WO2023174277A1 - 一种电能传输总成及车辆 - Google Patents

一种电能传输总成及车辆 Download PDF

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Publication number
WO2023174277A1
WO2023174277A1 PCT/CN2023/081357 CN2023081357W WO2023174277A1 WO 2023174277 A1 WO2023174277 A1 WO 2023174277A1 CN 2023081357 W CN2023081357 W CN 2023081357W WO 2023174277 A1 WO2023174277 A1 WO 2023174277A1
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WO
WIPO (PCT)
Prior art keywords
transmission assembly
shaped
electrical connection
rigid
assembly according
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CN2023/081357
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English (en)
French (fr)
Inventor
王超
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Jilin Zhong Ying High Technology Co Ltd
Original Assignee
Jilin Zhong Ying High Technology Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Jilin Zhong Ying High Technology Co Ltd filed Critical Jilin Zhong Ying High Technology Co Ltd
Priority to US18/847,201 priority Critical patent/US20250192458A1/en
Priority to EP23769779.2A priority patent/EP4496151A4/en
Publication of WO2023174277A1 publication Critical patent/WO2023174277A1/zh
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/01—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the form or arrangement of the conductive interconnection between the connecting locations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/10—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
    • B60L53/14—Conductive energy transfer
    • B60L53/16—Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/10—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
    • B60L53/14—Conductive energy transfer
    • B60L53/18—Cables specially adapted for charging electric vehicles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H01R4/023—Soldered or welded connections between cables or wires and terminals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
    • H01B5/12—Braided wires or the like
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H01R4/029—Welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/70—Energy storage systems for electromobility, e.g. batteries

Definitions

  • the present application relates to the technical field of automotive electrical appliances, and more specifically, to an electric energy transmission assembly and a vehicle.
  • New energy batteries for new energy vehicles use high-voltage power transmission assembly systems to replenish and transfer energy.
  • the high-voltage power transmission assembly also has a charging harness connector mechanism connected to the vehicle battery system.
  • the high-voltage harness is the most important unit in the high-voltage system of new energy vehicles.
  • High-voltage wiring harnesses use rigid bodies or flexible conductors as high-voltage cables.
  • the ends of the cables are connected to plug terminals and are electrically connected to the vehicle battery system and other electrical devices.
  • high-voltage cables are assembled solely using rigid cables or flexible cables to form connectors, which has problems such as difficulty in assembly or prone to abnormal noise.
  • One purpose of this application is to provide a new technical solution for an electric energy transmission assembly.
  • an electric energy transmission assembly including at least one electrical connection frame and connectors provided at both ends of the electrical connection frame.
  • the connector includes connection terminals, and the electrical connection frame Both ends are electrically connected to the connection terminals, and at least part of the electrical connection skeleton contains a flexible conductor.
  • connection frame and the connection terminal are connected by welding or crimping.
  • the electrical connection skeleton is a flexible conductor, and at least part of the length of the flexible conductor is formed into a rigid body by welding or crimping.
  • the flexible conductor is a multi-core cable or a braided cable or a flexible cable stacked with multiple layers of sheets.
  • the electrical connection skeleton includes a plurality of conductive core segments connected end to end, and at least one of the conductive core segments is a flexible conductor.
  • the conductive core segments connected to the connection terminals at both ends of the electrical connection frame are rigid bodies.
  • the conductive core segments connected to the connection terminals at both ends of the electrical connection frame are flexible conductors.
  • the conductive core section connected to the connection terminal at one end of the electrical connection frame is a rigid body, and the conductive core section connected to the connection terminal at the other end of the electrical connection frame is a flexible conductor.
  • the ends of two adjacent guide core segments are connected by crimping, welding, screwing, riveting or splicing.
  • At least one of the guide core segments is a rigid body, the end of the rigid guide core segment is provided with a cylindrical or U-shaped or V-shaped connecting part, and the adjacent rigid or flexible guide core segments are The ends are put into the connecting parts and connected by crimping.
  • At least one of the guide core segments is a rigid body, a first flat part is provided at the end of the rigid guide core segment, and a first through hole is provided on the first flat part; adjacent rigid or flexible A second flat portion is provided at the end of the guide core section, and a second through hole is provided on the second flat portion.
  • the first through hole and the second through hole are stacked and passed through bolts or rivets. fixed.
  • At least one of the guide core segments is a rigid body, a screw is provided at the end of the rigid guide core segment, and an internal thread is provided at the end of the adjacent rigid or flexible guide core segment, and the screw is connected to The internal thread is screwed for fixation.
  • the adjacent guide core segments are rigid bodies, and the ends of two adjacent rigid guide core segments are respectively provided with hinge shafts and hinge pins, and the hinge shafts and the hinge pins are cooperatively connected, The two adjacent guide core segments are allowed to rotate relative to each other.
  • the adjacent guide core segments are rigid bodies, the end of the rigid guide core segment is provided with a spherical concave surface, the end of the adjacent rigid guide core segment is provided with a spherical convex surface, and the spherical concave surface is Covering the spherical convex surface and the two can rotate relatively.
  • the electrical connection skeleton is covered with an insulating layer.
  • a shielding layer and an outer insulating layer are arranged in sequence outside the insulating layer.
  • the flexible conductor has a different cross-sectional shape than other parts of the electrical connection skeleton.
  • the cross-sectional area of the flexible conductor is different from other parts of the electrical connection frame.
  • the cross-sectional shape of the electrical connection skeleton is circular, elliptical, rectangular, polygonal, A-shaped, B-shaped, D-shaped, M-shaped, N-shaped, O-shaped, S-shaped, E-shaped, F-shaped, One or more of H-shape, K-shape, L-shape, T-shape, U-shape, V-shape, W-shape, X-shape, Y-shape, Z-shape, P-shape, semi-arc shape, arc shape, and wavy shape.
  • the cross-sectional shape of the electrical connection skeleton is a polygon, and all corners of the polygon are chamfered or rounded.
  • one of the connectors is a charging stand.
  • a vehicle including a body, an electrical device and an electric energy transmission assembly as described above, and the connector is detachably fixed on the vehicle body or the electrical device.
  • the electrical connection skeleton is arranged and fixed along the contour of the vehicle body.
  • the power transmission assembly of this application is configured as a flexible conductor at the bending point, which can reduce the difficulty of installation and improve work efficiency when assembled with a vehicle.
  • Figure 1 is a schematic structural diagram of an electric energy transmission assembly of the present application
  • Figures 2 to 11 are axial cross-sectional views of different embodiments of the electrical connection skeleton of the present application.
  • Figure 12 is a cross-sectional schematic diagram of the insulating layer covering the outside of the electrical connection frame in this application;
  • Figure 13 is a cross-sectional schematic diagram of the outer coating insulation layer, shielding layer and outer insulation layer of the electrical connection frame in this application.
  • any specific values are to be construed as illustrative only and not as limiting. Accordingly, other examples of the exemplary embodiments may have different values.
  • An electric energy transmission assembly of the present application includes at least one electrical connection frame 1 and connectors 2 arranged at both ends of the electrical connection frame 1.
  • the connectors 2 include connection terminals , both ends of the electrical connection frame 1 are electrically connected to the connection terminals, and at least part of the electrical connection frame 1 is a flexible conductor 3 .
  • the power transmission assembly of the present application is configured as a flexible conductor 3 at the bending point, which can reduce the difficulty of installation and improve work efficiency when assembled with a vehicle.
  • flexible cables when connected to the connection terminal in connector 2 and the connection terminal in the charging base, it can avoid abnormal noise due to vibration at the connection between the flexible cable and the connection terminal, which will lead to a decrease in customer experience. , and long-term vibration accelerates damage to the connection between the cable and the terminal, reducing the number of accidents.
  • the flexible conductor 3 can ensure that the electrical connection frame 1 can be bent at a larger angle to facilitate installation in a car body with a relatively large corner. At the same time, the flexible body can absorb the vibration of the electrical connection frame 1 so that the vibration of the electrical connection frame 1 will not affect the connector and other corresponding electrical devices on the vehicle body.
  • the electrical connection frame 1 can be fixed on the body shell of the electric vehicle to prevent vibration of the electrical connection frame 1 and prevent dislocation of the electrical connection frame 1.
  • connection terminal is made of copper or a copper alloy
  • electrical connection frame 1 is made of pure aluminum or an aluminum alloy with an aluminum content of more than 90%.
  • connection terminals containing copper or copper alloy can be widely used in various electrical transmission scenarios.
  • the electrical connection skeleton 1 made of aluminum or aluminum alloy has the advantages of good rigidity, light weight and high transmission efficiency, and is particularly suitable for the transmission of large currents.
  • the aluminum alloy is an aluminum-copper alloy, an aluminum-magnesium alloy, an aluminum-lithium alloy, an aluminum-manganese alloy, an aluminum-zinc alloy, or an aluminum-silicon alloy with an aluminum content of more than 90%.
  • the electrical connection frame 1 and the connection terminal are connected by welding or crimping.
  • the electrical connection skeleton 1 is connected to the connection terminal through welding or crimping.
  • the welding methods used include resistance welding, friction welding, ultrasonic welding, arc welding, laser welding, electron beam welding, pressure diffusion welding, and magnetic induction.
  • One or more types of welding use concentrated heat energy or pressure to create a molten connection at the contact position between the connection terminal and the electrical connection frame 1.
  • the welding method has a stable connection and can realize the connection of dissimilar materials. Since the contact positions are fused, the conductive effect is better good.
  • Resistance welding refers to a method that uses strong current to pass through the contact point between the electrode and the workpiece, and generates heat due to the contact resistance to achieve welding.
  • Friction welding refers to a method that uses the heat generated by friction on the contact surface of the workpiece as a heat source to cause plastic deformation of the workpiece under pressure for welding.
  • Ultrasonic welding uses high-frequency vibration waves to transmit to the surfaces of two objects to be welded. Under pressure, the surfaces of the two objects rub against each other to form fusion between the molecular layers.
  • the arc welding method refers to using the arc as a heat source and utilizing the physical phenomenon of air discharge to convert electrical energy into the thermal energy and mechanical energy required for welding, thereby achieving the purpose of joining metals.
  • the main methods include electrode arc welding, submerged arc welding, and gas shielding. Welding etc.
  • Laser welding is an efficient and precise welding method that uses high-energy-density laser beams as heat sources.
  • Friction welding refers to a method that uses the heat generated by friction on the contact surface of the workpiece as a heat source to cause plastic deformation of the workpiece under pressure for welding.
  • Electron beam welding refers to the use of accelerated and focused electron beams to bombard the welding surface placed in a vacuum or non-vacuum, so that the workpiece to be welded melts to achieve welding.
  • Pressure welding is a method of applying pressure to the weldment to bring the joint surfaces into close contact and produce a certain amount of plastic deformation to complete the welding.
  • the specific welding method selects an appropriate connection method or combination of connection methods based on the actual status of the electrical connection skeleton 1 and the connection terminal to achieve effective electrical connection.
  • Crimping is a production process in which after assembling the electrical connection frame 1 and the connection terminal, a crimping machine is used to stamp the two into one body.
  • the advantage of crimping is mass production. By using an automatic crimping machine, products of stable quality can be manufactured quickly and in large quantities.
  • the electrical connection skeleton 1 is a flexible conductor 3, and at least part of the length of the flexible conductor 3 is formed into a rigid body 4 by welding or crimping. .
  • the flexible conductor 3 by forming at least part of the flexible conductor 3 into a rigid body 4 (i.e., a rigid conductor), it can be easily fixed to the vehicle body when assembled with the vehicle body, and the vibration of the flexible conductor 3 can be reduced from being connected to the vehicle shell or both ends. to avoid abnormal noise between the connectors 2 and avoid breakage at the connection with the connecting terminals. At the same time, it is also prevented that the insulation layer of some flexible conductors 3 is damaged due to frequent friction with the car body, and the electrical connection between the flexible conductor 3 and the car body is short-circuited, which may cause the car to burn in severe cases.
  • a rigid body 4 i.e., a rigid conductor
  • the flexible conductor 3 is a multi-core cable or a braided cable or a flexible cable stacked with multiple layers of thin plates.
  • the flexible conductor 3 in the electrical connection skeleton 1 can also be set as a multi-core cable or a braided cable or a flexible cable stacked with multiple layers of thin plates, which can be easily installed on the car body.
  • the electrical connection skeleton 1 has excellent flexibility and is easy to install and store.
  • the electrical connection skeleton 1 includes a plurality of conductor core segments connected end to end in sequence. At least one of the conductor core segments is a flexible conductor 3 .
  • the rigid body 4 can be set at the position where the rigid body 4 is required, and the flexible conductor 3 can be set at the position that needs to be bent according to the preset situation. It can be easily assembled and stored and transported.
  • the material of at least one of the guide core segments contains pure aluminum or an aluminum alloy with an aluminum content of more than 90%.
  • the material of the guide core segment contains aluminum.
  • copper wires are used to conduct current. Copper has high conductivity and good ductility. However, as the price of copper continues to rise, the cost of using copper as a conductor material will become higher and higher. For this reason, people began to look for alternatives to metallic copper to reduce costs.
  • the content of metallic aluminum in the earth's crust is about 7.73%. After the refining technology is optimized, the price is relatively low.
  • aluminum is lighter in weight and its conductivity is second only to copper.
  • Aluminum can replace part of copper in the field of electrical connections. Therefore, replacing copper with aluminum is a development trend in the field of automotive electrical connections.
  • the electrical connection skeleton 1 made of aluminum or aluminum alloy has the advantages of good rigidity, light weight and high transmission efficiency, and is particularly suitable for the transmission of large currents.
  • the aluminum alloy is an aluminum-copper alloy, an aluminum-magnesium alloy, an aluminum-lithium alloy, an aluminum-manganese alloy, an aluminum-zinc alloy, or an aluminum-silicon alloy with an aluminum content of more than 90%.
  • the conductive core sections connected to the connection terminals at both ends of the electrical connection frame 1 are rigid bodies 4.
  • the conductive core section connected to the connection terminals at both ends of the electrical connection frame 1 as a rigid body 4, it is possible to avoid the electrical connection frame 1 from being damaged when the electrical connection frame 1 is connected to the connection terminals at both ends. Vibration produces abnormal noise.
  • the conductive core segments connected to the connection terminals at both ends of the electrical connection frame 1 are flexible conductors 3 .
  • the assembly of the two with the automobile casing can be more convenient and the operability is strong.
  • the processing error requirements of the electrical connection skeleton 1 can also be reduced.
  • the flexible conductor 3 at the end can be installed on the electrical device smoothly even if the rigid material error is large.
  • the conductive core section connected to the connection terminal at one end of the electrical connection frame 1 can also be a rigid body 4 , and the other end of the electrical connection frame 1 is connected to the connection terminal.
  • the conductive core segment is a flexible conductor 3.
  • the combination of the flexible conductor 3 and the rigid body 4 in the electrical connection frame 1 can be selected according to actual needs.
  • ends of two adjacent guide core segments are connected by crimping, welding, screwing, riveting or splicing.
  • the ends of two adjacent guide core segments are connected by crimping, welding, screwing, riveting or splicing, which can be selected according to actual needs.
  • At least one of the guide core segments is a rigid body 4, and a cylindrical or U-shaped or V-shaped connecting part is provided at the end of the rigid guide core segment.
  • the end of the rigid or flexible guide core segment is put into the connecting part and connected by crimping.
  • connection method between the conductive core section of the rigid body 4 and the conductive core section of the flexible conductor 3 can be designed according to actual needs, and the two are connected by crimping, so that the connection between the two can be made more secure. Firm to prevent the two from disconnecting.
  • At least one of the guide core segments is a rigid body 4, a first flat portion is provided at the end of the rigid guide core segment, and a first flat portion is provided on the first flat portion.
  • the first through hole 5 and the second The through holes 6 are stacked and fixed with bolts or rivets.
  • first through hole 5 and the second through hole 6 are connected to each other using bolts or rivets, so that they can rotate with each other, and the operator can select the required angle according to the needs, so the operability is strong.
  • At least one of the guide core sections is a rigid body 4, and a screw 7 is provided at the end of the rigid guide core section, and the adjacent rigid or flexible guide core section is An internal thread 8 is provided at the end, and the screw 7 is screwed to the internal thread 8 for fixation.
  • a screw 7 can be provided on one of the end of the rigid guide core section and the end of the adjacent rigid or flexible guide core section, and an internal thread 8 can be provided on the other.
  • the screw 7 and the internal thread 8 The screws are used for fixing, so that the two can be firmly connected and can rotate relative to each other, which facilitates operation when assembling the electric vehicle and reduces the difficulty of assembly.
  • adjacent guide core segments are rigid bodies 4, and the ends of two adjacent rigid guide core segments are respectively provided with hinge shafts and hinge pins, and the hinge shafts and hinge pins are cooperatively connected.
  • the two adjacent guide core segments are allowed to rotate relative to each other.
  • the hinge shafts and hinge pins can also enable relative rotation between the two guide core sections.
  • the adjacent guide core segments are rigid bodies 4, the ends of the rigid guide core segments are provided with spherical concave surfaces 10, and the ends of the adjacent rigid guide core segments are provided with spherical concave surfaces.
  • the convex surface 9, the spherical concave surface 10 covers the spherical convex surface 9 and the two can rotate relative to each other.
  • one guide core segment can rotate 360° relative to the circumference of the other guide core segment.
  • the axial rotation is until the angle between the two is less than 90 degrees.
  • the rotation angle between the two adjacent guide core segments is larger. Therefore, when the operator assembles the electric energy transmission assembly to the electric vehicle, The operation is more flexible.
  • the adjacent guide core segments are all rigid bodies 4, when they are fixed on the car shell, the operability is stronger and abnormal noise is less likely to occur.
  • the electrical connection frame 1 is covered with an insulating layer 11 .
  • Figure 11 shows an electrical connection skeleton 1 formed of a flexible strip stacked with multiple layers of thin plates, and is covered with an insulating layer 11 on the outside.
  • various forms of electrical connection skeletons 1 are covered with an insulating layer on the outside, which can prevent personnel from getting electric shock during use, and avoid short circuits caused by the positive electrode electrical connection skeleton 1 and the negative electrode electrical connection skeleton 1 coming into contact with each other, ensuring the use protect the personal safety of the user and avoid property damage.
  • a shielding layer 12 and an outer insulating layer 13 are arranged outside the insulating layer 11 in sequence.
  • the shielding layer 12 can reduce the interference of the electromagnetic radiation generated by the electrical connection frame 1 to other electrical devices in the car.
  • the shielding layer 12 is made of a conductor and needs to be grounded, so an insulation layer 11 is provided between the shielding layer 12 and the electrical connection frame 1 , to prevent the shielding layer 12 from contacting the electrical connection skeleton 1 .
  • the outer insulation layer 13 can further ensure the insulation effect of the electrical connection frame 1 and avoid accidents caused by short circuit between the electrical connection frame 1 and the vehicle body.
  • the specific form of the electrical connection skeleton 1 in Figures 12 and 13 is not particularly limited and can be any form of multi-core cable or a large-section rigid body.
  • the flexible conductor 3 has different cross-sectional shapes from other parts of the electrical connection frame 1 .
  • the cross-sectional shape of the flexible conductor 3 can be set to be different from the cross-sectional shape of the rest of the electrical connection frame 1 except the flexible conductor 3, and can be specifically set as needed to facilitate wiring on the vehicle.
  • the cross-sectional areas of the flexible conductor 3 and other parts of the electrical connection frame 1 are different.
  • the cross-sectional area of the flexible conductor 3 can be set to be different from the cross-sectional area of the rest of the electrical connection frame 1 except the flexible conductor 3.
  • the cross-sectional area can be set according to the specific materials used for the electrical connection frame 1 and the flexible conductor 3. Calculate their respective cross-sectional areas to ensure that the conduction current at each position of the electrical connection frame 1 is the same to meet the conditions for the use of the electric energy transmission assembly on the vehicle.
  • the cross-sectional shape of the electrical connection skeleton 1 is circular, elliptical, rectangular, polygonal, A-shaped, B-shaped, D-shaped, M-shaped, N-shaped, or O-shaped , S-shaped, E-shaped, F-shaped, H-shaped, K-shaped, L-shaped, T-shaped, U-shaped, V-shaped, W-shaped, X-shaped, Y-shaped, Z-shaped, P-shaped, semi-arc, arc, One or more of the wavy shapes.
  • the cross-sectional shape of the electrical connection skeleton 1 can be specifically designed according to the wiring space in the vehicle to facilitate the wiring in the vehicle and the operator to assemble the vehicle.
  • the cross-sectional shape of the electrical connection skeleton 1 is a polygon, and the corners of the polygon are all chamfered or rounded.
  • the corners of the electrical connection skeleton 1 with a polygonal cross-section are all chamfered or rounded, which can facilitate the connection between the electrical connection skeleton 1 and the connection terminal, so that the two are electrically connected during welding or crimping.
  • the connection between the skeleton 1 and the connection terminal is stronger, the contact area is larger, and the conduction current is better; it prevents the contact area between the electrical connection skeleton 1 and the connection terminal from being too small during the connection, resulting in excessive resistance, causing heating or even It can also prevent the occurrence of burning accidents; it can also prevent casualties and property losses caused by the edges formed by the two adjacent sides of the polygon from scratching the insulation layer during use.
  • one of the connectors 2 is a charging stand.
  • a charging stand With the increasing popularity of new energy vehicles, equipment and facilities for charging new energy vehicles have also developed. Since the rechargeable batteries on new energy vehicles need to meet the requirements of fast charging, they need to use a charging stand assembly.
  • This Apply for one of the connectors 2 It is a charging stand and is connected to a charging gun.
  • the connector 2 at the other end is a high-voltage connector and is connected to the vehicle-mounted rechargeable battery to achieve the purpose of charging the rechargeable battery.
  • a vehicle of the present application includes a body, an electrical device and an electric energy transmission assembly as described above.
  • the connector 2 is detachably fixed on the vehicle body or the electrical device, and the electrical connection skeleton 1. Arrange and fix along the contour of the vehicle body.

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  • Power Engineering (AREA)
  • Transportation (AREA)
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  • Electric Propulsion And Braking For Vehicles (AREA)
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Abstract

本申请公开了一种电能传输总成及车辆，包括至少一根电连接骨架和设置在所述电连接骨架两端的连接器，所述连接器包含连接端子，所述电连接骨架两端与所述连接端子电连接，所述电连接骨架中至少部分为柔性导体。根据本申请的一种电能传输总成，可在与车辆组装时，降低安装的难度，提高工作效率。

Description

一种电能传输总成及车辆
本申请要求享有2022年3月14日递交、申请号为202220548054.1、实用新型名称为“一种电能传输总成及车辆”的中国专利的优先权，该专利的所有内容在此全部引入。
技术领域
本申请涉及汽车电器技术领域，更具体地，涉及一种电能传输总成及车辆。
背景技术
新能源汽车的新能源电池，使用高压电能传输总成系统来补充和传递能量。高压电能传输总成中除了充电座以外，还有与车载电池系统连接的充电线束连接器机构，高压线束是新能源汽车高压系统中最重要的单元，
传统高压线束采用刚性体或柔性导体作为高压线缆，线缆末端连接插接端子，与车载电池系统和其他用电装置电连接。目前的高压线缆都是单独利用刚性线缆或者柔性线缆装配形成连接器，具有装配困难或者容易产生异响等问题。
因此，如何提供一种可降低装配难度，同时降低生产成本的一种电能传输总成已经成为本领域亟需解决的技术难题。
发明内容
本申请的一个目的是提供一种电能传输总成的新技术方案。
根据本申请的第一方面，提供了一种电能传输总成，包括至少一根电连接骨架和设置在所述电连接骨架两端的连接器，所述连接器包含连接端子，所述电连接骨架两端与所述连接端子电连接，所述电连接骨架中至少部分含有柔性导体。
可选地，所述电连接骨架与所述连接端子通过焊接或压接的方式连接。
可选地，所述电连接骨架为柔性导体，所述柔性导体中至少部分长度通过焊接或压接的方式形成刚性体。
可选地，所述柔性导体为多芯线缆或编织线缆或多层薄板叠加的软排。
可选地，所述电连接骨架包括多根首尾依次相连的导芯段，至少一根所述导芯段为柔性导体。
可选地，所述电连接骨架两端与所述连接端子连接的所述导芯段为刚性体。
可选地，所述电连接骨架两端与所述连接端子连接的所述导芯段为柔性导体。
可选地，所述电连接骨架一端与所述连接端子连接的所述导芯段为刚性体，所述电连接骨架另一端与所述连接端子连接的所述导芯段为柔性导体。
可选地，两个相邻的所述导芯段的端部通过压接或焊接或螺接或铆接或拼接的方式连接。
可选地，至少一根所述导芯段为刚性体，刚性的所述导芯段端部设置筒形或U型或V型的连接部，相邻的刚性或柔性的所述导芯段端部放入到所述连接部中，并通过压接的方式连接。
可选地，至少一根所述导芯段为刚性体，刚性的所述导芯段端部设置第一扁平部，所述第一扁平部上设置第一通孔；相邻的刚性或柔性的所述导芯段端部设置第二扁平部，所述第二扁平部上设置第二通孔，所述第一通孔和所述第二通孔叠放，并穿过螺栓或铆钉进行固定。
可选地，至少一根所述导芯段为刚性体，刚性的所述导芯段端部设置螺杆，相邻的刚性或柔性的所述导芯段端部设置内螺纹，所述螺杆与所述内螺纹螺接进行固定。
可选地，相邻的所述导芯段为刚性体，两个相邻的刚性的所述导芯段端部分别设置铰轴和铰销，所述铰轴和所述铰销配合连接，使相邻的两个所述导芯段可相对转动。
可选地，相邻的所述导芯段为刚性体，刚性的所述导芯段端部设置球形凹面，相邻的刚性的所述导芯段端部设置球形凸面，所述球形凹面包覆所述球形凸面且二者可相对转动。
可选地，所述电连接骨架套设绝缘层。
可选地，所述绝缘层外还依次套设屏蔽层和外绝缘层。
可选地，所述柔性导体与电连接骨架其他部分的横截面形状不同。
可选地，所述柔性导体与电连接骨架其他部分的横截面积不同。
可选地，所述电连接骨架横截面形状为圆形、椭圆形、矩形、多边形、A形、B形、D形、M形、N形、O形、S形、E形、F形、H形、K形、L形、T形、U形、V形、W形、X形、Y形、Z形、P形、半弧形、弧形、波浪形中的一种或几种。
可选地，所述电连接骨架的截面形状为多边形，所述多边形的角全部倒角或倒圆。
可选地，其中一个所述连接器为充电座。
根据本申请的第二方面，提供了一种车辆，包含车身、用电装置和如上所述的电能传输总成，所述连接器可拆卸的固定在所述车身上或所述用电装置上，所述电连接骨架沿所述车身轮廓布置固定。
根据本申请的一种电能传输总成，具有如下有益效果：
1、相对于刚性线缆，本申请的一种电能传输总成在需要折弯处设置为柔性导体，可在与车辆组装时，降低安装的难度，提高工作效率。
2、相对于柔性线缆，与连接器中的端子连接以及与充电座中的连接端子连接时，能够避免柔性线缆与其相连接处因振动而产生异响，导致客户体验好感度下降，以及因长期振动加速线缆与连接端子连接处损坏。
3、将线缆设置成刚性线缆与柔性线缆混合结构，将方便操作人员将线缆组装在车身，能够容许一定误差，缩短生产周期，降低生产成本，同时，降低产品的不合格率。
通过以下参照附图对本申请的示例性实施例的详细描述，本申请的其它特征及其优点将会变得清楚。
附图说明
被结合在说明书中并构成说明书的一部分的附图示出了本申请的实施例，并且连同其说明一起用于解释本申请的原理。
图1为本申请一种电能传输总成的结构示意图；
图2-图11为本申请的电连接骨架的不同实施例的轴向剖面图；
图12为本申请中电连接骨架外侧包覆绝缘层的横截面示意图；
图13为本申请中电连接骨架外侧包覆绝缘层，屏蔽层以及外绝缘层的横截面示意图。
图中标示如下：
1、电连接骨架；2、连接器；3、柔性导体；4、刚性体；5、第一通孔；6、第二通
孔；7、螺杆；8、内螺纹；9、球形凸面；10、球形凹面；11、绝缘层；12、屏蔽层；13、外绝缘层；14、固定件。
具体实施方式
现在将参照附图来详细描述本申请的各种示例性实施例。应注意到：除非另外具体说明，否则在这些实施例中阐述的部件和步骤的相对布置、数字表达式和数值不限制本申请的范围。
以下对至少一个示例性实施例的描述实际上仅仅是说明性的，决不作为对本申请及其应用或使用的任何限制。
对于相关领域普通技术人员已知的技术、方法和设备可能不作详细讨论，但在适当情况下，所述技术、方法和设备应当被视为说明书的一部分。
在这里示出和讨论的所有例子中，任何具体值应被解释为仅仅是示例性的，而不是作为限制。因此，示例性实施例的其它例子可以具有不同的值。
本申请的一种电能传输总成，如图1至图11所示，包括至少一根电连接骨架1和设置在所述电连接骨架1两端的连接器2，所述连接器2包含连接端子，所述电连接骨架1两端与所述连接端子电连接，所述电连接骨架1中至少部分为柔性导体3。
具体实施时，将线缆设置为柔性线缆与刚性线缆的混合体，将方便操作人员将线缆组装在车身，能够容许一定误差，缩短生产周期，降低生产成本。相对于刚性线缆，本申请的一种电能传输总成在需要折弯处设置为柔性导体3，可在与车辆组装时，降低安装的难度，提高工作效率。相对于柔性线缆，与连接器2中的连接端子连接以及与充电座中的连接端子连接时，能够避免柔性线缆与连接端子相连接处因振动而产生异响，导致客户体验好感度下降，以及因长期振动加速线缆与端子连接处损坏，减少事故发生次数。
柔性导体3能够保证电连接骨架1上能够做出较大的折弯角度，以方便设置在拐角比较大的车体内。同时，柔性体能够吸收电连接骨架1的振动，使电连接骨架1的振动不会影响到连接器以及对应的车身上的其他用电装置。
具体实施时，通过在电连接骨架1外周设置固定件14，可将电连接骨架1固定在电动汽车的车壳上，防止电连接骨架1的振动，同时防止电连接骨架1发生错位。
本申请的电能传输总成的一实施例中，所述连接端子的材质含有铜或铜合金，所述电连接骨架1的材质含有纯铝或铝含量在90％以上的铝合金。
具体实施时，铜或铜合金导电率高，并且耐摩擦，而且目前大多数的用电装置的接电部分材质都是铜，因此需要使用材质含有铜或铜合金的连接端子进行插拔连接，连接端子可以广泛应用于各种电传输场景。采用铝或铝合金材质的电连接骨架1，具有刚性好、质量轻、传输效率高的优点，特别适合大电流的传输。
采用纯铝或铝含量在90％以上的铝合金代替现有技术中通常使用的铜导体，由于铝的密度仅为铜的三分之一，而根据电气性能实心导体电阻率的差异，在满足相同导电性能的前提下，铝与铜的线径比只相差1.28倍，铝材重量只有相同载流量铜材的一半，在不增加电缆装车空间的情况下，可大大减轻线材重量，有利于实现车体的轻量化。而且采用比重小，材质价格便宜的铝导体(包括纯铝或其合金材料)代替比重大，材质价格高的铜导体，可减少材料成本和运输成本，节约机动车辆的生产成本。优选地，所述铝合金是铝含量在90％以上的铝铜合金或铝镁合金或铝锂合金或铝锰合金或铝锌合金或铝硅合金。
本申请的电能传输总成的一实施例中，所述电连接骨架1与所述连接端子通过焊接或压接的方式连接。
具体实施时，电连接骨架1通过焊接或压接方式与连接端子连接，所采用的焊接方式，包括电阻焊接、摩擦焊接、超声波焊接、弧焊、激光焊接、电子束焊接、压力扩散焊接、磁感应焊接的一种或几种，是采用集中热能或压力，使连接端子和电连接骨架1接触位置产生熔融连接，焊接方式连接稳固，可以实现异种材料的连接，由于接触位置相融，导电效果更好。
电阻焊接方式，是指一种利用强大电流通过电极和工件间的接触点，由接触电阻产生热量而实现焊接的一种方法。
摩擦焊方式，是指利用工件接触面摩擦产生的热量为热源，使工件在压力作用下产生塑性变形而进行焊接的方法。
超声波焊接方式，是利用高频振动波传递到两个需焊接的物体表面，在加压的情况下，使两个物体表面相互摩擦而形成分子层之间的熔合。
弧焊方式，是指以电弧作为热源，利用空气放电的物理现象，将电能转换为焊接所需的热能和机械能，从而达到连接金属的目的，主要方法有焊条电弧焊、埋弧焊、气体保护焊等。
激光焊接方式，是利用高能量密度的激光束作为热源的一种高效精密焊接方法。
摩擦焊接方式，是指利用工件接触面摩擦产生的热量为热源，使工件在压力作用下产生塑性变形而进行焊接的方法。
电子束焊接方式，是指利用加速和聚焦的电子束轰击置于真空或非真空中的焊接面，使被焊工件熔化实现焊接。
压力焊接方式，是对焊件施加压力，使接合面紧密地接触产生一定的塑性变形而完成焊接的方法。
磁感应焊接方式，是两个被焊工件在强脉冲磁场作用下，产生瞬间高速碰撞，材料表层在很高的压力波作用下，使两种材料的原子在原子间距离内相遇，从而在界面上形成稳定的冶金结合。是固态冷焊的一种，可以将属性相似或不相似的传导金属焊接在一起。
具体焊接方式根据电连接骨架1和连接端子的实际状态，选择合适的连接方式或者连接方式组合，实现有效的电性连接。
压接方式，压接是将电连接骨架1与连接端子装配后，使用压接机，将两者冲压为一体的生产工艺。压接的优点是量产性，通过采用自动压接机能够迅速大量的制造稳定品质的产品。
本申请的电能传输总成的一实施例中，如图2所示，所述电连接骨架1为柔性导体3，所述柔性导体3中至少部分长度通过焊接或压接的方式形成刚性体4。
具体实施时，通过将柔性导体3中至少部分形成刚性体4(即：刚性导体)，可方便在与车身组装时，固定到车身上，以及降低柔性导体3因振动与车壳或者两端连接的连接器2之间产生异响，以及避免与连接端子连接处发生断裂。同时也避免部分柔性导体3由于与车身经常的摩擦，导致绝缘层破损，柔性导体3与车身电连接发生短路现象，严重时造成汽车燃烧。
进一步的，如图2至图13所示，所述柔性导体3为多芯线缆或编织线缆或多层薄板叠加的软排。
具体实施时，电连接骨架1中的柔性导体3也可以设定为多芯线缆或编织线缆或多层薄板叠加的软排，这样可方便在汽车车身上安装，此时，电连接骨架1的弯曲性优异，方便安装及存储。
本申请的电能传输总成的一实施例中，如图3，图4，图6，图8，图10所示，所述电连接骨架1包括多根首尾依次相连的导芯段，所述导芯段至少一根为柔性导体3。
具体实施时，通过将电连接骨架1设置成为首尾依次连接的导芯段，可根据预设情况将在需要为刚性体4的位置处设置刚性体4，在需要折弯处设置柔性导体3，能够方便组装以及方便存储运输。
进一步的，至少一根所述导芯段的材质含有纯铝或铝含量在90％以上的铝合金。
具体实施时，导芯段的材质含有铝。在电气连接领域，都在使用铜导线进行电流的传导，铜的导电率高，延展性好。但是，随着铜价日益上涨，使用铜材作为导线的材料成本会越来越高。为此，人们开始寻找金属铜的替代品来降低成本。金属铝在地壳中的含量约为7.73％，提炼技术优化后，价格相对较低，并且相对于铜，铝的重量较轻，导电率仅次于铜，铝在电气连接领域可以替代部分铜。因此，在汽车电气连接领域中以铝代铜是发展趋势。采用铝或铝合金材质的电连接骨架1，具有刚性好、质量轻、传输效率高的优点，特别适合大电流的传输。
采用纯铝或铝含量在90％以上的铝合金代替现有技术中通常使用的铜导芯，由于铝的密度仅为铜的三分之一，而根据电气性能实心导芯电阻率的差异，在满足相同导电性能的前提下，铝与铜的线径比只相差1.28倍，铝材重量只有相同载流量铜材的一半，在不增加电缆装车空间的情况下，可大大减轻线材重量，有利于实现车体的轻量化。而且采用比重小，材质价格便宜的铝导芯(包括铝芯或其合金材料)代替比重大，材质价格高的铜导芯，可减少材料成本和运输成本，节约机动车辆的生产成本。优选地，所述铝合金是铝含量在90％以上的铝铜合金或铝镁合金或铝锂合金或铝锰合金或铝锌合金或铝硅合金。
进一步的，如图2，图3，图6，图9，图11所示，所述电连接骨架1两端与所述连接端子连接的所述导芯段为刚性体4。
具体实施时，通过将电连接骨架1两端与所述连接端子连接的所述导芯段设置为刚性体4，可将电连接骨架1与两端连接端子连接时，避免因电连接骨架1振动产生异响。
进一步的，如图7所示，所述电连接骨架1两端与所述连接端子连接的所述导芯段为柔性导体3。
具体实施时，通过将电连接骨架1两端与所述连接端子连接的所述导芯段设置为柔性导体3，可使的二者与汽车壳体组装更为方便，操作性强。同时也可以降低电连接骨架1的加工误差要求，末端的柔性导体3可以在刚性材质误差较大的情况下，也可以较顺利的安装到用电装置上。
进一步的，如图8所示，也可以将所述电连接骨架1一端与所述连接端子连接的所述导芯段为刚性体4，所述电连接骨架1另一端与所述连接端子连接的所述导芯段为柔性导体3。
具体实施时，电连接骨架1中的柔性导体3与刚性体4的搭配，可根据实际需要选择搭配。
进一步的，两个相邻的所述导芯段的端部通过压接或焊接或螺接或铆接或拼接的方式连接。
具体实施时，两个相邻的所述导芯段的端部通过压接或焊接或螺接或铆接或拼接的方式连接，具体可根据实际需要进行选择。
进一步的，如图9，图10所示，所述导芯段至少一根为刚性体4，刚性的所述导芯段端部设置筒形或U型或V型的连接部，相邻的刚性或柔性的所述导芯段端部放入到所述连接部中，并通过压接的方式连接。
具体实施时，刚性体4的所述导芯段与柔性导体3的所述导芯段的连接方式，可根据实际需要设计，将二者通过压接方式连接，可使得二者连接的更为牢固，避免二者断开。
进一步的，如图5，图6所示，所述导芯段至少一根为刚性体4，刚性的所述导芯段端部设置第一扁平部，所述第一扁平部上设置第一通孔5；相邻的刚性或柔性的所述导芯段端部设置第二扁平部，所述第二扁平部上设置第二通孔6，所述第一通孔5和所述第二通孔6叠放，并穿过螺栓或铆钉进行固定。
具体实施时，通过将第一通孔5以及第二通孔6，利用螺栓或铆钉相互连接，二者之间能够相互转动，操作者根据需要，选择需要的角度，操作性强。
进一步的，如图9，图10所示，所述导芯段至少一根为刚性体4，刚性的所述导芯段端部设置螺杆7，相邻的刚性或柔性的所述导芯段端部设置内螺纹8，所述螺杆7与所述内螺纹8螺接进行固定。
具体实施时，可以在刚性的导芯段端部和相邻的刚性或柔性的导芯段端部中的一者上设置螺杆7，另一者上设置内螺纹8，螺杆7与内螺纹8螺接进行固定，可使二者牢固连接，且可相对转动，方便在组装电动车辆时进行操作，降低装配难度。
进一步的，相邻的所述导芯段为刚性体4，两个相邻的刚性的所述导芯段端部分别设置铰轴和铰销，所述铰轴和所述铰销配合连接，使相邻的两个所述导芯段可相对转动。
具体实施时，两根设置为刚性体4的导芯段之间，通过铰轴和铰销，也可使得两导芯段之间相对转动。
进一步的，如图11所示，相邻的所述导芯段为刚性体4，刚性的所述导芯段端部设置球形凹面10，相邻的刚性的所述导芯段端部设置球形凸面9，所述球形凹面10包覆所述球形凸面9且二者可相对转动。
具体实施时，通过将相邻的所述导芯段端部设置成相互匹配的球形凸面9和球形凹面10，一根导芯段可相对另一根导芯段的周向旋转360°，可轴向旋转至二者之间的夹角小于90度，此实施例中，相邻的两导芯段之间转动角度更大，所以，操作者将电能传输总成装配到电动车辆上时，操作更灵活，同时由于相邻的导芯段均是刚性体4，将其固定在车壳上时，操作性更强，更不容易产生异响。
进一步的，所述电连接骨架1套设绝缘层11。如图11所示，图11为多层薄板叠加的软排形成的电连接骨架1外侧套设有绝缘层11。
具体实施时，各种形式的电连接骨架1外侧均套设有绝缘层，可保证在使用过程，防止人员触电，以及避免正极电连接骨架1与负极电连接骨架1相互接触导致短路，保证使用者的人身安全以及避免财产损失。
进一步的，如图13所示，所述绝缘层11外还依次套设屏蔽层12和外绝缘层13。
具体实施时，通过在设置屏蔽层12，可屏蔽掉电连接骨架1在使用过程中产生的电磁干扰，避免电连接骨架1在使用过程中，干扰其他仪器及设备。屏蔽层12能够降低电连接骨架1产生的电磁辐射对车内其他用电装置的干扰，屏蔽层12材质为导体，并且需要接地，所以在屏蔽层12和电连接骨架1之间设置绝缘层11，防止屏蔽层12与电连接骨架1接触。外绝缘层13能够进一步的保证电连接骨架1的绝缘效果，避免电连接骨架1与车身短路造成事故发生。
具体实施时，图12和图13中的电连接骨架1的具体形式，不做特别限制，可以是任何形式的多芯线缆，也可以是一种大截面刚性体。
本申请的电能传输总成的一实施例中,所述柔性导体3与电连接骨架1其他部分的横截面形状不同。
普通的导电线缆会要求每一段的横截面积都相同，可以导通相同的电流，但是对于不同形状的横截面相互连接的电连接骨架1来说，由于不同形状的截面中存在空腔的截面积不同，因此不同形状的电连接骨架1的横截面积并不相同。例如多芯的电连接骨架1和实心的电连接骨架1，由于多芯的电连接骨架1的线芯之间存在间隙，因此相同导通电流的情况下，多芯的电连接骨架1的横截面积要大于实心的电连接骨架1的横截面积。
具体实施时，可以将柔性导体3的横截面形状设置成不同于电连接骨架1上除柔性导体3外的其余部分的横截面形状，可根据需要具体设置，以方便在车辆上布线。
本申请的电能传输总成的一实施例中,所述柔性导体3与电连接骨架1其他部分的横截面积不同。
具体实施时，可以将柔性导体3的横截面积设置成不同于电连接骨架1上除柔性导体3外的其余部分的横截面积，可根据电连接骨架1以及柔性导体3的具体使用的材质计算各自的横截面积，保证电连接骨架1各个位置的导通电流相同，以满足电能传输总成在车辆上使用的条件。
普通的导电线缆会要求每一段的横截面积都相同，可以导通相同的电流，但是对于柔性导体3与电连接骨架1其他部分来说，由于柔性导体3中存在空腔，因此相同导通电流的柔性导体3与电连接骨架1其他部分的横截面积并不相同。例如多芯的柔性导体3和实心的电连接骨架1，由于多芯的柔性导体3的线芯之间存在间隙，因此相同导通电流的情况下，多芯的柔性导体3的横截面积要大于实心的电连接骨架1的横截面积。
本申请的电能传输总成的一实施例中,所述电连接骨架1横截面形状为圆形、椭圆形、矩形、多边形、A形、B形、D形、M形、N形、O形、S形、E形、F形、H形、K形、L形、T形、U形、V形、W形、X形、Y形、Z形、P形、半弧形、弧形、波浪形中的一种或几种。
具体实施时，电连接骨架1横截面形状可根据车内布线空间具体设计，以方便车内布线以及操作人员组装车辆。
本申请的电能传输总成的一实施例中,所述电连接骨架1的截面形状为多边形，所述多边形的角全部倒角或倒圆。
具体实施时，截面为多边形形状的电连接骨架1的角全部倒角或倒圆，可方便电连接骨架1与连接端子之间连接，使得二者之间在通过焊接或者压接时，电连接骨架1与连接端子之间连接的更为牢固，接触面积更大，导通电流更好；防止电连接骨架1与连接端子之间因连接时接触面积过小，导致电阻过大，引起发热甚至发生燃烧事故；也可防止在使用过程中，因多边形相邻的两条边形成的棱边划破绝缘层造成人员伤亡以及财产损失。
本申请的电能传输总成的一实施例中，其中一个所述连接器2为充电座。随着新能源汽车的越来越普及，为新能源汽车充电的设备和设施也随之发展起来，新能源汽车上的充电电池由于要达到快充的要求，需要用到充电座总成，本申请中其中一个连接器2 为充电座，连接充电枪，另一端的连接器2为高压连接器，连接车载充电电池，实现为充电电池充电的目的。
本申请的一种车辆，包含车身、用电装置和如上所述的电能传输总成，所述连接器2可拆卸的固定在所述车身上或所述用电装置上，所述电连接骨架1沿所述车身轮廓布置固定。
虽然已经通过例子对本申请的一些特定实施例进行了详细说明，但是本领域的技术人员应该理解，以上例子仅是为了进行说明，而不是为了限制本申请的范围。本领域的技术人员应该理解，可在不脱离本申请的范围和精神的情况下，对以上实施例进行修改。本申请的范围由所附权利要求来限定。

Claims (22)

  1. 一种电能传输总成，包括至少一根电连接骨架和设置在所述电连接骨架两端的连接器，其特征在于，所述连接器包含连接端子，所述电连接骨架两端与所述连接端子电连接，所述电连接骨架中至少部分含有柔性导体。
  2. 根据权利要求1所述的电能传输总成，其特征在于，所述电连接骨架与所述连接端子通过焊接或压接的方式连接。
  3. 根据权利要求1所述的电能传输总成，其特征在于，所述电连接骨架为柔性导体，所述柔性导体中至少部分长度通过焊接或压接的方式形成刚性体。
  4. 根据权利要求3所述的电能传输总成，其特征在于，所述柔性导体为多芯线缆或编织线缆或多层薄板叠加的软排。
  5. 根据权利要求1所述的电能传输总成，其特征在于，所述电连接骨架包括多根首尾依次相连的导芯段，至少一根所述导芯段为柔性导体。
  6. 根据权利要求5所述的电能传输总成，其特征在于，所述电连接骨架两端与所述连接端子连接的所述导芯段为刚性体。
  7. 根据权利要求5所述的电能传输总成，其特征在于，所述电连接骨架两端与所述连接端子连接的所述导芯段为柔性导体。
  8. 根据权利要求5所述的电能传输总成，其特征在于，所述电连接骨架一端与所述连接端子连接的所述导芯段为刚性体，所述电连接骨架另一端与所述连接端子连接的所述导芯段为柔性导体。
  9. 根据权利要求5所述的电能传输总成，其特征在于，两个相邻的所述导芯段的端部通过压接或焊接或螺接或铆接或拼接的方式连接。
  10. 根据权利要求5所述的电能传输总成，其特征在于，至少一根所述导芯段为刚性体，刚性的所述导芯段端部设置筒形或U型或V型的连接部，相邻的刚性或柔性的所述导芯段端部放入到所述连接部中，并通过压接的方式连接。
  11. 根据权利要求5所述的电能传输总成，其特征在于，至少一根所述导芯段为刚性体，刚性的所述导芯段端部设置第一扁平部，所述第一扁平部上设置第一通孔；相邻的刚性或柔性的所述导芯段端部设置第二扁平部，所述第二扁平部上设置第二通孔，所述第一通孔和所述第二通孔叠放，并穿过螺栓或铆钉进行固定。
  12. 根据权利要求5所述的电能传输总成，其特征在于，至少一根所述导芯段为刚性体，刚性的所述导芯段端部设置螺杆，相邻的刚性或柔性的所述导芯段端部设置内螺纹，所述螺杆与所述内螺纹螺接进行固定。
  13. 根据权利要求5所述的电能传输总成，其特征在于，相邻的所述导芯段为刚性体，两个相邻的刚性的所述导芯段端部分别设置铰轴和铰销，所述铰轴和所述铰销配合连接，使相邻的两个所述导芯段可相对转动。
  14. 根据权利要求5所述的电能传输总成，其特征在于，相邻的所述导芯段为刚性体，刚性的所述导芯段端部设置球形凹面，相邻的刚性的所述导芯段端部设置球形凸面，所述球形凹面包覆所述球形凸面且二者可相对转动。
  15. 根据权利要求1所述的电能传输总成，其特征在于，所述电连接骨架套设绝缘层。
  16. 根据权利要求15所述的电能传输总成，其特征在于，所述绝缘层外还依次套设屏蔽层和外绝缘层。
  17. 根据权利要求1所述的电能传输总成，其特征在于,所述柔性导体与电连接骨架其他部分的横截面形状不同。
  18. 根据权利要求1所述的电能传输总成，其特征在于,所述柔性导体与电连接骨架其他部分的横截面积不同。
  19. 根据权利要求1所述的电能传输总成，其特征在于,所述电连接骨架横截面形状为圆形、椭圆形、矩形、多边形、A形、B形、D形、M形、N形、O形、S形、E形、F形、H形、K形、L形、T形、U形、V形、W形、X形、Y形、Z形、P形、半弧形、弧形、波浪形中的一种或几种。
  20. 根据权利要求1所述的电能传输总成，其特征在于，所述电连接骨架的截面形状为多边形，所述多边形的角全部倒角或倒圆。
  21. 根据权利要求1所述的电能传输总成，其特征在于，其中一个所述连接器为充电座。
  22. 一种车辆，其特征在于，包含车身、用电装置和如权利要求1-21任一项所述的电能传输总成，所述连接器可拆卸的固定在所述车身上或所述用电装置上，所述电连接骨架沿所述车身轮廓布置固定。
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WO2026013220A1 (de) * 2024-07-11 2026-01-15 Lisa Dräxlmaier GmbH Stromschienenanordnung, elektrisches bordnetz für ein kraftfahrzeug, und herstellungsverfahren für eine stromschienenanordnung

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CN217823618U (zh) * 2022-03-14 2022-11-15 吉林省中赢高科技有限公司 一种电能传输总成及车辆
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