Straight type high-voltage connector for new energy automobile and assembling method of straight type high-voltage connector

Abstract

The invention relates to the technical field of connectors, and particularly discloses a straight high-voltage connector for a new energy automobile, which comprises a plug and a socket, the plug comprises a first shell, a first insulating sheath, a pin terminal and a wire clamp assembly; the pin terminal can be limited and fixed in the first insulating sheath through the elastic limiting piece and the limiting rod; the socket comprises a second shell, a second insulating sheath and jack terminals; the second shell and the first shell can be locked and connected in the butt joint direction through bolts. The pin terminals and the jack terminals can be positioned and butted more accurately, poor contact or loosening of the plug and the socket in use is prevented, and stability and safety are high; the electromagnetic shielding performance and the mechanical strength are good, the reliability is high, and the required assembly space is small; according to the assembling method, rapid and efficient connection of the cable at the plug end of the connector is realized, accurate positioning and butt joint of the socket and the plug in plugging use can be ensured, the connection stability of the connector is enhanced, and the connector is convenient to use.

Description

Technical Field

[0001] The present invention relates to the technical field of connectors, and in particular to a straight high-voltage connector for new energy vehicles and an assembly method thereof. Background Art

[0002] Connectors are a very important component of new energy vehicles. The main types include high-voltage connectors, battery replacement connectors, signal connectors, etc. Among them, high-voltage connectors are mainly used in the high-voltage and high-current circuits of new energy vehicles. The high-voltage connectors and conductive cables work at the same time, and can transmit the energy of the battery pack through different electrical circuits to various components of the vehicle system, for example, to the battery pack, motor controller, charger and other body power units.

[0003] Straight connectors have the advantage of achieving high-density connection in a limited space. General high-voltage connectors are equipped with interlocking circuits. When one of the connectors is disconnected with power, it will detect that the high-voltage interlocking circuit is broken. To protect personnel safety, an alarm will be immediately sounded and the electrical connection of the main high-voltage circuit will be disconnected. The safety and stability of the connection between the jack terminal and the pin terminal of the high-voltage connector are important indicators for evaluating the quality of high-voltage connectors. Traditional high-voltage connectors, such as the invention patent with patent number CN109004415A, disclose a 180° high-voltage connector. Although the plug and socket are locked by using a control rod and a secondary locking piece, the internal components of the connector also include insulating sheaths and seals, which have protrusions or occupy space in the plugging direction. The control rod and the secondary locking piece only lock the socket and plug from the outside of the shell, and the internal accessories consume and disperse the locking force. There is a lack of specific limit or locking of the specific plug-in jack and pin, which leads to the problem of poor contact or loose plug-in and loose plug-in during use.

[0004] In addition, most of the current connectors are integrated with many scattered parts, and the factory products are integrated plugs and sockets, which makes it inconvenient to connect cables. There are also problems such as the plugs or sockets are scattered parts, which makes the installation of plugs and sockets time-consuming and inefficient. Summary of the invention

[0005] The purpose of the present invention is to provide a straight high-voltage connector for new energy vehicles and an assembly method thereof, which is aimed at the problem that the connector in the prior art lacks specific limit or locking of the specific plug-in jack or pin, resulting in poor contact between the plug and the socket or loose plug-in during use.

[0006] In order to achieve the above object, the technical solution adopted by the present invention is:

[0007] A straight high-voltage connector for new energy vehicles, comprising: a plug and a socket that are mutually plugged in a straight line;

[0008] The plug comprises a first shell, a first insulating sheath, a pin terminal and a wire clamp assembly; the first insulating sheath is fixed in the first shell; a limit rod is provided in the first insulating sheath, and the limit rod is used to press against the end of the pin terminal away from the plug-in direction; the pin terminal can be fixed in the first insulating sheath by an elastic limiter and the limiter; two opposite inner side walls of the first insulating sheath are provided with connection grooves for riveting the elastic limiter; the wire clamp assembly is provided at the end of the pin terminal away from the plug-in, and can be detachably fixed to the first shell;

[0009] The socket includes a second shell, a second insulating sheath, and a socket terminal; the second shell can be locked and connected to the first shell in a mating direction by bolts; the second insulating sheath is fixed to the inner side of the second shell; and the socket terminal is fixed in the second insulating sheath.

[0010] The straight high-voltage connector for new energy vehicles described in the present invention is provided with a limit rod in the first insulating sheath and a connecting groove on two opposite inner side walls, and is riveted to the connecting groove through an elastic limit piece. After the pin terminal is placed in the first insulating sheath in the plug-in direction, the elastic limit piece can limit the pin to be fixed in the first insulating sheath through the action of the elastic limit piece, and cooperate with the limit rod in the opposite plug-in direction to press against the end of the pin terminal away from the plug-in, so that the pin terminal can be prevented from moving forward or falling out in the plug-in direction before or after the plug and the socket are connected. After the plug and the socket are connected, the pin terminal and the socket terminal can be more accurately positioned and connected, thereby reducing the risk of poor contact or looseness of the plug and the socket during use, and improving the stability and safety of the connector.

[0011] Preferably, in the straight high-voltage connector for new energy vehicles described in the present invention, the pin terminal is provided with a first limiting hole; the elastic limiting member includes a spring sheet and a fixing portion; one end of the spring sheet is integrally connected to the fixing portion; the other end of the spring sheet is tilted out perpendicular to the plug-in direction, and can then be buckled into the first limiting hole in the direction opposite to the plug-in direction; the fixing portion can be riveted to the connecting groove.

[0012] As a preferred solution of the present invention, by setting a first limiting hole in the pin terminal and cooperating with the spring sheet setting of the elastic member, the position of the first limiting hole is adjusted according to the actual insertion depth of the pin terminal or the specific length of the pin terminal, so that the position of different types of pin terminals can be accurately limited, and the plugging length of the pin terminal with the socket terminal after the plug and the socket are connected can be more accurately controlled, thereby reducing the risk of poor contact and damage caused by tight or loose insertion of the pin, and further improving the stability of the plugging.

[0013] Preferably, in the straight high-voltage connector for new energy vehicles described in the present invention, an L-shaped boss is provided in the middle of the pin terminal; a first protrusion is provided in the first insulating sheath; and the first protrusion can press against the L-shaped boss in the plugging direction of the pin terminal.

[0014] As a preferred embodiment of the present invention, an L-shaped boss is provided on the pin terminal, and a first boss is provided in coordination therewith, so that the first boss can be pressed against the pin terminal in the plugging direction of the pin terminal. On the one hand, the accuracy of limiting the pin terminal in the first insulating sheath is enhanced. On the other hand, since the pin terminal is a long metal plug, the plugging force or other locking force acting on the pin terminal in the plugging direction will cause the pin terminal to bend. By pressing the first boss against the L-shaped boss, the force in the plugging direction can be decomposed, thereby avoiding bending or damage of the pin terminal. This further improves the pin positioning accuracy, reduces the possibility of pin failure and damage, and improves the stability of the connector.

[0015] Preferably, in the straight high-voltage connector for new energy vehicles described in the present invention, the jack terminal is provided with a second limiting hole; the side wall of the second insulating sheath is provided with a second protrusion protruding perpendicular to the plug-in direction; the second protrusion is buckled into the second limiting hole in the plug-in direction.

[0016] As a preferred solution of the present invention, by means of the second limiting hole and the second protrusion, the position of the jack terminal inserted into the second insulating sheath can be limited more accurately, preventing the jack terminal from coming out in the direction opposite to the plugging direction, thereby further preventing the jack terminal from loosening before or after the plug and socket are plugged in, and further improving the stability of the connector during plugging or assembly.

[0017] Preferably, in the straight high-voltage connector for new energy vehicles described in the present invention, the socket terminal is provided with a third protrusion; the inner wall of the second insulating sheath is provided with a hanging platform perpendicular to the plug-in direction; the hanging platform can resist the third protrusion in the direction opposite to the plug-in direction.

[0018] As a preferred solution of the present invention, by providing the third protrusion and the hanging platform, the forward movement of the socket terminal in the plug-in direction can be stopped and positioned after the socket terminal is installed in the second insulating sheath, thereby preventing the socket terminal from moving or shifting in the plug-in direction, thereby enhancing the accuracy of the assembly or use positioning of the socket terminal and further ensuring the stability of the connector connection.

[0019] Preferably, in the straight high-voltage connector for new energy vehicles described in the present invention, the butt joint surface of the jack terminal is perpendicular to the copper busbar connection surface; the copper busbar connection surface is used to connect the user's copper busbar.

[0020] As a preferred embodiment of the present invention, when the connector is used in a car installation space, the cable routing direction of the plug end and the connection orientation of the copper bus are both limited. This preferred embodiment sets the mating surface of the jack terminal perpendicular to the connection surface of the copper bus, so that the socket can cooperate with the plug to achieve a straight connection while satisfying the original cable routing direction of the plug end and the connection orientation of the copper bus of the car, thereby making the straight connector suitable for the original car installation space, further improving the universality of the connector.

[0021] Preferably, the straight high-voltage connector for new energy vehicles described in the present invention also includes a first signal component and a second signal component; the second signal component and the first signal component are respectively arranged in the first insulating sheath and the second insulating sheath; the second signal component and the first signal component can be connected by electrical signals through plugging.

[0022] As a preferred embodiment of the present invention, a high-voltage interlocking mechanism consisting of a first signal component and a second signal component is provided. When the plug and the socket are plugged in, the first signal component and the second signal component can be connected and conducted by electrical signals, and the electrical signals can be transmitted to the control terminal of the high-voltage interlocking mechanism. Then, the control terminal can identify whether the plug and the socket are plugged in completely, thereby realizing the high-voltage interlocking function, avoiding the risk of high-voltage leakage due to incomplete plugging, and improving the safety of the use of the connector.

[0023] Preferably, in the straight high-voltage connector for new energy vehicles described in the present invention, the wire clamp assembly includes: a shielding outer sleeve, a shielding inner sleeve, a baffle, a wire sealing body, a jacket and a tail cover for the cable to pass through; the shielding inner sleeve is fixed in the shielding outer sleeve; the baffle abuts against the end of the shielding outer sleeve away from the plug-in; the wire sealing body abuts against the baffle; the jacket is connected to the wire sealing body by interference fit; the tail cover is pressed on the end face of the jacket, and is laterally buckled to the side wall of the shielding outer sleeve by a snap.

[0024] As a preferred embodiment of the present invention, through the specific structural setting of the wire clamp assembly, the setting of the shielding outer sleeve and the shielding inner sleeve can enhance the fastening and limiting effect of the cable insertion to avoid the swing of the cable. The setting of the baffle can push the shielding outer sleeve away from the plug-in end to avoid axial expansion and contraction of the cable, thereby avoiding the loosening of the cable and improving the stability of the cable connection. Then, through the coordinated setting of the jacket and the tail cover, the jacket is provided with a plurality of support plates extending axially toward the cable, and the plurality of support plates are circumferentially arrayed around the cable, thereby supporting the cable and the plug-in direction at a bending angle of the entry line, so that the cable can be stably clamped and supported when the entry line is bent or the entry angle changes, thereby avoiding the axial loosening of the cable due to bending or changing the entry direction, thereby further improving the firmness of the cable connection plug, and further enhancing the stability of the connector during installation and use.

[0025] Preferably, in the straight high-voltage connector for new energy vehicles described in the present invention, the first shell and the second shell are both made of metal; and the surfaces of the first shell and the second shell are both provided with a salt spray resistant coating.

[0026] As a preferred solution of the present invention, by providing a salt spray resistant coating on the surfaces of the first shell and the second shell, the connector can be used in an environment with salt water, such as a marine environment, thereby improving the corrosion resistance and universality of the connector.

[0027] To achieve the purpose of the present invention, the present invention also provides a method for assembling a straight high-voltage connector, comprising the following steps:

[0028] Assembly plug:

[0029] S1, installing the sealing ring into the docking surface of the first shell;

[0030] S2, riveting the elastic limiting member to the connecting groove; installing the first insulating sheath into the first shell from the butt joint surface of the first shell and fixing it in position;

[0031] S3, installing the bolt outside the first housing in the plugging direction;

[0032] S4, the pin terminal and the wire clamp assembly are packaged as loose parts;

[0033] Assembly socket:

[0034] T1. Install the sealing ring into the side of the second housing facing away from the docking surface;

[0035] T2. Install the second insulating sheath on the inner side of the second shell from the plug-in end of the second shell; and fasten the second insulating sheath to the second shell with screws;

[0036] T3, inserting the socket terminal into the second insulating sheath, and fixing the socket terminal by limiting the position through the second protrusion and the third protrusion;

[0037] T4, second signal assembly, terminal lock block and mounting plate end are packaged as loose parts.

[0038] The assembly method of the straight high-voltage connector described in the present invention preliminarily assembles the sealing ring, the first shell, the insulating sheath and the elastic limiter as a plug shell assembly through a method of assembling a plug, and the pin terminal and the wire clamp assembly are packaged as loose parts. When the connector is used in an automobile or equipment, the loose parts of the cable and the pin terminal and the wire clamp assembly can be connected, and then the pin terminal connected with the cable can be assembled to the plug shell assembly, so as to avoid the situation that the pin is forced and deviated due to the connection and installation of the cable, thereby avoiding the problem of loose or loose plugging between the plug and the socket; and the cable can be quickly and efficiently connected at the plug end of the connector, thereby improving the efficiency of plug installation; through the method of assembling the socket, the jack terminal can be limited and fixed to the second insulating sheath during assembly; the second insulating sheath is limited and fixed to the second shell, so as to avoid the jack terminal from loosening when the socket is in use, and ensure that the socket and the plug can be accurately positioned and docked in the next step of plugging and use, thereby enhancing the stability of the connector connection and facilitating user use.

[0039] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0040] 1. The straight high-voltage connector for new energy vehicles can prevent the pin terminal from moving forward or falling out in the plugging direction before or after the plug and the socket are connected. After the plug and the socket are connected, the pin terminal and the socket terminal can be more accurately positioned and docked, thereby reducing the risk of poor contact or looseness of the plug and the socket during use, ensuring the reliability of the plug and the socket, and improving the stability and safety of the connector;

[0041] 2. Compared with the pull rod type connector, the space for pulling the pull rod is reduced in terms of usage space, which further reduces the assembly space of the whole vehicle, and the structure is more compact, which is easy for the space layout of the whole vehicle;

[0042] 3. The assembly method of the straight high-voltage connector and the method of assembling the plug can avoid the situation where the pins are forced and deviated due to the connection and installation of the cable, thereby avoiding the problem of loose connection or looseness of the plug and socket; it can also achieve fast and efficient connection of the cable at the plug end of the connector, improving the efficiency of plug installation; the method of assembling the socket can avoid the phenomenon of the jack terminal of the socket being loose during use, ensure that the socket and the plug can be accurately positioned and docked during the next step of plug-in use, enhance the stability of the connector connection, and facilitate user use. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Figure 1 It is a schematic diagram of the socket and plug structure of the present invention;

[0044] Figure 2 is a structural exploded diagram of the plug of the present invention;

[0045] Figure 3 yes Figure 1 Sectional view along line AA;

[0046] Figure 4 is a schematic diagram of the three-dimensional structure of the first insulating sheath of the present invention;

[0047] Figure 5 yes Figure 4 Sectional view along the midline BB;

[0048] Figure 6 is a structural exploded diagram of the socket of the present invention;

[0049] Figure 7 It is a three-dimensional structural schematic diagram of the pin terminal of the present invention;

[0050] Figure 8 It is a schematic diagram of the three-dimensional structure of the elastic limiting member of the present invention;

[0051] Fig. 9 yes Figure 4 Sectional view of the mid-CC line;

[0052] Fig.10 It is a three-dimensional structural schematic diagram of the jack terminal of the present invention;

[0053] Fig.11 is a schematic diagram of the three-dimensional structure of the second insulating sheath of the present invention;

[0054] Fig.12 yes Fig.11 Sectional view along the mid-DD line;

[0055] Fig.13 yes Fig.11 Cross-sectional view along line EE.

[0056] Icons: 1. Plug; 11. First housing; 12. First insulating sheath; 121. Limit rod; 122. Connecting groove; 123. First protrusion; 13. Pin terminal; 131. First limiting hole; 132. L-shaped boss; 14. Wire clamp assembly; 141. Shielding outer sleeve; 142. Shielding inner sleeve; 143. Baffle; 144. Wire sealing body; 145. Jacket; 146. Tail cover; 1461. Buckle; 15. Elastic limiting member; 151. Shrapnel; 152. Fixing part; 2. Socket; 21. second shell; 22. second insulating sheath; 221. second protrusion; 222. hanging platform; 23. jack terminal; 231. second limiting hole; 232. third protrusion; 233. copper busbar connection surface; 2331. screw hole; 3. bolt; 4. first signal component; 41. third insulating sheath; 42. signal jack; 43. plug; 5. second signal component; 51. fourth insulating sheath; 52. signal pin; 6. terminal locking block; 7. mounting plate; 8. lip sealing ring. DETAILED DESCRIPTION

[0057] The present invention will be described in detail below in conjunction with the accompanying drawings.

[0058] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0059] Embodiment 1:

[0060] This embodiment provides a straight high-voltage connector for new energy vehicles, such as Figure 1-Figure 6 As shown, it comprises: a plug 1 and a socket 2 which are mutually plugged in a straight line;

[0061] The plug 1 comprises a first housing 11, a first insulating sheath 12, a pin terminal 13 and a wire clamp assembly 14; the first insulating sheath 12 is fixed in the first housing 11; a limiting rod 121 is provided in the first insulating sheath 12, and the limiting rod 121 is used to press against the end of the pin terminal 13 away from the plug-in direction; the pin terminal 13 can be fixed in the first insulating sheath 12 by an elastic limiting member 15 and the limiting rod 121; two opposite inner side walls of the first insulating sheath 12 are provided with connection grooves 122 for riveting the elastic limiting member 15; the wire clamp assembly 14 is provided at the end of the pin terminal 13 away from the plug-in, and can be detachably fixed to the first housing 11;

[0062] The socket 2 includes a second shell 21, a second insulating sheath 22, and a socket terminal 23; the second shell 21 can be locked and connected to the first shell 11 in the docking direction by bolts 3; the second insulating sheath 22 is fixed to the inner side of the second shell 21; and the socket terminal 23 is fixed in the second insulating sheath 22.

[0063] It should be noted that the fixation is understood as: the first insulating sheath 12, as a shell component, can be fixed and limited in the first shell 11 by elastic snap-fitting and concave-convex matching. For example, the inner wall of the first shell 11 is provided with a protrusion at a set position, and an elastic buckle is provided on the outer wall of the first insulating sheath 12. The elastic buckle can buckle the protrusion to achieve the limitation or fixation of the first insulating sheath 12.

[0064] It should also be noted that the detachable fixed connection is understood as that the wire clamp assembly 14 is assembled at the end of the pin terminal 13 away from the plug-in by means of interference fit or snap connection, and is detachably fixed to the first shell 11. When installation is required, the buckle 1461 of the wire clamp assembly 14 can be disassembled to loosen the connection with the first shell 11, and then the wire clamp assembly 14 and the first shell 11 can be disassembled. Specifically, the wire clamp assembly 14 can be separated from the first shell 11 and the pin terminal 13, packaged as a bulk accessory, and installed and fixed when the connector is used.

[0065] In this embodiment, the plugging direction is understood as follows Figure 1 The direction in which the plug 1 and the socket 2 are plugged into each other is as shown in FIG. Figure 1 As shown, the plugging direction of the plug 1 is vertically downward, and the plugging direction of the socket 2 is vertically upward.

[0066] It should be noted that the elastic stopper 15 is understood to be elastically deformed during the insertion of the pin terminal 13 into the first insulating sheath 12 to abut against the first insulating sheath 12, thereby exerting a force on the first insulating sheath 12 to achieve position limiting. Specifically, in this embodiment, refer to Figure 7 and Figure 8 As shown, the pin terminal 13 is provided with a first limiting hole 131; the elastic limiting member 15 includes a spring sheet 151 and a fixing portion 152; one end of the spring sheet 151 is integrally connected to the fixing portion 152; the other end of the spring sheet 151 is tilted out perpendicularly to the plug-in direction, and can then be buckled against the first limiting hole 131 in the direction opposite to the plug-in direction; the fixing portion 152 can be riveted to the connecting groove 122.

[0067] Specifically, the elastic stopper 15 includes at least two elastic stoppers 15 respectively located on both sides of the pin terminal 13; the two spring pieces 151 corresponding to the two elastic stoppers 15 are both tilted toward the side close to the pin terminal 13. Through the arrangement of the two elastic stoppers 15, they can be riveted into the two connection grooves 122 of the first insulating sheath respectively, and the pin terminal 13 is inserted through the two connection grooves 122, so that the two spring pieces 151 can be buckled into the first limit hole 131 from both sides of the pin terminal 13 through elastic deformation, so as to avoid the pin terminal 13 from tilting or deflecting due to the buckling force, enhance the stability of the buckling effect of the spring piece 151, and further improve the stability of the connector during plug-in use or assembly.

[0068] It should be noted that the pin terminal 13 and the socket terminal 23 of the present invention both include at least two for realizing the connection of the positive and negative electrodes of the cable, and each pin terminal 13 is provided with an elastic stopper 15 on both sides, for example, Figure 2 As shown, four elastic limiting members 15 are correspondingly provided to the two pin terminals 13 .

[0069] like Figure 7 and Fig. 9 As shown, an L-shaped boss 132 is provided in the middle of the pin terminal 13 of the present invention; a first protrusion 123 is provided in the first insulating sheath 12; and the first protrusion 123 can abut against the L-shaped boss 132 in the plugging direction of the pin terminal 13.

[0070] In this embodiment, specifically, Fig.10 and Fig.12 As shown, the socket terminal 23 is provided with a second limiting hole 231; the side wall of the second insulating sheath 22 is provided with a second protrusion 221 protruding perpendicular to the plugging direction; the second protrusion 221 is buckled against the second limiting hole 231 in the plugging direction. Through the cooperation of the second protrusion 221 and the second limiting hole 231, the socket terminal 23 can be restricted from withdrawing from the second insulating sheath 22 in the direction opposite to the plugging direction, or the socket terminal 23 can be restricted from being loosened from the second insulating sheath 22 in the reverse direction.

[0071] Cooperating with the second limiting hole 231, such as Fig.10 and Fig.13 As shown, the jack terminal 23 is also provided with a third protrusion 232; Fig.12 As shown, the inner wall of the second insulating sheath 22 is provided with a hanging platform 222 perpendicular to the plugging direction; the hanging platform 222 can abut against the third protrusion 232 in the direction opposite to the plugging direction. Through the cooperation between the third protrusion 232 and the hanging platform 222, the insertion of the socket terminal 23 into the second insulating sheath 22 can be limited beyond the limit on the basis of the second limiting hole 231 limiting the reverse loosening of the socket terminal 23, thereby more accurately positioning the position of the socket terminal 23.

[0072] Specifically, the butt joint surface of the jack terminal 23 is perpendicular to the copper bar connection surface 233; the copper bar connection surface 233 is used to connect the user copper bar. The copper bar connection surface 233 is provided with a screw hole 2331 for the copper bar and the copper bar connection surface 233 to be connected by a bolt 3.

[0073] It should be noted that the shell and the second shell 21 described in the present invention are both made of metal, and the first insulating sheath 12 and the second insulating sheath 22 are both wrapped by plastic and synthetic materials; specifically, the first shell 11 and the second shell 21 are both made of metal; the surfaces of the first shell 11 and the second shell 21 are both provided with a salt spray resistant coating.

[0074] The present invention can maintain the cable outlet angle of the plug 1 at 135° to 225° by vertically arranging the butt joint surface of the jack terminal 23 and the copper bar connection surface 233, and by coordinating the arrangement of the wire clamping assembly, and has good electromagnetic shielding performance and mechanical strength. Figure 2As shown, the wire clamp assembly 14 includes: a shielding outer sleeve 141 for the cable to pass through, a shielding inner sleeve 142, a baffle 143, a wire sealing body 144, a jacket 145 and a tail cover 146; the shielding inner sleeve 142 is fixed in the shielding outer sleeve 141; the baffle 143 abuts against the end of the shielding outer sleeve 141 away from the plug-in; the wire sealing body 144 abuts against the baffle 143; the jacket 145 is connected to the wire sealing body 144 by interference fit; the tail cover 146 is pressed on the end face of the jacket 145, and is laterally buckled to the side wall of the shielding outer sleeve 141 through the buckle 1461. It should be noted that the present invention is not limited to adapting to shielded cables, but is also adaptable to unshielded cables; the present invention is adaptable to harpoon terminals, sheet terminals, and composite material terminals.

[0075] In this embodiment, reference Figure 2 and Figure 6 As shown, a high-voltage interlocking mechanism is also provided in the connection, and the high-voltage interlocking structure specifically includes a first signal component 4 and a second signal component 5; the second signal component 5 and the first signal component 4 are respectively arranged in the first insulating sheath 12 and the second insulating sheath 22; the second signal component 5 and the first signal component 4 can be connected by electrical signals through plugging. It should be noted that the first signal component 4 and the second signal component 5 constitute a high-voltage interlocking mechanism, and the first signal component 4 is provided with a third insulating sheath 41, a signal jack 42 and a plug 43; the second signal component 5 is provided with a fourth insulating sheath 51 and a signal pin 52. The clamshell pin of the high-voltage interlocking mechanism adopts a modular and platform design, which reduces the number of parts and facilitates customer assembly.

[0076] In order to ensure the safe use of the connector, the present invention also provides a terminal locking block 6 and a mounting plate 7 at the tail of the socket 2; after the socket 2 and the plug 1 are plugged in and assembled, the terminal locking block 6 is used in combination with the mounting plate 7 and plugged into the tail of the socket 2 to achieve secondary locking of the connector.

[0077] Specifically, refer to Figure 2 and Figure 6 As shown, lip sealing rings 8 are respectively provided at one end of the first shell 11 and the second shell 21 for docking. By providing lip sealing rings 8 at one end of the first shell 11 and the second shell 21 for docking, after the plug 1 and the socket 2 are plugged in, the sealing effect of the two lip sealing rings 8 can avoid a small gap due to installation error, so that the first shell 11 and the second shell 21 can be tightly connected, preventing external water or dirt from entering the interior of the connector, reducing the failure rate and extending the service life of the connector.

[0078] It should be noted that the docking direction is understood to be the direction in which the plug 1 and the socket 2 are docked with each other. For example, the central axis of the docking of the socket 2 and the plug 1 can be the plugging direction of the plug 1 or the plugging direction of the socket 2. Figure 1As shown, the plug 1 and the socket 2 of the present invention are connected and fixed in the plugging direction by bolts 3 on the outside of the first shell 11 and the second shell 21, thereby ensuring the reliability of the plugging and fixing of the head seat, and the intersecting pull rod type connector reduces the space for pulling the pull rod in the use space, further reducing the assembly space of the whole vehicle.

[0079] Embodiment 2:

[0080] To assemble the straight high-voltage connector of the present invention, referring to the structural diagram of the assembled plug 1 and the socket 2, as shown in Figure 1, this embodiment discloses an assembly method of a straight high-voltage connector, including the following steps:

[0081] Assembly plug 1:

[0082] S1, installing the sealing ring into the docking surface of the first housing 11;

[0083] S2, riveting the elastic limiter 15 to the connection groove 122; inserting the first insulating sheath 12 into the first shell 11 from the butt joint surface of the first shell 11 and fixing it in a limited position;

[0084] S3, install the components of the first signal component 4 into the first insulating sheath 12; install the bolt 3 outside the first housing 11 in the plugging direction;

[0085] S4, pin terminal 13 and wire clamp assembly 14 are all packaged as loose parts;

[0086] Assembly socket 2:

[0087] T1. Install the sealing ring into the side of the second housing 21 facing away from the docking surface;

[0088] T2. Install the second insulating sheath 22 from the plug-in end of the second shell 21 to the inner side of the second shell 21; and fasten the second insulating sheath 22 to the second shell 21 with screws;

[0089] T3, insert the socket terminal 23 into the second insulating sheath 22, and limit and fix the socket terminal 23 by the second protrusion 221 and the third protrusion 232;

[0090] T4, the second signal component 5, the terminal locking block 6 and the mounting plate 7 are packaged as loose parts.

[0091] It should be noted that the docking surface is understood to be a side of the plug 1 used to dock with the socket 2; the side facing away from the docking surface in step T1 is a side of the second shell 21 used to install the terminal locking block 6 and the mounting plate 7; wherein, riveting is understood to be the usual riveting of mechanical structural parts, such as the riveting of the elastic limit member 15 and the connecting groove 122.

[0092] In this embodiment, if the connector includes a first signal component 4 and a second signal component 5 capable of achieving high-voltage interlocking, in step S3, the components of the first signal component 4 are first installed in the first insulating sheath 12, and then the bolt 3 is installed outside the first shell 11 in the plug-in direction, and the second signal component 5 is packaged as loose parts.

[0093] Specifically, in this embodiment, after the basic assembly of the plug 1 and the socket 2 is completed, in order to use the various accessories of the connector, the following assembly steps are also included:

[0094] Assembly of plug 1:

[0095] M1. Strip the cable and flip the shielding wire of the cable backwards to expose 20mm to 21mm of the cable core.

[0096] M2. Insert the tail cover 146, the jacket 145, the sealing body 144, the baffle 143, the shielding inner sleeve 142 and the shielding outer sleeve 141 into the cable at one time;

[0097] M3, welding the pin terminal 13 and the wire core by ultrasonic welding;

[0098] M4. Cover the folded shielding wire on the outside of the shielding inner sleeve 142, fix the shielding outer sleeve 141 on the outside of the shielding wire, and sleeve it on the shielding inner sleeve 142;

[0099] M5. Install the pin terminal 13 into the first insulating sheath 12; connect the wire sealing body 144 and the tail cover 146 to the first housing 11 in the plugging direction of the plug 1;

[0100] In this embodiment, the connector includes a first signal component 4 and a second signal component 5 capable of realizing high voltage interlocking, and also includes assembly of the socket 2 end;

[0101] N1, connect the signal pin 52 and the signal line, so that the tail end of the signal pin 52 is crimped to the core of the signal line;

[0102] N2. Install the crimped signal pin 52 into the fourth insulating sheath 51, and simultaneously install the fourth insulating sheath 51 and the signal pin 52 into the second insulating sheath 22; since the second insulating sheath 22 has been locked with the second shell 21 through assembly step T2, the second signal component 5 can be installed by installing the fourth insulating sheath 51 and the signal pin 52.

[0103] N3. Install and connect the terminal locking block 6 and the mounting plate 7 to the second insulating sheath 22 so that the terminal locking block 6 and the second insulating sheath 22 are buckled together.

[0104] After the plug 1 and the socket 2 are assembled separately, the connection and use of the plug 1 and the socket 2 include the following steps:

[0105] Install the socket 2 on the mounting plate 7 and lock the socket 2 on the mounting plate 7 with a hexagonal combination screw; insert the plug 1 into the socket 2 and lock the first shell 11 and the second shell 21 with the bolt 3. The recommended locking torque is 4±0.5N·m.

[0106] It should be noted that the assembly plug 1 and the assembly socket 2 of the assembly method described in the present invention are understood as the pre-assembly of the connector accessories before use, such as steps S1-S4 and steps T1-T4; and the assembly of the socket 2 end and the plug 1 end, such as M1-M5 and N1-N3, is understood as the assembly of the cable to be reconnected when the connector needs to be used, which is understood as the use assembly after pre-assembly; finally, the plug 1 and the socket 2 of the connector are connected and used to complete the use assembly of the connector.

[0107] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A straight high-voltage connector for new energy vehicles, characterized in that: include: A plug (1) and a socket (2) that are mutually plugged in a straight line; The plug (1) comprises a first shell (11), a first insulating sheath (12), a pin terminal (13) and a wire clamp assembly (14); the first insulating sheath (12) is fixed in the first shell (11); a limiting rod (121) is provided in the first insulating sheath (12), and the limiting rod (121) is used to press against the end of the pin terminal (13) away from the plug-in direction in the plug-in direction; the pin terminal (13) can be fixed in the first insulating sheath (12) by means of an elastic limiting member (15) and the limiting rod (121); two opposite inner side walls of the first insulating sheath (12) are provided with connection grooves (122) for riveting the elastic limiting member (15); the wire clamp assembly (14) is provided at the end of the pin terminal (13) away from the plug-in direction, and can be detachably fixed to the first shell (11); The socket (2) comprises a second shell (21), a second insulating sheath (22), and a socket terminal (23); the second shell (21) can be locked and connected to the first shell (11) in a mating direction by means of bolts (3); the second insulating sheath (22) is fixed to the inner side of the second shell (21); and the socket terminal (23) is fixed in the second insulating sheath (22).

2. The straight high-voltage connector for new energy vehicles according to claim 1, characterized in that: The pin terminal (13) is provided with a first limiting hole (131); the elastic limiting member (15) comprises a spring sheet (151) and a fixing portion (152); one end of the spring sheet (151) and the fixing portion (152) are integrally connected; the other end of the spring sheet (151) is tilted out perpendicular to the plugging direction, and can be buckled against the first limiting hole (131) in a direction opposite to the plugging direction; the fixing portion (152) can be riveted to the connecting groove (122).

3. The straight high-voltage connector for new energy vehicles according to claim 1, characterized in that: An L-shaped boss (132) is provided in the middle of the pin terminal (13); a first protrusion (123) is provided in the first insulating sheath (12); the first protrusion (123) can abut against the L-shaped boss (132) in the plugging direction of the pin terminal (13).

4. The straight high-voltage connector for new energy vehicles according to claim 1, characterized in that: The socket terminal (23) is provided with a second limiting hole (231); the side wall of the second insulating sheath (22) is provided with a second protrusion (221) protruding perpendicularly to the plugging direction; the second protrusion (221) is buckled against the second limiting hole (231) in the plugging direction.

5. The straight high-voltage connector for new energy vehicles according to claim 1, characterized in that: The socket terminal (23) is provided with a third protrusion (232); the inner wall of the second insulating sheath (22) is provided with a hanging platform (222) perpendicular to the plugging direction; the hanging platform (222) can abut against the third protrusion (232) in a direction opposite to the plugging direction.

6. The straight high-voltage connector for new energy vehicles according to claim 1, characterized in that: The butt joint surface of the jack terminal (23) is perpendicular to the copper busbar connection surface (233); the copper busbar connection surface (233) is used for connecting a user copper busbar.

7. The straight high-voltage connector for new energy vehicles according to any one of claims 1 to 6, characterized in that: It also comprises a first signal component (4) and a second signal component (5); the second signal component (5) and the first signal component (4) are respectively arranged in the first insulating sheath (12) and the second insulating sheath (22); the second signal component (5) and the first signal component (4) can be connected by electrical signals through plugging.

8. The straight high-voltage connector for new energy vehicles according to any one of claims 1 to 6, characterized in that: The wire clamp assembly (14) comprises: a shielding outer sleeve (141) for the cable to pass through, a shielding inner sleeve (142), a baffle (143), a wire sealing body (144), a jacket (145) and a tail cover (146); the shielding inner sleeve (142) is fixed in the shielding outer sleeve (141); the baffle (143) abuts against the end of the shielding outer sleeve (141) away from the plug-in; the wire sealing body (144) abuts against the baffle (143); the jacket (145) is connected to the wire sealing body (144) by interference fit; the tail cover (146) is pressed onto the end face of the jacket (145), and is laterally buckled to the side wall of the shielding outer sleeve (141) by a buckle (1461).

9. The straight high-voltage connector for new energy vehicles according to any one of claims 1 to 6, characterized in that: The first shell (11) and the second shell (21) are both made of metal; and surfaces of the first shell (11) and the second shell (21) are both provided with a salt spray resistant coating.

10. A method for assembling a straight high-voltage connector, characterized in that: The method for assembling a straight high-voltage connector for a new energy vehicle according to any one of claims 1 to 9 comprises the following steps: Assembling the plug (1): S1, installing the sealing ring into the docking surface of the first housing (11); S2, riveting the elastic limiting member (15) to the connecting groove (122); inserting the first insulating sheath (12) into the first shell (11) from the butt joint surface of the first shell (11) and fixing it in a limited position; S3, installing the bolt (3) outside the first housing (11) in the plugging direction; S4, the pin terminal (13) and the wire clamp assembly (14) are all packaged as loose parts; Mounting socket (2): T1. Install the sealing ring into the side of the second housing (21) facing away from the butt joint surface; T2. Install the second insulating sheath (22) on the inner side of the second shell (21) from the plug-in end of the second shell (21); and use screws to lock and fix the second insulating sheath (22) to the second shell (21); T3, inserting the socket terminal (23) into the second insulating sheath (22), and fixing the socket terminal (23) in a limited position by means of the second protrusion (221) and the third protrusion (232); T4, terminal lock block (6) and mounting plate (7) are packaged as loose parts.

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