Low-voltage module and DC charging dock

Abstract

This invention provides a low-voltage module that effectively prevents burnout of the low-voltage auxiliary circuit of a DC charging dock. [Solution] The low-voltage module comprises an insulator 2 and an electrical connection member. The electrical connection member includes a first contact portion used to electrically contact the PE terminal of the DC charging dock, a second contact portion used to electrically contact the A- terminal of the DC charging dock, and a connection portion that electrically connects the first contact portion and the second contact portion and is fixed to the insulator 2. When the low-voltage module 100 is installed in the insertion slot 14, the first contact portion and the second contact portion electrically contact the PE terminal and the A- terminal, respectively. The PE terminal and the A- terminal of the DC charging dock are electrically interconnected by the electrical connection member of the low-voltage module, realizing a common ground connection between the PE terminal and the A- terminal.

Description

Technical Field

[0001] Cross - reference to Related Applications This application claims priority to Chinese Patent Application No. CN202411997621.1, filed with the China National Intellectual Property Administration on December 31, 2024, the entire disclosure of which is incorporated herein by reference.

[0002] The present invention relates to the field of charging technologies for electric vehicles, and particularly to a low - voltage module of a DC charging dock and a DC charging dock equipped with the low - voltage module.

Background Art

[0003] In the prior art, the PE terminal (also known as the grounding protection terminal) and the A - terminal (also known as the negative terminal of the low - voltage auxiliary power supply) of a DC charging dock are provided separately. As a result, the PE terminal and the A - terminal are not commonly grounded, that is, the PE terminal and the A - terminal are not electrically interconnected and are not commonly grounded. Therefore, in actual applications, due to the fact that the PE terminal and the A - terminal are not commonly grounded, there may be a large voltage difference between the DC charging dock and the DC charging gun. Thereby, a large current may occur in the low - voltage auxiliary circuit connected to the A + terminal or the A - terminal of the DC charging dock, which may cause the low - voltage auxiliary circuit to be prone to burnout. <00​​​​​In conventional technology, to control the temperature rise of power terminals, a lead frame is typically mounted on a DC charging dock, and a low-voltage module is integrated into the lead frame. The low-voltage module of the DC charging dock includes a temperature sensor and a thermal pad wrapped around the temperature sensor. The thermal pad makes thermal contact with the power terminals, and the temperature sensor is electrically connected to the lead frame. However, in conventional technology, the lead frame is bulky and must be pre-installed in the charging dock housing, which is very inconvenient to use. In addition, in conventional technology, the charging dock housing must adopt a segmented design to facilitate the installation of the lead frame, which complicates the structure of the charging dock housing. In addition, existing lead frames need to be rotatable between a locked position that locks the power terminals and an unlocked position that unlocks the power terminals, which makes the lead frame and charging dock housing more complex, more difficult to assemble, and more expensive. [Overview of the project] [Problems that the invention aims to solve]

[0006] This invention was made to overcome or mitigate at least one of the above-mentioned drawbacks. [Means for solving the problem]

[0007] According to an aspect of the present invention, a low-voltage module for a DC charging dock is provided. The low-voltage module comprises an insulator and an electrical connection member. The electrical connection member includes a first contact portion used for electrically contacting the PE terminal of the DC charging dock, a second contact portion used for electrically contacting the A- terminal of the DC charging dock, and a connection portion that electrically connects the first contact portion and the second contact portion and is fixed to the insulator. The low-voltage module is suitable for external plug-in installation into an insertion slot of a charging dock housing, and when the low-voltage module is installed in the insertion slot, the first contact portion and the second contact portion electrically contact the PE terminal and the A- terminal, respectively, thereby electrically connecting the A- terminal to the PE terminal.

[0008] According to an exemplary embodiment of the present invention, the insulator is injection-molded directly onto the electrical connection member, so that the insulator and the electrical connection member become a single integrated component.

[0009] According to another exemplary embodiment of the present invention, the electrical connection member is a single-piece punched component.

[0010] According to another exemplary embodiment of the present invention, the first contact portion includes a pair of first spring pieces used to clamp the PE terminal, and / or the second contact portion includes a pair of second spring pieces used to clamp the A terminal.

[0011] According to another exemplary embodiment of the present invention, the insulator has a first locking portion that presses against the PE terminal when the low-voltage module is inserted into the insertion slot to lock the PE terminal to the charging dock housing, and / or the insulator has a second locking portion that abuts against the A- terminal when the low-voltage module is inserted into the insertion slot to lock the A- terminal to the charging dock housing.

[0012] According to another exemplary embodiment of the present invention, the low-voltage module further comprises a thermal pad mounted on an insulator for thermal contact with the power terminals of a DC charging dock, a temperature sensor provided on the thermal pad for detecting the temperature of the power terminals, and a conductive lead provided on the insulator and electrically connected to the temperature sensor. When the low-voltage module is installed in the insertion slot, the thermal pad makes thermal contact with the power terminals to transfer the heat from the power terminals to the temperature sensor.

[0013] According to another exemplary embodiment of the present invention, the insulator is injection-molded directly onto the conductive lead and the electrical connector so that the conductive lead, the electrical connector, and the insulator form a single integrated component.

[0014] According to another exemplary embodiment of the present invention, the conductive lead has a connecting end electrically connected to a temperature sensor and an external pin for electrically connecting to a connector located on the outside of the charging dock housing.

[0015] According to another exemplary embodiment of the present invention, the insulator includes a bracket portion suitable for insertion into an insertion slot of a charging dock housing and a mating portion configured to be positioned outside the charging dock housing, wherein a thermal pad and a temperature sensor are mounted on the bracket portion, and the mating portion has an insertion cavity into which a connector can be inserted, and the external pins of conductive leads extend into the insertion cavity to be electrically connected to the inserted connector.

[0016] According to another exemplary embodiment of the present invention, a seal ring mounting groove is formed on the outer circumferential surface of the bracket portion, and the low-voltage module further comprises a seal ring mounted in the seal ring mounting groove, wherein the seal ring is compressed between the support portion and the inner wall surface of the insertion slot of the charging dock housing to achieve a seal between the support portion and the inner wall surface of the insertion slot.

[0017] According to another exemplary embodiment of the present invention, the bracket portion has a cover plate portion for covering the entrance of the insertion slot of the charging dock housing, and the insulator also includes a plurality of buckles connected around the cover plate portion, the plurality of buckles distributed around the outer circumference of the cover plate portion and used to lock the low voltage module into the charging dock housing by engaging with a plurality of projections of the charging dock housing, respectively.

[0018] According to another exemplary embodiment of the present invention, the conductive leads include a positive lead and a negative lead that are electrically connected to the positive and negative pins of a temperature sensor, respectively, the external pins of the positive and negative leads extending into the insertion cavity of the mating portion for electrical connection to the inserted connector.

[0019] According to another exemplary embodiment of the present invention, the connection end of the positive lead is suitable for plug-in electrical connection with the positive pin of a temperature sensor, and / or the connection end of the negative lead is suitable for plug-in electrical connection with the negative pin of a temperature sensor.

[0020] According to another exemplary embodiment of the present invention, the connection end of the positive lead is in the shape of an elastic clip suitable for clamping the positive pin of a temperature sensor, and / or the connection end of the negative lead is in the shape of an elastic clip suitable for clamping the negative pin of a temperature sensor.

[0021] According to another exemplary embodiment of the present invention, the low-voltage module of a DC charging dock comprises a plurality of thermal pads and a plurality of temperature sensors, each of which is positioned on the plurality of thermal pads, wherein the plurality of thermal pads are used to make thermal contact with a plurality of power terminals, and the plurality of temperature sensors are used to detect the temperature of the plurality of power terminals.

[0022] According to another exemplary embodiment of the present invention, the conductive leads include a plurality of positive leads and a single negative lead. The connection ends of the plurality of positive leads are electrically connected to the positive pins of the plurality of temperature sensors respectively, and the single negative lead has a plurality of connection ends electrically connected to the negative pins of the plurality of temperature sensors respectively. The external pins of the plurality of positive leads and the external pin of the single negative lead extend into the insertion cavity of the fitting portion to be electrically connected to the inserted connector.

[0023] According to another exemplary embodiment of the present invention, the heat pad is in a block shape, a concave receiving portion is formed in the insulator, the heat pad is positioned and mounted in the receiving portion, a mounting slot is formed in the heat pad, the body of the temperature sensor is inserted into the mounting slot of the heat pad, and the positive and negative pins of the temperature sensor extend from the heat pad.

[0024] According to another exemplary embodiment of the present invention, the heat pad has an arcuate contact surface suitable for attaching to the outer peripheral surface of the power terminal, increasing the thermal contact area between the heat pad and the power terminal.

[0025] According to another exemplary embodiment of the present invention, the low-voltage module further includes a circuit board mounted and fixed to the insulator. The first contact portion and the second contact portion of the electrical connection member are contact spring pieces fixed to the circuit board, and the connection portion of the electrical connection member is a conductive trace formed on the circuit board.

[0026] According to another exemplary embodiment of the present invention, the low-voltage module further includes a heat pad for thermally contacting the power terminal of the DC charging dock when assembled to the circuit board, a temperature sensor provided on the heat pad for detecting the temperature of the power terminal, and external pins fixed to the circuit board for electrically connecting to a connector located outside the charging dock housing. The temperature sensor is electrically connected to the external pins via the conductive trace of the circuit board. When the low-voltage module is mounted in the insertion slot, the heat pad thermally contacts the power terminal and transfers the heat of the power terminal to the temperature sensor.

[0027] According to another aspect of the present invention, a DC charging dock is provided. The DC charging dock includes a charging dock housing in which a first socket, a second socket, and an insertion slot communicating with the first socket and the second socket are formed, a PE terminal assembly including a PE terminal and inserted into the first socket, an A-terminal assembly including an A-terminal and inserted into the second socket, and the above-mentioned low-voltage module inserted into the insertion slot from the outside of the charging dock housing. The first contact portion and the second contact portion of the electrical connection member are electrically contacted with the PE terminal and the A-terminal respectively to electrically connect the A-terminal to the PE terminal.

[0028] According to an exemplary embodiment of the present invention, the PE terminal assembly further includes a ground cable electrically connected to the PE terminal and led out from the first socket of the charging dock housing, and a first seal component injection-molded on the PE terminal. The first seal component is compressed between the PE terminal and the inner wall surface of the first socket to realize a seal between the PE terminal and the inner wall surface of the first socket.

[0029] According to another exemplary embodiment of the present invention, the A-terminal assembly further includes a second seal component injection-molded on the A-terminal. The second seal component is compressed between the A-terminal and the inner wall surface of the second socket to realize a seal between the A-terminal and the inner wall surface of the second socket.

[0030] According to another exemplary embodiment of the present invention, a plurality of protrusions are formed on the outer side of the peripheral wall of the insertion slot of the charging dock housing. The plurality of protrusions are dispersed at intervals around the insertion slot and respectively engaged with a plurality of buckles of the insulator of the low-voltage module, and are used to lock the low-voltage module to the charging dock housing.

[0031] According to another exemplary embodiment of the present invention, the axial direction of the insertion slot is perpendicular to the axial directions of the first socket and the second socket, and the low-voltage module is inserted into the insertion slot along the radial direction of the first socket and the second socket.

[0032] According to another exemplary embodiment of the present invention, a third socket is also formed in the charging dock housing, and an insertion slot is in communication with the third socket, and the DC charging dock further comprises a power terminal assembly inserted into the third socket, the power terminal assembly includes power terminals, and a thermal pad of the low-voltage module is in thermal contact with the power terminals to transfer the heat of the power terminals to a temperature sensor of the low-voltage module.

[0033] According to another exemplary embodiment of the present invention, the power terminal assembly further includes a high-voltage cable electrically connected to the power terminal and leading out from the charging dock housing, and a sealing plug fitted onto the high-voltage cable and inserted into a third socket. The sealing plug is compressed between the high-voltage cable and the inner wall surface of the third socket to achieve a seal between the high-voltage cable and the inner wall surface of the third socket.

[0034] According to another exemplary embodiment of the present invention, the power terminal includes a cylindrical portion used for mating with a mating power terminal and a weld portion connected to the rear end of the cylindrical portion and used for welding to a high-voltage cable, wherein the heating pad is in thermal contact with the outer circumferential surface of the cylindrical portion of the power terminal and is adjacent to the weld portion of the power terminal.

[0035] According to another exemplary embodiment of the present invention, a seal mounting groove is formed at the rear end of the cylindrical portion of the power terminal, and the power terminal assembly further includes a seal ring fitted into the seal mounting groove, the seal ring being compressed between the cylindrical portion of the power terminal and the inner wall surface of the third socket of the charging dock housing to achieve a seal between the cylindrical portion and the inner wall surface of the third socket.

[0036] According to another exemplary embodiment of the present invention, the charging dock housing has a plurality of third sockets, the DC charging dock has a plurality of power terminal assemblies inserted into each of the plurality of third sockets, the insertion slots communicate with the plurality of third sockets, and the low voltage module includes a plurality of thermal pads that thermally contact the power terminals of each of the plurality of power terminal assemblies, and a plurality of temperature sensors for detecting the temperature of each of the plurality of power terminals.

[0037] According to another exemplary embodiment of the present invention, the charging dock housing is a single injection-molded part.

[0038] In the above exemplary embodiment of the present invention, the electrical connection member of the low-voltage module of the DC charging dock can electrically interconnect the PE terminal and the A- terminal of the DC charging dock, thereby achieving common grounding between the PE terminal and the A- terminal and effectively preventing burnout of the low-voltage auxiliary circuit of the DC charging dock.

[0039] In addition, in the above exemplary embodiment of the present invention, the low-voltage module is not only small in size, but can also be inserted directly from the outside into the insertion slot of the charging dock housing, making its installation and use very convenient.

[0040] In addition, in the above exemplary embodiment of the present invention, the low-voltage module of the DC charging dock incorporates a temperature sensor for detecting the temperature of the power terminals of the DC charging dock, thereby preventing the DC charging dock from burning out due to excessive temperature.

[0041] The other features of the present invention will become clearer by describing exemplary embodiments of the present invention in detail with reference to the attached drawings. [Brief explanation of the drawing]

[0042] [Figure 1] This is a descriptive perspective view of a DC charging dock according to an exemplary embodiment of the present invention. [Figure 2]This is an exploded view illustrating an exemplary embodiment of a DC charging dock according to the present invention. [Figure 3] This is a descriptive perspective view of a low-voltage module, PE terminal, A- terminal, and power terminal according to an exemplary embodiment of the present invention. [Figure 4] This is an exploded view illustrating the low-voltage module and power terminals of a DC charging dock according to an exemplary embodiment of the present invention. [Figure 5] This is an explanatory perspective view from the front of the low-voltage module, PE terminal, and A- terminal of a DC charging dock according to an exemplary embodiment of the present invention. [Figure 6] This is an explanatory perspective view from the rear of the low-voltage module, PE terminal, and A- terminal of a DC charging dock according to an exemplary embodiment of the present invention. [Figure 7] This is an exploded view illustrating the low-voltage module, PE terminal, and A- terminal of a DC charging dock according to an exemplary embodiment of the present invention. [Figure 8] This is a descriptive perspective view of a low-voltage module of a DC charging dock according to an exemplary embodiment of the present invention. [Figure 9] This is an exploded view illustrating a low-voltage module of a DC charging dock according to an exemplary embodiment of the present invention. [Figure 10] This is another exploded schematic diagram of a low-voltage module of a DC charging dock according to an exemplary embodiment of the present invention. [Figure 11] This is a descriptive perspective view of conductive leads and temperature sensors of a low-voltage module for a DC charging dock according to an exemplary embodiment of the present invention. [Figure 12] This is a descriptive perspective view of a low-voltage module of a DC charging dock according to an exemplary embodiment of the present invention. [Figure 13] This is a descriptive perspective view of the electrical connection member of the low-voltage module of a DC charging dock according to an exemplary embodiment of the present invention. [Figure 14] This is an explanatory diagram illustrating the electrical connection in which the low-voltage module of a DC charging dock is electrically in contact with the PE terminal and the A- terminal, according to an exemplary embodiment of the present invention. [Figure 15]This is a descriptive perspective view of the power terminals of a DC charging dock according to an exemplary embodiment of the present invention. [Figure 16] This is a side view of a power terminal assembly of a DC charging dock according to an exemplary embodiment of the present invention. [Modes for carrying out the invention]

[0043] Illustrative embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings. In the drawings, the same reference numerals refer to the same elements. However, the present disclosure can be embodied in many different forms and should not be construed as being limited to the embodiments described herein. Rather, these embodiments are provided so as to make the present disclosure thorough and complete and so as to fully convey the concepts of the present disclosure to those skilled in the art.

[0044] The following detailed description includes numerous specific details for illustrative purposes to provide a thorough understanding of the disclosed embodiments. However, it will be apparent that one or more embodiments can be carried out without these specific details. In other examples, well-known structures and apparatus are shown schematically for the sake of simplifying the drawings.

[0045] According to the general concept of the present invention, a low-voltage module for a DC charging dock is provided. The low-voltage module comprises an insulator and an electrical connecting member. The electrical connecting member includes a first contact portion used for electrically contacting the PE terminal of the DC charging dock, a second contact portion used for electrically contacting the A- terminal of the DC charging dock, and a connecting portion that electrically connects the first contact portion and the second contact portion and is fixed to the insulator. The low-voltage module is suitable for external plug-in installation into an insertion slot of the charging dock housing, and when the low-voltage module is installed in the insertion slot, the first contact portion and the second contact portion electrically contact the PE terminal and the A- terminal, respectively, thereby electrically connecting the A- terminal to the PE terminal.

[0046] According to another general concept of the present invention, a DC charging dock is provided. The DC charging dock comprises a charging dock housing having a first socket, a second socket, and insertion slots communicating with the first and second sockets; a PE terminal assembly including a PE terminal and inserted into the first socket; an A- terminal assembly including an A- terminal and inserted into the second socket; and the low-voltage module described above, inserted into the insertion slot from the outside of the charging dock housing. The first and second contact portions of the electrical connection member electrically contact the PE terminal and the A- terminal, respectively, thereby electrically connecting the A- terminal to the PE terminal.

[0047] Figure 1 shows an explanatory perspective view of a DC charging dock according to an exemplary embodiment of the present invention. Figure 2 shows an explanatory exploded view of a DC charging dock according to an exemplary embodiment of the present invention. Figure 3 shows an explanatory perspective view of a low-voltage module 100, PE terminal 111, A- terminal 121, and power terminal 131 according to an exemplary embodiment of the present invention. Figure 4 shows an explanatory exploded view of the low-voltage module 100 and power terminal 131 according to an exemplary embodiment of the present invention. Figure 5 shows an explanatory perspective view of the low-voltage module 100, PE terminal 111, and A- terminal 121 of a DC charging dock according to an exemplary embodiment of the present invention, viewed from the front. Figure 6 shows an explanatory perspective view of the low-voltage module 100, PE terminal 111, and A- terminal 121 of a DC charging dock according to an exemplary embodiment of the present invention, viewed from the rear. Figure 7 shows an exploded view illustrating the low-voltage module 100, PE terminal 111, and A- terminal 121 according to an exemplary embodiment of the present invention. Figure 8 shows an explanatory perspective view of the low-voltage module 100 according to an exemplary embodiment of the present invention. Figure 9 shows an exploded view illustrating the low-voltage module 100 according to an exemplary embodiment of the present invention. Figure 10 shows another exploded schematic view of the low-voltage module 100 according to an exemplary embodiment of the present invention. Figure 11 shows an explanatory perspective view illustrating the conductive lead 6 and temperature sensor 4 of the low-voltage module 100 of the DC charging dock according to an exemplary embodiment of the present invention. Figure 12 shows an explanatory perspective view illustrating the low-voltage module 100 according to an exemplary embodiment of the present invention. Figure 13 shows an explanatory perspective view illustrating the electrical connection member 3 of the low-voltage module 100 of the DC charging dock according to an exemplary embodiment of the present invention. Figure 14 shows an explanatory diagram of the electrical contact between the electrical connection member 3 of the low-voltage module 100 and the PE terminal 111 and A- terminal 121 according to an exemplary embodiment of the present invention.

[0048] As shown in Figures 1 to 14, an exemplary embodiment of the present invention discloses a low-voltage module 100 for a DC charging dock. The low-voltage module 100 for the DC charging dock comprises an insulator 2 and an electrical connection member 3. The electrical connection member 3 includes a first contact portion 31, a second contact portion 32, and a connector portion 30. The first contact portion 31 is used to electrically contact the PE terminal 111 of the DC charging dock. The second contact portion 32 is used to electrically contact the A- terminal 121 of the DC charging dock. The connector portion 30 electrically connects the first contact portion 31 and the second contact portion 32 and is fixed to the insulator 2. The low-voltage module 100 is suitable for external plug-in mounting in an insertion slot 14 of the charging dock housing 1. When the low-voltage module 100 is installed in the insertion slot 14, the first contact portion 31 and the second contact portion 32 make electrical contact with the PE terminal 111 and the A- terminal 121, respectively, thereby electrically connecting the A- terminal 121 to the PE terminal 111.

[0049] As shown in Figures 1 to 14, in the illustrated embodiment, the insulator 2 is directly injection-molded onto the electrical connection member 3, so that the insulator 2 and the electrical connection member 3 become a single integrated component. This reduces manufacturing costs and improves manufacturing efficiency.

[0050] As shown in Figures 1 to 14, in the illustrated embodiments, the electrical connection member 3 may be a single stamped part. However, the present invention is not limited to the illustrated embodiments, and for example, the electrical connection member 3 may be welded together from a plurality of parts.

[0051] As shown in Figures 1 to 14, in the illustrated embodiment, the first contact portion 31 includes a pair of first spring pieces. The pair of first spring pieces are used to clamp the PE terminal 111. The second contact portion 32 includes a pair of second spring pieces. The pair of second spring pieces are used to clamp the A- terminal 121. However, the present invention is not limited to the illustrated embodiment, and other suitable elastic contact structures may be used for the first contact portion 31 and the second contact portion 32.

[0052] As shown in Figures 1 to 14, in the illustrated embodiment, the insulator 2 has a first locking portion 210 that presses against the PE terminal 111 when the low-voltage module 100 is installed in the insertion slot 14, locking the PE terminal 111 to the charging dock housing 1. The insulator 2 also has a second locking portion 220 that contacts the A- terminal 121 when the low-voltage module 100 is installed in the insertion slot 14, locking the A- terminal 121 to the charging dock housing 1.

[0053] As shown in Figures 1 to 14, in the illustrated embodiment, the low-voltage module 100 further comprises a thermal pad 5, a temperature sensor 4, and a conductive lead 6. The thermal pad 5 is mounted on an insulator 2 and makes thermal contact with the power terminals 131 of the DC charging dock. The temperature sensor 4 is mounted on the thermal pad 5 and detects the temperature of the power terminals 131. The conductive lead 6 is provided on the insulator 2 and is electrically connected to the temperature sensor 4. When the low-voltage module 100 is mounted in the insertion slot 14, the thermal pad 5 makes thermal contact with the power terminals 131 and transfers the heat from the power terminals 131 to the temperature sensor 4.

[0054] As shown in Figures 1 to 14, in the illustrated embodiment, the insulator 2 is directly injection-molded onto the conductive lead 6 and the electrical connection member 3, so that the conductive lead 6, the electrical connection member 3, and the insulator 2 become a single integrated component.

[0055] As shown in Figures 1 to 14, in the illustrated embodiment, the conductive lead 6 has a connecting end 6a for electrically connecting to the temperature sensor 4 and an external pin 6b for electrically connecting to a connector located on the outside of the charging dock housing 1.

[0056] As shown in Figures 1 to 14, in the illustrated embodiment, the insulator 2 includes a bracket portion 21 and a mating portion 22. The bracket portion 21 is suitable for insertion into the insertion slot 14 of the charging dock housing 1. The mating portion 22 is configured to be positioned on the outside of the charging dock housing 1. The thermal pad 5 and temperature sensor 4 are mounted on the bracket portion 21, and the mating portion 22 has an insertion cavity 20 into which a connector can be inserted. The external pins 6b of the conductive lead 6 extend into the insertion cavity 20 to electrically connect to the inserted connector.

[0057] As shown in Figures 1 to 14, in the illustrated embodiment, a seal ring mounting groove 24 is formed on the outer circumferential surface of the bracket portion 21. The low-voltage module 100 also includes a seal ring 26 mounted in the seal ring mounting groove 24, and the seal ring 26 is compressed between the bracket portion 21 and the inner wall surface of the insertion slot 14 of the charging dock housing 1, making it suitable for achieving a seal between the bracket portion 21 and the inner wall surface of the insertion slot 14.

[0058] As shown in Figures 1 to 14, in the illustrated embodiment, the bracket portion 21 has a cover plate portion 23 for covering the entrance of the insertion slot 14 of the charging dock housing 1, and the insulator 2 also includes a plurality of buckles 25 connected around the cover plate portion 23. The plurality of buckles 25 are distributed around the outer circumference of the cover plate portion 23 and are used to lock the low voltage module 100 into the charging dock housing 1 by engaging with a plurality of protrusions 15 of the charging dock housing 1, respectively.

[0059] As shown in Figures 1 to 14, in the illustrated embodiment, the conductive lead 6 includes a positive lead 61 and a negative lead 62 that are electrically connected to the positive pin 41 and negative pin 42 of the temperature sensor 4, respectively. The external pins 6b of the positive lead 61 and the negative lead 62 extend into the insertion cavity 20 of the mating portion 22 to be electrically connected to the inserted connector.

[0060] As shown in Figures 1 to 14, in the illustrated embodiment, the connection end 6a of the positive lead 61 is configured to be electrically connected to the positive pin 41 of the temperature sensor 4 in a pluggable manner. The connection end 6a of the negative lead 62 is suitable for plug-in electrical connection with the negative pin 42 of the temperature sensor 4.

[0061] As shown in Figures 1 to 14, in the illustrated embodiment, the connection end 6a of the positive lead 61 is in the shape of an elastic clip suitable for clamping the positive pin 41 of the temperature sensor 4. The connection end 6a of the negative lead 62 is in the shape of an elastic clip suitable for clamping the negative pin 42 of the temperature sensor 4.

[0062] As shown in Figures 1 to 14, in the illustrated embodiment, the low-voltage module 100 comprises a plurality of thermal pads 5 and a plurality of temperature sensors 4, each positioned on the plurality of thermal pads 5. The plurality of thermal pads 5 are used to make thermal contact with a plurality of power terminals 131, and the plurality of temperature sensors 4 are used to detect the temperature of the plurality of power terminals 131.

[0063] As shown in Figures 1 to 14, in the illustrated embodiment, the conductive lead 6 includes a plurality of positive leads 61 and a single negative lead 62. The connection ends 6a of the plurality of positive leads 61 are electrically connected to the positive pins 41 of the plurality of temperature sensors 4, and the single negative lead 62 has a plurality of connection ends 6a that are electrically connected to the negative pins 42 of the plurality of temperature sensors 4. The external pins 6b of the plurality of positive leads 61 and the external pins 6b of the single negative lead 62 extend into the insertion cavity 20 of the mating portion 22 to be electrically connected to the inserted connector.

[0064] As shown in Figures 1 to 14, in the illustrated embodiment, the thermal pad 5 is in the form of a block, and a concave receiving portion 205 is formed in the insulator 2. The thermal pad 5 is positioned and mounted in the receiving portion 205. A mounting slot 51 is formed in the thermal pad 5, and the body of the temperature sensor 4 is inserted into the mounting slot 51 of the thermal pad 5. The positive electrode pin 41 and negative electrode pin 42 of the temperature sensor 4 extend from the thermal pad 5.

[0065] As shown in Figures 1 to 14, in the illustrated embodiment, the heating pad 5 has an arc-shaped contact surface 5a suitable for attachment to the outer surface of the power terminal 131, thereby increasing the thermal contact area between the heating pad 5 and the power terminal 131.

[0066] It should be noted that the low-voltage module 100 of the present invention is not limited to the illustrated embodiment. For example, in another exemplary embodiment of the present invention, the low-voltage module further comprises a circuit board (not shown) attached to and fixed to an insulator 2. For ease of mounting, the insulator 2 may be in the shape of a shell. The first contact portion 31 and the second contact portion 32 of the electrical connection member 3 are contact spring pieces fixed to the circuit board, and the connection portion 30 of the electrical connection member 3 may be a conductive trace formed on the circuit board. In addition, in this embodiment, the low-voltage module of the DC charging dock further comprises a thermal pad 5, a temperature sensor 4, and an external pin 6b. The thermal pad 5 is mounted on the circuit board and thermally contacts the power terminal 131 of the DC charging dock. The temperature sensor 4 is mounted on the thermal pad 5 and detects the temperature of the power terminal 131. The external pin 6b is fixed to the circuit board 2 and electrically connected to a connector (not shown) located on the outside of the charging dock housing 1. The temperature sensor 4 is electrically connected to the external pin 6b via a conductive trace on the circuit board. When the low-voltage module 100 is installed in the insertion slot 14, the thermal pad 5 makes thermal contact with the power terminal 131 and transfers heat from the power terminal 131 to the temperature sensor 4.

[0067] As shown in Figures 1 to 14, a DC charging dock is also disclosed in another exemplary embodiment of the present invention. The DC charging dock comprises a charging dock housing 1, a PE terminal assembly 110, an A- terminal assembly 120, and a low-voltage module 100. The charging dock housing 1 is formed with a first socket 11, a second socket 12, and an insertion slot 14 communicating with the first socket 11 and the second socket 12. The PE terminal assembly 110 includes a PE terminal 111 and is inserted into the first socket 11. The A- terminal assembly 120 includes an A- terminal 121 and is inserted into the second socket 12. The low-voltage module 100 of the DC charging dock is inserted into the insertion slot 14 from the outside of the charging dock housing 1. The first contact portion 31 and the second contact portion 32 of the electrical connection member 3 electrically contact the PE terminal 111 and the A- terminal 121, respectively, thereby electrically connecting the A- terminal 121 to the PE terminal 111.

[0068] As shown in Figures 1 to 14, in the illustrated embodiment, the PE terminal assembly 110 further includes a grounding cable (not shown) and a first sealing component 112. The grounding cable is electrically connected to the PE terminal 111 and leads out from the first socket 11 of the charging dock housing 1. The first sealing component 112 is injected onto the PE terminal 111. The first sealing component 112 is compressed between the PE terminal 111 and the inner wall surface of the first socket 11 to achieve a seal between the PE terminal 111 and the inner wall surface of the first socket 11.

[0069] As shown in Figures 1 to 14, in the illustrated embodiment, the A-terminal assembly 120 further includes a second sealing component 122. The second sealing component 122 is injection molded onto the A-terminal 121. The second sealing component 122 is compressed between the A-terminal 121 and the inner wall surface of the second socket 12 to achieve a seal between the A-terminal 121 and the inner wall surface of the second socket 12.

[0070] As shown in Figures 1 to 14, in the illustrated embodiment, a plurality of protrusions 15 are formed on the outside of the peripheral wall of the insertion slot 14 of the charging dock housing 1. These protrusions 15 are spaced apart and distributed around the insertion slot 14 and are used to lock the low-voltage module 100 into the charging dock housing 1 by engaging with a plurality of buckles 25 on the insulator 2 of the low-voltage module 100, respectively.

[0071] As shown in Figures 1 to 14, in the illustrated embodiment, the axial direction of the insertion slot 14 is perpendicular to the axial directions of the first socket 11 and the second socket 12, and the low-voltage module 100 is inserted into the insertion slot 14 along the radial direction of the first socket 11 and the second socket 12.

[0072] As shown in Figures 1 to 14, in the illustrated embodiment, a third socket 13 is also formed in the charging dock housing 1, and the insertion slot 14 communicates with the third socket 13. The DC charging dock also includes a power terminal assembly 130 inserted into the third socket 13. The power terminal assembly 130 includes power terminals 131. The thermal pad 5 of the low-voltage module 100 is in thermal contact with the power terminals 131, transferring the heat from the power terminals 131 to the temperature sensor 4 of the low-voltage module 100.

[0073] Figure 15 shows an explanatory perspective view of the power terminal 131 of a DC charging dock according to an exemplary embodiment of the present invention. Figure 16 shows a side view of the power terminal assembly 130 of a DC charging dock according to an exemplary embodiment of the present invention.

[0074] As shown in Figures 15 and 16, in the illustrated embodiment, the power terminal assembly 130 further includes a high-voltage cable 134 and a sealing plug (not shown). The high-voltage cable 134 is electrically connected to the power terminal 131 and leads out from the charging dock housing 1. The sealing plug is fitted onto the high-voltage cable 134 and inserted into the third socket 13. The sealing plug is compressed between the high-voltage cable 134 and the inner wall surface of the third socket 13 to achieve a seal between the high-voltage cable 134 and the inner wall surface of the third socket 13.

[0075] As shown in Figures 15 and 16, in the illustrated embodiment, the power terminal 131 includes a cylindrical portion 132 and a welded portion 133. The cylindrical portion 132 is used for mating with a mating power terminal (not shown). The welded portion 133 is connected to the rear end of the cylindrical portion 132 for welding to a high-voltage cable 134. The heating pad 5 is in thermal contact with the outer circumferential surface of the cylindrical portion 132 of the power terminal 131 and is adjacent to the welded portion 133 of the power terminal 131.

[0076] As shown in Figures 15 and 16, in the illustrated embodiment, a seal mounting groove 135 is formed at the rear end of the cylindrical portion 132 of the power terminal 131. The power terminal assembly 130 also includes a seal ring (not shown) mounted in the seal mounting groove 135, which is pressed between the cylindrical portion 132 of the power terminal 131 and the inner wall surface of the third socket 13 of the charging dock housing 1 to achieve a seal between the cylindrical portion 132 and the inner wall surface of the third socket 13.

[0077] As shown in Figures 1 to 14, in the illustrated embodiment, the charging dock housing 1 has a plurality of third insertion holes 13, and the DC charging dock has a plurality of power terminal assemblies 130, each inserted into the plurality of third insertion holes 13. The insertion slots 14 communicate with a plurality of third sockets 13, and the low voltage module 100 includes a plurality of thermal pads 5 that thermally contact the power terminals 131 of the plurality of power terminal assemblies 130, and a plurality of temperature sensors 4 for detecting the temperature of the plurality of power terminals 131. In the illustrated embodiment, the charging dock housing 1 has two third sockets 13, the DC charging dock has two power terminal assemblies 130, and the low voltage module 100 includes two thermal pads 5 and two temperature sensors 4.

[0078] As shown in Figures 1 to 14, in the illustrated embodiment, the charging dock housing 1 is an integrally injection-molded part.

[0079] Those skilled in the art should understand that the embodiments described above are illustrative and not limiting. For example, those skilled in the art can make many modifications to the embodiments without structural or principle contradictions and can freely combine the various features described in different embodiments.

[0080] While several exemplary embodiments have been illustrated and described, it will be understood by those skilled in the art that various modifications or changes can be made to these embodiments without departing from the principles and spirit of this disclosure. The scope of this disclosure is defined in the claims and its equivalents.

[0081] When used herein, elements described in the singular form and preceded by the word "a" or "an" should be understood not to exclude the plural forms of such elements or steps unless it is explicitly stated that such exclusion is to be excluded. Furthermore, references to “one embodiment” of the present invention are not intended to be construed as excluding the existence of additional embodiments that likewise incorporate the described features. Moreover, unless it is expressly stated otherwise, embodiments that “compile” or “have” one or more elements having a particular characteristic may include additional such elements that do not possess that characteristic.

Claims

1. It is a low-voltage module for a DC charging dock, Insulator (2), The device comprises an electrical connection member (3), and the electrical connection member (3) is A first contact portion (31) used to electrically contact the PE terminal (111) of the DC charging dock, A second contact portion (32) used to electrically contact the A- terminal (121) of the DC charging dock, The first contact portion (31) and the second contact portion (32) are electrically connected, and the connecting portion (30) is fixed to the insulator (2). Includes, The low-voltage module (100) is suitable for being plugged into an insertion slot (14) of a charging dock housing (1) from the outside, and when the low-voltage module (100) is installed in the insertion slot (14), the first contact portion (31) and the second contact portion (32) electrically contact the PE terminal (111) and the A- terminal (121), respectively, thereby electrically connecting the A- terminal (121) to the PE terminal (111), the low-voltage module for a DC charging dock.

2. The low-voltage module for a DC charging dock according to claim 1, wherein the insulator (2) is directly injection-molded onto the electrical connection member (3), and the insulator (2) and the electrical connection member (3) become an integrated component.

3. The low-voltage module for a DC charging dock according to claim 1, wherein the electrical connection member (3) is a single-piece punched component.

4. The first contact portion (31) includes a pair of first spring pieces used to clamp the PE terminal (111), and / or The low-voltage module of a DC charging dock according to claim 1, wherein the second contact portion (32) includes a pair of second spring pieces used to clamp the A- terminal (121).

5. The insulator (2) has a first locking portion (210) that is pressed against the PE terminal (111) when the low-voltage module (100) is installed in the insertion slot (14) to lock the PE terminal (111) to the charging dock housing (1), and / or The low-voltage module for a DC charging dock according to claim 1, wherein the insulator (2) has a second locking portion (220) that contacts the A-terminal (121) when the low-voltage module (100) is mounted in the insertion slot (14) and locks the A-terminal (121) to the charging dock housing (1).

6. A heat pad (5) is assembled to the insulator (2) and is intended to make thermal contact with the power terminal (131) of the DC charging dock, A temperature sensor (4) is provided on the heating pad (5) to detect the temperature of the power terminal (131), A conductive lead (6) is provided on the insulator (2) and electrically connected to the temperature sensor (4). Furthermore, The low-voltage module for a DC charging dock according to claim 1, wherein when the low-voltage module (100) is installed in the insertion slot (14), the thermal pad (5) makes thermal contact with the power terminal (131) to transfer the heat from the power terminal (131) to the temperature sensor (4).

7. The low-voltage module for a DC charging dock according to claim 6, wherein the insulator (2) is directly injection-molded onto the conductive lead (6) and the electrical connection member (3), so that the conductive lead (6), the electrical connection member (3), and the insulator (2) form a single integrated component.

8. The low-voltage module for a DC charging dock according to claim 6, wherein the conductive lead (6) has a connecting end (6a) electrically connected to the temperature sensor (4) and an external pin (6b) for electrically connecting to a connector located outside the charging dock housing (1).

9. The insulator (2) is A bracket portion (21) suitable for insertion into the insertion slot (14) of the charging dock housing (1), A fitting portion (22) is configured to be positioned on the outside of the charging dock housing (1) and Includes, Low-voltage module for a DC charging dock according to claim 8, wherein the heating pad (5) and the temperature sensor (4) are mounted on the bracket portion (21), the mating portion (22) has an insertion cavity (20) into which the connector can be inserted, and the external pins (6b) of the conductive lead (6) extend into the insertion cavity (20) to be electrically connected to the inserted connector.

10. A seal ring mounting groove (24) is formed on the outer circumferential surface of the bracket portion (21), and the low voltage module (100) further comprises a seal ring (26) mounted in the seal ring mounting groove (24), wherein the seal ring (26) is compressed between the support portion (21) and the inner wall surface of the insertion slot (14) of the charging dock housing (1) to achieve a seal between the support portion (21) and the inner wall surface of the insertion slot (14), as described in claim 9.

11. Low voltage module for DC charging dock according to claim 9, wherein the bracket portion (21) has a cover plate portion (23) for covering the entrance of the insertion slot (14) of the charging dock housing (1), and the insulator (2) also includes a plurality of buckles (25) connected around the cover plate portion (23), the plurality of buckles (25) being distributed around the outer circumference of the cover plate portion (23) and engaging with a plurality of protrusions (15) of the charging dock housing (1) respectively to lock the low voltage module (100) to the charging dock housing (1).

12. The conductive lead (6) includes a positive lead (61) and a negative lead (62) that are electrically connected to the positive pin (41) and negative pin (42) of the temperature sensor (4), respectively. The low-voltage module for a DC charging dock according to claim 9, wherein the external pins (6b) of the positive lead (61) and the negative lead (62) extend into the insertion cavity (20) of the mating portion (22) to electrically connect to the inserted connector.

13. The connection end (6a) of the positive lead (61) is suitable for plug-in electrical connection with the positive pin (41) of the temperature sensor (4), and / or The low-voltage module for a DC charging dock according to claim 12, wherein the connection end (6a) of the negative lead (62) is suitable for plug-in electrical connection with the negative pin (42) of the temperature sensor (4).

14. The connecting end (6a) of the positive lead (61) is in the shape of an elastic clip suitable for clamping the positive pin (41) of the temperature sensor (4), and / or The low-voltage module for a DC charging dock according to claim 13, wherein the connecting end (6a) of the negative lead (62) is in the shape of an elastic clip suitable for clamping the negative pin (42) of the temperature sensor (4).

15. The low-voltage module (100) of the DC charging dock comprises a plurality of thermal pads (5) and a plurality of temperature sensors (4) each disposed on the plurality of thermal pads (5), wherein the plurality of thermal pads (5) are used to make thermal contact with a plurality of power terminals (131), and the plurality of temperature sensors (4) are used to detect the temperature of the plurality of power terminals (131), as described in claim 9.

16. The conductive lead (6) includes a plurality of positive lead leads (61) and a single negative lead lead (62). The connection ends (6a) of the plurality of positive leads (61) are electrically connected to the positive pins (41) of the plurality of temperature sensors (4), and the single negative lead (62) has a plurality of connection ends (6a) that are electrically connected to the negative pins (42) of the plurality of temperature sensors (4). The low-voltage module for a DC charging dock according to claim 15, wherein the external pins (6b) of the plurality of positive leads (61) and the external pins (6b) of the single negative lead (62) extend into the insertion cavity (20) of the mating portion (22) to electrically connect to the inserted connector.

17. The heating pad (5) is block-shaped, and a concave receiving portion (205) is formed in the insulator (2). The heating pad (5) is positioned and mounted in the receiving portion (205). A low-voltage module for a DC charging dock according to claim 6, wherein a mounting slot (51) is formed in the thermal pad (5), the body of the temperature sensor (4) is inserted into the mounting slot (51) of the thermal pad (5), and the positive pin (41) and negative pin (42) of the temperature sensor (4) extend from the thermal pad (5).

18. The low-voltage module for a DC charging dock according to claim 17, wherein the thermal pad (5) has an arc-shaped contact surface (5a) suitable for attachment to the outer surface of the power terminal (131), thereby increasing the thermal contact area between the thermal pad (5) and the power terminal (131).

19. The circuit board is further attached to and fixed to the insulator (2), The low-voltage module for a DC charging dock according to claim 1, wherein the first contact portion (31) and the second contact portion (32) of the electrical connection member (3) are contact spring pieces fixed to the circuit board, and the connection portion (30) of the electrical connection member (3) is a conductive trace formed on the circuit board.

20. A thermal pad (5) is mounted on the circuit board and is intended to make thermal contact with the power terminal (131) of the DC charging dock. A temperature sensor (4) is provided on the heating pad (5) to detect the temperature of the power terminal (131), External pins (6b) for electrically connecting to a connector fixed to the circuit board (2) and located on the outside of the charging dock housing (1) and Furthermore, The temperature sensor (4) is electrically connected to the external pin (6b) via a conductive trace on the circuit board. The low-voltage module for a DC charging dock according to claim 19, wherein when the low-voltage module (100) is installed in the insertion slot (14), the thermal pad (5) makes thermal contact with the power terminal (131) to transfer the heat from the power terminal (131) to the temperature sensor (4).

21. It is a DC charging dock, A charging dock housing (1) having a first socket (11), a second socket (12), and an insertion slot (14) communicating with the first socket (11) and the second socket (12), A PE terminal assembly (110) including a PE terminal (111) and inserted into the first socket (11), An A-terminal assembly (120) including an A-terminal (121) and inserted into the second socket (12), The low-voltage module (100) according to any one of claims 1 to 20 and The low-voltage module (100) is inserted into the insertion slot (14) from the outside of the charging dock housing (1). The first contact portion (31) and the second contact portion (32) of the electrical connection member (3) electrically contact the PE terminal (111) and the A- terminal (121), respectively, thereby electrically connecting the A- terminal (121) to the PE terminal (111), in a DC charging dock.

22. The PE terminal assembly (110) is A grounding cable electrically connected to the PE terminal (111) and led out from the first socket (11) of the charging dock housing (1), The first seal component (112) is injection molded on the PE terminal (111) and It further includes, The DC charging dock according to claim 21, wherein the first sealing component (112) is compressed between the PE terminal (111) and the inner wall surface of the first socket (11) to achieve a seal between the PE terminal (111) and the inner wall surface of the first socket (11).

23. The A-terminal assembly (120) further includes a second seal component (122) injection-molded on the A-terminal (121), The DC charging dock according to claim 21, wherein the second sealing component (122) is compressed between the A-terminal (121) and the inner wall surface of the second socket (12) to achieve a seal between the A-terminal (121) and the inner wall surface of the second socket (12).

24. A DC charging dock according to claim 21, wherein a plurality of protrusions (15) are formed on the outside of the peripheral wall of the insertion slot (14) of the charging dock housing (1), the plurality of protrusions (15) are spaced apart and distributed around the insertion slot (14), and each engages with a plurality of buckles (25) of the insulator (2) of the low voltage module (100) to be used to lock the low voltage module (100) into the charging dock housing (1).

25. The DC charging dock according to claim 21, wherein the axial direction of the insertion slot (14) is perpendicular to the axial directions of the first socket (11) and the second socket (12), and the low-voltage module (100) is inserted into the insertion slot (14) along the radial direction of the first socket (11) and the second socket (12).

26. A third socket (13) is also formed in the charging dock housing (1), and the insertion slot (14) is in communication with the third socket (13). The DC charging dock according to claim 21, further comprising a power terminal assembly (130) inserted into the third socket (13), the power terminal assembly (130) including a power terminal (131), and the thermal pad (5) of the low voltage module (100) thermally contacting the power terminal (131) to transfer heat from the power terminal (131) to the temperature sensor (4) of the low voltage module (100).

27. The power terminal assembly (130) is A high-voltage cable (134) is electrically connected to the power terminal (131) and is led out from the charging dock housing (1), A seal plug fitted onto the high-voltage cable (134) and inserted into the third socket and It further includes, The DC charging dock according to claim 26, wherein the sealing plug is compressed between the high-voltage cable (134) and the inner wall surface of the third socket (13) to achieve a seal between the high-voltage cable (134) and the inner wall surface of the third socket (13).

28. The aforementioned power terminal (131) is A cylindrical portion (132) used for mating with the power terminal of the other side, A welded portion (133) is connected to the rear end of the cylindrical portion (132) and is used for welding to the high-voltage cable (134). Includes, The DC charging dock according to claim 26, wherein the heating pad (5) is in thermal contact with the outer circumferential surface of the cylindrical portion (132) of the power terminal (131) and is adjacent to the welded portion (133) of the power terminal (131).

29. A seal mounting groove (135) is formed at the rear end of the cylindrical portion (132) of the power terminal (131), and the power terminal assembly (130) further includes a seal ring mounted in the seal mounting groove (135), the seal ring being compressed between the cylindrical portion (132) of the power terminal (131) and the inner wall surface of the third socket (13) of the charging dock housing (1) to achieve a seal between the cylindrical portion (132) and the inner wall surface of the third socket (13), as described in claim 28.

30. The charging dock housing (1) has a plurality of third sockets (13), and the DC charging dock has a plurality of power terminal assemblies (130) inserted into each of the plurality of third sockets (13). The DC charging dock according to claim 26, wherein the insertion slot (14) is in communication with the plurality of third sockets (13), and the low-voltage module (100) includes a plurality of thermal pads (5) that thermally contact the power terminals (131) of the plurality of power terminal assemblies (130), and a plurality of temperature sensors (4) for detecting the temperature of the plurality of power terminals (131), respectively.

31. The DC charging dock according to any one of claims 21 to 30, wherein the charging dock housing (1) is an integrally injection-molded part.

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