Connection mechanisms, electrical energy transmission devices, and automobiles

Abstract

The present invention provides a connection mechanism, an electric energy transmission device, and an automobile, the connection mechanism including a male end connection mechanism and a female end connection mechanism, the male end connection mechanism including a flat ribbon, a flat terminal, and a male end housing connected to the flat ribbon and the flat terminal, the female end connection mechanism including a mating terminal and a female end housing connected to the mating terminal, the male end connection mechanism and the female end connection mechanism are electrically connected by the flat terminal and the mating terminal, and the male end housing and the female end housing are assembled and connected to form the connection mechanism. The flat ribbons are stacked and arranged at appropriate intervals, which effectively reduces electromagnetic interference with other components after electricity is passed through the flat ribbons, thereby eliminating the shielding layer structure of the high voltage charging harness, and achieving the purpose of reducing costs and weight.

Description

Technical Field

[0001] This application claims the priority of a Chinese patent application filed on October 1, 2021, with an application number of 202111167062.8 and an invention title of "Connection Mechanism, Electric Energy Transmission Device and Automobile", and all the contents of the patent application are incorporated herein in their entirety. This application further claims the priority of a Chinese utility model application filed on October 1, 2021, with an application number of 202122400673.4 and a utility model title of "Connection Mechanism, Electric Energy Transmission Device and Automobile", and all the contents of the utility model application are incorporated herein in their entirety.

[0002] The present invention relates to the field of charging technology, and particularly to a connection mechanism, an electric energy transmission device and an automobile. [[ID= 10]]

Background Art

[0003] The new energy battery of a new energy vehicle is replenished with energy using a charging system. In the charging system, in addition to the charging dock, there is a high-voltage connection mechanism connected to the battery system. The charging harness is the most important unit in the high-voltage system of an electric vehicle. The traditional charging harness uses copper wire as the charging cable, and the end of the copper wire is connected to a plug-in terminal to be electrically connected to the battery system. The current high-voltage connection mechanisms are all connector structures with an assembled structure, and there are problems such as a complex structure, difficulty in assembly, and high connector cost. Also, the amount of copper material used for the cable and terminals is large, the connection process is relatively complex, which is also the reason for the high cost of the high-voltage connection mechanism remaining high.

[0004] When a large current flows through the high-voltage charging harness, it generates electromagnetic interference to other components. In order to avoid such electromagnetic interference, it is necessary to increase a shielding layer outside the high-voltage charging harness. Such shielding for the high-voltage charging harness significantly increases its cost and weight.

[0005] Furthermore, generally speaking, charging systems all have a temperature measurement structure installed in the charging dock, but not in the connection mechanism. However, since the conductive current is the same, if the temperature of the connection mechanism rises, it is necessary to monitor and stop the charging process in a timely manner to protect the safety of the charging harness and battery system.

[0006] As the electric vehicle market expands, charging systems urgently need connection mechanisms and electrical energy transmission devices that are simple in structure and cost-effective. [Overview of the Initiative]

[0007] The object of the present invention is to provide a connection mechanism that effectively reduces electromagnetic interference to other components after the flat ribbons are energized by laminating flat ribbons and providing appropriate spacing between them, thereby eliminating the need for a shielding layer structure in high-voltage charging harnesses and achieving the objectives of cost reduction and weight reduction.

[0008] The above objectives of the present invention are achieved by the following technical solutions.

[0009] The present invention provides a connection mechanism comprising a male-end connection mechanism and a female-end connection mechanism, wherein the male-end connection mechanism comprises a flat ribbon, a flat terminal, and a male-end housing connected to the flat ribbon and the flat terminal, and the female-end connection mechanism comprises a mating terminal and a female-end housing connected to the mating terminal, and the male-end connection mechanism and the female-end connection mechanism are electrically connected by the flat terminal and the mating terminal, and the male-end housing and the female-end housing are connected to form the connection mechanism.

[0010] In a preferred embodiment, the aspect ratio of the cross-section of the flat ribbon is 1:1 to 120:1.

[0011] In a preferred embodiment, the flat ribbons are at least two in number, the flat ribbons are stacked vertically, and the male end housing is integrally injection-molded with at least a portion of the flat ribbons and the outer circumference of the flat terminals to form an insulating structure.

[0012] In a preferred embodiment, the flat ribbon includes a flat core and an outer insulating layer, the outer insulating layer being partially stripped to expose the flat core, and the ends of the outer insulating layer being located within or in contact with the male end housing.

[0013] In a preferred embodiment, the flat ribbon includes a flat core having a hardness of 8 HV to 105 HV.

[0014] In a preferred embodiment, the flat ribbon consists of at least two ribbons, which are stacked vertically, and the flat ribbon includes a flat core, with a vertical distance of 27 cm or less between the two flat cores.

[0015] In a preferred embodiment, the flat ribbon comprises at least two flat ribbons, each flat ribbon includes a flat core, and the vertical distance between the two flat cores is 7 cm or less.

[0016] In a preferred embodiment, the flat ribbons consist of at least two ribbons, which are stacked vertically, and the flat ribbons include flat cores, with an overlap of 40% to 100% along the stacking direction of the two flat cores.

[0017] In a preferred embodiment, the flat ribbon includes a flat core whose tip is connected to the flat terminal, and the male end housing covers at least a portion of the flat terminal.

[0018] In a preferred embodiment, the flat ribbon includes a flat core that is integrated with the flat terminals.

[0019] In a preferred embodiment, at least a portion of the flat terminal protrudes from the male terminal housing, or the male terminal housing has a housing cavity, and at least a portion of the flat terminal protrudes from the bottom surface of the housing cavity but does not extend beyond the male terminal housing.

[0020] In a preferred embodiment, the flat ribbon includes a flat core and a bent portion between the flat core and the flat terminals, with an angle of 0° to 180°.

[0021] In a preferred embodiment, a conductive corrosion-preventive layer is provided on at least a portion of the flat terminal.

[0022] In a preferred embodiment, the thickness of the conductive corrosion-preventive layer is 0.3 μm to 3000 μm.

[0023] In a preferred embodiment, the thickness of the conductive corrosion-preventive layer is 2.5 μm to 1000 μm.

[0024] In a preferred embodiment, a chamfer is provided at the end of the flat terminal.

[0025] In a preferred embodiment, the male end connection mechanism includes an interlock connector, at least a portion of which is integrally injected into the male end housing.

[0026] In a preferred embodiment, the mating terminal includes a fixing portion and a cable clamp portion, the female end connection mechanism further includes a cable, the fixing portion is electrically connected to a conductive portion at the end of the cable, and the cable clamp portion is electrically connected to the flat terminal.

[0027] In a preferred embodiment, a clip made of a shape memory alloy is sleeved on the cable clamping portion.

[0028] In a preferred embodiment, the transformation temperature of the shape memory alloy is set within the range of 40°C to 70°C. When the temperature of the clip is lower than the transformation temperature, the clip is in an expanded state. When the temperature of the clip is higher than the transformation temperature, the clip is in a clamped state.

[0029] In a preferred embodiment, a clip including a side wall and an elastic unit fixed to the side wall is sleeved on the cable clamping portion. The elastic unit is in contact with and connected to the outside of the cable clamping portion.

[0030] In a preferred embodiment, the range of the force applied by the elastic unit to the cable clamping portion is 3N to 200N.

[0031] In a preferred embodiment, the elastic unit is elastic rubber, a spring or a metal dome.

[0032] In a preferred embodiment, the cable clamping portion of the fitting terminal is formed by stacking a plurality of layers of sheet-like terminals. Concave grooves for fitting and connecting in matching with the flat ribbon are formed in the sheet-like terminals.

[0033] In a preferred embodiment, the gap between two adjacent sheet-like terminals is less than 0.2mm.

[0034] In a preferred embodiment, at least a part of the material of the sheet-like terminal is a shape memory alloy.

[0035] In a preferred embodiment, the transformation temperature of the memory alloy is set within the range of 40°C to 70°C, and when the temperature of the sheet-like terminal is lower than the transformation temperature, the plurality of grooves are in an expanded state, and when the temperature of the sheet-like terminal is higher than the transformation temperature, the plurality of grooves are in a clamped state.

[0036] In a preferred embodiment, the female end housing is integrally injection-molded with at least a portion of the outer circumference of the mating terminal to form an insulating structure.

[0037] In a preferred embodiment, the female terminal connection mechanism further includes a cable electrically connected to the mating terminal, wherein the mating terminal and at least a portion of the cable are provided within the female terminal housing, and at least a portion of the mating terminal is exposed outside the female terminal housing.

[0038] In a preferred embodiment, at least a portion of the cable clamp portion protrudes from the outer wall of the female end housing, or an opening boss is provided in the female end housing, and at least a portion of the cable clamp portion is provided within the opening boss.

[0039] In a preferred embodiment, the female terminal connection mechanism has a high-voltage interlock structure that is electrically connected to the interlock connector to form a circuit.

[0040] In a preferred embodiment, the female end connection mechanism and / or the male end connection mechanism have a sealing structure.

[0041] In a preferred embodiment, the seal structure is secondary injection molded into the female end housing and / or the male end housing.

[0042] In a preferred embodiment, the female-end connection mechanism and / or the male-end connection mechanism has at least one temperature measuring structure for measuring the temperature of the mating terminal and / or the flat ribbon and / or the flat terminal.

[0043] In a preferred embodiment, the temperature measuring structure is bonded to the mating terminal and / or the flat ribbon and / or the flat terminal to measure the temperature of the mating terminal and / or the flat ribbon and / or the flat terminal.

[0044] In a preferred embodiment, the male terminal connection mechanism has at least one temperature measuring structure, the flat ribbons are at least two, and the temperature measuring structure is positioned between the flat ribbons to measure the temperature of the flat ribbons.

[0045] In a preferred embodiment, the male end connection mechanism and the female end connection mechanism are connected by one or more of the following methods: adhesive connection, magnetic attraction connection, bayonet connection, plug-in connection, locking connection, binding connection, screw connection, rivet connection, and weld connection.

[0046] In a preferred embodiment, the mating terminal includes a cable clamp portion, the flat terminal is mated to the cable clamp portion and electrically connected, and the plug-in force between the flat terminal and the cable clamp portion is 3N to 150N.

[0047] In a preferred embodiment, the plug-in force between the flat terminal and the cable clamp portion is 10N to 130N.

[0048] In a preferred embodiment, the contact resistance between the flat terminal and the mating terminal is less than 9 mΩ.

[0049] In a preferred embodiment, the contact resistance between the flat terminal and the mating terminal is less than 1 mΩ.

[0050] In a preferred embodiment, the number of insertions and removals between the male-end connector and the female-end connector is nine or more.

[0051] In a preferred embodiment, the weight of the male connector mechanism is 305 g or less.

[0052] In a preferred embodiment, the height of the male terminal connection mechanism along the insertion / removal direction is 108 mm or less.

[0053] In a preferred embodiment, an electrical energy transmission device comprising the connection mechanism described in any one of the above-mentioned items.

[0054] A motor vehicle that includes the connection mechanism described in any one of the above items.

[0055] The features and advantages of this invention are as follows.

[0056] 1. The connection mechanism of the present invention is provided with an injection-molded male end housing, which makes it easy to manufacture, low-cost, allows for direct injection and insulation into the flat ribbon, reduces the need to attach the flat ribbon, eliminates the need to consider assembly issues, allows the tip of the flat ribbon to be molded into various shapes according to demand, saves processing steps and reduces processing costs.

[0057] 2. The connection mechanism of the present invention, by providing flat ribbons in a stacked configuration with appropriate spacing, effectively reduces electromagnetic interference to other components after the flat ribbons are energized, thereby eliminating the need for a shielding layer structure in high-voltage charging harnesses and meeting the demands for cost reduction and weight reduction.

[0058] 3. In the connection between the flat terminal and the mating terminal, the conductive corrosion prevention layer reduces the occurrence of electrochemical reactions between the flat terminal and the mating terminal of the flat ribbon, thereby solving the technical problem that the flat ribbon can only be connected to other terminals or electrical devices via a copper terminal.

[0059] 4. The mating terminal consists of multiple sheet-like terminals stacked and arranged. The sheet-like terminals are easily deformable and can be plugged into the flat terminals of the flat ribbon. The flat terminals of the flat ribbon and the strip-shaped grooves of the sheet-like terminals come into contact with each other, achieving an electrical connection and thus ensuring the stability of the connection between the mating terminal and the flat ribbon.

[0060] 5. The flat core and flat terminals of the flat ribbon are integrated into a single structure and directly connected to the mating terminal, solving the problem of high cost and low efficiency that would otherwise be required to connect copper terminals to the flat ribbon, and enabling safe and rapid insertion and removal.

[0061] 6. The mating terminal has a memory function, and when it is below the transformation temperature, the strip-shaped groove of the mating terminal is normally in an expanded state. At this time, the flat terminal of the flat ribbon can be butted together without insertion force, facilitating the simple mating of electrical equipment by the operator. When current is conducted through the mating terminal during operation, the temperature of the mating terminal gradually rises due to the action of resistance. When the temperature rises above the transformation temperature, the strip-shaped groove of the mating terminal contracts radially. The rise in temperature increases the contact area and contact force between the strip-shaped groove of the mating terminal and the flat terminal of the flat ribbon, improving the reliability of the contact and eliminating the need for insertion force, making the work easier and increasing work efficiency.

[0062] 7. The insert-type high-pressure interlock structure, unlike conventional assembled high-pressure interlocks, is fixed to the connection mechanism by integral injection molding, eliminating the need for assembly, reducing costs, and fully satisfying the high-pressure interlock effect.

[0063] 8. Instead of attaching a separate seal ring to the connection mechanism, the sealing structure of the connection mechanism adopts a secondary injection seal structure instead of a traditional seal ring, allowing it to be molded directly into the connection mechanism, resulting in better injection bonding and reduced costs.

[0064] 9. By employing a temperature measurement mechanism, the temperature of the terminals inside the connection mechanism can be monitored independently, thus avoiding the inability to monitor the temperature of the connection mechanism due to damage to temperature sensors in other locations. [Brief explanation of the drawing]

[0065] To more clearly explain the technical concept of the present invention, the following briefly introduces the drawings necessary for describing the embodiments. As will be clear, the drawings in the following description are only a few embodiments of the present invention, and those skilled in the art can obtain other drawings based on these without any creative effort. [Figure 1] This is a schematic diagram of the connection mechanism in the present invention. [Figure 2] This is a schematic diagram of the structure of the male terminal connection mechanism in the present invention. [Figure 3] This is a schematic diagram of the structure of the flat core in the present invention. [Figure 4] This is a schematic diagram of the female terminal connection mechanism in the present invention. [Figure 5] This is a schematic diagram of the structure of the mating terminal in the present invention. [Figure 6] This is a schematic diagram of the plug-in structure of the flat core and mating terminal in the present invention. [Figure 7] This is a schematic diagram of the structure of the interlock connector in the present invention. [Figure 8] This is a schematic diagram of the high-pressure interlock structure in the present invention. [Figure 9] This is a schematic diagram of the magnetic field structure of the flat core in the present invention. [Figure 10] This is a schematic diagram illustrating the vertical distance structure of the flat core in the present invention. [Figure 11] This is a schematic diagram of the structure of the flat core in the present invention. [Figure 12] This is a schematic diagram of the clip structure according to the present invention. [Figure 13] This is a schematic cross-sectional view in direction A of the connection mechanism in Figure 1 of the present invention. [Modes for carrying out the invention]

[0066] The following describes the technical concepts in the embodiments of the present invention clearly and completely with reference to the drawings of the embodiments, and it is clear that the embodiments described are only a part of the embodiments of the present invention, not all of them. All other embodiments obtained by those skilled in the art without creative work based on the embodiments of the present invention are all within the scope of protection of the present invention.

[0067] As shown in Figures 1 to 4, the connection mechanism includes a male end connection mechanism 10 and a female end connection mechanism 20. The male end connection mechanism 10 includes a flat ribbon 11, a flat terminal 113, and a male end housing 12 connected to the flat ribbon 11 and the flat terminal 113. The female end connection mechanism 20 includes a mating terminal 23 and a female end housing 22 connected to the mating terminal 23. The male end connection mechanism 10 and the female end connection mechanism 20 are electrically connected by the flat terminal 113 and the mating terminal 23, and the male end housing 12 is connected to the female end housing 22 to form the connection mechanism.

[0068] By layering flat ribbons and providing appropriate spacing, electromagnetic interference to other components after the flat ribbons are energized is effectively reduced, thereby eliminating the need for a shielding layer structure in high-voltage charging harnesses and meeting the demands for cost reduction and weight reduction.

[0069] Furthermore, the flat ribbon 11 offers significant advantages in both heat dissipation and assembly. The large aspect ratio of the conductive portion of the flat ribbon 11, meaning a large flat surface in contact with the external environment, allows for effective heat dissipation, rapidly reducing the temperature rise of the cable due to current and extending the cable's lifespan. Additionally, when assembling cables, if the height of the installation environment is insufficient, the flat ribbon 11 can be used to reduce the cable laying height, allowing for effective assembly in close contact with the installation environment, thereby reducing the demand for installation space and improving space utilization.

[0070] In some embodiments, the material of the flat ribbon 11, flat terminal 113, and mating terminal 23 is a metallic conductive material containing one or more of the following: nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium, beryllium, and lead. These materials are stable and have good conductivity, and preferred materials are those containing copper or copper alloys or aluminum or aluminum alloys.

[0071] In some embodiments, the material of the flat ribbon 11 contains one or more of the following: aluminum, phosphorus, tin, copper, iron, manganese, chromium, titanium, and lithium. The inclusion of aluminum or aluminum alloy in the material of the flat ribbon 11 is one of the main means of recent energy conservation and cost reduction. In the field of electrical connections, copper wires are used to conduct electric current, and copper has high conductivity and good ductility. However, as the price of copper rises day by day, the material cost of using copper as a conductor is increasing. Therefore, people have begun to look for alternatives to metallic copper to reduce costs. The metallic aluminum content in the Earth's crust is approximately 7.73%, and after the optimization of refining technology, its price is relatively low. Furthermore, aluminum is lighter than copper, and its conductivity is second only to copper. Therefore, in the field of electrical connections, aluminum can replace some copper. Consequently, replacing copper with aluminum in the field of automotive electrical connections is a developing trend.

[0072] In one embodiment, the aspect ratio of the cross-sectional area of ​​the flat ribbon 11 is 1:1 to 120:1.

[0073] To verify the effect of the aspect ratio of the cross-section of the flat ribbon 11 on the temperature rise and tensile strength of the flat ribbon 11, the inventors selected samples of flat ribbon 11 with the same cross-sectional area but different aspect ratios, tested the temperature rise and tensile strength of the flat ribbon 11, and the test results are shown in Table 1.

[0074] Test method for temperature rise of flat ribbon 11: The same current is passed through the flat ribbon 11, and the temperature of the flat ribbon 11 at the same location is detected in a sealed environment before energization and after the temperature has stabilized. The difference is subtracted and the absolute value is taken. In this embodiment, a temperature rise greater than 50K is considered a failure.

[0075] Test method for the tensile strength of the flat ribbon 11: Using a universal tensile testing machine, both ends of the flat ribbon 11 sample are fixed to the tensile fixture of the universal tensile testing machine, and the ribbon is pulled at a speed of 50 mm / min. The tensile force value at the time of final fracture is recorded. In this embodiment, a tensile force value greater than 1600 N is considered a passing value.

[0076] Table 1: Effect of aspect ratio of the cross-section of the flat ribbon 11 on the temperature rise and tensile strength of the flat ribbon 11 [Table 1] As can be seen from Table 1 above, if the aspect ratio of the cross-section of the flat ribbon 11 is less than 1:1, the flat ribbon 11 that has a temperature rise greater than 50K is unacceptable. If the aspect ratio of the cross-section of the flat ribbon 11 is 1:1 or greater, the flat ribbon 11 that has a temperature rise less than 50K is acceptable, and the condition improves further. This is because the larger the aspect ratio of the cross-section of the flat ribbon 11, the larger the heat dissipation area of ​​the flat ribbon 11. For the same temperature rise, a flat ribbon 11 with better heat dissipation will have a lower temperature rise. If the aspect ratio of the cross-section of the flat ribbon 11 is greater than 120:1, the flat ribbon 11 is too thin. When the flat ribbon 11 is subjected to tensile force, the flat ribbon 11 that is too thin cannot withstand the large tensile force and will break. In this case, the tensile strength of the flat ribbon 11 does not meet the requirements for an acceptable value. Therefore, the inventor set the aspect ratio of the cross-section of the flat ribbon 11 to 1:1 to 120:1.

[0077] In one embodiment, as shown in Figure 2, there are at least two flat ribbons 11, which are stacked vertically, and the male end housing 12 is integrally injection-molded around the outer circumference of at least some of the flat ribbons 11 and flat terminals 113 to form an insulating structure.

[0078] Typical conductive circuits consist of two circuits; for example, a DC charging dock has a DC positive electrode charging cable and a DC negative electrode charging cable, and an AC charging dock has an AC live wire charging cable and an AC neutral wire charging cable. By stacking the flat ribbons 11 vertically, the assembly space can be used effectively and electromagnetic interference can be canceled out. After the two flat ribbons 11 are stacked vertically, the material for the male end housing 12 is injected using an injection mold between the flat ribbons 11 and around the outer circumference to form the male end housing 12.

[0079] In some embodiments, when there are many circuits that need to be connected, the flat ribbon 11 may consist of three, four, or more ribbons, connecting different circuits.

[0080] In this embodiment, the connection mechanism is provided with an injection-molded male end housing 12, which simplifies processing, reduces costs, allows for direct injection into the flat ribbon 11 for insulation, reduces the number of flat ribbon 11 attachments, eliminates the need to consider assembly issues, and allows the tip of the flat ribbon 11 to be molded into various shapes according to demand, thereby reducing processing steps and lowering processing costs.

[0081] Furthermore, the flat ribbon 11 offers significant advantages in both heat dissipation and assembly. The large aspect ratio of the conductive portion of the flat ribbon 11, meaning a large flat surface in contact with the external environment, allows for effective heat dissipation, rapidly reducing the temperature rise of the cable due to current and extending the cable's lifespan. Additionally, when assembling cables, if the height of the installation environment is insufficient, the flat ribbon 11 can be used to reduce the cable laying height, allowing for effective assembly in close contact with the installation environment, thereby reducing the demand for installation space and improving space utilization.

[0082] In one embodiment, the flat ribbon 11 includes a flat core 111 and an outer insulating layer 112, a portion of which the outer insulating layer 112 is peeled off to expose the flat core 111, and the end of the outer insulating layer 112 is inside or in contact with the male end housing 12.

[0083] The flat core 111 is the conductive portion of the flat ribbon 11, and the outer insulating layer 112 is the insulating portion of the flat ribbon 11. Before injecting the male end housing 12, it is necessary to peel off a portion of the outer insulating layer 112 of the flat ribbon 11 to expose the internal flat core 111, and then integrally injection mold the male end housing 12.

[0084] Preferably, the flat ribbon 11 includes a flat core 111 having a hardness of 8 HV to 105 HV.

[0085] To verify the effect of the hardness of the flat core 111 on the force that causes the flat terminal 113 to peel off the flat core 111 and the torque that causes the flat core 111 to bend in the XY direction, the inventors selected samples of flat core 111 of the same dimensional specifications but with different hardness levels and tested the force that causes the flat terminal 113 to peel off the flat core 111 and the torque that causes the flat core 111 to bend. The test results are shown in Table 2.

[0086] Test method for the force required to detach the flat terminal 113: Using a universal tensile testing machine, the flat terminal 113 and the flat core 111 are fixed perpendicularly to the tensile jig of the universal tensile testing machine, and pulled at a speed of 50 mm / min. The tensile force value at which the flat terminal 113 finally detaches from the flat core 111 is recorded. In this embodiment, a tensile force value greater than 900 N is considered a passing value. Test method for the torque required when the flat core 111 is bent: Using a torque testing machine, the flat core 111 is bent 90° at the same radius and speed. The torque value of the deformation of the flat core 111 during bending is tested. In this embodiment, a torque value less than 30 N·m is considered a passing value.

[0087] Table 2: Effect of the hardness of the flat core 111 on the force that causes the flat terminal 113 to peel off and the torque when the flat core 111 is bent. [Table 2] As can be seen from Table 2 above, if the hardness of the flat core 111 is less than 8HV, the tensile force required to detach the flat terminal 113 from the flat core 111 is less than the acceptable value. In this case, the flat terminal 113 connected to the flat core 111 is easily detached from the flat core 111 by external force, preventing the flat core 111 from conducting electricity and causing a loss of function in the flat core 111. This prevents the objective of electrical energy transmission from being achieved and, in serious cases, can lead to a short circuit and a combustion accident. If the hardness of the flat core 111 is greater than 105HV, the hardness of the flat core 111 itself is high, so if it is necessary to bend the flat core 111, a larger torque is required to deform the flat core 111, and in this case, the torque value does not meet the requirements of the acceptable value. Therefore, the inventor set the hardness of the flat core 111 to 8HV to 105HV.

[0088] As can be seen from the data in Table 2, when the hardness of the flat core 111 is 10HV to 55HV, the tensile force value when the flat terminal 113 peels off from the flat core 111 and the torque value when the flat core 111 is bent in the XY direction are both within a good range. Therefore, the inventors prefer that the hardness of the flat core 111 be 10HV to 55HV.

[0089] Furthermore, there are at least two flat ribbons 11, the flat ribbons 11 are stacked vertically, the flat ribbons 11 include flat cores 111, and the vertical distance between the two flat cores 111 is 27 cm or less.

[0090] Furthermore, the flat ribbon 11 consists of at least two flat ribbons, each flat ribbon 11 includes a flat core 111, and the vertical distance between the two flat cores 111 is 7 cm or less.

[0091] As shown in Figure 9, the flat ribbon 11 generates an induced magnetic field when energized, and this induced magnetic field causes electromagnetic interference to the outside. A common solution in the prior art is to provide an electromagnetic shielding layer on the outside of the flat ribbon 11. In order to eliminate the shielding structure, reduce costs, and reduce weight, the present invention employs the following design, and the vehicle electrical energy transmission system includes two flat ribbons 11 arranged in a stack.

[0092] When two flat ribbons 11 are stacked vertically, the resulting magnetic fields are as shown in Figures 9 to 11. Since the flat core 111 has a flattened structure, the strongest magnetic field is located at the part with the largest surface area. By stacking the two flat cores 111, the magnetic fields of the two flat cores 111 cancel each other out (because the magnitude of the current is the same and the current direction A is opposite in the two flat cores 111, the induced magnetic fields have the same strength but opposite directions). This eliminates electromagnetic interference with other electrical components when the flat core 111 is energized.

[0093] Preferably, the width directions of the two flat ribbons 11 are parallel to each other. The flat ribbons 11 are mirror images of each other. The distance between the two flat cores 111 is H. The stacking direction of the two flat ribbons 11 is the vertical direction in Figure 10.

[0094] When the degree of overlap along the stacking direction of the two flat ribbons 11 is 100%, Table 3 shows the effect of the distance H between the flat cores 111 on magnetic field cancellation, and a percentage of magnetic field cancellation greater than 30% is considered acceptable.

[0095] Table 3: Effect of distance H between flat cores 111 on magnetic field cancellation when the stacking superposition of two flat ribbons 11 is 100%. [Table 3] Here, the degree of overlap refers to the percentage of the area of ​​one flat ribbon 11 that is covered by the overlapping area of ​​the two flat ribbons 11 along the stacking direction.

[0096] As can be seen from Table 3, when the degree of overlap along the stacking direction of the two flat ribbons 11 is 100%, and the distance H between the two flat cores 111 is 27 cm or less, the percentage of magnetic field cancellation is satisfactory, and there is a certain effect in preventing electromagnetic interference. Preferably, when the vertical distance between the two flat cores 111 is 7 cm or less, the magnetic field can be effectively canceled out, and the effect is remarkable. Therefore, the distance H between the two flat cores 111 is further set to 7 cm or less.

[0097] In this embodiment, the connection mechanism is provided with stacked flat ribbons 11 and appropriate spacing between them, thereby effectively reducing electromagnetic interference to other components after the flat ribbons 11 are energized. This eliminates the need for shielding devices in the connection structure, thus meeting the demands for cost reduction and weight reduction.

[0098] In one embodiment, the flat ribbon 11 consists of at least two ribbons, which are stacked vertically, and the flat ribbon 11 includes a flat core 111, with an overlap of 40% to 100% along the stacking direction of the two flat cores 111.

[0099] When the flat ribbons 11 are stacked vertically, the flat ribbons 11 have a flattened structure, and the strongest magnetic field is located at the part with the largest surface area. Therefore, by stacking the flat ribbons 11, the magnetic fields of the positive and negative electrode flat cores 111 cancel each other out, thereby eliminating electromagnetic interference with other electrical components when the flat ribbons 11 are energized.

[0100] The distance between the flat ribbons 11 and the degree of stacking and overlapping of the flat ribbons 11 have a significant effect on the degree of magnetic field cancellation. The present invention effectively cancels the magnetic fields of the flat ribbons 11 by designing the stacking of the two flat ribbons 11 and controlling the stacking distance and degree of overlap of the two flat ribbons.

[0101] When the distance between the flat cores 111 of the two flat ribbons 11 is 7 cm, Table 4 shows the effect of the degree of overlap along the stacking direction of the two flat ribbons 11 on magnetic field cancellation, and a percentage of magnetic field cancellation greater than 30% is considered acceptable.

[0102] Table 4: Effect of stacked superposition area of ​​flat ribbon 11 on magnetic field cancellation when the distance between two flat cores 111 is 7 cm. [Table 4] As can be seen from Table 4, when the distance between the two flat cores 111 is 7 cm, the degree of overlap along the stacking direction of the flat ribbons 11 is 40% to 100%, the percentage of magnetic field cancellation is acceptable, and there is a certain effect in preventing electromagnetic interference. When the degree of overlap along the stacking direction of the two flat ribbons 11 is 90% or more, the effect is significant, and when the degree of overlap along the stacking direction of the two flat ribbons 11 is 100%, the effect is optimal.

[0103] In one embodiment, as shown in Figures 2 to 3, the flat ribbon 11 includes a flat core 111 whose tip is connected to a flat terminal 113, and the male end housing 12 covers at least a portion of the flat terminal 113. The flat ribbon 11 has an outer insulating layer 112 that is peeled off to expose the flat core 111, and the portion that is electrically connected to the mating terminal 23 is the flat terminal 113. By providing the flat terminal 113, the ribbon can be effectively mated and connected to the mating terminal 23, thereby achieving effective electrical connection of the connection mechanism.

[0104] As shown in Figure 6, in order to enable the flat terminal 113 to be effectively mated and connected to the mating terminal 23, it is necessary to provide the flat terminal 113 exposed to the outside of the male end housing 12 during the integral molding of the flat ribbon 11 and the male end housing 12, in order to prevent the flat terminal 113 and the mating terminal 23 from being unable to be plugged in due to the covering of the male end housing 12.

[0105] Preferably, the method by which the tip of the flat core 111 is connected to the flat terminal 113 is one or more of the following: resistance welding, friction welding, ultrasonic welding, arc welding, laser welding, electron beam welding, pressure diffusion welding, magnetic induction welding, screwing, locking, splicing, and crimping.

[0106] Resistance welding is a method of welding that uses a strong current to pass through the contact point between the electrode and the workpiece, generating heat due to contact resistance. The tip of the flat core 111 and the conductive portion of the flat terminal 113 are welded using resistance welding.

[0107] Friction welding is a welding method that utilizes heat generated by friction at the contact surface of the workpiece as a heat source, and uses pressure to plastically deform the workpiece for welding. The tip of the flat core 111 and the conductive portion of the flat terminal 113 are welded by friction welding.

[0108] The ultrasonic welding method utilizes high-frequency vibration waves to be transmitted to the surfaces of two objects to be welded. When pressure is applied, the surfaces of the two objects are rubbed against each other to form a fusion between molecular layers. The tip of the flat core 111 and the conductive portion of the flat terminal 113 are welded using ultrasound.

[0109] Arc welding is a welding method that uses an arc as a heat source and utilizes the physical phenomenon of air discharge to convert electrical energy into the thermal and mechanical energy necessary for welding, thereby achieving the purpose of joining metals. The main methods include welding rod arc welding, submerged arc welding, and gas shielded welding.

[0110] Laser welding is a highly efficient and precise welding method that utilizes a high-energy-density laser beam as a heat source.

[0111] Electron beam welding is a welding method that uses an accelerated and focused electron beam to irradiate a welding surface placed in a vacuum or non-vacuum, melting the workpiece to be welded.

[0112] Pressure welding is a method of welding in which pressure is applied to the materials to be welded, causing the splicing surfaces to come into close contact and generating a certain amount of plastic deformation to complete the welding process.

[0113] Diffusion welding is a solid-state welding method that applies high temperature and pressure to the workpiece, but without causing visual deformation or relative movement.

[0114] Magnetic induction welding is a method in which two workpieces to be welded collide instantaneously at high speed due to the action of a strong pulsed magnetic field. The high pressure wave on the surface of the materials causes the atoms of the two materials to meet within the interatomic distance, thereby forming a stable metallurgical bond at the interface.

[0115] A screw connection is a removable connection where connected materials (or the threaded portion of the connected materials) are joined together as a single unit. Commonly used screw connection materials include bolts, studs, screws, and fastening screws, most of which are standard-sized products.

[0116] The locking method involves providing locking claws or locking grooves corresponding to the connection ends or connection surfaces, and assembling and connecting them using the locking grooves and locking claws. The advantages of the locking method are that connection is quick and detachable.

[0117] The splicing method involves providing corresponding grooves and protrusions on the connection ends or connection surfaces, and then joining them together by juggling or splicing them using these grooves and protrusions. The advantages of the splicing method are that the connection is stable and detachable.

[0118] Crimping is a production process in which the connecting end and the connecting surface are assembled, and then stamped together as a single unit using a crimping machine. The advantage of crimping is its excellent mass-production capability; by employing an automatic crimping machine, it is possible to quickly manufacture a large quantity of products with consistent quality.

[0119] With the above connection method, an appropriate connection method or combination of connection methods can be selected depending on the actual usage conditions of the tip of the flat core 111 and the conductive portion of the flat terminal 113, according to the actual usage environment, thereby achieving an effective electrical connection.

[0120] In some embodiments, the flat ribbon 11 includes a flat core 111 that is integrated with the flat terminals 113. The flat core 111 and the flat terminals 113 may be manufactured from the same material, which reduces the use of the flat terminals 113, lowers material costs and processing time, and allows the tip of the flat core 111 to be molded into various shapes as needed without having to consider assembly issues.

[0121] Furthermore, at least a portion of the flat terminal 113 protrudes from the male end housing 12, or the male end housing 12 has a housing cavity in which at least a portion of the flat terminal 113 protrudes from the bottom surface of the housing cavity but does not extend beyond the male end housing 12. The flat terminal 113 may protrude from the outside of the male end housing 12 and be directly mated to a mating terminal 23 in the female end housing 22, or it may be provided inside the housing cavity of the male end housing 12, with the mating terminal 23 in the female end housing 22 being inserted into the back of the housing cavity and mated to the flat terminal 113.

[0122] By connecting the flat terminal 113 to the mating terminal 23, the flat terminal 113 of the flat ribbon 11 itself functions as a terminal and is directly connected to the mating terminal 23. This solves the problem of high cost and low efficiency that would otherwise be required to connect copper terminals to the flat ribbon 11, enabling safe and rapid insertion and removal.

[0123] In one embodiment, as shown in Figure 3, the flat ribbon 11 includes a flat core 111 and a bent portion 1131 between the flat core 111 and the flat terminal 113, with an angle of 0° to 180°. The bent portion 1131 is provided at different bending angles and has different shapes, allowing for connection mechanisms to be applied to different directions of mating terminals 23. Depending on the needs of the mounting environment and the need to simplify the structure of the connection mechanism and reduce the connection space, the designer can change the direction of cable travel on both sides of the connection mechanism by setting the bent portion 1131 at different angles to connect to mating terminals 23 at different angles. Furthermore, the body of the flat ribbon 11 and the flat terminal 113 are connected via the bent portion 1131, and the bent portion 1131 adjusts the extension direction of the flat ribbon 11, facilitating adaptation of the flat ribbon 11 to the mounting environment.

[0124] In this embodiment, an advantage of the flat ribbon 11 is that it facilitates bending. Specifically, the flat ribbon 11 can maintain its shape after being bent, allowing it to be positioned to match the sheet metal of the vehicle body, saving space and facilitating fixing. It can be bent at different positions as needed.

[0125] In one embodiment, a conductive corrosion-preventive layer is provided on at least a portion of the flat terminal 113. If the materials of the flat terminal 113 and the mating terminal 23 do not match, the conductivity between them will cause electrochemical corrosion due to the potential difference, reducing the service life of the flat terminal 113 and the mating terminal 23. To reduce such electrochemical corrosion, a conductive corrosion-preventive layer may be provided on the flat terminal 113. By using a metal material whose potential potential is between that of the materials of the flat terminal 113 and the mating terminal 23, the flat terminal 113 and the mating terminal 23 are isolated, electrochemical corrosion is mitigated, and the service life of the flat terminal 113 and the mating terminal 23 can be extended.

[0126] In the connection between the flat terminal 113 and the mating terminal 23, the conductive corrosion prevention layer reduces the occurrence of electrochemical reactions between the flat terminal 113 and the mating terminal 23 of the flat ribbon 11, thereby solving the technical problem that the flat ribbon 11 can only be connected to other terminals or electrical devices via terminals made of other materials.

[0127] Furthermore, the conductive corrosion prevention layer is attached to at least a portion of the surface of the flat terminal 113 by one or more of the following methods: electroplating, electroless plating, magnetron sputtering, vacuum plating, pressure welding, diffusion welding, friction welding, resistance welding, ultrasonic welding, or laser welding.

[0128] Electroplating is a process that uses the principle of electrolysis to thinly plate another metal or alloy onto the surface of a metal.

[0129] Electroless plating is a deposition process that generates metal through a controllable oxidation-reduction reaction catalyzed by the metal.

[0130] The magnetron sputtering method utilizes the interaction of magnetic and electric fields to cause electrons to travel in a spiral pattern near the target surface, thereby increasing the probability that electrons will collide with argon gas and generate ions. The generated ions are then collided with the target surface by the action of the electric field and sputtered from the target.

[0131] Vacuum plating is a method in which various metal and non-metallic thin films are deposited on the surface of a molded object under vacuum conditions by methods such as distillation or sputtering.

[0132] Pressure welding is a method of welding in which pressure is applied to the materials to be welded, causing the splicing surfaces to come into close contact and generating a certain amount of plastic deformation to complete the welding process.

[0133] Friction welding is a welding method that utilizes heat generated by friction between the contact surfaces of the workpiece as a heat source, and uses pressure to plastically deform the workpiece for welding.

[0134] Resistance welding is a method of welding that uses a strong electric current to pass through the contact point between the electrode and the workpiece, generating heat through contact resistance.

[0135] Ultrasonic welding utilizes high-frequency vibration waves to be transmitted to the surfaces of two objects to be welded. When pressure is applied, the friction between the two object surfaces creates fusion between molecular layers.

[0136] Laser welding is a highly efficient and precise welding method that utilizes a high-energy-density laser beam as a heat source.

[0137] Diffusion welding is a solid-state welding method in which the workpiece is pressurized at high temperatures, but no visual deformation or relative movement occurs. By employing any of the above methods or combinations thereof, a conductive corrosion-preventive layer can be stably provided on the surface of the flat terminal 113.

[0138] In one embodiment, the thickness of the conductive corrosion prevention layer is 0.3 μm to 3000 μm.

[0139] In one embodiment, the thickness of the conductive corrosion prevention layer is 2.5 μm to 1000 μm.

[0140] To test the effect of different conductive corrosion-preventive layer thicknesses on voltage drop, the inventors applied conductive corrosion-preventive layers of different thicknesses to flat terminals 113 using patching sections of the same material and structure, and then tested the voltage drop after the flat terminals 113 were plugged into mating terminals 23. The results are shown in Table 5.

[0141] In this embodiment, a device is deemed unacceptable if the voltage drop after the flat terminal 113 is plugged into the mating terminal 23 is greater than 4mV.

[0142] Table 5: Effect of different conductive corrosion protection layer thicknesses on voltage drop (mV) [Table 5] As can be seen from the above data, when the thickness of the conductive corrosion prevention layer is greater than 3000 μm and less than 0.3 μm, the voltage drop in the plug-in structure between the flat terminal 113 and the mating terminal 23 is greater than 4 mV, which does not meet the required value. Therefore, the inventor selected a thickness of the conductive corrosion prevention layer between 0.3 μm and 3000 μm. Here, when the thickness of the conductive corrosion prevention layer is within the range of 2.5 μm to 1000 μm, the voltage drop in the plug-in structure between the flat terminal 113 and the mating terminal 23 is the optimal value. Therefore, the inventor prefers to select a thickness of the conductive corrosion prevention layer between 2.5 μm and 1000 μm.

[0143] In one embodiment, the material of the conductive corrosion-preventive layer contains one or more of the following: nickel, cadmium, manganese, zirconium, cobalt, tin, titanium, chromium, gold, silver, zinc, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite-silver, graphene-silver, hard silver, and silver-gold-zirconium alloy.

[0144] Preferably, the material of the conductive corrosion-preventive layer is the same as the material of the battery electrodes that overlap the flat terminal 113. This design can enhance the surface strength of the flat terminal 113 and prevent corrosion caused by the overlapping connection of the flat terminal 113 with dissimilar metals.

[0145] Similarly, using the flat ribbon 11 as an example, the inventors provided a conductive corrosion-preventive layer on the flat terminal 113 and conducted a series of corrosion resistance time tests using flat terminals 113 of the same specifications and materials but with different conductive corrosion-preventive materials, in order to verify the effect of different conductive corrosion-preventive materials on the performance of the flat terminal 113. The experimental results are shown in Table 6.

[0146] In the corrosion resistance time test shown in Table 6, a sample of the flat terminal 113 was placed in a salt spray test box, salt water was sprayed at each position of the flat terminal 113, and the sample was removed and cleaned every 20 hours to observe the surface corrosion status. One cycle was considered to be one test, and the test was stopped when the surface corrosion area of ​​the flat terminal 113 sample exceeded 10% of the total area, and the number of cycles at that time was recorded. In this embodiment, samples with fewer than 80 cycles were considered to have failed.

[0147] Table 6: Effect of different conductive corrosion protection layer materials on the corrosion resistance of flat terminal 113 samples [Table 6] As can be seen from Table 6, when the conductive corrosion-preventive layer material contains commonly used metals such as tin, nickel, and zinc, the experimental results are inferior to those of other selected metals, while the experimental results when other metals are selected often exceed standard values ​​and exhibit stable performance. Therefore, the inventor selected a conductive corrosion-preventive layer material that contains (or is) one or more of the following: nickel, cadmium, manganese, zirconium, cobalt, tin-titanium, chromium, gold, silver, zinc-tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite-silver, graphene-silver, hard silver, and silver-gold-zirconium alloy. A more preferred form is to select a conductive corrosion-preventive layer material that contains (or is) one or more of the following: cadmium, manganese, zirconium, cobalt, titanium, chromium, gold, silver, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite-silver, graphene-silver, hard silver, and silver-gold-zirconium alloy.

[0148] In one embodiment, a chamfer is provided on the end of the flat terminal 113. During both the processing and attachment of the flat ribbon 11, there are assembly errors when attaching the mating terminal 23. At this time, there are similarly large assembly errors in the assembly of the flat terminal 113 and the mating terminal 23. Therefore, it is necessary to provide a chamfer on the end of the flat terminal 113 to facilitate accurate mating connection of the flat terminal 113 to the mating terminal 23, and the chamfer serves as a guide when inserted into the mating terminal 23.

[0149] In one embodiment, as shown in Figures 7 and 13, the male-end connection mechanism 10 includes an interlock connector 14 in which at least a portion is integrally injected into the male-end housing 12. A high-voltage interlock is a safety design method that uses a low-voltage signal to monitor the integrity of a high-voltage circuit. Specific implementations of high-voltage interlocks vary depending on the specific requirements. High-voltage interlocks monitor for unintended interruptions in high-voltage circuits and prevent damage to the vehicle in the event of a sudden loss of power. As shown in Figure 13, the high-voltage interlock in this embodiment is an interlock connector 14, which is a U-shaped or V-shaped low-voltage circuit with two mating pins at one end, and the two mating pins are electrically connected. It does not need to be mounted and is molded directly into the male end housing 12 by an integral injection molding method. It is matched and connected to the high-voltage interlock structure 24 in the female end connection mechanism 20 to form a low-voltage monitoring circuit. If the connection mechanism in this embodiment is unintentionally disconnected, the interlock connector 14 and the high-voltage interlock structure 24 are also disconnected simultaneously, and the low-voltage monitoring circuit sends an alarm to the central control system to control the vehicle and prevent damage from a sudden loss of power.

[0150] In one embodiment, as shown in Figure 5, the mating terminal 23 includes a fixing portion 231 and a cable clamp portion 232, and the female end connection mechanism 20 further includes a cable 21, the fixing portion 231 is electrically connected to the conductive portion at the end of the cable 21, and the cable clamp portion 232 is electrically connected to the flat terminal 113. The cable clamp portion 232 of the mating terminal 23 and the flat terminal 113 are mated together to achieve an electrical connection, and the flat ribbon 11 and the cable 21 can be electrically connected.

[0151] Furthermore, the fixed portion 231 and the conductive portion at the end of the cable 21 are connected by one or more of the following methods: resistance welding, friction welding, ultrasonic welding, arc welding, laser welding, electron beam welding, pressure diffusion welding, magnetic induction welding, screwing, locking, splicing, and crimping.

[0152] Resistance welding is a method of welding that uses a strong current to pass through the contact point between the electrode and the workpiece, generating heat through contact resistance. The fixed part 231 and the conductive part of the cable 21 are welded using resistance welding.

[0153] Friction welding is a welding method that utilizes heat generated by friction at the contact surface of the workpiece as a heat source, and uses pressure to plastically deform the workpiece for welding. The fixed part 231 and the conductive part of the cable 21 are welded using friction welding.

[0154] The ultrasonic welding method utilizes high-frequency vibration waves to be transmitted to the surfaces of two objects to be welded. When pressure is applied, the surfaces of the two objects are rubbed against each other to form a fusion between molecular layers. The fixed part 231 and the conductive part of the cable 21 are welded using ultrasound.

[0155] Arc welding is a welding method that uses an arc as a heat source and utilizes the physical phenomenon of air discharge to convert electrical energy into the thermal and mechanical energy necessary for welding, thereby achieving the purpose of joining metals. The main methods include welding rod arc welding, submerged arc welding, and gas shielded welding.

[0156] Laser welding is a highly efficient and precise welding method that utilizes a high-energy-density laser beam as a heat source.

[0157] Electron beam welding is a welding method that uses an accelerated and focused electron beam to irradiate a welding surface placed in a vacuum or non-vacuum, melting the workpiece to be welded.

[0158] Pressure welding is a method of welding in which pressure is applied to the materials to be welded, causing the splicing surfaces to come into close contact and generating a certain amount of plastic deformation to complete the welding process.

[0159] Diffusion welding is a solid-state welding method that applies high temperature and pressure to the workpiece, but without causing visual deformation or relative movement.

[0160] Magnetic induction welding is a method in which two workpieces to be welded collide instantaneously at high speed due to the action of a strong pulsed magnetic field. The high pressure wave on the surface of the materials causes atoms of the two materials to meet within the interatomic distance, forming a stable metallurgical bond at the interface. It is a type of solid-phase cold welding and can weld a fixed part 231 and the conductive part of the cable 21, which have similar or dissimilar properties.

[0161] A screw connection is a removable connection where connected materials (or the threaded portion of the connected materials) are joined together as a single unit. Commonly used screw connection materials include bolts, studs, screws, and fastening screws, most of which are standard-sized products.

[0162] The locking method involves providing corresponding locking claws or grooves at the connection ends or connection surfaces, and assembling and connecting them using the locking grooves and claws. The advantages of the locking method are that connection is quick and detachable.

[0163] The splicing method involves providing grooves and protrusions corresponding to the connection ends or connection surfaces, and assembling and connecting them by juggling or splicing them together using these grooves and protrusions. The advantages of the splicing method are that the connection is stable and detachable.

[0164] Crimping is a production process in which the connecting end and the connecting surface are assembled, and then stamped together as a single unit using a crimping machine. The advantage of crimping is its excellent mass-production capability; by employing an automatic crimping machine, it is possible to quickly manufacture a large quantity of products with consistent quality.

[0165] With the above connection method, an appropriate connection method or combination of connection methods can be selected depending on the actual usage conditions of the fixed part 231 and the conductive part of the cable 21, according to the actual usage environment, thereby achieving an effective electrical connection.

[0166] In some embodiments, a clip 30 is sleeved in the cable clamp portion 232, and as shown in Figure 12, the material of the clip 30 is a memory alloy. The clip 30 can clamp the cable clamp portion 232. The memory alloy is an intelligent metal with memory properties, and its microstructure has two relatively stable states: at high temperatures, such an alloy can change into any desired shape; at low temperatures, the alloy can be stretched, but when reheated, it remembers its original shape and returns to its original state. The memory alloy has different crystal structures above and below its transformation temperature, and when the temperature changes above or below the transformation temperature, the memory alloy shrinks or expands, changing its shape. In some embodiments, the memory alloy is a nickel-titanium alloy.

[0167] Furthermore, the transformation temperature of the memory alloy is set within the range of 40°C to 70°C. When the temperature of the clip 30 is lower than the transformation temperature, the clip 30 is in an expanded state, and when the temperature of the clip 30 is higher than the transformation temperature, the clip 30 is in a clamped state.

[0168] Generally, the transformation temperature is selected between 40°C and 70°C because if the transformation temperature is lower than 40°C, when there is no current flowing, the ambient temperature of the cable clamp portion 232 and the clip 30 will also approach 40°C. At this time, the clip 30 will be in a clamped state, the gap in the cable clamp portion 232 will become small, and the flat terminal 113 will not be able to be inserted into the cable clamp portion 232. As a result, the plug-in structure between the flat terminal 113 and the cable clamp portion 232 will not be able to be plugged in, and the device will not function.

[0169] In some embodiments, a clip 30 is sleeved in the cable clamp portion 232, and the clip 30 includes a side wall 31 and an elastic unit 32 fixed to the side wall 31, the elastic unit 32 being in contact with and connected to the outside of the cable clamp portion 232.

[0170] The clip 30 applies pressure to the cable clamp portion 232 by an elastic unit 32 provided on its side wall, allowing the strip-shaped groove of the cable clamp portion 232 to further clamp the flat terminal 113 of the flat ribbon 11. This ensures a contact area between the cable clamp portion 232 and the flat terminal 113, reduces contact resistance, and improves conductivity.

[0171] The installation of clip 30 ensures a close connection between the cable clamp portion 232 and the flat terminal 113.

[0172] Furthermore, the range of force applied by the elastic unit 32 to the cable clamp portion 232 is 3N to 200N.

[0173] To verify the effect of the pressure applied by the elastic unit 32 to the cable clamp portion 232 on the contact resistance and insertion / removal status after plugging in a flat terminal 113 with a large eccentricity, the inventors selected flat cores 111 and cable clamp portions 232 of the same dimensional specifications, and after applying pressure to the cable clamp portion 232 with different elastic units 32, they selected flat terminals 113 with the same degree of eccentricity and mated them with the cable clamp portion 232. They then tested the contact resistance between the terminals after mating and the success rate of inserting the flat terminals 113 in multiple insertion / removal experiments, and the test results are shown in Table 7.

[0174] Contact resistance test method: A micro-resistance meter is used. One end of the micro-resistance meter is placed on the flat terminal 113, and the other end is placed on the cable clamp portion 232. The position is the same for each measurement. After that, the contact resistance reading on the micro-resistance meter is read. In this embodiment, a contact resistance greater than 1 mΩ is considered a failure.

[0175] Test method for mating success rate: Each type of elastic unit 32 is mated with 100 flat terminals 113 of the same eccentricity at the pressure value applied to the cable clamp portion 232. The number of successful insertions at one time is recorded and multiplied by 100% in proportion to the total number. In this embodiment, a mating success rate of less than 95% is considered a failure.

[0176] Table 7: Effects of different pressures on contact resistance and mating success rate [Table 7] As can be seen from Table 7, when the pressure applied by the elastic unit 32 to the cable clamp portion 232 is less than 3N, the mating success rate is acceptable. However, when the contact resistance between the mating terminal 23 and the cable clamp portion 232 is greater than 1mΩ, the contact resistance is too high. Therefore, when the pressure applied by the elastic unit 32 to the cable clamp portion 232 is greater than 200N, the mating success rate is less than 95%, and the application requirements cannot be met. For this reason, the inventor set the pressure applied by the elastic unit 32 to the cable clamp portion 232 to 3N to 200N.

[0177] Furthermore, the elastic unit 32 is elastic rubber, a spring, or a metal dome. The elastic unit 32 may be elastic rubber, and the elastic force of the compressed elastic rubber ensures the pressure applied to the cable clamp portion 232. The elastic unit 32 may be a compression spring, and the elastic force of the compressed compression spring ensures the pressure applied to the cable clamp portion 232. The elastic unit 32 may be a metal dome, and the metal dome may be integrally molded with the clip 30, and may be in the form of a single-ended dome with one end fixed and the other end free, or in the form of a double-ended dome with both ends fixed and a projection in the middle, and the elastic force of the metal dome itself ensures the pressure applied to the cable clamp portion 232.

[0178] In one embodiment, the cable clamp portion 232 of the mating terminal 23 is formed by stacking multiple layers of sheet-like terminals 234, with grooves formed in the sheet-like terminals 234 to match and mat with the flat ribbon 11. The flat terminal 113 is plugged into the groove and electrically connected to the cable clamp portion 232, and the groove clamps the flat terminal 113 of the flat ribbon 11, fixing the flat ribbon 11 and the mating terminal 23, ensuring a large contact area between them and guaranteeing the reliability of the electrical connection. By adjusting the width of the groove or the number of sheet-like terminals 234, the magnitude of the clamping force can be controlled, facilitating compatibility with the flat terminal 113 and meeting various mating requirements.

[0179] As shown in Figure 5, the mating terminal 23 is made up of multiple sheet-like terminals 234 stacked and arranged on top of each other. The sheet-like terminals 234 are easily deformable and can be plugged into the flat terminals 113 of the flat ribbon 11. The flat terminals 113 of the flat ribbon 11 and the grooves of the sheet-like terminals 234 come into contact with each other, achieving an electrical connection and thus ensuring the stability of the connection between the mating terminal 23 and the flat ribbon 11.

[0180] Specifically, the cable clamp portion 232 is formed by stacking multiple layers of sheet-like terminals 234, and grooves are formed in the sheet-like terminals 234 so that they can be plugged into the flat terminals 113 of the flat ribbon 11 to achieve electrical connection.

[0181] In some embodiments, the gap between two adjacent sheet terminals 234 is less than 0.2 mm. One purpose of providing a gap between the two sheet terminals 234 is to allow air to circulate between the sheet terminals 234, thereby reducing the temperature rise between the flat terminal 113 and the mating terminal 23, protecting the conductive corrosion-resistant layer of the flat terminal 113, extending the service life of the flat terminal 113, and ensuring the plug-in force between the flat terminal 113 and the mating terminal 23. If the gap is greater than 0.2 mm, rather than increasing its heat dissipation function, the mating terminal 23 with the same contact area occupies a larger width, wasting usable space.

[0182] In some embodiments, at least a portion of the material of the sheet-like terminal 234 is a memory alloy. As previously mentioned, a memory alloy is an intelligent metal with memory properties, and its microstructure has two relatively stable states: at high temperatures, such an alloy can change into any desired shape; at low temperatures, the alloy can be stretched, but upon reheating, it remembers its original shape and returns to its original state; the memory alloy has different crystal structures above and below its transformation temperature, and as the temperature changes above and below the transformation temperature, the memory alloy shrinks or expands, changing its form. In some embodiments, the memory alloy is a nickel-titanium alloy.

[0183] Furthermore, the transformation temperature of the memory alloy is set within the range of 40°C to 70°C. When the temperature of the sheet-like terminal 234 is lower than the transformation temperature, the multiple grooves are in an expanded state, and when the temperature of the sheet-like terminal 234 is higher than the transformation temperature, the multiple grooves are in a clamped state.

[0184] Generally, the transformation temperature is selected and set within the range of 40°C to 70°C because if the transformation temperature is lower than 40°C, when there is no conductive current, the ambient temperature of the mating terminal 23 will also approach 40°C. At this time, the multiple sheet-like terminals 234 will be in a clamped state, the groove of the mating terminal 23 will become smaller, the flat terminal 113 will not be able to be inserted into the mating terminal 23, the plug-in structure between the flat terminal 113 and the mating terminal 23 will not be able to plug in, and the device will not function.

[0185] At room temperature, the flat terminal 113 begins to conduct electricity after being mated with the mating terminal 23. Initially, multiple sheet-like terminals 234 are in an expanded state, resulting in a small contact area between the flat terminal 113 and the mating terminal 23, leading to a large current. The sheet-like terminals 234 begin to heat up after being plugged in, and if the transformation temperature is higher than 70°C, the time during which the mating terminal 23 heats up increases. This prolonged high-current state in the plug-in structure between the flat terminal 113 and the mating terminal 23 makes it susceptible to electrical degradation. In severe cases, the plug-in structure between the flat terminal 113 and the mating terminal 23 can be overloaded and damaged, causing unnecessary losses.

[0186] Therefore, generally, the transformation temperature of memory alloys is set between 40°C and 70°C.

[0187] The mating terminal 23 has a memory function, and when it is below the transformation temperature, the groove of the mating terminal 23 is normally in an expanded state. At this time, the flat terminal 113 of the flat ribbon 11 can be butted together without insertion force, making it easy for an operator to easily mate electrical equipment. When current is conducted through the mating terminal 23 during operation, the temperature of the mating terminal 23 gradually rises due to the action of resistance. When the temperature rises above the transformation temperature, the groove of the mating terminal 23 contracts radially. The rise in temperature increases the contact area and contact force between the groove of the mating terminal 23 and the flat terminal 113 of the flat ribbon 11, improving the reliability of the contact and eliminating the need for insertion force, making the work easier and increasing work efficiency.

[0188] In one embodiment, the female end housing 22 is integrally injection-molded around the outer circumference of at least some of the mating terminals 23 to form an insulating structure. By providing the injection-molded female end housing 22 in the connection mechanism of this embodiment, processing is simple, costs are low, and insulation can be achieved by directly injecting it to the outside of the mating terminals 23.

[0189] In one embodiment, the female terminal connection mechanism 20 further includes a cable 21 electrically connected to the mating terminal 23, the mating terminal 23 and at least a portion of the cable 21 are provided within the female terminal housing 22, and at least a portion of the mating terminal 23 is exposed outside the female terminal housing 22. The cable 21 connected to the mating terminal 23, and the electrical connection between the mating terminal 23 and the flat terminal 113, electrically connect the flat ribbon 11 and the cable 21, thereby achieving circuit conductivity and enabling current conduction.

[0190] In one embodiment, at least a portion of the cable clamp portion 232 protrudes from the outer wall of the female end housing 22, or an opening boss is provided on the female end housing 22, and at least a portion of the cable clamp portion 232 is provided within the opening boss. In the above embodiment, the flat terminal 113 protrudes from the male end housing 12 and can be fitted and connected to the cable clamp portion 232 provided within the opening boss. Alternatively, the male end housing 12 has a groove, and the flat terminal 113 protrudes from the bottom surface of the groove but does not extend beyond the male end housing 12, and can be fitted and connected to the cable clamp portion 232 protruding from the outer wall of the female end housing 22.

[0191] In one embodiment, as shown in Figure 8, the female-end connection mechanism 20 has a high-voltage interlock structure 24 that is electrically connected to the interlock connector 14 to form a circuit. The high-voltage interlock is a safety design method that uses a low-voltage signal to monitor the integrity of the high-voltage circuit. The high-voltage interlock monitors for unintended disconnection of the high-voltage circuit and prevents damage to the vehicle in the event of a sudden loss of power. In this embodiment, as shown in Figure 13, the high-voltage interlock is an interlock connector 14, which is a U-shaped or V-shaped low-voltage circuit with two mating pins, the two mating pins being electrically connected at one end, and two plug-in terminals provided within the female-end connection mechanism 20 that connect the low-voltage circuit at the other end. The plug-in terminals of the high-voltage interlock structure 24 are matched and connected to the mating pins of the interlock connector 14 to form a low-voltage monitoring circuit. If the connection mechanism in this embodiment is unintended, the interlock connector 14 and the high-voltage interlock structure 24 are simultaneously disconnected, and the low-voltage monitoring circuit sends an alarm to the central control system to control the vehicle and prevent damage from a sudden loss of power.

[0192] The insert-type high-pressure interlock structure 24 replaces conventional assembled high-pressure interlocks by being fixed within the connector through integral injection molding, eliminating the need for assembly, reducing costs, and fully satisfying the high-pressure interlock effect.

[0193] In one embodiment, the female terminal connection mechanism 20 and / or the male terminal connection mechanism 10 have a sealing structure 40. The sealing structure 40 seals the flat terminal 113, mating terminal 23, some of the flat ribbon 11 and cable 21 within the connection mechanism, preventing damage and corrosion to the internal conductive mechanism by external dust and water, and significantly extending the service life of the connection mechanism.

[0194] Furthermore, the seal structure 40 is secondary injection molded into the female end housing 22 and / or male end housing 12. By adopting the secondary injection seal structure 40 instead of a traditional seal ring, rather than attaching an additional separate seal ring, the seal structure 40 of the connection mechanism can be molded directly into the connection mechanism, resulting in better injection bonding and reduced costs.

[0195] Furthermore, the material of the seal structure 40 is rubber, soft rubber, or silica gel. By selecting one of these materials, the material can be heated and melted using an injection molding machine and injected into the corresponding mold for molding. This makes processing easy, provides a strong bond, and significantly extends the service life of the seal structure 40. In addition, some of these materials have good elasticity, are compressed and deformed during the assembly of the connecting mechanism, fill the gap, and achieve good sealing performance. Moreover, they are water and oil resistant materials, ensuring that the seal structure 40 has a long service life and safe sealing performance.

[0196] Furthermore, the maximum gap between the seal structure 40 and the male end connection mechanism 10 and / or female end connection mechanism 20 is less than 520 nm.

[0197] To verify the effect of the gap size between each seal structure 40 and the adjacent device on the seal level, the inventors tested the sealing device using the dry air method, controlling the internal and external pressures of the sample under test to be different by vacuum or air pressurization. If a leak is present, the difference in internal and external pressures will decrease. By detecting the change in air pressure, the sealing performance can be detected. The detection medium is dry air, which is harmless and non-toxic, does not damage the object under test, and ensures a clean detection environment. As an example, the inventors completely sealed other connection points after the male end connection mechanism 10 and the female end connection mechanism 20 were connected, selected seal structures 40 with different degrees of sealing, extracted some dry air from the seal structure 40, lowered the air pressure inside the seal structure 40 to be lower than the external air pressure, and continuously detected the air pressure inside the seal structure 40. They found that an increase in air pressure indicated failure, and the test results are shown in Table 8.

[0198] Table 8: Effect of pressure changes on the maximum gap between the seal structure 40 and the male end connection mechanism 10 and / or female end connection mechanism 20 [Table 8] As can be seen from Table 8, if the maximum gap between the seal structure 40 and the male end connection mechanism 10 and / or the female end connection mechanism 20 exceeds 520 nm, it means that the air pressure has changed and gas has entered the seal structure 40, resulting in a test failure. Therefore, the inventor selected a maximum gap of 520 nm or more between the seal structure 40 and the male end connection mechanism 10 and / or the female end connection mechanism 20.

[0199] In one embodiment, the female-end connection mechanism 20 and / or the male-end connection mechanism 10 have at least one temperature measuring structure for measuring the temperature of the mating terminal 23 and / or the flat ribbon 11 and / or the flat terminal 113. The temperature measuring structure is at a certain distance from the mating terminal 23 and / or the flat ribbon 11, and the heat dissipation from the mating terminal 23 and / or the flat ribbon 11 is transmitted to the temperature measuring structure, and the temperature of the mating terminal 23 and / or the flat ribbon 11 is measured by the temperature measuring mechanism, or the temperature measuring structure may include a conductive element, the conductive element may be attached to the mating terminal 23 and / or the flat ribbon 11, and the temperature of the mating terminal 23 and / or the flat ribbon 11 may be measured by the temperature transmitted by the conductive element. Then, the current flowing through the mating terminal 23 and / or the flat ribbon 11 is adjusted and communicated to a control system to adjust the temperature of the female-end connection mechanism 20 or the male-end connection mechanism 10.

[0200] Furthermore, the temperature measuring structure is attached to the mating terminal 23 and / or the flat ribbon 11 and / or the flat terminal 113 to measure the temperature of the mating terminal 23 and / or the flat ribbon 11 and / or the flat terminal 113. The temperature measuring structure is a temperature sensor and is directly attached to the mating terminal 23 and / or the flat ribbon 11 and / or the flat terminal 113, allowing the actual temperature of the mating terminal 23 and / or the flat ribbon 11 and / or the flat terminal 113 to be obtained directly. There is no need to obtain the actual temperature of the mating terminal 23 and / or the flat ribbon 11 and / or the flat terminal 113 by calculation, resulting in a simpler structure and more accurate temperature measurement.

[0201] In one embodiment, the male end connection mechanism 10 has at least one temperature measuring structure, and the flat ribbon 11 is at least two, with the temperature measuring structure positioned between the flat ribbons 11 to measure the temperature of the flat ribbons 11. By positioning the temperature measuring structure between the flat ribbons 11, the heat conducted from multiple flat ribbons 11 can be acquired simultaneously, the amount of heat generated by the multiple flat ribbons 11 can be made uniform, the number of temperature measuring structures can be reduced, and the highest temperature of the multiple flat ribbons 11 can be directly acquired, playing a good role in temperature control of the flat ribbons 11.

[0202] The temperature measurement structure may be a temperature sensor, which may be an NTC temperature sensor or a PTC temperature sensor, and it will accurately and promptly monitor the temperature of the male terminal connection mechanism 10 or the female terminal connection mechanism 20.

[0203] The temperature sensor is either an NTC temperature sensor or a PTC temperature sensor. The advantages of using these two types of temperature sensors are their small size, ability to measure gaps that other thermometers cannot measure, ease of use, selectable resistance values ​​between 0.1 and 100 kΩ, ease of processing into complex shapes, mass production capability, good stability, high overload capacity, and suitability for products requiring small size and stable performance, such as conversion fittings.

[0204] By employing a temperature measurement mechanism, the temperature of the terminals inside the connection mechanism can be monitored independently, preventing the loss of temperature monitoring of the connection mechanism due to damage to temperature sensors in other locations.

[0205] Furthermore, the male end connection mechanism 10 and the female end connection mechanism 20 are connected by one or more of the following methods: adhesive connection, magnetic attraction connection, bayonet connection, plug-in connection, locking connection, binding connection, screw connection, rivet connection, and welding connection.

[0206] In the first feasible technical proposal, an adhesive structure may be employed, for example, an adhesive layer may be provided on the splicing surfaces of the male end connection mechanism 10 and the female end connection mechanism 20, and the two are fixedly connected by adhesive.

[0207] In the second feasible technical proposal, a magnetic attraction structure may be employed. For example, magnetic attraction material may be provided on the splicing surfaces of the male end connection mechanism 10 and the female end connection mechanism 20, thereby making the connection convenient and quick.

[0208] In the third feasible technical proposal, a plug-in structure may be adopted, in which a plug is provided in the housing of the male terminal connection mechanism 10, a slot is provided on the surface of the housing of the female terminal connection mechanism 20, and the plug is fixedly connected after being inserted into the slot, thereby fixing the male terminal connection mechanism 10 and the female terminal connection mechanism 20 and realizing the connection between the male terminal connection mechanism 10 and the female terminal connection mechanism 20.

[0209] In the fourth feasible technical proposal, a locking structure may be adopted, for example, a snap is provided on the male end shielding case of the male end connection mechanism 10, and locking grooves are provided on the female end of the female end connection mechanism 20, and the male end connection mechanism 10 and the female end connection mechanism 20 are fixedly connected by fixing the snap and the locking groove after they are assembled.

[0210] In the fifth feasible technical proposal, a bolted connection structure may be adopted, which includes a bolt and a nut, wherein the bolt is fixed to the splicing surface of the male end connection mechanism 10 and the nut is provided on the splicing surface of the female end connection mechanism 20 and is rotatable, and after the bolt and nut are screwed and tightened together, the splicing surfaces of the male end connection mechanism 10 and the female end connection mechanism 20 are fixedly connected. The bolted connection structure employs a bolt and nut of minimum size M3, and the tightening torque of the bolted connection structure is minimum 0.2 N·m.

[0211] In the sixth feasible technical proposal, a crimping structure may be employed, which includes a rivet and a fixing hole, the fixing hole being provided on the splicing surfaces of the male end connection mechanism 10 and the female end connection mechanism 20, the rivet passing through the fixing hole, deforming one end through which the rivet passes, and tightening the fixing hole, thereby fixing the splicing surfaces of the male end connection mechanism 10 and the female end connection mechanism 20 together.

[0212] In the seventh feasible technical proposal, a welded structure may be employed, for example, by applying welding material to the splicing surfaces of the male end connection mechanism 10 and the female end connection mechanism 20, and using a welding machine to melt the welding material and connect them, thereby fixing the splicing surfaces of the male end connection mechanism 10 and the female end connection mechanism 20 together. The welding machine includes a hot melt welding machine and an ultrasonic welding machine.

[0213] In the eighth feasible technical proposal, a fastening structure may be adopted, which includes a fastening material, and grooves are provided on the surfaces of the male end connection mechanism 10 and the female end connection mechanism 20, and the splicing surfaces of the male end connection mechanism 10 and the female end connection mechanism 20 are fixedly connected by fastening the splicing surfaces of the male end connection mechanism 10 and the female end connection mechanism 20 at the position of the grooves using the fastening material. The fastening material includes cable ties, ferrules, hook locks, etc.

[0214] In the ninth feasible technical proposal, a locking structure may be employed, which includes a locking device provided on a surface adjacent to the splicing surface of the male end connection mechanism 10 and the female end connection mechanism 20, or on the splicing surface, and the splicing surfaces of the male end connection mechanism 10 and the female end connection mechanism 20 are fixedly connected by the locking device.

[0215] In one embodiment, the mating terminal 23 includes a cable clamp portion 232, and the flat terminal 113 and the cable clamp portion 232 are mated and electrically connected, and the plug-in force between the flat terminal 113 and the cable clamp portion 232 is 3N to 150N.

[0216] To verify the influence of the plug-in force between the flat terminal 113 and the cable clamp portion 232 on the contact resistance and mating condition between the flat ribbon 11 and the mating terminal 23, the inventor selected a flat ribbon 11 and a mating terminal 23 of the same shape and dimensions, designed different plug-in forces between the flat ribbon 11 and the mating terminal 23, and observed the contact resistance and the condition after multiple mating cycles.

[0217] The contact resistance detection method involves using a micro-resistance meter to measure the resistance at the contact point between the flat terminal 113 and the cable clamp portion 232, and reading the value from the micro-resistance meter as the contact resistance between the flat terminal 113 and the cable clamp portion 232. In this embodiment, a contact resistance of less than 50 μΩ is the ideal value.

[0218] The test method for the mating condition between the flat terminal 113 and the cable clamp portion 232 involves mating the flat terminal 113 and the cable clamp portion 232 50 times, observing the number of times they fall out after insertion and removal, and the number of times they cannot be inserted or removed. The number of times they fall out after insertion and removal must be less than 3, and the number of times they cannot be inserted or removed must be less than 5.

[0219] Table 9, Effect of plug-in force between different flat terminals 113 and cable clamp portion 232 on contact resistance and mating conditions [Table 9] As can be seen from Table 9 above, if the plug-in force between the flat terminal 113 and the cable clamp portion 232 is less than 3N, the coupling force between the flat terminal 113 and the cable clamp portion 232 is too low, resulting in a contact resistance higher than the ideal value, and the number of times it falls after insertion and removal exceeds 3, which is a failure. If the plug-in force between the flat terminal 113 and the cable clamp portion 232 is greater than 150N, the number of times it cannot be inserted or removed between the flat terminal 113 and the cable clamp portion 232 exceeds 5, which is also a failure. Therefore, the inventor set the plug-in force between the flat terminal 113 and the cable clamp portion 232 between 3N and 150N.

[0220] As can be seen from Table 9 above, when the plug-in force between the flat terminal 113 and the cable clamp portion 232 is between 10N and 130N, there are no cases of the terminal falling out after insertion or insertion being impossible, and the contact resistance value is within the ideal range. Therefore, the inventor prefers to set the plug-in force between the flat terminal 113 and the cable clamp portion 232 to between 10N and 135N.

[0221] In one embodiment, the contact resistance between the flat terminal 113 and the mating terminal 23 is less than 9 mΩ. Preferably, the contact resistance between the flat terminal 113 and the mating terminal 23 is less than 1 mΩ. Generally, when it is necessary to conduct a large current between the flat terminal 113 and the mating terminal 23, if the contact resistance between the flat terminal 113 and the mating terminal 23 is greater than 9 mΩ, a large temperature rise occurs at the contact point, and as time passes, the temperature increases further. The temperature between the flat terminal 113 and the mating terminal 23 becomes too high, and the different materials cause different thermal expansion coefficients, resulting in unsynchronized mechanical deformation. This generates internal stress between the conductive corrosion prevention layer and the flat terminal 113, and between the mating terminal 23 and the terminal plating layer, which in severe cases can cause the conductive corrosion prevention layer and the terminal plating layer to detach, preventing the protective effect from being achieved. On the other hand, excessively high temperatures between the flat terminal 113 and the mating terminal 23 can conduct to the insulating layer of the flat ribbon 11 and the insulating layer of the conductor connected to the mating terminal 23, causing the corresponding insulating layers to melt and fail to perform their insulating protection function. In serious cases, this can lead to damage to the connection structure due to a short circuit in the line, and ultimately to safety accidents such as combustion. Therefore, the inventor set the contact resistance between the flat terminal 113 and the mating terminal 23 to less than 9 mΩ.

[0222] To verify the effect of contact resistance between the flat terminal 113 and the mating terminal 23 on the temperature rise and conductivity of the connection mechanism, the inventors selected the same flat ribbon 11 and mating terminals 23 with different contact resistances and performed tests on the conductivity and temperature rise of the mating structure.

[0223] The conductivity test involves mating the flat terminal 113 with the mating terminal 23, then energizing the mating structure, and subsequently detecting the conductivity of the corresponding mating location. In this embodiment, a conductivity greater than 99% is considered ideal.

[0224] The temperature rise test involves applying the same current to the plug-in structure, detecting the temperature at the same location on the flat terminal 113 and mating terminal 23 in a sealed environment before energization and after the temperature has stabilized, and subtracting the difference to obtain the absolute value. In this embodiment, a temperature rise greater than 50K is considered a failure.

[0225] Table 10: Effect of different contact resistances between flat terminals 113 and mating terminals 23 on conductivity and temperature rise [Table 10] As can be seen from Table 10 above, when the contact resistance between the flat terminal 113 and the mating terminal 23 is greater than 9 mΩ, the temperature rise of the plug-in structure exceeds 50 K, and the conductivity of the plug-in structure is less than 99%, failing to meet the standard requirements. Therefore, the inventor set the contact resistance between the flat terminal 113 and the mating terminal 23 to less than 9 mΩ. At the same time, the inventor discovered that when the contact resistance is less than 1 mΩ, the temperature rise decreases even more significantly, and the conductivity is also high. Therefore, in this invention, it is preferable that the contact resistance between the flat terminal 113 and the mating terminal 23 is less than 1 mΩ.

[0226] In one embodiment, the number of insertions and removals between the male-end connector 10 and the female-end connector 20 is nine or more. When assembling the connector with an electrical device, it is necessary to assemble the male-end connector 10 and the female-end connector 20. However, if subsequent maintenance or assembly removal is required, it may be necessary to separate the male-end connector 10 and the female-end connector 20 before insertion or removal. Therefore, the number of insertions and removals between the male-end connector 10 and the female-end connector 20 should not be less than nine. If it is less than nine, the male-end connector 10 or the female-end connector 20 may be damaged during a single removal or maintenance, rendering it unable to conduct electricity. In this case, the entire connector, including the harness, would need to be replaced, increasing not only maintenance time but also maintenance costs. Therefore, both the selection of materials for the male-end connector 10 and the female-end connector 20, as well as the design of the insertion / removal mechanism, locking mechanism, and sealing mechanism between the male-end connector 10 and the female-end connector 20, require at least nine removals and reassemblies. This ensures that the requirements for using the connector are met.

[0227] In one embodiment, the weight of the male connector 10 is 305g or less. As shown in Figure 1, the male connector is located above the connector and plugged into the female connector 20. If the weight of the male connector 10 is too great, the gravitational force acting on the female connector 20 will also be great. When the electrical device vibrates, the entire connector follows the vibration, and due to inertia, the male connector 10 will experience large vibrations, generating abnormal noise. The generation of abnormal noise during the use of the electrical device is unacceptable.

[0228] To verify the effect of the weight of the male end connection mechanism 10 on the generation of abnormal noise in the connection mechanism, the inventors assembled samples of the same female end connection mechanism 20 and male end connection mechanisms 10 of different weights, mounted them on a vibration test stand, and performed vibration tests. They observed whether or not abnormal noise was generated in the male end connection mechanism 10 during the vibration tests, and the test results are shown in Table 11.

[0229] Table 11: Effect of the weight of the male terminal connection mechanism 10 on the generation of abnormal noise in the connection mechanism [Table 11] As can be seen from Table 11, after the weight of the male connector mechanism 10 exceeded 305g, an abnormal noise occurred in the male connector mechanism 10 during the vibration test, resulting in a failure of the test. Therefore, the inventor selected a weight of 305g or less for the male connector mechanism 10.

[0230] In one embodiment, the height of the male connector 10 along the insertion / removal direction is 108 mm or less. After assembling the male connector 10 and the female connector 20, they need to be attached to an electrical device. Generally, the spare space in electrical devices is small, and if the male connector 10 is too tall, it cannot be attached to the electrical device, and raw materials are wasted. Therefore, the male connector 10 needs to be lower than a certain height during the design phase.

[0231] To verify the effect of the height of the male end connector 10 along the insertion / removal direction on the mounting condition of the connection mechanism, the inventors used samples of the same female end connector 20 and male end connector 10 with different heights along the insertion / removal direction, assembled them, mounted them to an electrical device, and observed whether the male end connector 10 interfered with other parts of the electrical device during mounting. The test results are shown in Table 12.

[0232] Table 12: Effect of the height of the male terminal connection mechanism 10 along the insertion / removal direction on the mounting status of the connection mechanism. [Table 12] As can be seen from Table 12, if the height of the male terminal connection mechanism 10 along the insertion / removal direction exceeds 108 mm, it cannot be installed in the specified position of the electrical device, and the test fails. The height of the male terminal connection mechanism 10 along the insertion / removal direction is 108 mm or less.

[0233] The present invention further provides an electrical energy transmission device including the above-described connection mechanism.

[0234] The present invention further provides an automobile including the above-described connection mechanism and electrical energy transmission device.

[0235] The connection mechanism of the present invention, by providing an injection-molded male end housing 12, is easy to manufacture, low-cost, can be directly injected into the flat ribbon 11 for insulation, reduces the number of flat ribbon 11 attachments, eliminates the need to consider assembly issues, and allows the tip of the flat ribbon 11 to be molded into various shapes according to demand, thereby saving processing steps and reducing processing costs.

[0236] The connection mechanism of the present invention effectively reduces electromagnetic interference to other components after the flat ribbons 11 are energized by stacking them and providing appropriate spacing, thereby eliminating the need for a shielding layer structure in high-voltage charging harnesses and meeting the demands for cost reduction and weight reduction.

[0237] The flat ribbon 11 may be made of a material containing aluminum or an aluminum alloy, which is lighter in weight, lower in price, and better meets the requirements for energy saving, emission reduction, and cost reduction in automobiles.

[0238] The flat ribbon 11 eliminates the need to manufacture flat terminals 113 separately. By simply bending and chamfering the tip of the flat core 111, it can be used as a flat terminal 113, reducing the processing cost of flat terminals 113, decreasing the number of connections between the flat core 111 and flat terminals 113, reducing the voltage drop of the flat ribbon 11, and improving the mechanical and electrical performance of the connection mechanism.

[0239] In the connection between the flat terminal 113 and the mating terminal 23, the conductive corrosion prevention layer reduces the occurrence of electrochemical reactions between the flat terminal 113 and the mating terminal 23 of the flat ribbon 11, thereby solving the technical problem that the flat ribbon 11 can only be connected to other terminals or electrical devices via copper terminals.

[0240] The mating terminal 23 is made up of multiple sheet-like terminals 234 stacked and arranged on top of each other. The sheet-like terminals 234 are easily deformable and can be plugged into the flat terminals 113 of the flat ribbon 11. The flat terminals 113 of the flat ribbon 11 and the strip-shaped grooves of the sheet-like terminals 234 come into contact with each other, achieving an electrical connection and thus ensuring the stability of the connection between the mating terminal 23 and the flat ribbon 11.

[0241] By connecting the flat terminal 113 to the mating terminal 23, the flat terminal 113 of the flat ribbon 11 itself functions as a terminal and is directly connected to the mating terminal 23. This solves the problem of high cost and low efficiency that would otherwise be required to connect copper terminals to the flat ribbon 11, enabling safe and rapid insertion and removal.

[0242] The mating terminal 23 has a memory function, and when it is below the transformation temperature, the strip-shaped groove of the mating terminal 23 is normally in an expanded state. At this time, the flat terminal 113 of the flat ribbon 11 can be butted together without insertion force, facilitating the simple mating of electrical equipment by the operator. When current is conducted through the mating terminal 23 during operation, the temperature of the mating terminal 23 gradually rises due to the action of resistance. When the temperature rises above the transformation temperature, the strip-shaped groove of the mating terminal 23 contracts radially. The rise in temperature increases the contact area and contact force between the strip-shaped groove of the mating terminal 23 and the flat terminal 113 of the flat ribbon, improving the reliability of the contact and eliminating the need for insertion force, making the work easier and increasing work efficiency.

[0243] The insert-type high-pressure interlock structure 24 replaces conventional assembled high-pressure interlocks by being fixed to the connection mechanism by integral injection molding, eliminating the need for assembly, reducing costs, and fully satisfying the high-pressure interlock effect.

[0244] The sealing structure of the connection mechanism does not require the installation of any further separate sealing rings. Instead, a secondary injection-molded sealing structure is adopted as a replacement for the traditional sealing ring, allowing it to be molded directly into the connection mechanism, resulting in better injection bonding and reduced costs.

[0245] By employing a temperature measurement mechanism, the temperature of the terminals inside the connection mechanism can be monitored independently, preventing the loss of temperature monitoring of the connection mechanism due to damage to temperature sensors in other locations.

[0246] The above are merely some embodiments of the present invention, and those skilled in the art can make various changes or modifications to the embodiments of the present invention without departing from the spirit and scope of the invention, based on the information disclosed in the application documents. [Explanation of symbols]

[0247] 10 Male connector mechanism 11 Flat Ribbon 111 Flat Core 112 Outer insulating layer 113 Flat terminal 1131 Folding section 12 Male connector housing 14 Interlock Connectors 20 Female terminal connection mechanism 21 Cables 22 Female terminal housing 23 Mating terminals 231 Fixed part 232 Cable clamp section 234 Sheet-type terminals 24 High-voltage interlock structure 30 clips 31 Side wall 32 elastic units 40 Seal structure

Claims

1. A connection mechanism including a male end connection mechanism and a female end connection mechanism, The male end connection mechanism includes a flat ribbon, a flat terminal, and a male end housing connected to the flat ribbon and the flat terminal; the female end connection mechanism includes a mating terminal and a female end housing connected to the mating terminal; the male end connection mechanism and the female end connection mechanism are electrically connected by the flat terminal and the mating terminal, and the male end housing is connected to the female end housing to form the connection mechanism. The flat ribbon consists of at least two independent pieces, spaced apart, and includes a plate-shaped flat core which is the conductive portion of the flat ribbon, with the tip of the flat core bent to form the flat terminal. The male terminal housing is integrally injection-molded with at least a portion of the flat ribbon other than the flat terminal and the outer circumference of the flat terminal to form an insulating structure. The mating terminal includes a fixing portion placed on the bottom of the female end housing and a clamping portion having a groove formed therein for mating with the flat terminal. The aforementioned fixing portion is formed by stacking parts of multiple sheet-like terminals, The clamp portion is formed by bending the other parts of each of the sheet-like terminals relative to a portion of the sheet-like terminals. The other part of the sheet-like terminal includes a pair of gripping parts for gripping the flat terminal, The width of the groove in the second horizontal direction, which is perpendicular to the first horizontal direction in which the other parts of the plurality of sheet-like terminals are arranged, is smaller than the width of the gripping portion in the second horizontal direction. A connection mechanism characterized by the following:

2. The connection mechanism according to claim 1, characterized in that the aspect ratio of the cross-section of the flat ribbon is 1:1 to 120:

1.

3. The connection mechanism according to claim 1, characterized in that the flat ribbons are stacked vertically.

4. The connection mechanism according to claim 1, wherein the flat ribbon further includes an external insulating layer, a portion of which is peeled off to expose the flat core, and the end of the external insulating layer is located inside or in contact with the male end housing.

5. The connection mechanism according to claim 1, characterized in that the flat core has a hardness of 8 HV to 105 HV.

6. The connection mechanism according to claim 1, characterized in that the flat ribbons are stacked vertically, and the vertical distance between the two flat cores is 27 cm or less.

7. The connection mechanism according to claim 6, characterized in that the vertical distance between the two flat cores is 7 cm or less.

8. The connection mechanism according to claim 1, characterized in that the flat ribbons are stacked vertically, and the degree of overlap along the stacking direction of the two flat cores is 40% to 100%.

9. At least a portion of the flat terminal protrudes from the male terminal housing, or The connection mechanism according to claim 1, characterized in that the male terminal housing has a housing cavity, and at least a portion of the flat terminal protrudes from the bottom surface of the housing cavity but does not extend beyond the male terminal housing.

10. The connection mechanism according to claim 1, characterized in that a bent portion having an angle of 0° to 180° is included between the flat core and the flat terminal.

11. The connection mechanism according to claim 1, characterized in that a conductive corrosion prevention layer is provided on at least a portion of the flat terminal.

12. The connection mechanism according to claim 11, characterized in that the thickness of the conductive corrosion prevention layer is 0.3 μm to 3000 μm.

13. The connection mechanism according to claim 12, characterized in that the thickness of the conductive corrosion prevention layer is 2.5 μm to 1000 μm.

14. The connection mechanism according to claim 1, characterized in that a chamfer is provided at the end of the flat terminal.

15. The connection mechanism according to claim 1, characterized in that the male terminal connection mechanism includes an interlock connector in which at least a portion is integrally injected into the male terminal housing.

16. The connection mechanism according to claim 1, wherein the female terminal connection mechanism further includes a cable, and the fixing portion is electrically connected to the conductive portion at the tip of the cable.

17. The connection mechanism according to claim 16, characterized in that a clip made of a memory alloy is sleeved in the clamp portion.

18. The connection mechanism according to claim 17, wherein the transformation temperature of the memory alloy is set within the range of 40°C to 70°C, and when the temperature of the clip is lower than the transformation temperature, the clip is in an expanded state, and when the temperature of the clip is higher than the transformation temperature, the clip is in a clamped state.

19. The connection mechanism according to claim 16, wherein a clip including a side wall and an elastic unit fixed to the side wall is sleeved in the clamp portion, and the elastic unit is connected in contact with the outside of the clamp portion.

20. The connection mechanism according to claim 19, characterized in that the range of force applied by the elastic unit to the clamp portion is 3N to 200N.

21. The connection mechanism according to claim 19, characterized in that the elastic unit is elastic rubber, a spring, or a metal dome.

22. The connection mechanism according to claim 1, characterized in that the gap between the other parts of two adjacent sheet-like terminals is less than 0.2 mm.

23. The connection mechanism according to claim 21, characterized in that the material of the sheet-like terminal is a memory alloy.

24. The connection mechanism according to claim 23, wherein the transformation temperature of the memory alloy is set within the range of 40°C to 70°C, and when the temperature of the sheet-like terminal is lower than the transformation temperature, the plurality of grooves are in an expanded state, and when the temperature of the sheet-like terminal is higher than the transformation temperature, the plurality of grooves are in a clamped state.

25. The connection mechanism according to claim 1, characterized in that the female end housing is integrally injection-molded with at least a portion of the outer circumference of the mating terminal to form an insulating structure.

26. The connection mechanism according to claim 1, wherein the female terminal connection mechanism further includes a cable electrically connected to the mating terminal, the mating terminal and at least a portion of the cable are provided within the female terminal housing, and at least a portion of the mating terminal is exposed outside the female terminal housing.

27. At least a portion of the clamp portion protrudes from the outer wall of the female end housing, or The connection mechanism according to claim 1, characterized in that an opening boss is provided in the female end housing, and at least a part of the clamp portion is provided within the opening boss.

28. The connection mechanism according to claim 15, characterized in that the female terminal connection mechanism has a high-voltage interlock structure that is electrically connected to the interlock connector to form a circuit.

29. The connection mechanism according to claim 1, characterized in that the female end connection mechanism and / or the male end connection mechanism have a sealing structure.

30. The connection mechanism according to claim 29, characterized in that the seal structure is secondarily injection molded onto the female end housing and / or the male end housing.

31. The connection mechanism according to claim 1, characterized in that the female terminal connection mechanism and / or the male terminal connection mechanism has at least one temperature measuring structure for measuring the temperature of the mating terminal and / or the flat ribbon and / or the flat terminal.

32. The connection mechanism according to claim 31, characterized in that the temperature measuring structure is attached to the mating terminal and / or the flat ribbon and / or the flat terminal so as to measure the temperature of the mating terminal and / or the flat ribbon and / or the flat terminal.

33. The connection mechanism according to claim 1, wherein the male terminal connection mechanism has at least one temperature measuring structure, the flat ribbons are at least two, and the temperature measuring structure is positioned between the flat ribbons to measure the temperature of the flat ribbons.

34. The connection mechanism according to claim 1, characterized in that the male end connection mechanism and the female end connection mechanism are connected by one or more of the following methods: adhesive connection, magnetic attraction connection, bayonet connection, plug-in connection, locking connection, binding connection, screw connection, rivet connection, and welding connection.

35. The connection mechanism according to claim 1, characterized in that the flat terminal is fitted into the clamp portion and electrically connected, and the plug-in force between the flat terminal and the clamp portion is 3N to 150N.

36. The connection mechanism according to claim 35, characterized in that the plug-in force between the flat terminal and the clamp portion is 10N to 130N.

37. The connection mechanism according to claim 1, characterized in that the contact resistance between the flat terminal and the mating terminal is less than 9 mΩ.

38. The connection mechanism according to claim 37, characterized in that the contact resistance between the flat terminal and the mating terminal is less than 1 mΩ.

39. The connection mechanism according to claim 1, characterized in that the number of insertions and removals between the male end connection mechanism and the female end connection mechanism is nine or more.

40. The connection mechanism according to claim 1, characterized in that the weight of the male terminal connection mechanism is 305 g or less.

41. The connection mechanism according to claim 1, characterized in that the height of the male end connection mechanism along the insertion / removal direction is 108 mm or less.

42. An electrical energy transmission device characterized by including a connection mechanism according to any one of claims 1 to 41.

43. An automobile characterized by including a connection mechanism according to any one of claims 1 to 41.

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