises a gasket positioned around a first through-hole in the aluminum busbar joint, the gasket including a cylindrical portion fitted into the inner wall of the first through-hole and an annular portion on one side surface of the aluminum busbar joint around the first through-hole.

[0006] In one embodiment, the aluminum busbar connection assembly further comprises a guide sleeve, the guide sleeve having a flange at one end thereof, the flange in contact with the annular portion of the gasket, and the guide sleeve being aligned with a first through-hole in the aluminum busbar joint.

[0007] In one embodiment, the aluminum busbar housing is configured to surround the guide sleeve and the aluminum busbar joint, with the other end of the guide sleeve extending beyond a first opening in the aluminum busbar housing.

[0008] In one embodiment, a groove is provided around the end of a first opening, a clamping ring is housed in the groove, and the clamping ring is configured to secure the other end of the guide sleeve to the first opening of the aluminum busbar housing.

[0009] According to an embodiment of another aspect of the present disclosure, a charging socket is provided, comprising a terminal connection assembly, a conductive bolt, and an aluminum busbar connection assembly as described in any embodiment of the present disclosure, wherein the terminal connection assembly includes a sheet terminal and a conductive terminal ferrule, the terminal ferrule including a female thread and maintaining contact with the terminal, and when the terminal connection assembly and the aluminum busbar connection assembly are assembled together, the terminal ferrule and a first through hole in the aluminum busbar joint are aligned with each other, and the bolt passes through the first through hole in the aluminum busbar joint of the aluminum busbar connection assembly and is screwed into the terminal ferrule of the terminal connection assembly, thereby connecting the terminal ferrule and the aluminum busbar joint to each other.

[0010] In one embodiment, a bolt stud is inserted from a second opening in the aluminum busbar housing through a first through-hole in the aluminum busbar joint, and thus through a guide sleeve, and can extend from the guide sleeve, the portion of the stud extending from the guide sleeve having threads.

[0011] In one embodiment, the second opening of the aluminum busbar housing includes an outwardly projecting cylindrical aluminum bar cavity for housing the bolt head of a bolt, the bolt head of the bolt being able to slide within the aluminum bar cavity.

[0012] In one embodiment, an insulating cap is provided on the bolt head of the bolt, and the insulating cap can seal the aluminum bar cavity, so that the bolt head is electrically insulated from the outside of the aluminum bar cavity.

[0013] In one embodiment, a stopper is provided at the open end of the cylindrical aluminum bar cavity to prevent the bolt head housed in the aluminum bus bar cavity from sliding out of the aluminum bar cavity.

[0014] In one embodiment, the terminal connection assembly includes a terminal housing configured to surround a terminal and a terminal ferrule, the terminal housing including a third opening, a second through-hole provided at the end of the terminal, the terminal ferrule being fixed to the terminal on the side opposite to the third opening, and the terminal ferrule, the second through-hole of the terminal, and the third opening being aligned with respect to each other.

[0015] In one embodiment, an outwardly projecting terminal cavity is provided in a third opening of the terminal housing, and the terminal cavity can receive the portion of the guide sleeve of the aluminum busbar connection assembly that extends from the aluminum busbar housing, so that the guide sleeve is aligned with the third opening.

[0016] In one embodiment, the other end of the guide sleeve extends from the aluminum busbar housing at a first opening in the aluminum busbar housing, and when the terminal connection assembly and the aluminum busbar connection assembly are assembled together, the other end of the guide sleeve is inserted into the terminal cavity, and the edge of the first opening in the aluminum busbar housing and the edge of the terminal cavity in the terminal housing have a snap-fit ​​structure, so that the first opening and the terminal cavity are engaged and locked together.

[0017] In exemplary embodiments of this disclosure, a charging socket connected to an aluminum busbar is divided into two parts: one part is an aluminum busbar connection assembly, and the other part is a terminal connection assembly. The two parts are connected by conductive bolts. Equipment manufacturers can manufacture the aluminum busbar connection assembly and the terminal connection assembly separately by standard technical means. During installation, the two parts are connected by inserting one part into the other, and the installation is completed by tightening the bolts. This is extremely advantageous in the interior of a vehicle where space is limited. At the same time, because the aluminum busbar connection assembly is connected by insertion, it can be rotated to face multiple angles, which can meet mounting requirements at different angles and allows for greater versatility.

[0018] The following further description of this disclosure, with reference to the accompanying drawings and specific embodiments, is intended to clarify its purpose, features, and advantages and to facilitate understanding. [Brief explanation of the drawing]

[0019] [Figure 1] This is a perspective view of an aluminum busbar connection assembly according to an embodiment of the present disclosure. [Figure 2] This is a cross-sectional view of an aluminum busbar connection assembly according to an embodiment of the present disclosure. [Figure 3] This is a perspective view of an aluminum busbar joint and a cross-sectional view of the first through-hole portion of an aluminum busbar connection assembly according to embodiments of the present disclosure. [Figure 4] This is a perspective view of a charging socket according to an embodiment of the present disclosure. [Figure 5] Cross-sectional view of a charging socket according to an embodiment of the disclosure. [Figure 6] This is a perspective view of the terminals and terminal ferrules of a charging socket according to an embodiment of the present disclosure. [Modes for carrying out the invention]

[0020] The present disclosure will be fully described with reference to the accompanying drawings that illustrate preferred embodiments of the disclosure. Before this description, however, it should be understood by those skilled in the art that the disclosure described herein can be modified while realizing the technical advantages of the disclosure. Accordingly, it should be understood that the above description is intended to be a broad disclosure to those skilled in the art and is not intended to limit the disclosure to the exemplary embodiments described herein.

[0021] Furthermore, in the following detailed description, numerous specific details are set forth for the purpose of providing a thorough understanding of the embodiments disclosed herein. However, it will be apparent that one or more embodiments can be practiced without these specific details. In other instances, well-known structures and devices are shown schematically for the purpose of simplifying the drawings.

[0022] According to the overall concept of the present disclosure, there is provided an aluminum busbar connection assembly comprising an aluminum busbar joint and an aluminum busbar housing. The aluminum busbar joint is provided with a first through hole, and the aluminum busbar housing is configured to surround the aluminum busbar joint. The aluminum busbar of the aluminum busbar joint extends from the aluminum busbar housing. The aluminum busbar housing includes a first opening and a second opening, and the first opening and the second opening are respectively provided on each side of the aluminum busbar joint and are aligned with the first through hole.

[0023] According to the overall concept of the present disclosure, a charging socket is provided, which includes a terminal connection assembly, a conductive bolt, and the aluminum busbar connection assembly as described above. The terminal connection assembly includes a sheet-shaped terminal and a conductive terminal ferrule. The terminal ferrule has a female thread and maintains contact with the terminal. When the terminal connection assembly and the aluminum busbar connection assembly are assembled with each other, the terminal ferrule and the first through-hole of the aluminum busbar joint are aligned with each other. The bolt passes through the first through-hole of the aluminum busbar joint of the aluminum busbar connection assembly and is screwed into the terminal ferrule of the terminal connection assembly, thereby connecting the terminal ferrule and the aluminum busbar joint to each other.

[0024] The charging socket according to an embodiment of the present disclosure is advantageous in that the charging socket connected to the aluminum busbar is divided into two parts, and the two parts are connected by a conductive bolt. During installation, it is only necessary to connect the two parts to each other by an insertion operation and tighten the bolt to complete the installation work. In addition, one part can be rotated relative to the other part at multiple angles, thereby realizing the installation requirements at different angles and enabling high versatility.

[0025] FIG. 1 is a perspective view of an aluminum busbar connection assembly according to an embodiment of the present disclosure, FIG. 2 is a cross-sectional view of the aluminum busbar connection assembly according to an embodiment of the present disclosure, and FIG. 3 shows a perspective view of an aluminum busbar joint and a cross-sectional view of a first through-hole portion of the aluminum busbar connection assembly according to an embodiment of the present disclosure.

[0026] As shown in the figures, an aluminum busbar connection assembly 100 according to an embodiment of the present disclosure comprises an aluminum busbar connector 110 and an aluminum busbar housing 120. The aluminum busbar connection 110 is provided with a first through-hole 111. The aluminum busbar housing 120 is configured to surround the aluminum busbar connection 110, and the aluminum busbars 112 of the aluminum busbar connection 110 extend from the aluminum busbar housing 120. The aluminum busbar housing 120 includes a first opening 121 and a second opening 122, the first opening 121 and the second opening 122 respectively provided on each side of the aluminum busbar connection 110 and aligned with the first through-hole 111. This allows the stud 151 of the bolt 150 to be connected to the terminal side of the aluminum busbar through the first opening 121, the first through hole 111, and the second opening 122 of the aligned aluminum busbar, thereby forming an electrical connection with the terminal side.

[0027] In one embodiment, the aluminum busbar connection assembly 100 further comprises a gasket 130 positioned around the first through-hole 111 of the aluminum busbar joint 110. The gasket 130 includes a cylindrical portion 131 fitted into the inner wall of the first through-hole 111 and an annular portion 132 extending around the first through-hole 111 on one side surface of the aluminum busbar joint 110. The gasket 130 is provided to reinforce the shape of the first through-hole 111 of the aluminum busbar and to prevent wear of the first through-hole 111 of the aluminum busbar after the insertion of the bolts 150.

[0028] In one embodiment, the aluminum busbar connection assembly 100 further comprises a guide sleeve 140 having a flange 141 at one end. The flange 141 contacts the annular portion 132 of the gasket 130. The guide sleeve 140 is aligned with the first through hole 111 of the aluminum busbar joint 110. This arrangement forms a channel perpendicular to the aluminum busbar on one side of the aluminum busbar, guiding the extension direction of the stud 151 of the bolt 150 after it has been inserted into the first through hole 111 of the aluminum busbar.

[0029] In one embodiment, the aluminum busbar housing 120 is configured to surround the guide sleeve 140 and the aluminum busbar joint 110, with the other end of the guide sleeve 140 extending beyond the first opening 121 of the aluminum busbar housing 120.

[0030] In this embodiment, a groove 123 is provided around the end of the first opening 121. A clamping ring 223 is housed in the groove 123, fixing the other end of the guide sleeve 140, i.e., the free end, to the first opening 121 of the aluminum busbar housing 120, thereby fixing the position of the guide sleeve 140 relative to the first through hole 111 of the aluminum busbar and preventing the guide sleeve 140 and the aluminum busbar housing 120 from sliding relative to each other.

[0031] Figure 4 is a perspective view of the charging socket 300 according to an embodiment of the present disclosure, Figure 5 is a cross-sectional view of the charging socket 300 according to an embodiment of the present disclosure, and Figure 6 is a perspective view of the terminals 210 and terminal ferrules 220 of the charging socket 300 according to an embodiment of the present disclosure.

[0032] As shown in the figures, the charging socket 300 according to an embodiment of the present disclosure comprises a terminal connection assembly 200, a conductive bolt 150, and the above-mentioned aluminum busbar connection assembly 100. As shown in Figure 6, the terminal connection assembly 200 includes a sheet terminal 210 and a conductive terminal ferrule 220, the terminal ferrule 220 including a female thread 221 provided to maintain contact with the terminal 210, and when the terminal connection assembly 200 and the aluminum busbar connection assembly 100 are assembled together, the terminal ferrule 220 of the terminal connection assembly 200 is aligned with the first through hole 111 of the aluminum busbar joint 110, and the bolt 150 passes through the first through hole 111 of the aluminum busbar joint 110 of the aluminum busbar connection assembly 100 and is screwed into the terminal ferrule 220 of the terminal connection assembly 200, thereby mechanically and electrically connecting the terminal ferrule 220 and the aluminum busbar joint 110 to each other.

[0033] As shown in the figure, the stud 151 of the bolt 150 is inserted through the first through hole 111 of the aluminum busbar joint 110 from the second opening 122 of the aluminum busbar housing 120 and thus into the guide sleeve 140, and can extend out of the guide sleeve 140, the portion of the stud 151 extending out of the guide sleeve 140 having threads 152 and being configured to engage with the female threads 221 of the terminal ferrule 220 of the terminal connection assembly 200.

[0034] In an embodiment, as shown in the figure, the second opening 122 of the aluminum busbar housing 120 includes an outwardly projecting cylindrical aluminum busbar cavity portion 160 for housing the bolt head 153 of the bolt 150. The bolt head 153 of the bolt 150 can slide within the aluminum busbar cavity portion 160. In addition, the aluminum busbar cavity portion 160 can also function as a guide for the bolt 150 to slide.

[0035] In one embodiment, an insulating cap 154 ​​is provided on the bolt head 153 of the bolt 150. The insulating cap 154 ​​can seal the aluminum busbar cavity 160, thereby electrically insulating the bolt head 153 from the outside of the aluminum busbar cavity 160. Furthermore, this arrangement can help prevent dust from entering the aluminum busbar cavity 160 and thus the aluminum busbar connection assembly 100.

[0036] In one embodiment, a stopper 161 is provided at the open end of the cylindrical aluminum busbar cavity 160 to prevent the bolt head 153 housed in the aluminum busbar cavity 160 from sliding out of the aluminum busbar cavity 160. In this way, the bolt 150 can be considered as a component connected to the aluminum busbar connection assembly 100 rather than a separate component, and the bolt 150 can be prevented from falling and being lost.

[0037] In an embodiment, as shown in the figure, the terminal connection assembly 200 includes a terminal housing 230 configured to surround a terminal 210 and a terminal ferrule 220, the terminal housing 230 including a third opening 240. A second through hole 211 is provided at the end of the terminal 210, and the terminal ferrule 220 is fixed to the terminal 210 on the side opposite to the third opening 240, and the terminal ferrule 220, the second through hole 211 of the terminal 210, and the third opening 240 of the terminal housing 230 are aligned with each other.

[0038] In one embodiment, as shown in the figure, an outwardly projecting terminal cavity portion 241 is located in a third opening 240 of the terminal housing 230, and the terminal cavity portion 241 can receive the portion of the guide sleeve 140 of the aluminum busbar connection assembly 100 that extends from the aluminum busbar housing 120, so that the guide sleeve 140 is aligned with the third opening 240.

[0039] The other end of the guide sleeve 140 extends from the aluminum busbar housing 120 through the first opening 121 of the aluminum busbar housing 120. When the terminal connection assembly 200 and the aluminum busbar connection assembly 100 are assembled together, the other end of the guide sleeve 140 is inserted into the terminal cavity portion 241. The edges of the first opening 121 of the aluminum busbar housing 120 and the edges of the terminal cavity portion 241 of the terminal housing 230 each have a snap-fit ​​structure, so that the first opening 121 and the terminal cavity portion 241 engage and lock together.

[0040] The charging socket according to this disclosure is advantageous in that, at least, the charging socket connected to the aluminum busbar is divided into two parts, one of which is the aluminum busbar connection assembly and the other is the terminal connection assembly. The two parts are connected by conductive bolts, which are connected to the aluminum busbar connection assembly, thereby reducing the number of parts. Equipment manufacturers can manufacture the aluminum busbar connection assembly and the terminal connection assembly separately by standard technical means. During installation, the two parts are simply connected by insertion and bolts are tightened to complete the installation. This is a significant advantage in the limited space of a vehicle's interior. At the same time, because the aluminum busbar connection assembly is plug-in, it can be rotated to face multiple angles, which can meet different angle mounting requirements and allows for greater versatility.

[0041] Those skilled in the art will understand that the above embodiments are illustrative and can be improved upon by those skilled in the art. The structures described in the various embodiments can be freely combined without structural or principle contradiction, thereby enabling a wider variety of aluminum busbar connection assemblies and charging sockets based on solving the technical problems described in this disclosure.

[0042] After describing preferred embodiments of this disclosure in detail, those skilled in the art will readily understand that various modifications and changes can be made without departing from the scope and spirit of the appended claims, and that this disclosure is not limited to the exemplary embodiments described herein. Note that the words “comprising,” “comprise,” “including,” “include,” “have,” or “having” do not exclude other elements or steps, and the words “a” or “an” do not exclude plurals. Furthermore, any reference numerals in the claims should not be construed as limiting the scope of the invention.

Claims

1. Aluminum busbar connection assembly (100), - Aluminum busbar joint (110) and - Aluminum busbar housing (120) and Equipped with, A first through hole (111) is provided in the aluminum busbar joint (110), the aluminum busbar housing (120) is configured to surround the aluminum busbar joint (110), and the aluminum busbar (112) of the aluminum busbar joint (110) extends from the aluminum busbar housing (120). The aluminum busbar housing (120) includes a first opening (121) and a second opening (122) provided on each side of the aluminum busbar joint (110), the first opening (121) and the second opening (122) being aligned with the first through hole (111), the aluminum busbar connection assembly (100).

2. The aluminum busbar connection assembly (100) further comprises a gasket (130), The gasket (130) is positioned around the first through hole (111) of the aluminum busbar joint (110). The aluminum busbar connection assembly (100) according to claim 1, wherein the gasket (130) includes a cylindrical portion (131) fitted into the inner wall of the first through hole (111) and an annular portion (132) on one side surface of the aluminum busbar joint (110) surrounding the first through hole (111).

3. The aluminum busbar connection assembly (100) according to claim 2, further comprising a guide sleeve (140), wherein a flange (141) is provided at one end of the guide sleeve (140), the flange (141) is in contact with the annular portion (132) of the gasket (130), and the guide sleeve (140) is aligned with the first through hole (111) of the aluminum busbar joint (110).

4. The aluminum busbar connection assembly (100) according to claim 3, wherein the aluminum busbar housing (120) is configured to surround the guide sleeve (140) and the aluminum busbar joint (110), and the other end of the guide sleeve (140) extends beyond the first opening (121) of the aluminum busbar housing (120).

5. A groove (123) is provided around the end of the first opening (121), The aluminum busbar connection assembly (100) according to claim 4, wherein a tightening ring (223) is housed in the groove (123), and the tightening ring (223) is configured to fix the other end of the guide sleeve (140) and the first opening (121) of the aluminum busbar housing (120) to each other.

6. A charging socket (300), Terminal connection assembly (200), Conductive bolt (150) and, An aluminum busbar connection assembly (100) according to any one of claims 3 to 5 and Equipped with, The terminal connection assembly (200) includes a sheet-like terminal (210) and a conductive terminal ferrule (220), The terminal ferrule (220) includes a female thread (221) and is provided to maintain contact with the terminal (210). A charging socket (300) in which, when the terminal connection assembly (200) and the aluminum busbar connection assembly (100) are assembled together, the terminal ferrule (220) and the first through hole (111) of the aluminum busbar joint (110) are aligned with each other, and the bolt (150) passes through the first through hole (111) of the aluminum busbar joint (110) of the aluminum busbar connection assembly (100) and is screwed into the terminal ferrule (220) of the terminal connection assembly (200), thereby connecting the terminal ferrule (220) and the aluminum busbar joint (110) to each other.

7. The stud (151) of the bolt (150) is inserted from the second opening (122) of the aluminum busbar housing (120) through the first through hole (111) of the aluminum busbar joint (110), and thus through the guide sleeve (140), and can extend out of the guide sleeve (140), The charging socket (300) according to claim 6, wherein the portion of the stud (151) extending from the guide sleeve (140) includes a screw thread (152).

8. The second opening (122) of the aluminum busbar housing (120) includes an outwardly projecting cylindrical aluminum busbar cavity (160) for housing the bolt head (153) of the bolt (150). The charging socket (300) according to claim 6, wherein the bolt head (153) of the bolt (150) can slide in the aluminum busbar cavity (160).

9. The charging socket (300) according to claim 8, wherein an insulating shut-off cap (154) is provided on the bolt head (153) of the bolt (150), and the insulating shut-off cap (154) can seal the aluminum busbar cavity portion (160), so that the bolt head (153) is electrically insulated from the outside of the aluminum busbar cavity portion (160).

10. The charging socket (300) according to claim 9, wherein a stopper (161) is provided at the open end of the cylindrical aluminum bar cavity portion (160), and the stopper (161) is configured to prevent the bolt head (153) housed in the aluminum busbar cavity portion from sliding out of the aluminum bar cavity portion (160).

11. The terminal connection assembly (200) includes a terminal housing (230), The terminal housing (230) is configured to surround the terminal (210) and the terminal ferrule (220), The terminal housing (230) includes a third opening (240), A second through hole (211) is provided at the end of the terminal (210). The terminal ferrule (220) is fixed to the terminal (210) on the side opposite to the third opening (240), The charging socket (300) according to claim 6, wherein the terminal ferrule (220), the second through hole (211) of the terminal (210), and the third opening (240) are aligned with each other.

12. A terminal cavity portion (241) protruding outward is provided in the third opening (240) of the terminal housing (230), The charging socket (300) according to claim 11, wherein the terminal cavity (241) can receive the portion of the guide sleeve (140) of the aluminum busbar connection assembly (100) that extends from the aluminum busbar housing (120), and so the guide sleeve (140) is aligned with the third opening (240).

13. The other end of the guide sleeve (140) extends from the aluminum busbar housing (120) at the first opening (121) of the aluminum busbar housing (120). When the terminal connection assembly (200) and the aluminum busbar connection assembly (100) are assembled together, the other end of the guide sleeve (140) is inserted into the terminal cavity portion (241). The charging socket (300) according to claim 12, wherein the edge of the first opening (121) of the aluminum busbar housing (120) and the edge of the terminal cavity portion (241) of the terminal housing (230) each have a snap-fit ​​structure, and therefore the first opening (121) and the terminal cavity portion (241) are engaged and locked together.

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