A high-voltage connector with EMI suppression function and a manufacturing method thereof

Abstract

The present application relates to the technical field of high-voltage connector, in particular to a high-voltage connector with EMI suppression function and a manufacturing method thereof, comprising a connector shell, a busbar, a fastener and a filter assembly integrally arranged on the connector shell, the busbar and the fastener both extend out of the connector shell, and the filter assembly and the fastener are both connected with the busbar; the busbar is provided with a high-frequency anti-interference assembly.The present application has the beneficial effects that: the connector shell, the busbar, the fastener and the filter assembly are combined into one body by injection molding, realizing high-integration installation of the filter assembly and the high-frequency anti-interference assembly, which can not only solve the technical problems of serious EMI interference and poor system stability at the interface of the existing high-voltage connector, but also save installation space and improve assembly efficiency.

Description

Technical Field

[0001] This invention relates to the field of high-voltage connector technology, and in particular to a high-voltage connector with EMI suppression function and its manufacturing method. Background Technology

[0002] With the rapid development of electric drive systems for new energy vehicles, EMI interference during operation has become a significant pain point in the industry. This interference primarily originates from the high-frequency conduction current generated by the high-frequency switching of semiconductor devices in the electric drive system. This high-frequency conduction current leads to high voltage peaks and radiation. This interference radiation can also couple to the vehicle's low-voltage system and other electronic components, causing EMC exceedances and malfunctions. Furthermore, the wiring harnesses within the vehicle system are the most effective antennas for receiving and transmitting interference. High-frequency conduction currents radiate interference both inside and outside the system, and between high and low voltage levels, further exacerbating the EMC exceedance problem of the entire vehicle system. This issue is particularly prominent at high-voltage connector interfaces.

[0003] Currently, the industry typically addresses these issues by: 1) shielding all high-voltage wiring harnesses in the vehicle by adding a metal shielding mesh between the insulation and the copper wires to reduce high-frequency conducted radiation; 2) adding filtering and anti-interference components within the controller to reduce radiation generated by the high-frequency switching of semiconductor devices; and 3) using metal housings for connectors to isolate external / internal electromagnetic noise from affecting low-voltage ports. However, with the increasing emphasis on high voltage, high speed, high integration, and lightweight design in vehicles, these methods are no longer sufficient to meet market demands. High voltage and high speed require higher switching frequencies for semiconductor devices, resulting in greater interference radiation; high integration demands more compact internal space for controllers, while the current method of adding filtering and anti-interference components within the controller occupies significant installation space, becoming a key factor hindering integrated development; furthermore, metal connector housings do not meet the requirements of lightweight design. Summary of the Invention

[0004] This invention proposes a high-voltage connector with EMI suppression function and its manufacturing method, which solves the problems of large installation space occupied by separate connector housing and filter components and large weight of connector metal housing in the prior art.

[0005] The technical solution of this invention is implemented as follows: A high-voltage connector with EMI suppression function includes a connector housing and a busbar, fasteners, and a filter assembly integrated on the connector housing. The busbar and fasteners extend out of the connector housing, and the filter assembly and fasteners are connected to the busbar. A high-frequency anti-interference component is provided on the busbar. Integrating the filter assembly and high-frequency anti-interference component onto the high-voltage connector effectively solves the technical problems of severe EMI interference and poor system stability at the interface of existing high-voltage connectors, while also saving installation space and improving assembly efficiency.

[0006] The bus includes a positive bus and a negative bus, each with a first electrical connection terminal and a second electrical connection terminal. The second electrical connection terminal is integrally connected to the first electrical connection terminal via an intermediate section, which is embedded within the connector housing. The second electrical connection terminals of the positive and negative bus are arranged in parallel to facilitate connector insertion. The intermediate section has a C-shaped structure, connecting the first and second electrical connection terminals as a single unit, reducing intermediate contact resistance and making signal transmission more stable. Simultaneously, the C-shaped structure increases the torque capacity of the connector housing and bus, preventing deformation due to uneven stress.

[0007] The connector housing includes an integrally injection-molded first cavity, a housing body, and a second cavity. A busbar extends out of the second cavity, fasteners extend out of the first cavity, a filter assembly is located on the housing body, and a high-frequency anti-interference assembly is located in the second cavity.

[0008] The filtering component includes a differential-mode filter and a common-mode filter, which are respectively connected to the first electrical connection terminal. The differential-mode filter can filter out differential-mode interference current, and the common-mode filter can filter out common-mode interference current.

[0009] The differential mode filtering component includes an X capacitor. The first pin of the X capacitor is connected to the positive bus via an electrical connection, and the second pin of the X capacitor is connected to the negative bus via an electrical connection. The X capacitor, the positive bus, and the negative bus form a loop to filter out differential mode interference current. The common mode filtering component includes two Y capacitors. The first pin of one Y capacitor is connected to the positive bus via an electrical connection, and the first pin of the other Y capacitor is connected to the negative bus via an electrical connection. The second pins of both Y capacitors are grounded.

[0010] The electrical connection portion includes a conductive sheet injection-molded inside the connector housing, and the portion of the conductive sheet protruding from the connector housing is electrically connected to the X capacitor or the Y capacitor.

[0011] One end of the fastener is located inside the connector housing, and a through hole is provided at the first electrical connection end. The other end of the fastener passes through the through hole and extends out of the connector housing, exposed within the first cavity. The exposed portion of the fastener is used to connect with the first connecting element, thereby connecting the first connecting element with the first electrical connection end.

[0012] The high-frequency anti-interference component is a magnetic element with interference suppression function. The high-frequency anti-interference component is fixedly sealed inside the second cavity with sealant. The magnetic element is a magnetic ring or an inductor. The magnetic element is sleeved on the busbar by a gap fit, and then sealant is filled between the magnetic element and the second cavity.

[0013] The outer side of the second cavity is provided with an annular sealing groove, and a sealing ring is provided inside the sealing groove. The sealing ring cooperates with the second connecting element to achieve end face sealing of the connector.

[0014] A method for manufacturing a high-voltage connector with EMI suppression function includes the following steps: Step S1: Connect the electrical connections of the bus, fasteners and filter components; pre-assemble the bus, fasteners and electrical connections to facilitate the subsequent injection molding of the connector housing; Step S2: Injection molding the connector housing, fixing the electrical connection parts of the bus, fasteners and filter components inside the connector housing by injection molding; realizing the integrated installation of fasteners and filter components on the connector housing, reducing the connector size; Step S3: Place the X capacitor and Y capacitor of the filter component into the reserved capacitor slots on the connector housing, and connect the electrical connection part to the pins of the X capacitor and Y capacitor; the X capacitor can filter out differential mode interference current, and the Y capacitor can filter out common mode interference current. Step S4: Install the high-frequency anti-interference component on the busbar and use the impedance characteristics of the high-frequency anti-interference component to absorb interference signals in a certain frequency band and convert them into heat. Step S5: Fill the gaps between the X capacitor and the capacitor slot, between the Y capacitor and the capacitor slot, and between the high-frequency anti-interference component and the second cavity on the connector housing with sealant to fix the X capacitor, Y capacitor and the high-frequency anti-interference component and seal the connector; the sealant can stably fix the X capacitor and Y capacitor in the capacitor slot, ensuring the stable installation of the X capacitor and Y capacitor, and at the same time, the sealant can seal the high-frequency anti-interference component and the second cavity, thereby ensuring the sealing performance of the connector; Step S6: The sealing ring is placed around the sealing groove outside the second cavity, and an end face seal is achieved by cooperating with the second connector element. The sealing groove limits the position of the sealing ring to ensure that the sealing ring is stable when the high-voltage connector is connected to the second connector element, thus ensuring the sealing performance between the two.

[0015] The beneficial effects of this invention are: this invention integrates the connector housing, busbar, fasteners, and filter components into one unit through injection molding, achieving a high degree of integration of the filter components and high-frequency anti-interference components. This not only effectively solves the technical problems of severe EMI interference and poor system stability at the existing high-voltage connector interface, but also saves installation space and improves assembly efficiency.

[0016] Meanwhile, due to the complex manufacturing process and high manufacturing and maintenance costs of traditional high-voltage shielded wire harnesses, and the fact that the shells of traditional shielded connectors are made of metal materials with good conductivity, which are costly and heavy, this invention can switch the matching high-voltage shielded wire harness to an unshielded wire harness, and change the connector shell to a one-piece injection molded non-metallic material, which greatly reduces the system cost and weight.

[0017] The first and second pins of the X capacitor in the filter component are connected to the first electrical connection terminals of the positive and negative busbars respectively through electrical connection components to filter out differential mode interference current; the first pins of the two Y capacitors in the filter component are connected to the first electrical connection terminals of the positive and negative busbars respectively, and the second pins of the two Y capacitors in the filter component are grounded to filter out common mode interference current; by utilizing the impedance characteristics of the high-frequency anti-interference component, interference signals in a certain frequency band can be absorbed and converted into heat, and with the sealing component, the end face sealing with the first connector element and the second connector element, as well as the fixing and sealing of the filter component and the high-frequency anti-interference component are achieved. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is an exploded view of the main structure of the high-voltage connector of the present invention; Figure 2 This is a schematic diagram of the high-voltage connector filter assembly structure; Figure 3 This is a schematic diagram of a high-voltage connector busbar structure; Figure 4 This is a schematic diagram of the high-voltage connector housing; Figure 5 Top view of the high-voltage connector; Figure 6 for Figure 5 Sectional view of AA; Figure 7 This is a magnified view of a partial Y-capacitor grounding structure; Figure 8 This is a schematic diagram showing the assembly and connection of the high-voltage connector, wiring harness assembly, and controller.

[0020] In the diagram, 1 is the connector housing, 2 is the busbar, 3 is the fastener, 4 is the filter assembly, 5 is the high-frequency anti-interference assembly, 7 is the sealing ring, 8 is the sealant, 9 is the second connector element, 10 is the bushing, 11 is the single-ended screw, 12 is the first connector element, 13 is the nut, 101 is the first cavity, 102 is the housing body, 104 is the second cavity, 1021 is the capacitor slot, 1022 is the through hole, 1041 is the sealing groove, and 1042 is the support. Support ribs, 21 is the positive busbar, 22 is the negative busbar, 201 is the second electrical connection terminal, 202 is the intermediate section, 203 is the first electrical connection terminal, 401A is the X capacitor, 401B is the Y capacitor, 402 is the electrical connection component, 402A is the orifice connector, 402A1 is the Z-type orifice connector, 402A2 is the short straight orifice connector, 402A3 is the long straight orifice connector, 402B is the conductive sheet, and 402C is the press-fit screw. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Example 1, such as Figure 1 , Figure 8 As shown, a high-voltage connector with EMI suppression function includes a connector housing 1 and a busbar 2, fasteners 3, and a filter assembly 4 integrated on the connector housing 1. Both the busbar 2 and fasteners 3 extend out of the connector housing 1, and both the filter assembly 4 and fasteners 3 are connected to the busbar 2. A high-frequency anti-interference component 5 is provided on the busbar 2. The connector housing 1 provides inter-component docking functionality, the busbar 2 and fasteners 3 provide signal transmission functionality between components, and the filter assembly 4 and high-frequency anti-interference component 5 achieve EMI interference suppression for the electric drive system of new energy vehicles. The integration of fasteners 3, filter assembly 4, and high-frequency anti-interference component 5 onto the connector housing 1 effectively reduces the size of the high-voltage connector and saves installation space.

[0023] Furthermore, such as Figure 2 , Figure 3As shown, the busbar 2 includes a positive busbar 21 and a negative busbar 22. Both the positive busbar 21 and the negative busbar 22 include a first electrical connection terminal 203 and a second electrical connection terminal 201. The second electrical connection terminal 201 is integrally connected to the first electrical connection terminal 203 through an intermediate section 202. The intermediate section 202 and the first electrical connection terminal 203 are embedded in the connector housing 1. The second electrical connection segment 201 passes through the cavity on the connector housing 1 and the high-frequency anti-interference component 5. The first electrical connection end 203 is electrically connected to the filter component 4 and the conductive parts of the first connector element 12 via the fastener 3. The second electrical connection segment 201 is electrically connected to the conductive parts of the second connector element 9. The positive bus 21 and the negative bus 22 have the same structure and are arranged symmetrically. The second electrical connection segment 201 has a linear structure. The second electrical connection ends 201 of the positive bus 21 and the negative bus 22 are arranged in parallel to facilitate the insertion of the second electrical connection segment 201 into the second connector element 9. In this embodiment, the bus 2 is made of C1100-1 / 2H material, the first connector element 12 is a wire harness assembly, and the second connector element 9 is a controller. The first electrical connection end 203 is provided with a connection hole with a diameter of M8. The fastener 3 can pass through this connection hole and be electrically connected to the electrical connection part 402 of the filter component 4 and the wire harness assembly. The second electrical connection terminal 201 has a connection hole with a diameter of M8 at its head, which is electrically connected to the conductive parts of the controller by means of bolt fastening.

[0024] Furthermore, the plane containing the first electrical connection terminal 203 is perpendicular to the plane containing the second electrical connection terminal 201. The intermediate section 202 has a C-shaped structure, which connects the first electrical connection terminal 203 and the second electrical connection terminal 201 into one unit, reducing the intermediate connection contact resistance and making the signal transmission more stable. At the same time, this structure can increase the torque that the connector housing 1 and the busbar 2 can withstand, preventing the connector housing 1 and the busbar 2 from deforming due to uneven stress.

[0025] Furthermore, such as Figure 4 , Figure 5As shown, the connector housing 1 includes an integrally injection-molded first cavity 101, a housing body 102, and a second cavity 104. A busbar 2 extends out of the second cavity 104, a fastener 3 extends out of the first cavity 101, a filter assembly 4 is located on the housing body 102, and a high-frequency anti-interference assembly 5 is located within the second cavity 104. The first cavity 101 mates with the wiring harness assembly, and the second cavity 104 mates with the controller. The housing body 102 has a capacitor slot 1021 and a through hole 1022. The capacitor of the filter assembly 4 is installed in the capacitor slot 1021. A matching bushing 10 is placed in the through hole 1022, and the bushing 10 is fixed to the through hole 1022 by integral injection molding. The housing body 102 is fixedly engaged with the first connector element 12 and the second connector element 9 by a single-headed screw 11 passing through the bushing 10. In this embodiment, the connector housing 1 is made of PPS-GF40, and the bushing 10 is made of 1215MS. The bushing 10 has an upper and lower two-layer annular serrated structure on its exterior. This structure can enhance the connection strength with the connector housing 1. The through holes 1022 are circular, numbered four and symmetrically distributed at the four corners of the main body 102 of the connector housing 1. The diameter of the through holes 1022 is M3.5. The connector housing 1 is fixed to the controller 9 by a single-headed screw 11 passing through the bushing 10, which ensures both mechanical connection strength and good grounding effect.

[0026] Example 2 differs from Example 1 in that, as Figure 2 As shown, the filter assembly 4 includes a differential mode filter and a common mode filter, which are respectively connected to the first electrical connection terminal 203. The filter assembly 4 includes at least one capacitor and an electrical connection component. The capacitor of the filter assembly 4 is placed in the capacitor slot 1021, and the differential mode filter and the common mode filter are respectively disposed on both sides of the second cavity 104 of the connector housing 1.

[0027] Furthermore, such as Figure 2 , Figure 5As shown, the differential mode filtering assembly includes an X capacitor 401A. The first pin of the X capacitor 401A is connected to the positive bus 21 via an electrical connection part 402, and the second pin of the X capacitor 401A is connected to the negative bus 22 via the electrical connection part 402. The X capacitor 401A is placed in the capacitor slot 1021 on the connector housing 1. The electrical connection part 402 includes a conductive sheet 402B and a U-shaped connector 402A. The conductive sheet 402B is fixed to the inside of the connector housing 1 by integral injection molding. The U-shaped connector 402A includes a long straight U-shaped connector 402A3. The conductive sheet 402B is connected to one end of the long straight U-shaped connector 402A3 by a rivet screw 402C. In this embodiment, the X capacitor 401A can be a 50uF metal film capacitor, and the material of the electrical connection part 402 is C1100-1 / 2H. Specifically, the conductive sheet 402B has a Z-shaped structure, which can increase the torque that the conductive sheet 402B can withstand and prevent deformation due to uneven force. Furthermore, one end of the conductive sheet 402B is designed with a connection hole with a diameter of M8. The fastener 3 passes through the connection hole and is electrically connected to the first electrical connection terminal 203 of the busbar 2. The other end of the conductive sheet 402B is designed with a connection hole with a diameter of M2.5. The rivet screw 402C is placed in the connection hole with a diameter of M2.5 and is fixed to the inside of the connector housing 1 together with the conductive sheet 402B by integral injection molding. One end of the long straight-type orifice connector 402A3 is designed with a connection hole of diameter M2.5. The conductive piece 402B and the long straight-type orifice connector 402A3 are pressed together by the crimp screw 402C to achieve electrical connection. The other end of the long straight-type orifice connector 402A3 is designed with a connection hole of diameter M1.2. The first or second pin of the X capacitor 401A passes through the connection hole of the long straight-type orifice connector 402A3 and is connected to the long straight-type orifice connector 402A3. The specific connection method can be welding. Furthermore, the first pin of the X capacitor 401A is electrically connected to the positive bus 21 through the long straight-type orifice connector 402A3 and the conductive piece 402B, and the second pin of the X capacitor 401A is electrically connected to the negative bus 21 through the long straight-type orifice connector 402A3 and the conductive piece 402B, thereby achieving the filtering of differential mode interference current.

[0028] Furthermore, the common-mode filtering component includes two Y capacitors 401B. The first pin of one Y capacitor 401B is connected to the positive bus 21 through the electrical connection part 402, and the first pin of the other Y capacitor 401B is connected to the negative bus 22 through the electrical connection part 402. The second pins of both Y capacitors 401B are grounded. The Y capacitor 401B is placed in the capacitor slot 1021 on the connector housing 1. The electrical connection part 402 includes a conductive sheet 402B and a via connector 402A. The conductive sheet 402B is fixed to the inside of the connector housing 1 by integral injection molding. The via connector 402A includes a Z-type via connector 402A1 and a short straight via connector 402A2. The first pin of the Y capacitor 401B is electrically connected to the first electrical connection terminal 203 of the bus 2 through the short straight via connector 402A2. The second pin of the Y capacitor 401B is grounded through the Z-type via connector 402A1. In this embodiment, the Y capacitor 401B can be a 0.22uf metal film capacitor. Specifically, one end of the Z-type connector 402A1 is designed with a connection hole of diameter M3.5, and the other end is designed with a connection hole of diameter M1.2. The first pin of one Y capacitor 401B is electrically connected to the first electrical connection terminal 203 of the positive bus 21 through the short straight-line connector 402A2 and the conductive plate 402B. The first pin of the other Y capacitor 401B is electrically connected to the first electrical connection terminal 203 of the negative bus 22 through the short straight-line connector 402A2 and the conductive plate 402B. The second pins of the two Y capacitors 401B are connected to the Z-type connector 402A1 through the connection hole of the Z-type connector 402A1 with a diameter of M1.2. The specific connection method can be soldering. The other end of the Z-type connector 402A1 is fixedly connected to the second connector element 9 through the connection hole of M3.5. Preferably, as shown in the example Figure 6 , Figure 7 As shown, the plane where the Z-type orifice connector 402A1 is located needs to be about 0.1mm higher than the plane where the second end 103 of the connector housing is located, to ensure that the second pin of the Y capacitor 401B is well grounded through the housing of the controller 9, thereby achieving the purpose of filtering out common mode interference current.

[0029] Example 3 differs from Example 2 in that, as Figure 6As shown, one end of the fastener 3 is located inside the connector housing 1, and a through hole is provided at the first electrical connection end 203. The other end of the fastener 3 passes through the through hole and extends out of the connector housing 1, exposed inside the first cavity 101. The fastener 3, the first electrical connection end 203, and the conductive sheet 402B are fixed inside the connector housing 1 by integral injection molding. In this embodiment, the fastener 3 is made of 10B21 material, specifically a square-headed irregular bolt with a diameter of M8*23. The threaded portion of the fastener 3 is exposed inside the first cavity 101 of the connector housing 1, and a matching nut 13 is provided on the fastener 3. A certain torque is applied by the nut 13 to achieve electrical connection between the first electrical connection end 203, the conductive sheet 402B, and the wire harness assembly. Furthermore, the fastener 3 is designed with an annular serrated structure, which can enhance the connection strength with the connector housing 1. There are two fasteners 3, which are fixedly connected to the first electrical connection end 203, the conductive sheet 402B, and the wire harness assembly through the connection hole with a diameter of M8 at the head of the first electrical connection end 203.

[0030] Furthermore, the high-frequency anti-interference component 5 is a magnetic element with interference suppression function. The high-frequency anti-interference component 5 is fixedly sealed inside the second cavity 104 by sealant 8. The high-frequency anti-interference component 5 is a magnetic ring or an inductor. In this embodiment, the high-frequency anti-interference component 5 is a magnetic ring made of ferrite and shaped as a hollow cuboid. In this embodiment, the magnetic ring is fitted onto the second electrical connection end 201 of the busbar 2 by a gap fit. The inner wall of the second cavity 104 is provided with a support rib 1042, which provides a limit for the magnetic ring. The sealant 8 is filled between the second cavity 104 and the magnetic ring to fix the magnetic ring inside the second cavity 104. By utilizing the impedance characteristics of the high-frequency anti-interference component 5, interference signals in a certain frequency band are absorbed and converted into heat, cutting off the path of electromagnetic interference propagating along the wiring harness and achieving electromagnetic interference protection.

[0031] Example 4 differs from Example 3 in that the high-frequency anti-interference component 5 consists of three magnetic rings. Two of them are hollow cylindrical magnetic rings, which are fixed within the first cavity 101 of the connector housing 1 and are respectively disposed on the threaded portion of the fastener 3 exposed within the first cavity 1 via a clearance fit. The third is a hollow cuboid magnetic ring, which is fixed within the second cavity 104 of the connector housing 1 and is fitted onto the second electrical connection end 201 via a clearance fit. Utilizing the impedance characteristics of the high-frequency anti-interference component 5, interference signals in a certain frequency band are absorbed and converted into heat, cutting off the path of electromagnetic interference propagation along the wiring harness, thereby achieving electromagnetic interference protection.

[0032] Furthermore, an annular sealing groove 1041 is provided on the outer side of the second cavity 104, and a sealing ring 7 is provided in the sealing groove 1041. In this embodiment, the sealing ring 7 is made of silicone and its surface is coated with grease to improve assembly convenience. Preferably, in this embodiment, there are two sealing rings 7, which are placed at a certain distance in the sealing groove 10401 outside the cavity structure 104 to enhance the end face sealing performance between the connector housing 1 and the controller 9.

[0033] Example 4, based on Example 3, provides a method for manufacturing a high-voltage connector with EMI suppression function, comprising the following steps: Step S1: Connect the bus 2, fastener 3 and the electrical connection part 402 of the filter assembly 4; the fastener 3 connects the first electrical connection end 203 of the bus 2 and the conductive piece 402B of the electrical connection part 402. The bus 2 and the fastener 3 enable the signal transmission function of the connector. The conductive piece 402B connects the first electrical connection end 203 and the capacitor of the filter assembly 4 to achieve filtering.

[0034] Step S2: Injection mold the connector housing 1. The busbar 2, fastener 3 and the electrical connection part 402 of the filter assembly 4 are fixed in the connector housing 1 by injection molding. After injection molding, the first electrical connection end 203 and the middle section 202 of the busbar 2, the head of the fastener 3 and the conductive piece 402B of the electrical connection part 402 are all embedded in the connector housing 1 to ensure the stable connection between the fastener 3, the conductive piece 402B and the first electrical connection end 203.

[0035] Step S3: Place the X capacitor 401A and Y capacitor 401B of the filter assembly 4 into the reserved capacitor slot 1021 on the connector housing 1, and connect the electrical connection part 402 to the pins of the X capacitor 401A and Y capacitor 401B; specifically, the first pin of the X capacitor 401A is connected to the conductive piece 402B connected to the positive bus 21 through the long straight-line U-shaped connector 402A3, and the second pin of the X capacitor 401A is connected to the conductive piece 402B connected to the negative bus 22 through the long straight-line U-shaped connector 402A3, thereby filtering out differential mode interference current; the first pin of the Y capacitor 401B is connected to the conductive piece 402B through the short straight-line U-shaped connector 402A2, and the second pin of the Y capacitor 401B is grounded through the Z-shaped U-shaped connector 402A1, thereby filtering out common mode interference current.

[0036] Step S4: The high-frequency anti-interference component 5 is fitted onto the busbar 2. The impedance characteristics of the high-frequency anti-interference component 5 are used to absorb interference signals in a certain frequency band and convert them into heat. The high-frequency anti-interference component 5 is a magnetic ring. The high-frequency anti-interference component 5 is located in the second cavity 104 on the connector housing 1. The support rib 1042 provided on the inner side of the second cavity 104 provides support for the high-frequency anti-interference component 5, ensuring that the high-frequency anti-interference component 5 is installed stably. The high-frequency anti-interference component 5 is installed with a clearance fit between itself and the busbar 2 and between itself and the second cavity 104.

[0037] Step S5: Fill the gaps between X capacitor 401A and capacitor slot 1021, between Y capacitor 401B and capacitor slot 1021, and between high-frequency anti-interference component 5 and the second cavity 104 on connector housing 1 with sealant 8 to fix X capacitor 401A, Y capacitor 401B and high-frequency anti-interference component 5 and seal the connector; after the sealant 8 solidifies, X capacitor 401A, Y capacitor 401B and high-frequency anti-interference component 5 are stably installed on connector housing 1.

[0038] Step S6: The sealing ring 7 is placed around the sealing groove 1041 outside the second cavity 104 to achieve end face sealing by cooperating with the second connector element 9. In this embodiment, there are two sealing rings 7, which are placed at a certain distance in the sealing groove 10401 outside the cavity structure 104 to enhance the end face sealing performance between the connector housing 1 and the controller 9.

[0039] 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, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-voltage connector with EMI suppression function, comprising a connector housing (1), characterized in that, The connector housing (1) is integrated with a busbar (2), a fastener (3) and a filter assembly (4). The busbar (2) and the fastener (3) both extend out of the connector housing (1). The filter assembly (4) and the fastener (3) are both connected to the busbar (2). The busbar (2) is provided with a high-frequency anti-interference component (5). Busbar (2) includes a positive busbar (21) and a negative busbar (22). Both the positive busbar (21) and the negative busbar (22) include a first electrical connection terminal (203) and a second electrical connection terminal (201). The second electrical connection terminal (201) is integrally connected to the first electrical connection terminal (203) through an intermediate section (202). The intermediate section (202) and the first electrical connection terminal (203) are embedded in the connector housing (1). The connector housing (1) includes an integrally injection molded first cavity (101), a housing body (102), and a second cavity (104). A busbar (2) extends out of the second cavity (104), a fastener (3) extends out of the first cavity (101), a filter assembly (4) is located on the housing body (102), and a high-frequency anti-interference assembly (5) is located inside the second cavity (104). The housing body (102) is provided with a capacitor groove (1021) and a through hole (1022). The capacitor of the filter assembly (4) is installed in the capacitor groove (1021). The filter component (4) includes a differential mode filter and a common mode filter, which are respectively connected to the first electrical connection terminal (203); The differential mode filtering assembly includes an X capacitor (401A), the first pin of which is connected to the positive bus (21) via an electrical connection (402), and the second pin of which is connected to the negative bus (22) via an electrical connection (402). The common mode filtering assembly includes two Y capacitors (401B), the first pin of which is connected to the positive bus (21) via an electrical connection (402), and the first pin of which is connected to the negative bus (22) via an electrical connection (402). The second pins of both Y capacitors (401B) are grounded. The electrical connection part (402) includes a conductive sheet (402B) injection molded inside the connector housing (1), and the portion of the conductive sheet (402B) exposed in the connector housing (1) is electrically connected to the X capacitor (401A) or the Y capacitor (401B).

2. The high-voltage connector with EMI suppression function according to claim 1, characterized in that, One end of the fastener (3) is located inside the connector housing (1), and a through hole is provided at the first electrical connection end (203). The other end of the fastener (3) extends out of the connector housing (1) after passing through the through hole, and the other end of the fastener (3) is located inside the first cavity (101).

3. The high-voltage connector with EMI suppression function according to claim 2, characterized in that, The high-frequency anti-interference component (5) is a magnetic element with interference suppression function. The high-frequency anti-interference component (5) is fixed and sealed inside the second cavity (104) by sealant (8).

4. The high-voltage connector with EMI suppression function according to claim 3, characterized in that, The outer side of the second cavity (104) is provided with an annular sealing groove (1041), and a sealing ring (7) is provided inside the sealing groove (1041).

5. A method for manufacturing a high-voltage connector with EMI suppression function as described in claim 4, characterized in that, Includes the following steps: Step S1: Connect the bus (2), fastener (3) and conductive piece (402B) of the electrical connection part (402); Step S2: Injection molding connector housing (1), fixing bus (2), fastener (3) and conductive sheet (402B) inside connector housing (1) by injection molding; Step S3: Place the X capacitor (401A) and Y capacitor (401B) of the filter component (4) into the reserved capacitor slot (1021) on the connector housing (1), and connect the part of the conductive sheet (402B) protruding from the connector housing (1) to the pin of the X capacitor (401A) or the Y capacitor (401B). Step S4: Place the high-frequency anti-interference component (5) on the busbar (2) and use the impedance characteristics of the high-frequency anti-interference component (5) to absorb the interference signal of a certain frequency band and convert it into heat. Step S5: Fill the gaps between X capacitor (401A) and capacitor slot (1021), between Y capacitor (401B) and capacitor slot (1021), and between high frequency anti-interference component (5) and the second cavity (104) on connector housing (1) with sealant (8) to achieve fixation of X capacitor (401A), Y capacitor (401B) and high frequency anti-interference component (5) and sealing of connector; Step S6: Place the sealing ring (7) around the sealing groove (1041) outside the second cavity (104).

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