Adapter for electric transportation device and manufacturing process thereof

Abstract

The present invention relates to an adapter for an electric transportation device and a manufacturing process thereof, wherein a power supply pin is provided at the center of an electricity supply unit, a pair of signal transmission / reception pins are installed on both sides of the power supply pin, a pair of guide pins are provided on both sides of the power supply pin in another direction, a power reception pipe to which the power supply pin is coupled is provided at the center of an electricity reception unit, a signal transmission / reception pipe to which one signal transmission / reception pin is coupled is provided on one side of the power reception pipe, a space into which one signal transmission / reception pin is inserted in a non-contact manner is formed on the other side thereof, and a pair of guide holes to which the guide pins are coupled are provided on both sides of the power reception pipe in another direction, whereby the coupling structure of the electricity supply unit and the electricity reception unit has excellent insulation and durability, and is a bidirectional connection type capable of conducting electricity even when the coupling direction of the electricity transmission unit and the electricity reception unit is changed by 180 degrees, thereby increasing convenience of use.

Description

Adapter for electric transport devices and the manufacturing process thereof

[0001] The present invention relates to an adapter for an electric transport device and a manufacturing process thereof, and in particular, to an adapter for an electric transport device and a manufacturing process thereof that has excellent insulation and durability in the combined structure of an electric transmitter and an electric receiver, and is a bidirectional connection type that allows current to be conducted even when the combined direction of the electric transmitter and the electric receiver is switched 180 degrees, thereby increasing convenience of use.

[0002] Generally, electric transportation devices are vehicles that operate using electricity, including electric cars and electric motorcycles. Driven by stricter global regulations on environmental pollution and the trend toward energy conservation, the development and dissemination of electric transportation devices are gradually expanding across the globe.

[0003] Electric transportation devices can be broadly classified into pure electric vehicles (Battery Powered Electric Vehicles) and hybrid electric vehicles. Pure electric vehicles are driven using only electricity and are generally referred to as electric vehicles, while hybrid electric vehicles refer to vehicles that run using both electricity and fossil fuels. Electric motorcycles can also be classified in the same way.

[0004] Traditionally, an autobicycle or motorcycle refers to a two-wheeled vehicle equipped with an engine that uses it as its power source. Commonly referred to as a "motorcycle," most models feature an engine mounted below the middle of the two wheels, connected to the rear wheel via a belt or chain. These vehicles are useful for short-distance travel or for carrying cargo. Motorcycles are sold at various prices depending on their performance, design, and other factors.

[0005] Meanwhile, as time goes on, not only are the prices of the aforementioned petroleum fuels skyrocketing, but the smoke and other pollutants generated from the combustion of these fuels are also a cause of serious environmental pollution.

[0006] Accordingly, electric motorcycles are designed to drive a motor using power supplied from a battery and to travel using the driving force generated by the motor, and their usage trends have been increasing recently.

[0007] Unlike conventional motorcycles, these electric motorcycles can be driven solely by the power of the battery and electric motor when climbing hills or traveling long distances, and they are gaining popularity as an eco-friendly mode of transportation due to their low exhaust emissions and noise.

[0008] An electric transport device including a motorcycle is equipped with a battery that stores current to operate a driving function, and the driving function is operated by charging the battery by receiving current from an external power source and driving an electric motor.

[0009] Accordingly, adapters are essential interface devices installed in electric transport equipment to connect electricity from an external power source. There is an increasing need for such adapters that offer excellent insulation and durability against external moisture, as well as improved convenience during connection operations.

[0010] (Prior Art Literature)

[0011] Korean Patent Publication No. 10-1676652.

[0012] Republic of Korea Published Patent Application No. 10-2018-0085973.

[0013] The present invention is intended to solve the above-mentioned problems, and the objective of the present invention is to provide an adapter for an electric transport device and a manufacturing process thereof, which has excellent insulation and durability in the combined structure of the electric transmitter and the electric receiver, and is a bidirectional connection type that allows current to be conducted even when the combined direction of the electric transmitter and the electric receiver is switched 180 degrees, thereby increasing convenience of use.

[0014] The present invention for achieving the above objective comprises an adapter for an electric transport device, comprising an electric supply unit connected to a power supply unit and an electric receiving unit connected to a battery unit, wherein

[0015] A power supply pin is provided at the center of the above-mentioned power supply unit, a pair of signal transmission and reception pins are installed on both sides of the power supply pin, and a pair of guide pins are provided on both sides in the other direction of the power supply pin;

[0016] An adapter for an electric transport device is provided, characterized in that a power receiving tube to which a power supply pin is coupled is provided at the center of the electric receiving part, a signal transmitting and receiving tube to which one of the signal transmitting and receiving pins is coupled is provided on one side of the power receiving tube, a space for which one of the signal transmitting and receiving pins is non-contactually inserted is formed on the other side, and a pair of guide holes to which the guide pins are coupled are provided on both sides of the power receiving tube in the other direction.

[0017] The above-mentioned electric supply unit and the above-mentioned electric receiving unit are each provided with a sealing pad of the same shape on the surface in contact with the flat surface of the transport device;

[0018] The sealing pad is coupled inwardly, avoiding the screw fastening through holes formed in the electrical supply unit and the electrical receiver unit, thereby preventing moisture from penetrating through the through holes.

[0019] Another present invention for achieving the above-mentioned purpose comprises, in a process for manufacturing an adapter for an electric transport device comprising an electric supply unit connected to a power supply unit and an electric receiving unit connected to a battery unit,

[0020] The process of manufacturing the above-mentioned electric supply unit is,

[0021] A process of fixing the power supply pins integrally to the center of the PCB cover using molding;

[0022] Process of mounting a connector on a PCB board;

[0023] A process of soldering signal transmission terminal pins to the PCB substrate;

[0024]

[0025] * Process of fixing the above PCB substrate to the above PCB cover by hot melting:

[0026] A process of forming a power supply unit on the above PCB cover and the above PCB substrate by overmolding;

[0027] The process consists of fixing a sealing pad to the above-mentioned power supply unit;

[0028]

[0029] The process of manufacturing the above-mentioned electric receiver is,

[0030] A process of integrally fixing a power receiving tube, to which the power supply pin is coupled, to the center of the PCB cover using molding;

[0031] Process of mounting a connector on a PCB board;

[0032] Process of assembling signal crown springs;

[0033] A process of soldering signal transmission terminal pins to the PCB substrate;

[0034] Process of fixing the above PCB substrate to the above PCB cover by hot melting:

[0035] A process of forming a power receiving part on the above PCB cover and the above PCB substrate by overmolding;

[0036] A process of mounting a positive crown spring, a negative crown spring, and a negative terminal ring on the above power receiving tube;

[0037] The present invention provides a manufacturing process for an adapter for an electric transport device, characterized by comprising a process of fixing a sealing pad to the power receiving part.

[0038] As described above, the present invention has the effect of increasing convenience of use by having excellent insulation and durability in the combined structure of the electric transmitter and the electric receiver in an adapter for an electric transport device, and by being a bidirectional connection type that allows current to be conducted even when the combined direction of the electric transmitter and the electric receiver is switched 180 degrees.

[0039] FIGS. 1 and 2 are perspective views of an electric supply unit of an adapter for an electric transport device according to an embodiment of the present invention, and

[0040] FIGS. 3 and 4 are perspective views of an electric receiving part of an adapter for an electric transport device according to an embodiment of the present invention, and

[0041] FIG. 5 is a cross-sectional view of an adapter for an electric transport device according to an embodiment of the present invention, and

[0042] FIG. 6 is an exploded perspective view of a guide pin and a guide hole of an adapter for an electric transport device according to an embodiment of the present invention, and

[0043] FIG. 7 is a perspective view of a PCB of an adapter for an electric transport device according to an embodiment of the present invention, and

[0044] FIG. 8 is a perspective view showing the usage state of an adapter for an electric transport device according to an embodiment of the present invention.

[0045] FIG. 9 is a manufacturing process diagram of an electric supply unit of an adapter for an electric transport device according to an embodiment of the present invention, and

[0046] FIG. 10 is a manufacturing process diagram of an electric receiving part of an adapter for an electric transport device according to an embodiment of the present invention.

[0047]

[0048] The following detailed description of the invention refers to the accompanying drawings, which illustrate specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. It should be understood that various embodiments of the invention are different but need not be mutually exclusive. For example, specific shapes, structures, and characteristics described herein may be implemented in other embodiments without departing from the spirit and scope of the invention in relation to one embodiment. It should also be understood that the location or arrangement of individual components within each disclosed embodiment may be changed without departing from the spirit and scope of the invention. Accordingly, the following detailed description is not intended to be limiting, and the scope of the invention is limited only by the appended claims, including all equivalents to those claimed therein, provided appropriately described. Similar reference numerals in the drawings refer to the same or similar functions across various aspects.

[0049] Hereinafter, preferred embodiments of the present invention will be described in more detail with reference to the drawings.

[0050] The adapter for an electric transport device according to the present embodiment is used to supply power to an electric transport device, such as an electric vehicle or an electric motorcycle, from an electric charging station applied to the device or from a power supply installed in a home. In particular, the adapter according to the present embodiment is more suitable for use in two-wheeled transport devices such as motorcycles.

[0051] FIGS. 1 and 2 are perspective views of the power supply portion of an adapter for an electric transport device according to an embodiment of the present invention, FIGS. 3 and 4 are perspective views of the power receiving portion of an adapter for an electric transport device according to an embodiment of the present invention, and FIG. 5 is a cross-sectional view of an adapter for an electric transport device according to an embodiment of the present invention.

[0052] The adapter of the present embodiment consists of an electric supply unit (100) connected to the power supply side and an electric receiving unit (100) connected to the battery side mounted on the electric transport device.

[0053] A power supply pin (110) is provided at the center of the power supply unit (100), and a pair of signal transmission / reception pins (120) are installed on both sides of the power supply pin (110). A power terminal (112) is provided at the top of the power supply unit (100) to be connected to the power supply pin (110) and to receive power from a power supply device, and a signal terminal (122) is provided to be connected to the signal transmission / reception pins (120) and to receive a signal from a power supply device.

[0054] Main power for charging the battery is supplied through the power supply pin (110), and information regarding the charge amount of the battery, etc., is transmitted bidirectionally through the signal transmission / reception pin (120).

[0055] And, FIG. 6 is an exploded perspective view of a guide pin and a guide hole of an adapter for an electric transport device according to an embodiment of the present invention, FIG. 7 is a perspective view of a PCB of an adapter for an electric transport device according to an embodiment of the present invention, and FIG. 8 is a perspective view showing the usage state of an adapter for an electric transport device according to an embodiment of the present invention.

[0056] A pair of guide pins (130) are provided on each side of the other direction of the power supply pin (110).

[0057] After the power supply pin (110), signal transmission / reception pin (120), guide pin (130), power terminal (112), and signal terminal (122) are combined in the power supply unit (100), a cover (104) is attached to the upper part to protect these parts.

[0058] A power receiving tube (210) to which a power supply pin (110) is coupled is provided at the center of the electric receiving unit (200).

[0059] As shown in FIG. 6, the power supply pin (110) is made of a metal material capable of conducting electricity and is subdivided into an anode axis (110-1) and a cathode tube (110-2) located around it, and the axis (110-1) and the tube (110-2) are assembled together to conduct electricity.

[0060] The power receiving tube (210) is also made of a metal material capable of conducting electricity, and is subdivided into a positive axis (210-1) that contacts the axis (110-1) and a negative tube (210-2) located around it that contacts the negative tube (110-2), and the axis (210-1) and the tube (210-2) are assembled together to conduct electricity.

[0061] By connecting the power supply pin (110) to the power receiving tube (210), the structural center of the combined state of the power supply unit (100) and the power receiving unit (200) is maintained while power is supplied.

[0062] And, in the electric receiving unit (200), a signal transmitting and receiving tube (220) to which a signal transmitting and receiving pin (120) is coupled is provided on one side of the power receiving tube (210), and a space (222) into which a signal transmitting and receiving pin (120) is non-contactually inserted is formed on the other side.

[0063] A pair of signal transmission / reception pins (120) are arranged at 180-degree intervals on both sides of the power supply pin (110), and only one signal transmission / reception tube (220) to which the signal transmission / reception pins (120) are coupled is installed, and a space (222) is formed in the other part. Therefore, no matter which direction the power supply unit (100) is coupled, only one signal transmission / reception pin (120) is connected to the signal transmission / reception tube (220), so the same signal transmission effect occurs. Accordingly, the user can conveniently combine the power supply unit (100) and the power reception unit (200) without being constrained by the directionality of the power supply unit (100).

[0064] Meanwhile, in this embodiment, the power supply pin (110) and the signal transmission / reception pin (120) are installed in the power supply unit (100), and the power reception tube (210) and the signal transmission / reception tube (220) are provided in the power reception unit (200). However, they may be installed in the opposite positions. That is, the same purpose can be achieved even if the power reception tube (210) and the signal transmission / reception tube (220) are provided in the power supply unit (100), and the power supply pin (110) and the signal transmission / reception pin (120) are installed in the power reception unit (200).

[0065] On both sides of the power receiving tube (210) in the other direction, a pair of guide holes (230) are provided to which guide pins (130) are coupled. By these guide pins (130), the positions of the power supply unit (100) and the power receiving unit (200) are determined, so that the signal transmitting / receiving pin (120) can be accurately coupled to the signal transmitting / receiving tube (220).

[0066] On the mutually facing surfaces of the electric supply unit (100) and the electric receiving unit (200), grooves (102, 202) of the same shape are formed, and sealing pads (140, 240) are inserted into the grooves (102, 202) and fixed by adhesive. The sealing pads (140, 240) are intended to maintain watertightness by contacting the flat surface of the transport device when the adapter of the present invention is mounted on the transport device.

[0067] Additionally, the sealing pad (140, 240) is coupled inwardly, avoiding the screw fastening through holes (104, 204) formed in the electric supply unit (100) and electric receiving unit (200), thereby preventing moisture from penetrating into the guide pin (130), power supply pin (110), and signal transmission / reception pin (120) through the through holes (104, 204).

[0068] The guide pin (130), power supply pin (110), and signal transmission / reception pin (120) are all protected from short circuits caused by moisture penetration by these sealing pads (140, 240). The sealing pads (140, 240) are preferably made of silicone, which is a soft material with high contact density.

[0069] The lower part of the electric receiving unit (200) is provided with a power terminal (212) for supplying power to a battery from the electricity received by the power receiving tube (210), and the signal transmitting and receiving tube (220) is provided with a signal terminal (222) for transmitting a transmitted signal to a battery.

[0070]

[0071] Meanwhile, the present invention applies a PCB (122-1, 224-1) to the signal terminals (122, 224) of the power supply unit and the power receiver unit for signal transmission.

[0072] In the case of a standard adapter, since it only handles the electrical transmitter and receiver, 180˚ assembly is not difficult.

[0073] However, in the case of an adapter for an electric transport device, the present invention requires a separate signal transmission / reception pin (hereinafter referred to as "pin") for signal transmission and reception in addition to the electric transmitter and receiver. For 180° assembly, this pin must also be connected with a point-symmetric structure (hereinafter referred to as "symmetric structure").

[0074] Currently, connections between pins are mostly made by users soldering wires; however, this method causes problems such as product damage due to heat and quality degradation including cold, insufficient, or excessive soldering. Furthermore, the soldering process is inconvenient to use, and connecting and disconnecting the pins and transmitters is very difficult.

[0075] In order to resolve the above problems, a symmetrical structure of signal transmission and reception pins is implemented through a PCB pattern, eliminating the need for additional user processes for connecting pins, and connecting and disconnecting pins and transmitters is made easy through the PCB connector.

[0076] In addition, the present invention applies hotmelt.

[0077] PCBs (122-1,224-1) are vulnerable in terms of water resistance, insulation, heat resistance, and rigidity. Therefore, to protect the PCB, it must be manufactured as an integrated unit embedded within the product to compensate for these vulnerabilities. Although insert injection molding is mostly used for this integrated structure, the general heat resistance of a PCB is 130–160°C, whereas the plastic injection temperature is 250–280°C, which is a very high temperature; consequently, there is a very high possibility of PCB breakage.

[0078] To this end, a hotmelt bond material is first injected (low temperature low pressure injection / 135~145 ℃) to improve the waterproofness, insulation, and heat resistance of the PCB, and the PCB can be protected from high temperatures when the second plastic injection is performed.

[0079]

[0080] In the case of a general adapter, since it only handles the electric transmitter and receiver, 180° rotation assembly is not difficult. On the other hand, in the case of an adapter for an electric transport device, in addition to the electric transmitter and receiver, separate signal transmission and reception pins are required for signal transmission and reception, and for 180° rotation assembly, these pins must also have a point-symmetric structure and be interconnected.

[0081] Most pin connections are made by users soldering wires, but this causes product damage due to heat and quality degradation issues such as cold solder, insufficient solder, and excessive solder due to soldering, and makes it very difficult to connect and disconnect pins and transmitters.

[0082] The above problems can be resolved by utilizing PCBs and patterns to implement a symmetrical structure for signal transmission and reception pins, thereby eliminating additional user processing steps for connecting pins and simplifying the connection and disconnection between pins and transmitters / receivers through PCB connectors.

[0083] However, because PCBs are weak in terms of water resistance, heat resistance, and rigidity, it is generally difficult to integrate them into adapters. Therefore, our company applied a manufacturing method in which the PCB is insert-molded with hotmelt, a bonding material, followed by a secondary injection molding process. A mold capable of shaping the hotmelt was created using the primary plastic injection molding, and this was insert-molded together with the PCB to form the hotmelt. Subsequently, a unified product was produced through the secondary plastic injection molding.

[0084] The hot melt and secondary plastic injection molding were designed to be molded even inside the electrical transmitter / receiver. Through the above method, water ingress was prevented based on the hot melt, including the electrical transmitter / receiver and signal transmission / reception pins, thereby maximizing waterproofing. In addition, the PCB was protected from the high-temperature and high-pressure plastic injection resin used for integration by the hot melt applied earlier.

[0085]

[0086] The above problems can be resolved by utilizing PCBs and patterns to implement a symmetrical structure for signal transmission and reception pins, thereby eliminating additional user processing steps for connecting pins and simplifying the connection and disconnection between pins and transmitters / receivers through PCB connectors.

[0087] However, because PCBs are weak in terms of water resistance, heat resistance, and rigidity, it is generally difficult to integrate them into adapters.

[0088] Therefore, our company applied a method of insert injection molding with hotmelt, which is a bond material, and then performing a second injection molding.

[0089] A mold capable of forming the shape of the hotmelt was created using a first plastic injection molding process, and the hotmelt was formed by insert injection molding together with the PCB. Subsequently, an integrated product was produced through a second plastic injection molding process.

[0090] The hot melt and secondary plastic injection molded parts were made so that they could also be molded inside the electrical transmitter / receiver.

[0091] Through the above method, waterproofing was maximized by preventing moisture ingress based on hotmelt, including the electrical transmitter / receiver and signal transmitter / receiver pins.

[0092] In addition, the PCB can be protected from the high-temperature and high-pressure plastic injection resin used for integration by the hot melt applied earlier during injection.

[0093]

[0094] Meanwhile, a process for manufacturing an adapter for an electric transport device, comprising an electric supply unit connected to the power supply side and an electric receiving unit connected to the battery side, is described with reference to FIGS. 9 and 10.

[0095] First, the process of manufacturing the electrical supply unit is,

[0096] A process of fixing the power supply pins integrally to the center of the PCB cover using molding;

[0097] Process of mounting a connector on a PCB board;

[0098] A process of soldering signal transmission terminal pins to the PCB substrate;

[0099] Process of fixing the above PCB substrate to the above PCB cover by hot melting:

[0100] A process of forming a power supply unit on the above PCB cover and the above PCB substrate by overmolding;

[0101] The process consists of fixing a sealing pad to the power supply unit.

[0102] And, the process of manufacturing the electric receiver is,

[0103] A process of integrally fixing a power receiving tube, to which the power supply pin is coupled, to the center of the PCB cover using molding;

[0104] Process of mounting a connector on a PCB board;

[0105] Process of assembling signal crown springs;

[0106] A process of soldering signal transmission terminal pins to the PCB substrate;

[0107] Process of fixing the above PCB substrate to the above PCB cover by hot melting:

[0108] A process of forming a power receiving part on the above PCB cover and the above PCB substrate by overmolding;

[0109] A process of mounting a positive crown spring, a negative crown spring, and a negative terminal ring on the above power receiving tube;

[0110] The process consists of fixing a sealing pad to the power receiving unit.

[0111]

[0112] The present invention is not limited thereto and may be modified in various forms by those skilled in the art without departing from the spirit and scope of the following appended claims; therefore, such modifications should be interpreted as being within the scope of the present invention.

Claims

1. A process for manufacturing an adapter for an electric transport device comprising an electric supply unit connected to a power supply unit and an electric receiving unit connected to a battery unit, The process of manufacturing the above-mentioned electric supply unit is, A process of fixing the power supply pins integrally to the center of the PCB cover using molding; Process of mounting a connector on a PCB board; A process of soldering signal transmission terminal pins to the PCB substrate; Process of fixing the above PCB substrate to the above PCB cover by hot melting: A process of forming a power supply unit on the above PCB cover and the above PCB substrate by overmolding; The process consists of fixing a sealing pad to the above-mentioned power supply unit; The process of manufacturing the above-mentioned electric receiver is, A process of integrally fixing a power receiving tube, to which the power supply pin is coupled, to the center of the PCB cover using molding; Process of mounting a connector on a PCB board; Process of assembling signal crown springs; A process of soldering signal transmission terminal pins to the PCB substrate; Process of fixing the above PCB substrate to the above PCB cover by hot melting: A process of forming a power receiving part on the above PCB cover and the above PCB substrate by overmolding; A process of mounting a positive crown spring, a negative crown spring, and a negative terminal ring on the above power receiving tube; A manufacturing process for an adapter for an electric transport device, characterized by a process of fixing a sealing pad to the power receiving part.

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