A high-reliability pressure-resistant watertight junction box and manufacturing method thereof

Abstract

The present invention discloses a high-reliability pressure-resistant watertight junction box and a manufacturing method thereof, comprising a built-in pressure-resistant box assembly with a branch cable and a main cable docking space, the pressure-resistant box assembly is provided with a branch cable perforation and a main cable threading piece, the inside of the docking space is densely filled with insulating sealant to form an internal pressure-bearing sealing structure; the outside of the pressure-resistant box assembly is coated with a rubber vulcanization layer by vulcanization to form an external watertight packaging structure; the insulating sealant, the built-in pressure-resistant box assembly and the rubber vulcanization layer form an integrated three-layer pressure-bearing sealing structure. The high-reliability pressure-resistant watertight junction box, through the built-in pressure-resistant box assembly, the injected insulating sealant and the externally coated rubber vulcanization layer together form an integrated three-layer pressure-bearing sealing structure, performs pressure-bearing and watertight packaging, the pressure-bearing sealing has high reliability, high yield, low cost, greatly improves the quality of the product, and can be widely used in underwater equipment.

Description

Technical Field

[0001] The invention relates to the technical field of watertight junction boxes, and in particular to a high-reliability pressure-resistant watertight junction box and a manufacturing method thereof. Background Art

[0002] As my country increases its efforts in marine development, the research and development of various underwater equipment, such as underwater submersibles and underwater robots, is in full swing. In the research and development stage of these equipment, a large amount of test data often needs to be collected. It is usually necessary to install various sensors on the outer wall of the equipment, and transmit the signals to the watertight compartment through watertight cables to collect and store data. In order to reduce the number of openings in the watertight compartment of the equipment, a watertight junction box is often set outside the cabin to aggregate multiple signals and then enter the cabin through a main cable. There are two types of existing watertight junction boxes. One is mechanical sealing, that is, a sealed cavity composed of a metal shell, an end cover, and a sealing ring. The main cable entering the warehouse and the branch cable core wires of the sensor are connected in the cavity. The other is to first connect the main cable and the branch cable core wires, and then seal them with mold vulcanized rubber.

[0003] The first mechanical seal has disadvantages such as high cost, heavy weight, and insufficient reliability. Mechanical seals require high machining accuracy at the seal, so the cost is also high. In addition, metal shells and metal end covers often lead to a large overall weight. In addition, improper operation of the seal ring during installation, such as contamination of the seal groove, scratches by sharp objects, etc., or inadequate anti-loosening and anti-corrosion measures for the metal structure in the later stage will lead to seal failure. This will lead to seal failure, internal short circuit of the junction box, and inability to provide power supply and transmit signals.

[0004] The second method is full rubber vulcanization, which has the disadvantage of low yield rate during the production process. During the vulcanization process, heating and pressurization are usually required to ensure the watertight reliability of the product. During the heating and pressurization process, the core wires that have been connected often pull off, causing product failure.

[0005] In addition, the main cable entry into the cabin often adopts the method of squeezing the cable through a stuffing box. Since the outer sheath of the cable is flexible, it produces irreversible deformation during the extrusion process, and there is a risk of sealing failure after multiple extrusions.

[0006] In view of the defects of the existing technology, it is necessary to design a watertight junction box to solve the shortcomings of mechanical seals and all-rubber vulcanized seals. Summary of the invention

[0007] The purpose of the present invention is to solve the problems that the existing watertight junction box adopts a mechanical sealing method, which has the problems of high cost, large weight, insufficient reliability, resulting in sealing failure, internal short circuit of the junction box, and inability to supply power and transmit signals, and the method of adopting full rubber vulcanization has the disadvantage of low yield in the production process, the core wires that have been connected during the heating and pressurization process are often pulled off, resulting in product failure, and the outer sheath of the main cable entering the cabin produces irreversible deformation during the extrusion process, and there is a risk of sealing failure after multiple extrusions. A high-reliability pressure-resistant watertight junction box and a manufacturing method thereof are provided, which can effectively resist the water pressure and vulcanization pressure during use while providing a docking space for branch cables and main cables, protect the cable core wires and welding points, and form an integrated three-layer pressure-bearing sealing structure with an internal filling of insulating sealant, a built-in pressure-resistant box component and an external rubber vulcanization layer for pressure-bearing watertight packaging, so that the watertight reliability is greatly improved, the cost is low, the product yield is high, the sealing failure problem is avoided, and the product reliability is improved.

[0008] The technical solution adopted by the present invention to achieve its first invention purpose is: a high-reliability pressure-resistant watertight junction box, including a built-in pressure-resistant box assembly with a branch cable and a main cable docking space, a branch cable perforation and a main cable threading piece are arranged on the pressure-resistant box assembly, the interior of the docking space is densely filled with insulating sealant to form an internal pressure-bearing sealing structure; the outside of the pressure-resistant box assembly is coated with a rubber vulcanization layer by vulcanization to form an external watertight packaging structure; the insulating sealant, the built-in pressure-resistant box assembly and the rubber vulcanization layer form an integrated three-layer pressure-bearing sealing structure. The high-reliability pressure-resistant watertight junction box, by providing a built-in pressure-resistant box assembly, is used to provide a branch cable and a main cable docking space while realizing a pressure-bearing function to protect the branch cable and the main cable core wire and welding point. The branch cable penetrates into the pressure-resistant box assembly through the branch cable perforation, and the main cable penetrates into the pressure-resistant box assembly through the main cable threading piece, and enters the cabin through the main cable threading piece, thereby avoiding the sealing failure caused by the deformation of the main cable directly entering the cabin. In order to increase the pressure bearing capacity and protect the wire core, the insulation sealant is densely filled inside the built-in pressure-resistant box assembly, so that the insulation sealant inside the docking space is dense and free of bubbles to improve the underwater pressure resistance. The presence of bubbles inside the top-secret sealant will cause weak points to form at the bubbles during use, and impact points will be formed during the underwater pressure bearing process, causing the watertight junction box to deform, thereby squeezing the internal cables. The dense insulation sealant forms an internal pressure-bearing sealing structure. The insulation sealant forms an integrated structure with the built-in pressure-resistant box assembly in the docking space with the branch cable and the main cable, which not only achieves insulation sealing, but also improves the pressure bearing capacity, and will not cause the wire core to be pulled off due to external force. In order to achieve all-round watertight packaging of the pressure-resistant box assembly, after the branch cable and the main cable are connected and filled with glue, the pressure-resistant box assembly is externally vulcanized, so that a rubber vulcanization layer is coated on the outside of the pressure-resistant box assembly for watertight packaging. The rubber vulcanization layer forms an external watertight packaging structure, which plays an overall watertight role.An integrated three-layer pressure-bearing sealing structure is formed by the built-in pressure-resistant box assembly, the internal insulating sealant and the externally coated rubber vulcanized layer. The watertight junction box of the integrated three-layer pressure-bearing sealing structure adopts an internal and external pressure-bearing structure of three structures and different materials. The external rubber vulcanized layer has good elasticity and elastic pressure-bearing, the pressure-resistant box assembly bears pressure rigidly, and the internal insulating sealant realizes compact pressure-bearing. The three-layer sealing pressure-bearing layer bears pressure from the outside to the inside to protect the cable, which can meet the underwater pressure of various depths, realizes effective pressure-bearing and watertight packaging, and the built-in pressure-resistant The box assembly does not need to increase the thickness of the inner shell and the end cover to enhance the pressure resistance performance, and the lightweight design of the built-in pressure-resistant box assembly can be realized. The insulating sealant filled inside plays the role of insulation sealing and pressure bearing. The rubber vulcanization layer is coated on the outside to achieve watertight packaging, avoiding the problem of pulling off the docking core wire of the full rubber vulcanization seal, resulting in product failure. Therefore, it not only solves the problems of high cost, heavy weight, and insufficient reliability of mechanical seals, but also solves the problems of pulling off the core wire after docking of the full rubber vulcanization seal, resulting in product failure. The high-reliability pressure-resistant watertight junction box has high pressure-bearing sealing reliability, high yield rate, and low cost, which greatly improves the quality of the product and can be widely used in underwater equipment.

[0009] Preferably, the insulating sealant is filled in the docking space by vacuum pouring, and is integrated with the branch cable and the main cable. In order to ensure that the insulating sealant is poured evenly and without bubbles during the pouring process, the filling is performed by vacuum pouring. The specific method can be to set a vacuum hole and a pouring hole on the pressure-resistant box component, and perform the pouring operation while vacuuming through the vacuum hole. It can also be performed by placing the built-in pressure-resistant assembly into a vacuum pouring device for vacuum pouring, or by other methods. The insulating sealant can be various existing insulating glues such as polyurethane glue and silicone glue, which are not specifically limited and can be selected according to needs.

[0010] Preferably, the insulating sealant is polyurethane glue, silicone glue or liquid rubber. The insulating sealant can be polyurethane glue, silicone glue or liquid rubber. The insulating sealant can be selected according to different working conditions to meet the needs of underwater pressure-bearing sealing at different depths.

[0011] Preferably, the pressure-resistant box assembly comprises an inner shell and an end cap covering the inner shell, and the inner shell cavity for forming a docking space is provided inside the pressure-resistant box assembly; the insulating sealant is filled inside the inner shell cavity. The inner shell cavity is provided to facilitate the docking of the branch cable and the main cable core wire, and to provide a protective space for the branch cable and the main cable core wire, so as to facilitate the protection of the branch cable and the main cable by pouring the insulating sealant and bear the pressure.

[0012] Preferably, a support is further provided inside the inner shell. Providing the support inside the inner shell can further enhance the pressure bearing capacity, and the support can be provided according to the pressure bearing requirements of the watertight junction box. At the same time, the support can be made of non-metallic materials, which can reduce weight and achieve good internal insulation.

[0013] Preferably, the rubber vulcanized layer is coated on the outside of the inner shell and the end cover to form a watertight packaging structure of the box body. The rubber vulcanized layer can only be coated on the outside of the inner shell and the end cover for watertight packaging, which can reduce costs while achieving watertight packaging.

[0014] Preferably, the rubber vulcanized layer is coated on the outside of the inner shell and the end cover, the outside of the branch cable, the main cable threading parts and the main cable to form an integral watertight package vulcanized layer. As another preferred solution, the rubber vulcanized layer can also be coated on the outside of the inner shell and the end cover, and can also coat the branch cable, the main cable threading parts and the main cable to achieve more effective watertight packaging, thereby increasing service life and improving product quality.

[0015] Preferably, the pressure-resistant box assembly is provided with a pressure-bearing seat for supporting and fixing the branch cable in an integrated or split manner. In order to achieve fixed support for the branch cable, the pressure-resistant box assembly can be provided with an integrated or split pressure-bearing seat.

[0016] Preferably, the pressure-bearing seat is provided with a branch cable positioning groove, and the branch cable positioning groove is provided with a cable pressing block. As a preferred solution, a branch cable positioning groove can be provided on the pressure-bearing seat, and the branch cable is supported inside the branch cable positioning groove after passing through the inner shell cavity and fixed by the cable pressing block, thereby ensuring that the branch cable will not move during vulcanization and use, and preventing the core wire from being pulled off.

[0017] Preferably, the pressure-bearing seat comprises a seat body and a fire-resistant sealing body coated on the outside of the seat body, and the pressure-bearing seat is provided with a seat body perforation. As another preferred solution, the seat body perforation can also be provided on the pressure-bearing seat, and the branch cable penetrating into the inner shell cavity can be fixed by the seat body perforation, and the branch cable and the seat body perforation can be sealed by providing a fire-resistant sealing body on the outside of the seat body, which can also ensure that the branch cable will not move during vulcanization and use.

[0018] Preferably, the branch cable perforation is filled with a fire-resistant sealing layer. As a preferred solution, after the branch cable is inserted, the fire-resistant sealing layer can be filled in the gap between the branch cable perforation and the branch cable, or the branch cable can be directly inserted into the fire-resistant sealing layer, and then the fire-resistant sealing layer is filled into the branch cable perforation, so as to achieve a sealed connection between the branch cable and the branch cable perforation.

[0019] Preferably, an elastic hole clamp is provided inside the branch cable perforation, and a fire-resistant sealing layer is filled and coated outside the elastic hole clamp and extends to both ends of the branch cable perforation. As another preferred solution, in order to achieve a quick sealed connection between the branch cable perforation and the branch cable, the branch cable can be clamped by the elastic hole clamp, and then the elastic hole clamp is directly clamped and positioned inside the branch cable perforation, and then the gap between the branch cable perforation and the elastic hole clamp and the inner and outer ends are coated with a fire-resistant sealing layer to achieve sealing, thereby further improving the overall sealing performance of the watertight junction box, being more conducive to bearing underwater pressure, and not failing after long-term use.

[0020] The technical solution adopted by the present invention to achieve the second invention object is a method for manufacturing a high-reliability pressure-resistant watertight junction box, comprising the following steps:

[0021] Step 1: Component production: Make the inner shell, end cover, support rod, and main cable threading parts respectively;

[0022] Step 2: Fix the main cable guide to the inner shell;

[0023] Step 3: Strip the branch cable to a suitable length, insert the branch cable core wire into the inner shell, and fix it with the pressure-bearing seat;

[0024] Step 4: Strip the main cable to a suitable length and insert the main cable core wire into the main cable threading piece. Then use a crimping machine to pressurize the main cable threading piece to 300-350 MPa and press the tail end of the main cable threading piece to the main cable.

[0025] Step 5: Connect the core wires inside the pressure-resistant box assembly and connect the branch cable core wire with the main cable core wire;

[0026] Step 6: Install the support member in the inner shell and close the end cover;

[0027] Step 7: After the installation, the pressure-resistant box assembly with the branch cable and the main cable is vacuumed and filled with insulating sealant;

[0028] Step 8: Place the glue-filled pressure-resistant box assembly into a vulcanizer, heat it to 110-130°C, and pressurize it to 3-10Mpa for vulcanization, so that a layer of rubber vulcanization layer is vulcanized on the outside of the pressure-resistant box assembly as a watertight packaging layer, completing the production of a high-reliability pressure-resistant watertight junction box.

[0029] The manufacturing method of the high-reliability pressure-resistant watertight junction box adopts the method of vacuum filling to vacuum-fill the inside of the pressure-resistant box assembly, which solves the problem that the existing technology cannot solve the problem that there are bubbles inside the filling sealant, which will cause weak points due to the generation of bubbles during the pressure-bearing process, and cannot truly meet the underwater pressure-bearing sealing function, and also leads to the problem of low yield rate. This is also the reason why the current watertight junction box does not adopt internal glue filling and sealing. At the same time, the internal glue filling can effectively solve the problem of core wire pulling off during the external rubber vulcanization process. The insulating sealant, the pressure-resistant box assembly and the rubber vulcanization layer form an integrated three-layer pressure-bearing sealing structure. When in use, the external rubber vulcanization layer has good elasticity and elastic pressure-bearing, while the pressure-resistant box assembly bears rigid pressure, and the internal insulating sealant realizes compact pressure-bearing. The three-layer sealing pressure-bearing layer bears pressure from the outside to the inside to protect the cable, which can meet the underwater pressure-bearing of various depths. The sealing performance is good, the reliability is high, the yield rate is high, the product quality is greatly improved, the production cost is reduced, and the manufacturing is convenient.

[0030] The beneficial effects of the present invention are as follows: the high-reliability pressure-resistant watertight junction box, through the built-in pressure-resistant box assembly, the injected insulating sealant and the externally coated rubber vulcanized layer, together form an integrated three-layer pressure-bearing sealing structure for pressure-bearing and watertight packaging, which not only solves the problems of high cost, heavy weight, and insufficient reliability of mechanical seals, but also solves the problems of core wire pulling off after docking, resulting in product failure, etc. The high-reliability pressure-resistant watertight junction box has high reliability of pressure-bearing sealing, high yield rate, and low cost, which greatly improves the quality of the product and can be widely used in underwater equipment. The insulating sealant is filled inside by vacuum filling to form a dense internal pressure-bearing sealing structure, which effectively solves the problem of pores and difficulty in bearing pressure when the insulating sealant is filled inside the existing watertight junction box. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 The present invention is a schematic structural diagram of a high-reliability pressure-resistant watertight junction box.

[0032] Figure 2 It is a structural schematic diagram of the high-reliability pressure-resistant watertight junction box of the present invention from another angle.

[0033] Figure 3 It is a schematic diagram of the exploded structure of the high-reliability pressure-resistant watertight junction box of the present invention.

[0034] Figure 4 It is a cross-sectional view of the high-reliability pressure-resistant watertight junction box of the present invention.

[0035] Figure 5 It is a cross-sectional view of the high-reliability pressure-resistant watertight junction box of the present invention from another direction.

[0036] Figure 6 It is a structural schematic diagram of the inner shell and the end cover of the present invention.

[0037] Figure 7 The invention discloses a schematic diagram of a connection structure of the inner core wires of the high-reliability pressure-resistant watertight junction box.

[0038] Figure 8 It is a structural schematic diagram of the present invention in which an insulating sealing layer is provided at the core wire connection.

[0039] Fig. 9 The present invention is a schematic diagram of an application structure of a high-reliability pressure-resistant watertight junction box.

[0040] Fig.10 It is a structural schematic diagram of a high-reliability pressure-resistant watertight junction box in Example 2 of the present invention.

[0041] Fig.11 It is a cross-sectional view of the high-reliability pressure-resistant watertight junction box in Example 2 of the present invention.

[0042] Fig.12 It is a structural schematic diagram of a high-reliability pressure-resistant watertight junction box in Example 3 of the present invention.

[0043] Fig.13 It is a structural schematic diagram of the pressure bearing seat and the inner shell in Example 3.

[0044] In the figure: 1. Pressure-resistant box assembly;

[0045] 2. main cable threading part, 21. sleeve body, 22. sleeve flange, 23. tail end, 24. clamping part;

[0046] 3. main cable, 31. main cable core wire, 32. main cable vulcanized layer;

[0047] 4. branch cable, 41. branch cable core wire, 42. branch cable vulcanization layer;

[0048] 5. Rubber vulcanization layer;

[0049] 6. inner shell, 61. side shell surface, 62. end surface, 63. bottom surface, 64. inner shell opening, 65. buckle structure, 66. vacuum hole;

[0050] 7. end cover, 71. cover structure, 72. glue injection hole;

[0051] 8. Supporting parts;

[0052] 9. Cable pressing block, 91. Cable pressing groove, 92. Connecting block, 93. Fastening hole;

[0053] 10. Inner shell cavity, 11. Branch cable perforation;

[0054] 12. pressure bearing seat, 121. seat body, 122. fire-resistant sealing body, 123. seat body perforation;

[0055] 13. Branch cable positioning groove, 14. Sleeve fixing hole, 15. Support member positioning hole groove, 16. Insulation sealing layer, 17. Card slot;

[0056] 20. Bulkhead, 30. Entry seal assembly;

[0057] 40. fire-resistant sealing layer, 401. fire-resistant filling layer, 402. fire-resistant sealing adhesive layer, 403. elastic hole clamp, 404. cable hole;

[0058] 50. Insulating sealant. DETAILED DESCRIPTION

[0059] The various aspects of the present invention are described in detail below through specific embodiments in conjunction with the accompanying drawings.

[0060] Embodiment 1:

[0061] exist Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 In the illustrated embodiment, a high-reliability pressure-resistant watertight junction box comprises a main cable 3, a branch cable 4, and a built-in pressure-resistant box assembly 1 having a docking space between the branch cable 4 and the main cable 3; the pressure-resistant box assembly 1 is provided with a branch cable through-hole 11 and a main cable through-piece; the interior of the docking space is densely filled with insulating sealant; the insulating sealant 50 forms an internal pressure-bearing sealing structure; the outside of the pressure-resistant box assembly 1 is coated with a rubber vulcanization layer 5 for achieving watertight packaging through vulcanization; the rubber vulcanization layer 5 forms an external watertight packaging structure; the insulating sealant, the pressure-resistant box assembly 1 and the rubber vulcanization layer 5 form an integrated three-layer pressure-bearing sealing structure.

[0062] The insulating sealant 50 is filled in the docking space by vacuum pouring and integrated with the branch cable and the main cable. In this embodiment, the pressure-resistant box assembly 1 is placed inside a vacuum pouring device for vacuum pouring, and the insulating sealant is polyurethane glue.

[0063] In this embodiment, the main cable penetration part 2 adopts a metal sleeve. Of course, in other embodiments, the main cable penetration part can also adopt a hard plastic sleeve, or a sleeve of other hard materials to facilitate the insertion of the main cable into the cabin.

[0064] The pressure-resistant box assembly 1 includes an inner shell 6 and an end cover 7 covering the inner shell 6. The inner shell cavity 10 for connecting the branch cable and the main cable is provided inside the pressure-resistant box assembly 1; the insulating sealant 50 is filled inside the inner shell cavity. A support member is provided inside the inner shell 10. In this embodiment, the support member 8 is a support rod. Of course, in other embodiments, the support member can also be a support block or a support frame, as long as the pressure-bearing function is achieved.

[0065] In this embodiment, the rubber vulcanization layer 5 coated on the outside of the pressure-resistant box assembly 1 is a box body watertight packaging structure coated on the outside of the inner shell and the end cover.

[0066] like Figure 6 As shown, the inner shell 6 is arranged in a rectangular structure as a whole, and the inner shell 6 includes two side shell surfaces 61, two end surfaces 62, a bottom surface 63 and an inner shell opening 64. A buckling structure 65 is arranged on the inner shell opening 64, and a covering structure 71 is arranged on the end cover 7. After the end cover 7 is buckled on the inner shell 6, an inner shell cavity 10 is formed. The covering structure 71 on the end cover 7 cooperates with the buckling structure 65 on the inner shell 6 to form a box body sealing structure.

[0067] A plurality of branch cable through-holes 11 are respectively arranged on the two side shell surfaces 61 of the inner shell 6, and a pressure-bearing seat 12 is respectively arranged along the two side shell surfaces 61 inside the inner shell 6. The pressure-bearing seat 12 is formed integrally with the inner walls of the two side shell surfaces 61, and the height of the pressure-bearing seat 12 is lower than the branch cable through-hole 11. Branch cable positioning grooves 13 are arranged on the pressure-bearing seat 12 in one-to-one correspondence with the branch cable through-hole 11, and the branch cable positioning grooves 13 are arranged in a semicircular arc structure, and the branch cable positioning grooves 13 are arranged coaxially with the branch cable through-hole 11.

[0068] The branch cable 4 passes through the branch cable through hole 11 and is supported in the branch cable positioning groove 13 , and is fastened together with the pressure bearing seat 12 through the cable pressing block 9 . The branch cable 4 and the branch cable through hole 11 are sealed.

[0069] The cable compression block 9 includes an integrally arranged cable compression groove 91 and a connecting block 92. The cable compression groove 91 is arranged in an arc-shaped structure, and the connecting block 92 is arranged in a plate-shaped structure. A fastening hole 93 is arranged on the connecting block 92. The arc diameter of the cable compression groove 91 is slightly smaller than the diameter of the branch cable 4. The branch cable 4 can be fastened inside the branch cable positioning groove 91 through the cable compression groove 91.

[0070] A sleeve fixing hole 14 is provided at the center of the bottom surface of the inner shell 6 , and the sleeve fixing hole 14 passes through the bottom surface 63 of the inner shell. Support member positioning hole grooves 15 are respectively provided on the bottom surface 63 of the inner shell on both sides of the sleeve fixing hole 14 .

[0071] The support rod 8 is a stepped support column, the small end of the support rod 8 is positioned inside the support member positioning hole groove 15, and the large end surface of the support rod 8 is supported on the inner side surface of the end cover 7.

[0072] The metal sleeve includes a sleeve body 21 and a sleeve flange 22. The sleeve flange 22 is disposed on the sleeve fixing hole 14 of the bottom surface 63 of the inner shell 6 and is fixedly connected to the bottom surface 63 of the inner shell. The sleeve body 21 extends through the sleeve fixing hole 14 and is disposed outside the inner shell cavity 10. One end of the sleeve body 21 away from the inner shell is set as a tail end 23.

[0073] The main cable 3 passes through the metal sleeve and extends into the inner shell cavity 10 . The tail end 23 of the metal sleeve away from the pressure-resistant box assembly is pressed together with the main cable 3 to form a sealed fit.

[0074] The metal sleeve tail end 23 is pressed together with the main cable 3 by a metal crimping machine to prevent the main cable 3 from being displaced during the vulcanization process, thereby ensuring the reliability and sealing of the connection.

[0075] like Figure 7 As shown, the branch cable core wire 41 of the branch cable 4 is connected to the main cable core wire 31 of the main cable 3 inside the inner shell.

[0076] After the docking is completed, the end caps are closed, and then vacuuming and glue pouring are performed. In order to realize the vacuuming operation, a vacuuming hole 66 is provided on the bottom surface 63 of the inner shell 6, and a glue pouring hole 72 is provided on the end cap 7.

[0077] The high-reliability pressure-resistant watertight junction box is provided with a pressure-resistant box assembly 1 inside, which can be used to provide a docking space for the branch cable and the main cable, and can also resist external pressure including water pressure during use and pressure during the vulcanization process, and protect the core wires and welding points of the cables (including the main cable and the branch cable). Filling the pressure-resistant box assembly 1 with insulating sealant 50 and arranging a support rod 8 can realize the insulating sealing function, improve the pressure resistance performance, protect the branch cable and the main cable, and limit the displacement of the branch cable 4 during the vulcanization process.

[0078] A method for manufacturing a high-reliability pressure-resistant watertight junction box:

[0079] Step 1: Make the inner shell 6, end cover 7, support rod 8, cable pressing block 9, metal sleeve and other components respectively.

[0080] Step 2: Fix the metal sleeve to the inner shell 6. The fixing method may be screw connection but is not limited to screw connection. It may also be welding or riveting, or it may be snap connection.

[0081] Step 3: Strip the branch cable 4 to obtain the branch cable core wire 41 of appropriate length, insert it into the inner shell 6, and press it tightly with the cable pressing block 9.

[0082] Step 4: After stripping the main cable 3 of a suitable length of the main cable core wire 31, insert it into the metal sleeve, and then use a crimping machine to pressurize it to 300-350Mpa. In this embodiment, the pressure is 350Mpa, and the tail end 23 of the metal sleeve (the end away from the inner shell) is pressed against the main cable 3, thereby achieving a tight connection between the main cable 3 and the metal sleeve.

[0083] Step 5: Connect the core wires inside the inner shell 6 of the pressure-resistant box assembly 1, connect the branch cable core wire 41 with the main cable core wire 31, and set an insulating sealing layer 16 at the core wire connection point (see Figure 8 ), to achieve insulation coating.

[0084] Step 6: Install the support rod 8 inside the support member positioning hole groove 15 of the inner shell 6. The support rod 8 can be fixed inside the support member positioning hole groove 15 by bonding, or by a tight fit, or by other fixing methods, as long as the support rod 8 and the inner shell 6 can be relatively fixed.

[0085] Step 7: Install the end cover 7, snap it onto the inner shell opening 64 of the inner shell 6, and set glue at the inner shell opening 64 to bond and seal the end cover 7 and the inner shell 6. The connection between the end cover 7 and the inner shell 6 can be by snapping, snapping, or any other form of connection. The specific structure is set according to needs and is not limited, as long as it can ensure that the end cover and the inner shell are sealed.

[0086] Step 8: Place the installed pressure-resistant box assembly with the branch cable and the main cable into the vacuum glue-pouring device, evacuate the pressure and fill the pressure-resistant box assembly with polyurethane glue to form an internal pressure-bearing sealing structure. Specifically, place the pressure-resistant box assembly into the vacuum glue-pouring device, and evacuate the inside of the vacuum device through the vacuum equipment, so that a pressure difference is formed between the vacuum box and the inside of the pressure-resistant box assembly through the vacuum hole 66 on the bottom surface 63, and fill the polyurethane glue into the inside through the glue hole 72 through the automatic glue-pouring machine, so as to form an internal pressure-bearing sealing structure. After the glue-pouring is completed, the glue-pouring hole and the vacuum hole are sealed with a metal material of the same material as the pressure-resistant box assembly to avoid the formation of a weak point in the pressure-bearing seal.

[0087] Step 9: Place the pressure-resistant box assembly 1 after glue filling into a vulcanizer, heat it to 110-130°C and pressurize it to 3-10Mpa for vulcanization. In this embodiment, the vulcanizer is heated to 130°C and pressurized to 10Mpa for vulcanization, so that the pressure-resistant box assembly 1 and / or the branch cable and the main cable are externally vulcanized with a rubber vulcanization layer 5 as a watertight packaging layer to form an external watertight packaging structure, thereby completing a high-reliability pressure-resistant watertight junction box.

[0088] like Fig. 9 As shown, when the high-reliability pressure-resistant watertight junction box is used, the metal sleeve is directly sleeved in the cabin entry sealing component 30 on the bulkhead, so that the main cable 3 passes through the cabin entry sealing component 30 and extends to the inner side of the bulkhead 20, and the metal sleeve is sealed and fixed to the cabin entry sealing component 30 by a fastening member, and the watertight junction box belt is arranged on the outside of the bulkhead 20. Since the watertight junction box has a pressure-resistant box component 1 filled with insulating sealant inside and a rubber vulcanized layer 5 coated on the outside; the pressure-resistant box component 1 is watertightly packaged by the external rubber vulcanized layer 5, forming an integrated three-layer The pressure-bearing sealing structure greatly improves the watertight reliability and is less affected by processing and assembly, thereby reducing the processing cost; the internal pressure-resistant box assembly 1 withstands pressure and protects the core wire and welding points very well, which greatly improves the yield rate and saves the production cost; the pressure-resistant box assembly 1 enhances the pressure resistance through insulating sealant and built-in support rods 8, rather than increasing the thickness of the inner shell and the end cover, which greatly reduces the product weight; the metal sleeve enters the cabin instead of the main cable directly entering the cabin, which avoids the problem of sealing failure caused by deformation of the cable outer sheath and improves the product's reliability.

[0089] Embodiment 2:

[0090] exist Fig.10 In the illustrated embodiment, a high-reliability pressure-resistant watertight junction box is provided, comprising a main cable 3, a branch cable 4, and a built-in pressure-resistant box assembly 1 with a docking space between the branch cable 4 and the main cable 3. The pressure-resistant box assembly 1 is provided with a branch cable through-hole 11 and a main cable through-piece 2. The interior of the docking space is densely filled with insulating sealant, and the insulating sealant 50 forms an internal pressure-bearing sealing structure. The outside of the pressure-resistant box assembly 1 is coated with a rubber vulcanization layer 5 for achieving watertight packaging through vulcanization. The rubber vulcanization layer 5 forms an external watertight packaging structure. The insulating sealant, the pressure-resistant box assembly 1 and the rubber vulcanization layer 5 form an integrated three-layer pressure-bearing sealing structure.

[0091] The insulating sealant 50 is filled in the docking space by vacuum filling and is integrated with the branch cable and the main cable. In this embodiment, the pressure-resistant box assembly 1 is directly vacuum filled, and the insulating sealant is silica gel.

[0092] In this embodiment, the main cable passing part 2 is a plastic sleeve.

[0093] The pressure-resistant box assembly 1 comprises an inner shell 6 and an end cover 7 covering the inner shell 6. The inner shell cavity 10 for connecting the branch cable and the main cable is provided inside the pressure-resistant box assembly 1. A support member 8 is provided inside the inner shell 10. In this embodiment, the support member is a support block.

[0094] In this embodiment, the rubber vulcanization layer 5 coated on the outside of the pressure-resistant box assembly 1 is a box body watertight packaging structure coated on the outside of the inner shell and the end cover.

[0095] The inner shell 6 is arranged in a rectangular structure as a whole, and the inner shell 6 includes two side shell surfaces 61, two end surfaces 62, a bottom surface 63 and an inner shell opening 64. A buckling structure 65 is arranged on the inner shell opening 64, and a covering structure 71 is arranged on the end cover 7. After the end cover 7 is buckled on the inner shell 6, an inner shell cavity 10 is formed. The covering structure 71 on the end cover 7 cooperates with the buckling structure 65 on the inner shell 6 to form a box body sealing structure.

[0096] A plurality of branch cable through-holes 11 are respectively arranged on the two side shell surfaces 61 of the inner shell 6, and a pressure-bearing seat 12 is respectively arranged along the two side shell surfaces 61 inside the inner shell 6. The pressure-bearing seat 12 is formed integrally with the inner walls of the two side shell surfaces 61, and the height of the pressure-bearing seat 12 is lower than the branch cable through-hole 11. Branch cable positioning grooves 13 are arranged on the pressure-bearing seat 12 in one-to-one correspondence with the branch cable through-hole 11, and the branch cable positioning grooves 13 are arranged in a semicircular arc structure, and the branch cable positioning grooves 13 are arranged coaxially with the branch cable through-hole 11.

[0097] The branch cable 4 passes through the branch cable through hole 11 and is supported in the branch cable positioning groove 13 , and is fastened together with the pressure bearing seat 12 through the cable pressing block 9 . The branch cable 4 and the branch cable through hole 11 are sealed.

[0098] A fire-resistant sealing layer 40 is filled between the branch cable 4 and the branch cable perforation 11, and the fire-resistant sealing layer 40 includes a fire-resistant filling layer 401 and a fire-resistant sealant layer 402. The fire-resistant sealing layer is made of any one or more of fire-resistant sealing materials such as fire-resistant sheets, aluminum silicate wool, high-purity ceramic fiber, inorganic fire-resistant fiber, rock wool, and organic fire-resistant fiber.

[0099] The fire-resistant sealing layer 40 is provided with an elastic hole clamp 403 matched with the branch cable perforation structure, and the elastic hole clamp 403 is provided with a cable hole 404. When in use, the branch cable 4 is first inserted into the cable hole 404, and then the elastic hole clamp is clamped on the hole wall of the branch cable perforation 11, and then the fire-resistant sealing layer 40 is coated on the elastic hole clamp 403 and the branch cable 4 and the inner and outer walls of the branch cable perforation, so that the branch cable 4 can be sealed and fixedly connected with the branch cable perforation 11, and the pressure-resistant function is realized. The elastic hole clamp is annular in structure as a whole, with a cable hole inside, an inner clamp body can be provided inside the cable hole, and an elastic clamp body or an elastic clamp body is provided outside to clamp or clamp on the hole wall of the branch cable perforation.

[0100] The cable compression block 9 includes an integrally arranged cable compression groove 91 and a connecting block 92. The cable compression groove 91 is arranged in an arc-shaped structure, and the connecting block 92 is arranged in a plate-shaped structure. A fastening hole 93 is arranged on the connecting block 92. The arc diameter of the cable compression groove 91 is slightly smaller than the diameter of the branch cable 4. The branch cable 4 can be fastened inside the branch cable positioning groove 91 through the cable compression groove 91.

[0101] A sleeve fixing hole 14 is provided at the center of the bottom surface of the inner shell 6 , and the sleeve fixing hole 14 passes through the bottom surface 63 of the inner shell. Support member positioning hole grooves 15 are respectively provided on the bottom surface 63 of the inner shell on both sides of the sleeve fixing hole 14 .

[0102] The support member positioning hole groove 15 is arranged corresponding to the support block, and the support block is positioned inside the support member positioning hole groove 15 .

[0103] like Fig.11 As shown, the plastic sleeve includes a sleeve body 21 and a clamping portion 24. The clamping portion 24 is configured as a clamping protrusion, and a clamping groove 17 is correspondingly provided on the outside of the sleeve fixing hole 14 on the bottom surface of the inner shell 6. When in use, the clamping protrusion cooperates with the clamping groove 17, and a fire-resistant sealing layer 40 is coated at the connection between the clamping protrusion and the clamping groove 17, thereby realizing a sealed connection between the plastic sleeve and the inner shell 6.

[0104] The sleeve body 21 passes through the sleeve fixing hole 14 and extends to be arranged outside the inner shell cavity 10. One end of the sleeve body 21 away from the inner shell is arranged as a tail end 23.

[0105] The main cable 3 passes through the gold plastic sleeve and extends into the inner shell cavity 10. The tail end 23 of the plastic sleeve away from the pressure-resistant box assembly is pressed together with the main cable 3 to form a sealed fit.

[0106] The tail end 23 of the plastic sleeve is pressed together with the main cable 3 by a metal crimping machine to prevent the main cable 3 from being displaced during the vulcanization process, thereby ensuring the reliability and sealing of the connection.

[0107] The branch cable core wire 41 of the branch cable 4 is connected to the main cable core wire 31 of the main cable 3 inside the inner shell.

[0108] After the docking is completed, the end caps are closed, and then vacuuming and glue pouring are performed. In order to realize the vacuuming operation, a vacuuming hole 66 is provided on the bottom surface 63 of the inner shell 6, and a glue pouring hole 72 is provided on the end cap 7.

[0109] The high-reliability pressure-resistant watertight junction box is provided with a pressure-resistant box assembly 1 inside, which can be used to provide a docking space for the branch cable and the main cable, and can also resist external pressure including water pressure during use and pressure during the vulcanization process, and protect the core wires and welding points of the cables (including the main cable and the branch cable). Filling the pressure-resistant box assembly 1 with insulating sealant 50 and arranging a support rod 8 can realize the insulating sealing function, improve the pressure resistance performance, protect the branch cable and the main cable, and limit the displacement of the branch cable 4 during the vulcanization process.

[0110] A method for manufacturing a high-reliability pressure-resistant watertight junction box:

[0111] Step 1: Make the inner shell 6, end cover 7, support block, cable pressing block 9, plastic sleeve and other components respectively.

[0112] Step 2: Fix the plastic sleeve and the inner shell 6 by the clamping portion 24 and the clamping slot 17 .

[0113] Step 3: After stripping the branch cable 4 to a suitable length, the branch cable core wire 41 is inserted into the cable hole 404 of the elastic hole clamp 403, and then the elastic hole clamp 403 is clamped inside the branch cable through-hole 11, and a fire-resistant sealing layer 40 of a certain thickness is coated on the outside, and finally the branch cable is pressed into the branch cable positioning groove 13 of the pressure-bearing seat by the cable pressing block 9 to ensure that no movement occurs during the rubber vulcanization process.

[0114] Step 4: After stripping the main cable 3 of the main cable core wire 31 of appropriate length, insert it into the plastic sleeve, and coat a layer of fire-resistant sealing layer 40 at the joint between the internal clamping part 24 and the clamping groove 17 of the inner shell 6; then use a crimping machine to pressurize 325Mpa to press the tail end 23 of the plastic sleeve (the end away from the inner shell) and the main cable 3, so as to achieve a tight connection between the main cable 3 and the plastic sleeve.

[0115] Step 5: perform core wire docking inside the inner shell 6 of the pressure-resistant box assembly 1, dock the branch cable core wire 41 with the main cable core wire 31, and set an insulating sealing layer 16 at the core wire docking point to achieve insulating sheathing.

[0116] Step 6: Install a support block inside the support member positioning hole groove 15 of the inner shell 6. The support block can be fixed inside the support member positioning hole groove 15 by bonding.

[0117] Step 7: Install the end cover 7, snap it onto the inner shell opening 64 of the inner shell 6, and set glue at the inner shell opening 64 to bond and seal the end cover 7 and the inner shell 6. The connection between the end cover 7 and the inner shell 6 can be by snapping, snapping, or any other form of connection. The specific structure is set according to needs and is not limited, as long as it can ensure that the end cover and the inner shell are sealed.

[0118] Step 8: After the installation, the pressure-resistant box assembly with the branch cable and the main cable is directly vacuumed and filled with silicone inside the pressure-resistant box assembly to form an internal pressure-bearing sealing structure. Specifically, the vacuum hole 66 is connected to the vacuum equipment to vacuum the inside of the pressure-resistant box assembly. At the same time, silicone is filled into the inside from the glue hole 72 by an automatic glue filling machine to form an internal pressure-bearing sealing structure. After the glue filling is completed, the glue filling hole and the vacuum hole are blocked with a metal material of the same material as the pressure-resistant box assembly to avoid the formation of a weak point in the pressure-bearing seal.

[0119] Step 9: Put the pressure-resistant box assembly 1 after glue filling into the vulcanizer, and vulcanize it by heating it to 110-130°C and pressurizing it to 3-10Mpa, so that the pressure-resistant box assembly 1 or / and the branch cable and the main cable are externally vulcanized with a rubber vulcanized layer 5 as a watertight packaging layer to form an external watertight packaging structure, and complete a high-reliability pressure-resistant watertight junction box. In this embodiment, the vulcanizer is heated to 120°C and pressurized to 5Mpa for vulcanization.

[0120] Embodiment 3:

[0121] exist Fig.12 In the illustrated embodiment, a high-reliability pressure-resistant watertight junction box comprises a main cable 3, a branch cable 4, and a built-in pressure-resistant box assembly 1 having a docking space between the branch cable 4 and the main cable 3; the pressure-resistant box assembly 1 is provided with a branch cable through-hole 11 and a main cable through-piece; the interior of the docking space is densely filled with insulating sealant; the insulating sealant 50 forms an internal pressure-bearing sealing structure; the outside of the pressure-resistant box assembly 1 is coated with a rubber vulcanization layer 5 for achieving watertight packaging through vulcanization; the rubber vulcanization layer 5 forms an external watertight packaging structure; the insulating sealant, the pressure-resistant box assembly 1 and the rubber vulcanization layer 5 form an integrated three-layer pressure-bearing sealing structure.

[0122] The insulating sealant 50 is filled in the docking space by vacuum filling and is integrated with the branch cable and the main cable. In this embodiment, the pressure-resistant box assembly 1 is placed in a vacuum filling container for vacuum filling. The insulating sealant 50 is made of liquid rubber. Liquid rubber has a long curing time and can be adjusted to achieve curing time. The curing time can be set as needed. Moreover, as a casting elastomer, liquid rubber has a low density and good elasticity. It is not easy to form bubbles during the casting process. It is easier to solidify and has good pressure-bearing performance and high strength. The prior art uses liquid rubber to seal the gaps in the waterproof sheath. However, due to the limitations of various conditions such as external environmental conditions and manufacturing conditions, it is limited to local and external use, and cannot be used for the entire interior of the box, let alone underwater pressure-bearing sealing.

[0123] In this embodiment, the main cable threading member 2 is an elastic sleeve made of a material with a certain elasticity to facilitate the threading of the main cable into the cabin.

[0124] The pressure-resistant box assembly 1 comprises an inner shell 6 and an end cover 7 covering the inner shell 6. The inner shell cavity 10 for connecting the branch cable and the main cable is provided inside the pressure-resistant box assembly 1. A support member is provided inside the inner shell 10. In this embodiment, the support member 8 is a support frame.

[0125] In this embodiment, the rubber vulcanized layer 5 is respectively coated on the outside of the inner shell 6 and the end cover 7, the outside of the branch cable 4, the main cable passing part and the outside of the main cable 3 to form an integral watertight package vulcanized layer.

[0126] The inner shell 6 is arranged in a rectangular structure as a whole, and the inner shell 6 includes two side shell surfaces 61, two end surfaces 62, a bottom surface 63 and an inner shell opening 64. A buckling structure 65 is arranged on the inner shell opening 64, and a covering structure 71 is arranged on the end cover 7. After the end cover 7 is buckled on the inner shell 6, an inner shell cavity 10 is formed. The covering structure 71 on the end cover 7 cooperates with the buckling structure 65 on the inner shell 6 to form a box body sealing structure.

[0127] A plurality of branch cable through holes 11 are respectively arranged on the two side shell surfaces 61 of the inner shell 6, and a pressure bearing seat 12 is respectively arranged along the two side shell surfaces 61 inside the inner shell 6. Fig.13As shown, in this embodiment, the pressure-bearing seat 12 is separately provided from the inner shell 6, and the pressure-bearing seat 12 includes a seat body 121 and a fire-resistant sealing body 122 coated on the outside of the seat body. The pressure-bearing seat 12 is sealed and bonded to the inner wall of the inner shell, and the upper end surface of the pressure-bearing seat is provided with a seat body perforation 123 corresponding to the branch cable perforation 11 on the inner shell. The branch cable passes through the branch cable perforation and then passes through the seat body perforation and then passes through the cavity of the inner shell from the seat body perforation. The branch cable is sealed and connected to the seat body perforation. The seat body perforation 123 is coaxially arranged with the branch cable perforation 11.

[0128] A sleeve fixing hole 14 is provided at the center of the bottom surface of the inner shell 6 , and the sleeve fixing hole 14 passes through the bottom surface 63 of the inner shell. Support member positioning hole grooves 15 are respectively provided on the bottom surface 63 of the inner shell on both sides of the sleeve fixing hole 14 .

[0129] The support frame is positioned inside the support member positioning hole 15 through a fixing member.

[0130] The elastic sleeve includes a sleeve body 21 and a sleeve flange 22. The sleeve flange 22 is arranged on the sleeve fixing hole 14 of the bottom surface 63 of the inner shell 6 and is fixedly connected to the bottom surface 63 of the inner shell. The sleeve body 21 extends through the sleeve fixing hole 14 and is arranged outside the inner shell cavity 10. One end of the sleeve body 21 away from the inner shell is set as the tail end 23.

[0131] In another embodiment, the elastic sleeve may also include a sleeve body, a collet, and a fire-resistant sealing layer covering the sleeve body and the collet.

[0132] The main cable 3 passes through the elastic sleeve and extends into the inner shell cavity 10. The tail end 23 of the elastic sleeve away from the pressure-resistant box assembly is pressed together with the main cable 3 to form a sealed fit.

[0133] The elastic sleeve tail end 23 is pressed together with the main cable 3 by a crimping machine to prevent the main cable 3 from being displaced during the vulcanization process, thereby ensuring the reliability and sealing of the connection.

[0134] The branch cable core wire 41 of the branch cable 4 is connected to the main cable core wire 31 of the main cable 3 inside the inner shell.

[0135] After the docking is completed, the end caps are closed, and then vacuuming and glue pouring are performed. In order to realize the vacuuming operation, a vacuuming hole 66 is provided on the bottom surface 63 of the inner shell 6, and a glue pouring hole 72 is provided on the end cap 7.

[0136] The high-reliability pressure-resistant watertight junction box is provided with a pressure-resistant box assembly 1 inside, which can be used to provide a docking space for the branch cable and the main cable, and can also resist external pressure including water pressure during use and pressure during the vulcanization process, and protect the core wires and welding points of the cables (including the main cable and the branch cable). Filling the pressure-resistant box assembly 1 with insulating sealant 50 and arranging a support rod 8 can realize the insulating sealing function, improve the pressure resistance performance, protect the branch cable and the main cable, and limit the displacement of the branch cable 4 during the vulcanization process.

[0137] A method for manufacturing a high-reliability pressure-resistant watertight junction box:

[0138] Step 1: respectively manufacture the inner shell 6, the end cover 7, the support frame, the elastic sleeve and other components;

[0139] Step 2: Fix the elastic sleeve to the inner shell 6.

[0140] Step 3: After stripping the branch cable 4 to a suitable length, the branch cable core wire 41 is inserted into the branch cable through hole 11 on the inner shell 6, and then inserted into the seat body through hole 123, and the fire-resistant sealing body 122 is coated on the outside of the seat body to achieve fixed sealing of the branch cable to ensure that it will not move during the vulcanization process.

[0141] Step 4: Strip the main cable 3 to a suitable length of the main cable core wire 31 and insert it into the elastic sleeve, then use a crimping machine to pressurize it to 300-350Mpa. In this embodiment, pressurize it to 300Mpa and press the tail end 23 of the elastic sleeve (the end away from the inner shell) to the main cable 3, so as to achieve a tight connection between the main cable 3 and the elastic sleeve.

[0142] Step 5: perform core wire docking inside the inner shell 6 of the pressure-resistant box assembly 1, dock the branch cable core wire 41 with the main cable core wire 31, and set an insulating sealing layer 16 at the core wire docking point to achieve insulating sheathing.

[0143] Step 6: Install the support frame inside the support member positioning hole groove 15 of the inner shell 6.

[0144] Step 7: Install the end cover 7, snap it onto the inner shell opening 64 of the inner shell 6, and set glue at the inner shell opening 64 to bond and seal the end cover 7 and the inner shell 6. The connection between the end cover 7 and the inner shell 6 can be by snapping, snapping, or any other form of connection. The specific structure is set according to needs and is not limited, as long as it can ensure that the end cover and the inner shell are sealed.

[0145] Step 8: Place the installed pressure-resistant box assembly with the branch cable and the main cable into a vacuum-pumping and glue-filling device for vacuuming and filling with liquid rubber. Specifically, in this embodiment, the vacuum-pumping device adopts a vacuum-pumping box. Place the pressure-resistant box assembly into the vacuum-pumping box, evacuate the vacuum-pumping box, and form a pressure difference between the vacuum box and the inside of the pressure-resistant box assembly through the vacuum-pumping hole 66 on the bottom surface 63. Use an automatic filling machine to slowly and continuously fill the pressure-resistant box assembly from the glue-filling hole 72. By controlling the vacuum degree of the vacuum box and combining indicators such as the concentration of liquid rubber and the curing time, the liquid rubber is densely filled within the set time, thereby forming a pressure-bearing sealing structure inside the pressure-resistant box assembly.

[0146] After the glue filling operation is completed, the pressure-resistant box assembly after glue filling is taken out, and the cured liquid rubber overflowing from the vacuum hole and the outside of the glue filling hole is cleaned up. There is no need to seal the glue filling port and the vacuum hole, and the next step of rubber vulcanization operation can be carried out.

[0147] Step 9: Place the pressure-resistant box assembly 1 after glue filling into a vulcanizer, heat it to 110~130℃ and pressurize it to 3~10Mpa for vulcanization. In this embodiment, the vulcanizer is heated to 110℃ and pressurized to 3Mpa for vulcanization, so that the outside of the pressure-resistant box assembly 1 is vulcanized with a rubber vulcanization layer 5, the branch cable 4 is partially vulcanized to a branch cable vulcanization layer 42, and the main cable 3 (including the elastic sleeve) is vulcanized with a main cable vulcanization layer 32 as a watertight packaging layer, thereby forming an external watertight packaging structure to complete a high-reliability pressure-resistant watertight junction box.

[0148] The vacuum filling method realizes the formation of an internal bubble-free pressure-bearing sealing structure, which effectively solves the problem that the existing watertight junction box cannot be sealed by filling the internal insulating sealant.

[0149] When the high-reliability pressure-resistant watertight junction box in the above-mentioned embodiment is put into specific application, the main cable passing part is directly sleeved into the cabin entry sealing assembly 30 on the bulkhead, so that the main cable 3 passes through the cabin entry sealing assembly 30 and extends to the inner side of the bulkhead 20, and the main cable passing part 2 is sealed and fixed to the cabin entry sealing assembly 30 by a fastening member, and the watertight junction box belt is arranged on the outside of the bulkhead 20. Since the inside of the watertight junction box is filled with a pressure-resistant box assembly 1 of insulating sealant, the insulating sealant forms an internal pressure-bearing sealing structure, and the outside is coated with a rubber vulcanization layer 5, and the rubber vulcanization layer forms an external watertight packaging structure; the insulating sealant, the pressure-resistant box assembly and the rubber vulcanization layer form an integrated three-layer pressure-bearing sealing structure, and the internal and external seals are pressure-bearing, and the pressure-bearing sealing performance is good. In addition, a vulcanized layer can also be provided on the outside of the main cable and the branch cable for watertight packaging, which greatly improves the watertight reliability, is less affected by processing and assembly, and reduces the processing cost; the internal pressure-resistant box assembly 1 and the insulating sealant withstand pressure, which well protects the core wire and welding points, greatly improves the yield rate, and saves the production cost; the pressure-resistant box assembly 1 can also enhance the pressure resistance through the built-in support member 8, and the insulating sealant and the support member withstand pressure, instead of increasing the thickness of the inner shell and the end cover to enhance the pressure resistance, which greatly reduces the weight of the product; the main cable passing part enters the cabin instead of the main cable directly entering the cabin to avoid the sealing failure problem caused by the deformation of the cable outer sheath, and improves the reliability of the product. At the same time, in order to further increase the pressure-bearing and watertight performance, an elastic clip can be provided inside the branch cable perforation 11 and the external fire-resistant sealing layer 40 can be coated to further improve the watertight performance and fireproof performance.

[0150] The above specific implementation modes / embodiments are specific implementation modes of the present invention, which are used to illustrate the concept of the present invention, are explanatory and exemplary, and should not be interpreted as limiting the implementation modes of the present invention and the scope of the present invention. In addition to the embodiments described herein, those skilled in the art can also adopt other obvious technical solutions based on the contents disclosed in the claims and the specification of this application, and these technical solutions include any obvious replacement and modification of the embodiments described herein, which are within the protection scope of the present invention.

Claims

1. A high reliability pressure-resistant watertight junction box, characterized in that: The invention comprises a built-in pressure-resistant box assembly (1) with a space for connecting a branch cable (4) and a main cable (3), wherein the pressure-resistant box assembly (1) is provided with a branch cable through hole (11) and a main cable through-piece (2), and the pressure-resistant box assembly (1) comprises an inner shell (6) and an end cover (7), wherein a vacuum hole (66) is provided on the bottom surface of the inner shell, and a glue injection hole (72) is provided on the end cover (7); the pressure-resistant box assembly is placed in a vacuum injection glue injection device, and the inside of the vacuum injection device is vacuumed by a vacuum extraction device, so that a pressure difference is formed between the vacuum injection glue injection device and the inside of the pressure-resistant box assembly through the vacuum injection hole (66), and the glue is injected into the inside through the glue injection hole (72) by an automatic glue injection machine. Insulating sealant is filled, and the interior of the docking space is densely filled with insulating sealant (50) to form an internal pressure-bearing sealing structure; the pressure-resistant box assembly (1) after the filling is placed in a vulcanizer, and the vulcanizer is heated to 110-130°C and pressurized to 3-10 MPa for vulcanization, so that a rubber vulcanization layer (5) is vulcanized on the outside of the pressure-resistant box assembly (1) and the branch cable and the main cable as a watertight packaging layer, and the rubber vulcanization layer (5) is coated on the outside of the pressure-resistant box assembly (1) by vulcanization to form an external watertight packaging structure; the insulating sealant (50), the pressure-resistant box assembly (1) and the rubber vulcanization layer (5) form an integrated three-layer pressure-bearing sealing structure.

2. The high reliability pressure-resistant watertight junction box according to claim 1, characterized in that: The insulating sealant (50) is filled in the butt joint space by means of vacuum injection and is integrated with the branch cable and the main cable.

3. The high reliability pressure-resistant watertight junction box according to claim 1, characterized in that: The insulating sealant is made of polyurethane glue, silicone or liquid rubber.

4. The high reliability pressure-resistant watertight junction box according to claim 1, characterized in that: An inner shell cavity (10) for forming a docking space is arranged inside the pressure-resistant box assembly (1); the insulating sealant (50) is filled inside the inner shell cavity.

5. The high reliability pressure-resistant watertight junction box according to claim 4, characterized in that: A support member (8) is also provided in the inner shell cavity (10).

6. The high reliability pressure-resistant watertight junction box according to claim 4, characterized in that: The rubber vulcanized layer (5) is coated on the outside of the inner shell (6) and the end cover (7) to form a watertight packaging structure of the box body.

7. The high reliability pressure-resistant watertight junction box according to claim 4, characterized in that: The rubber vulcanized layer (5) is respectively coated on the outside of the inner shell (6) and the end cover (7), the outside of the branch cable (4), the main cable threading part and the outside of the main cable (3) to form an integral watertight package vulcanized layer.

8. The high reliability pressure-resistant watertight junction box according to claim 1, characterized in that: The pressure-resistant box assembly (1) is provided with a pressure-bearing seat (12) for supporting and fixing a branch cable (4) in an integrated or separate manner; the pressure-bearing seat (12) is provided with a branch cable positioning groove (13), and the branch cable positioning groove (13) is provided with a cable compression block (9); or, the pressure-bearing seat (12) is provided with a seat body through hole (123).

9. The high-reliability pressure-resistant watertight junction box according to any one of claims 1 to 8, characterized in that: The branch cable through hole (11) is filled with a fire-resistant sealing layer (40); or, an elastic hole clamp (403) is provided inside the branch cable through hole (11), and the fire-resistant sealing layer (40) is filled and coated outside the elastic hole clamp (403) and extends to both ends of the branch cable through hole (11).

10. A method for manufacturing a high-reliability pressure-resistant watertight junction box according to any one of claims 1 to 9, characterized in that The following steps are involved: Step 1: Component production: Make the inner shell, end cover, support rod, and main cable threading parts respectively; Step 2: Fix the main cable guide to the inner shell; Step 3: Strip the branch cable to a suitable length, insert the branch cable core wire into the inner shell, and fix it with the pressure-bearing seat; Step 4: Strip the main cable to a suitable length and insert the main cable core wire into the main cable threading piece. Then use a crimping machine to pressurize the main cable threading piece to 300-350 MPa and press the tail end of the main cable threading piece to the main cable. Step 5: Connect the core wires inside the pressure-resistant box assembly and connect the branch cable core wire with the main cable core wire; Step 6: Install the support member in the inner shell and close the end cover; Step 7: After the installation is completed, the pressure-resistant box assembly with the branch cable and the main cable is vacuumed and filled with insulating sealant; Step 8: Place the glue-filled pressure-resistant box assembly into a vulcanizer, heat it to 110-130°C, and pressurize it to 3-10Mpa for vulcanization, so that a layer of rubber vulcanization layer is vulcanized on the outside of the pressure-resistant box assembly as a watertight packaging layer, completing the production of a high-reliability pressure-resistant watertight junction box.

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