Universal watertight oil-filled connector and assembling method thereof

Abstract

The invention discloses a connector technology, and aims to provide a universal watertight oil-filled connector and an assembling method thereof, and the technical scheme is characterized in that the universal watertight oil-filled connector comprises a plug connector module and a socket connector module; the plug connector module comprises an oil-filled plug shell, an oil-filled tail clamp, an oil-filled plug front insulator, an oil-filled plug rear insulator and an electric jack; the oil-filled threaded sleeve is sleeved on the plug connector module and is used for being in threaded locking connection with an oil-filled socket shell of the socket connector module after the socket connector module is connected with the plug connector module; the positioning pin jack and the electric jack are respectively pressed in preset mounting holes of the oil-filled plug front insulator and the oil-filled plug rear insulator, and the oil-filled plug front insulator and the oil-filled plug rear insulator form a plug side insulator assembly; the plug side insulator assembly is located in an axial cavity of the oil-filled plug shell; the invention is suitable for the technical field of connectors.

Description

TECHNICAL FIELD

[0001] The present application relates to a connector technology, more particularly, to a universal watertight oil-filled connector and an assembling method thereof. BACKGROUND

[0002] In the application scenarios such as ocean resource development and deep-sea exploration, which have high requirements for equipment reliability and service life, the performance of the oil-filled watertight electrical connector as a key electrical connection component directly affects the stable operation of the entire system. The core sealing and pressure bearing mechanism of this type of connector is unique: through the internal filling of insulating oil medium, the incompressibility of the insulating oil medium is utilized to balance the external hydrostatic pressure, effectively avoiding the deformation or damage of the shell structure under high water pressure, and ensuring the mechanical structure integrity; at the same time, the high dielectric strength and excellent hydrophobicity of the insulating oil can build a durable and stable insulating protective barrier for the internal electrical contact, resist moisture intrusion and electrochemical corrosion, and ensure the signal transmission integrity and contact reliability during long-term service, meeting the use requirements in complex environments such as deep sea and harsh working conditions.

[0003] The existing oil-filled watertight electrical connector has a significant economic shortcoming. Due to the limitation of the technical principle, its structure is complex, the process is rigorous, and it is highly dependent on materials and processes, resulting in high manufacturing and maintenance costs; therefore, there is an urgent need for a connector with universality and low maintenance cost. SUMMARY

[0004] In view of the deficiencies in the prior art, the purpose of the present application is to provide a universal watertight oil-filled connector and an assembling method thereof.

[0005] To achieve the above-mentioned purpose, the present application provides the following technical solution: a universal watertight oil-filled connector, comprising a plug connector module and a socket connector module; the plug connector module comprises an oil-filled plug shell, an oil-filled tail clamp, an oil-filled plug front insulator, an oil-filled plug rear insulator, an electrical jack, a positioning pin insertion hole, and an oil-filled sleeve provided on the plug connector module for threaded locking connection with the oil-filled socket shell of the socket connector module after the socket connector module is connected with the plug connector module; the positioning pin insertion hole and the electrical jack are respectively press-fitted in the preset mounting hole of the oil-filled plug front insulator and the oil-filled plug rear insulator, and the oil-filled plug front insulator and the oil-filled plug rear insulator form a plug-side insulator assembly; the plug-side insulator assembly is located in the axial cavity of the oil-filled plug shell; the oil-filled tail clamp is screwed on the tail part of the oil-filled plug shell, and is used to generate an axial compression force on the oil-filled PU tube sleeved on the cable bundle; the oil-filled plug shell is provided with an oil injection port for injecting insulating oil medium and an oil-filled plug for preventing leakage of the insulating oil medium;

[0006] The socket connector module includes an oil-filled socket housing, a front insulator of the oil-filled socket, a rear insulator of the oil-filled socket, an electrical pin, and a positioning pin. The positioning pin and the electrical pin are respectively press-fitted into the preset mounting holes of the front and rear insulators of the oil-filled socket. The front and rear insulators of the oil-filled socket constitute a socket-side insulator assembly. The socket-side insulator assembly is located in the axial cavity of the oil-filled socket housing. The electrical pin is adapted to an electrical socket hole, and the positioning pin is adapted to a positioning pin hole and is used for positioning when the plug connector module and the socket connector module are mated. The oil-filled socket housing is provided with an oil inlet for injecting insulating oil and an oil-filled pin for preventing leakage of insulating oil.

[0007] Electrical connection in a watertight environment is achieved by mating the plug connector module and the socket connector module.

[0008] The present invention is further configured such that: both the plug-side insulator assembly and the socket-side insulator assembly are fitted with O-rings, which are located in the axial cavity of the oil-filled plug housing and the axial cavity of the oil-filled socket housing, respectively, and the compression of the O-ring in the sealing groove is 15%-25% of its own diameter.

[0009] The present invention is further configured such that: the fit gap between the oil-filled PU tube and the cable bundle is ≤0.5mm, and the fit between the oil-filled PU tube and the tail interface of the oil-filled plug housing is an interference fit with an interference amount of 0.1-0.3mm.

[0010] A method for assembling a universal watertight oil-filled connector, characterized by comprising the following steps:

[0011] S1. Contact-Insulator Pre-assembly: First, press the positioning pin socket and the electrical socket into the preset mounting holes of the front insulator and the rear insulator of the oil-filled plug, respectively. Second, press the positioning pin and the electrical pin into the preset mounting holes of the front insulator and the rear insulator of the oil-filled socket, respectively. At the same time, check the O-ring seal to ensure that it is intact and located in the preset sealing groove, and that the compression of the O-ring seal is between 15% and 25%, so as to form a reliable radial static seal that meets the design requirements.

[0012] S2. Insulator Closure and Core Wire Welding: The front and rear insulators of the oil-filled plug, after the contact components have been installed, are aligned and closed along the axial reference surface, and fixed with fasteners or snap-fit ​​structures to form the plug-side insulator assembly; then, the core wires of the external cable are welded to the tail terminals of the electrical socket using a welding process. After welding, a continuity test is performed to ensure reliable electrical connection; then, the front and rear insulators of the oil-filled socket, after the contact components have been installed, are aligned and closed along the axial reference surface, and fixed with fasteners or snap-fit ​​structures to form the socket-side insulator assembly;

[0013] S3. Assembly Installation and Tail-End Processing: Push the plug-side insulator assembly with integrated contact and core wire into the axial cavity of the oil-filled plug housing until its limiting structure is tightly fitted with the inner stop surface of the oil-filled plug housing; at the same time, orderly lead out the core wire from the outlet hole at the tail of the oil-filled plug housing; then push the socket-side insulator assembly into the axial cavity of the oil-filled socket housing until its limiting structure is tightly fitted with the inner stop surface of the oil-filled socket housing.

[0014] S4. Tail sealing and mechanical fixation: Install an oil-filled PU tube on the lead-out core wire, so that one end of the oil-filled PU tube is tightly fitted with the core wire, and the other end is interference-fitted with the tail interface of the oil-filled plug shell; then, screw the oil-filled tail clamp to generate axial clamping force, causing the oil-filled PU tube to deform radially and form a stress seal.

[0015] S5. Vacuum oil filling and sealing: Insulating oil medium is injected into the sealed cavity of the assembled plug connector module and socket connector module through the oil filling port on the oil-filled plug shell and the oil-filled socket shell in a vacuum environment. The vacuum degree in the cavity is monitored during the oil filling process. When the vacuum degree is ≤10Pa, the state is maintained and oil filling is continued until oil overflows from the oil filling port.

[0016] S6. Plug and socket mating test: Position and mate the plug connector module and the socket connector module using locating pins. After mating, tighten and fix them with oil-filled screws and then perform a water tightness test. Place the mated connector in a water pressure test device, apply the design water pressure and maintain it for 24 hours, and check for leakage. At the same time, perform electrical performance tests.

[0017] S7. Finished Product Inspection and Packaging: Conduct a visual inspection on the assembled and tested connectors to ensure there is no structural damage; recheck the insulation performance, water tightness performance and electrical performance, and package them after they all meet the design requirements.

[0018] The present invention is further configured such that, in step S5, the method for determining vacuum oil injection is as follows: when the vacuum degree is >10Pa, continue to evacuate until the vacuum degree is ≤10Pa; start oil injection while maintaining the vacuum degree ≤10Pa, monitor the vacuum degree in real time during the oil injection process, and if the vacuum degree is >10Pa, stop oil injection, evacuate again until the vacuum degree is ≤10Pa and then continue oil injection; when oil overflows from the oil injection port, stop oil injection and seal the oil injection port, and check the vacuum degree in the cavity again after sealing. If the change in vacuum degree within 1 hour is ≤5Pa, the oil injection is deemed qualified; if the change is >5Pa, the vacuum oil injection step is repeated.

[0019] The present invention is further configured such that: in step S6, the water tightness test includes: after applying the design water pressure, checking for leakage every 2 hours; if there is no leakage within 24 hours, the water tightness is deemed qualified; if leakage is found at hour t, where t≤24, the leakage location and leakage amount are recorded, the test is then paused and the connector is removed to check the sealing structure. After replacing the damaged seal, steps S1-S6 are repeated; if there is no leakage within 24 hours of the second water tightness test, the test is deemed qualified; if there is still leakage, the connector assembly is deemed a failure.

[0020] The present invention is further configured such that, in step S6, the electrical performance test specifically involves: measuring the contact resistance; if the contact resistance is ≤5mΩ, the electrical performance is qualified; if the contact resistance is >5mΩ, first check whether there is a cold solder joint; if there is a cold solder joint, resolder it, and measure the contact resistance again after resoldering; if the contact resistance is ≤5mΩ, it is qualified; if there is no cold solder joint, check whether the contact component is deformed or oxidized, replace the contact component, reassemble and measure the contact resistance until the contact resistance is ≤5mΩ; if the contact resistance is still >5mΩ after three replacements or treatments, the connector assembly is determined to be a failure.

[0021] The beneficial effects of this invention are:

[0022] 1. Compared with existing technologies, the universal watertight oil-filled connector of this invention uses a modular design to separate the plug connector module and the socket connector module, clearly defining the assembly relationship and functional division of each component. Its core advantages are reflected in the dual guarantee of watertightness and universality. Both the plug side and the socket side use insulator assemblies to encapsulate the contacts, forming a sealed cavity with the oil-filled shell. The setting of the oil injection port and the oil-filled pin ensures reliable injection and sealing of insulating oil. After the insulating oil medium fills the gap, it can prevent moisture intrusion and meet the electrical connection requirements in a watertight environment. The matching design of the positioning pin and the positioning pin hole ensures the accuracy of the mating and avoids contact misalignment damage. The threaded locking structure of the oil-filled threaded sleeve enhances the connection stability, and the axial pressing design of the oil-filled tail clamp on the oil-filled PU tube further strengthens the tail seal. The overall structure takes into account the ease of assembly and environmental adaptability, and can be widely adapted to various electrical connection scenarios that require watertight protection.

[0023] 2. The universal watertight oil-filled connector of this invention significantly improves the sealing reliability of the connector by incorporating an O-ring seal in the insulator assembly and limiting the compression to 15%-25%. The reasonable compression of the O-ring seal within the sealing groove ensures a tight fit with the outer shell cavity, forming an effective radial static seal, while avoiding permanent deformation and accelerated aging of the seal due to excessive compression, or sealing gaps due to insufficient compression. This precise compression design effectively prevents moisture and impurities from intruding through the gap between the insulator and the shell. Combined with the sealing effect of the insulating oil, it forms double protection, greatly reducing the risk of leakage. At the same time, the standardized assembly design of the O-ring seal simplifies the assembly process, ensures consistent sealing performance, and enables the connector to maintain a stable seal under different water pressure environments, providing a key guarantee for the safety and stability of the electrical connection.

[0024] 3. In this invention, a fit clearance of ≤0.5mm and an interference fit design of 0.1-0.3mm are used to further strengthen the tail seal. The small gap fit between the oil-filled PU tube and the cable bundle reduces the oil leakage channels and prevents the insulating oil from leaking out from the gap between the core wire and the PU tube. The interference fit with the shell interface directly forms an initial sealing barrier. Combined with the axial clamping force of the oil-filled tail clamp, the PU tube deforms radially and fits tightly with the core wire and the shell, forming a stress-sealing structure. This multi-fit design effectively solves the problem of weak sealing at the connector tail caused by the cable lead-out. It not only prevents external moisture intrusion but also prevents internal insulating oil leakage, ensuring the integrity of the sealing cavity. The reasonable interference parameters take into account both assembly feasibility and sealing effect, avoiding excessive interference which would lead to difficulty in PU tube assembly or damage, and insufficient interference which would affect sealing performance. This ensures the reliability and durability of the tail seal and further improves the overall water tightness of the connector.

[0025] 4. The present invention has a simple and reasonable structure, is easy to manufacture and operate, avoids the defects of the prior art, and is suitable for promotion and application. Attached Figure Description

[0026] Fig. 1 This is a structural diagram of the plug connector module in the universal watertight oil-filled connector of the present invention.

[0027] Fig. 2 This is a structural diagram of the socket connector module in the universal watertight oil-filled connector of the present invention.

[0028] Figs. 1-2 Reference numerals in the attached diagram: 1. Oil-filled plug housing; 2. Oil-filled tail clip; 3. Front insulator of oil-filled plug; 4. Rear insulator of oil-filled plug; 5. Electrical socket; 6. Positioning pin socket; 7. Oil-filled screw sleeve; 8. Oil-filled socket housing; 9. Front insulator of oil-filled socket; 10. Rear insulator of oil-filled socket; 11. Electrical pin; 12. Positioning pin; 13. O-ring seal. Detailed Implementation

[0029] Reference Figs. 1-2 The embodiments of the universal watertight oil-filled connector and its assembly method of the present invention are further described below.

[0030] For ease of explanation, spatial relative terms such as “up,” “down,” “left,” and “right” are used in the embodiments to describe the relationship of one element or feature shown in the figures relative to another element or feature. It should be understood that, in addition to the orientations shown in the figures, spatial terms are intended to include different orientations of the device in use or operation. For example, if the device in the figures is inverted, an element described as being “down” of other elements or features would be positioned “up” of those other elements or features. Therefore, the exemplary term “down” can encompass both up and down orientations. The device may be positioned in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0031] Moreover, relational terms such as “first” and “second” are used merely to distinguish one component from another that has the same name, without necessarily requiring or implying any such actual relationship or order between the components.

[0032] Figs. 1-2 The diagram shows a universal watertight oil-filled connector, comprising a plug connector module and a socket connector module. The plug connector module includes an oil-filled plug housing 1, an oil-filled tail clip 2, an oil-filled plug front insulator 3, an oil-filled plug rear insulator 4, an electrical socket 5, a positioning pin socket 6, and an oil-filled threaded sleeve 7 fitted onto the plug connector module for threaded locking with the oil-filled socket housing 8 of the socket connector module after the socket connector module is connected to the plug connector module. The positioning pin socket 6 and the electrical socket 5 are respectively press-fitted into the oil-filled socket housing 8 of the socket connector module. The oil-filled plug front insulator 3 and the oil-filled plug rear insulator 4 are located in the preset mounting holes, forming a plug-side insulator assembly. The plug-side insulator assembly is located in the axial cavity of the oil-filled plug housing 1. The oil-filled tail clip 2 is screwed onto the tail of the oil-filled plug housing 1 to generate axial clamping force on the oil-filled PU tube fitted on the cable bundle. The oil-filled plug housing 1 is provided with an oil inlet for injecting insulating oil medium and an oil-filled pin for preventing leakage of insulating oil medium.

[0033] The socket connector module includes an oil-filled socket housing 8, an oil-filled socket front insulator 9, an oil-filled socket rear insulator 10, an electrical pin 11, and a positioning pin 12. The positioning pin 12 and the electrical pin 11 are respectively press-fitted into the preset mounting holes of the oil-filled socket front insulator 9 and the oil-filled socket rear insulator 10. The oil-filled socket front insulator 9 and the oil-filled socket rear insulator 10 constitute a socket-side insulator assembly. The socket-side insulator assembly is located in the axial cavity of the oil-filled socket housing 8. The electrical pin 11 is adapted to the electrical socket 5, and the positioning pin 12 is adapted to the positioning pin socket 6 and is used for positioning when the plug connector module and the socket connector module are mated. The oil-filled socket housing 8 is provided with an oil inlet for injecting insulating oil medium and an oil-filled pin for preventing leakage of insulating oil medium.

[0034] Electrical connection in a watertight environment is achieved by mating the plug connector module and the socket connector module.

[0035] By modularly designing the plug connector module and socket connector module, the assembly relationship and functional division of each component are clearly defined. The core advantage lies in the dual guarantee of water tightness and versatility. Both the plug and socket sides use insulator assemblies to encapsulate the contacts, forming a sealed cavity with the oil-filled shell. The setting of the oil injection port and oil-filled pin ensures reliable injection and sealing of insulating oil. After the insulating oil medium fills the gap, it can prevent moisture intrusion and meet the electrical connection requirements in watertight environments. The matching design of the positioning pin 12 and the positioning pin socket 6 ensures the accuracy of the docking and avoids contact misalignment damage. The threaded locking structure of the oil-filled sleeving 7 enhances the connection stability, and the axial pressing design of the oil-filled tail clip 2 on the oil-filled PU tube further strengthens the tail seal. The overall structure takes into account the ease of assembly and environmental adaptability, and can be widely adapted to various electrical connection scenarios that require water tightness protection.

[0036] Both the plug-side insulator assembly and the socket-side insulator assembly are fitted with O-ring seals 13, which are located in the preset sealing grooves of the axial cavity of the oil-filled plug housing 1 and the axial cavity of the oil-filled socket housing 8. The compression of the O-ring seal 13 in the sealing groove is 15%-25% of its own diameter.

[0037] By incorporating an O-ring 13 into the insulator assembly and limiting its compression to 15%-25%, the sealing reliability of the connector is significantly improved. The appropriate compression of the O-ring 13 within the sealing groove ensures a tight fit with the housing cavity, forming an effective radial static seal, while preventing permanent deformation and accelerated aging of the O-ring due to excessive compression, or gaps caused by insufficient compression. This precise compression design effectively prevents moisture and impurities from intruding through the gap between the insulator and the housing. Combined with the sealing effect of the insulating oil, this forms double protection, significantly reducing the risk of leakage. At the same time, the standardized assembly design of the O-ring 13 simplifies the assembly process, ensures consistent sealing performance, and enables the connector to maintain a stable seal under different water pressure environments, providing crucial assurance for the safety and stability of the electrical connection.

[0038] The fit gap between the oil-filled PU tube and the cable bundle is ≤0.5mm, and the fit between the oil-filled PU tube and the tail interface of the oil-filled plug housing 1 is an interference fit with an interference amount of 0.1-0.3mm.

[0039] The tail seal is further reinforced by a fit clearance of ≤0.5mm and an interference fit design of 0.1-0.3mm. The small gap fit between the oil-filled PU tube and the cable bundle reduces the oil leakage channels and prevents the insulating oil from leaking out from the gap between the core wire and the PU tube. The interference fit with the shell interface directly forms an initial sealing barrier. Combined with the axial clamping force of the oil-filled tail clip 2, the PU tube deforms radially and fits tightly with the core wire and shell, forming a stress-sealing structure. This multi-fit design effectively solves the problem of weak sealing at the connector tail caused by the cable lead-out. It not only prevents external moisture intrusion but also prevents internal insulating oil leakage, ensuring the integrity of the sealing cavity. The reasonable interference parameters take into account both assembly feasibility and sealing effect. It avoids excessive interference causing difficulty or damage to the PU tube assembly, and insufficient interference affecting sealing performance, ensuring the reliability and durability of the tail seal and further improving the overall water tightness of the connector.

[0040] A method for assembling a universal watertight oil-filled connector, characterized by comprising the following steps:

[0041] S1. Pre-assembly of contact components and insulators: First, press the positioning pin socket 6 and the electrical socket 5 into the preset mounting holes of the front insulator 3 and the rear insulator 4 of the oil-filled plug, respectively. Second, press the positioning pin 12 and the electrical pin 11 into the preset mounting holes of the front insulator 9 and the rear insulator 10 of the oil-filled socket, respectively. At the same time, check the O-ring seal 13 to ensure that it is intact and located in the preset sealing groove, and that the compression of the O-ring seal 13 is between 15% and 25%, so as to form a reliable radial static seal that meets the design requirements.

[0042] S2. Insulator Closure and Core Wire Welding: The front insulator 3 and rear insulator 4 of the oil-filled plug, after the contact components have been installed, are aligned and closed along the axial reference surface, and fixed with fasteners or snap-fit ​​structures to form a plug-side insulator assembly; then, the core wire of the external cable is welded to the tail terminal of the electrical socket 5 using a welding process. After welding, a continuity test is performed to ensure reliable electrical connection; then, the front insulator 9 and rear insulator 10 of the oil-filled socket, after the contact components have been installed, are aligned and closed along the axial reference surface, and fixed with fasteners or snap-fit ​​structures to form a socket-side insulator assembly;

[0043] S3. Assembly Installation and Tail-End Processing: Push the plug-side insulator assembly with integrated contact and core wire into the axial cavity of the oil-filled plug housing 1 until its limiting structure is tightly fitted with the inner stop surface of the oil-filled plug housing 1; at the same time, orderly lead out the core wire from the outlet hole at the tail of the oil-filled plug housing 1; then push the socket-side insulator assembly into the axial cavity of the oil-filled socket housing 8 until its limiting structure is tightly fitted with the inner stop surface of the oil-filled socket housing 8.

[0044] S4. Tail sealing and mechanical fixation: Install an oil-filled PU tube on the lead-out core wire, so that one end of the oil-filled PU tube is tightly fitted with the core wire, and the other end is interference-fitted with the tail interface of the oil-filled plug shell 1; then, screw the oil-filled tail clip 2, so that the oil-filled tail clip 2 generates axial clamping force, causing the oil-filled PU tube to deform radially, forming a stress seal.

[0045] S5. Vacuum oil filling and sealing: Insulating oil medium is injected into the sealed cavity of the assembled plug connector module and socket connector module through the oil filling port on the oil-filled plug shell 1 and the oil-filled socket shell 8 in a vacuum environment. The vacuum degree in the cavity is monitored during the oil filling process. When the vacuum degree is ≤10Pa, the state is maintained and oil filling is continued until oil overflows from the oil filling port.

[0046] S6. Plug and socket mating test: Position and mate the plug connector module and the socket connector module using the positioning pin 12. After mating, tighten and fix them with the oil-filled screw sleeve 7 and then perform a water tightness test. Place the mated connector in a water pressure test device, apply the design water pressure and maintain it for 24 hours, and check for leakage. At the same time, perform an electrical performance test.

[0047] S7. Finished Product Inspection and Packaging: Conduct a visual inspection on the assembled and tested connectors to ensure there is no structural damage; recheck the insulation performance, water tightness performance, and electrical performance, and package them after they all meet the design requirements.

[0048] The process of "pre-assembly - welding - assembly - sealing and oiling - testing and acceptance" ensures process standardization and quality control. S1, the pre-assembly of contacts and insulators and the inspection of sealing rings, avoids sealing defects from the outset. S2, the welding and continuity testing of core wires, ensures reliable electrical connections and reduces later failures. S3-S4, the assembly installation and tail sealing, enhance structural stability and sealing performance through precise positioning and stress-sealing design. S5, the vacuum oiling process, effectively removes air from the cavity, preventing air bubbles from affecting insulation and sealing performance. S6-S7, the docking test and finished product inspection, achieve full-process quality control. This method has clear steps and coherent logic, making it suitable for large-scale production and reducing assembly errors through quality verification at each stage, ensuring that the watertightness and electrical performance of each connector meet design requirements.

[0049] In step S5, the method for determining vacuum oil injection is as follows: when the vacuum degree is >10Pa, continue to evacuate until the vacuum degree is ≤10Pa; start oil injection while maintaining the vacuum degree ≤10Pa, monitor the vacuum degree in real time during the oil injection process, if the vacuum degree is >10Pa, stop oil injection, evacuate again until ≤10Pa and then continue oil injection; when oil overflows from the oil injection port, stop oil injection and seal the oil injection port, and check the vacuum degree in the cavity again after sealing. If the change in vacuum degree within 1 hour is ≤5Pa, the oil injection is deemed qualified; if the change is >5Pa, the vacuum oil injection step is repeated.

[0050] By strictly controlling vacuum parameters, monitoring the oil injection process, and verifying the vacuum level after sealing, the quality of oil injection is ensured. Oil injection under vacuum conditions can completely eliminate air and moisture in the sealed cavity, avoiding the formation of air bubbles that could lead to a decrease in the insulating performance of the insulating oil or seal failure. Real-time monitoring of the vacuum level and pausing oil injection when it exceeds the limit can prevent insufficient oil injection due to insufficient vacuum. The verification requirement that the change in vacuum level within 1 hour after sealing is ≤5Pa further verifies the sealing performance of the sealed cavity and the integrity of the oil injection.

[0051] In step S6, the water tightness test includes: after applying the design water pressure, checking for leakage every 2 hours. If there is no leakage within 24 hours, the water tightness is deemed acceptable. If leakage is found at hour t (t≤24), the leakage location and leakage amount are recorded. The test is then paused, and the connector is removed to check the sealing structure. After replacing the damaged seal, steps S1-S6 are repeated. If there is no leakage within 24 hours of the second water tightness test, the test is deemed acceptable. If there is still leakage, the connector assembly is deemed a failure.

[0052] The connector's watertight performance is fully verified through a 24-hour continuous water pressure test, a 2-hour leakage inspection, and a leakage handling mechanism. The 24-hour long-term pressure holding test simulates the long-term watertight environment in actual use of the connector, fully exposing potential sealing defects. The timed inspection mechanism can promptly detect leakage problems and record relevant information, providing a basis for subsequent investigation. The secondary assembly and testing process after leakage ensures that the repaired products meet the requirements through rigorous secondary testing, preventing unqualified products from entering the market.

[0053] In step S6, the electrical performance test specifically involves: measuring the contact resistance. If the contact resistance is ≤5mΩ, the electrical performance is qualified. If the contact resistance is >5mΩ, first check if there is a cold solder joint. If there is a cold solder joint, resolder it and measure the contact resistance again. If the contact resistance is ≤5mΩ, it is qualified. If there is no cold solder joint, check if the contact component is deformed or oxidized. Replace the contact component, reassemble, and measure the contact resistance again until the contact resistance is ≤5mΩ. If the contact resistance is still >5mΩ after three replacements or treatments, the connector assembly is considered a failure.

[0054] By employing tiered troubleshooting and setting a three-stage processing limit, the reliability of electrical connections is ensured. Contact resistance is a key indicator of electrical connection quality; a requirement of ≤5mΩ ensures smooth current transmission and reduces energy consumption and heat generation. Targeted treatment for different fault causes can accurately resolve issues such as welding defects and contact damage, avoiding blind component replacement. Setting a three-stage processing limit ensures the possibility of product repair while avoiding increased costs or unstable product performance due to over-repair. This ensures that the electrical performance of the connector meets design specifications, improves the stability and safety of current transmission, and extends product lifespan.

[0055] By replacing different modular oil-filled components within a fixed external structure, a series of products with different core counts, current capacities, or signal types can be quickly derived, greatly shortening the new product development cycle and improving versatility. Standardized external structural components enable large-scale mass production, reducing unit costs. At the same time, it significantly reduces investment in mold development and the variety of parts in inventory, achieving cost reduction and efficiency improvement. In on-site maintenance and spare parts management, only the corresponding modular internal components need to be replaced to achieve product function conversion or repair, simplifying the operation process and reducing life cycle maintenance costs. All modular components inherit the inherent advantages of oil-filled watertight technology, ensuring stable high voltage resistance, high insulation, and long-term reliability in various harsh environments.

[0056] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any ordinary changes and substitutions made by those skilled in the art within the scope of the technical solution of the present invention should be included within the protection scope of the present invention.

Claims

1. A universal watertight oil-filled connector, characterized in that: The system includes a plug connector module and a socket connector module. The plug connector module includes an oil-filled plug housing (1), an oil-filled tail clip (2), an oil-filled plug front insulator (3), an oil-filled plug rear insulator (4), an electrical socket (5), a positioning pin socket (6), and an oil-filled threaded sleeve (7) fitted onto the plug connector module for threaded locking connection with the oil-filled socket housing (8) of the socket connector module after the socket connector module is connected to the plug connector module. The positioning pin socket (6) and the electrical socket (5) are respectively press-fitted onto the oil-filled plug front insulator. The pre-installed mounting holes of the insulator (3) and the rear insulator (4) of the oil-filled plug constitute the plug-side insulator assembly; the plug-side insulator assembly is located in the axial cavity of the oil-filled plug housing (1); the oil-filled tail clip (2) is screwed onto the tail of the oil-filled plug housing (1) to generate axial clamping force on the oil-filled PU tube mounted on the cable bundle; the oil-filled plug housing (1) is provided with an oil inlet for injecting insulating oil medium and an oil-filled pin for preventing leakage of insulating oil medium; The socket connector module includes an oil-filled socket housing (8), an oil-filled socket front insulator (9), an oil-filled socket rear insulator (10), an electrical pin (11), and a positioning pin (12). The positioning pin (12) and the electrical pin (11) are respectively pressed into the preset mounting holes of the oil-filled socket front insulator (9) and the oil-filled socket rear insulator (10). The oil-filled socket front insulator (9) and the oil-filled socket rear insulator (10) constitute a socket-side insulator assembly. The socket-side insulator assembly is located in the axial cavity of the oil-filled socket housing (8). The electrical pin (11) is adapted to the electrical socket (5), and the positioning pin (12) is adapted to the positioning pin socket (6) and is used for positioning when the plug connector module and the socket connector module are mated. The oil-filled socket housing (8) is provided with an oil inlet for injecting insulating oil medium and an oil-filled pin for preventing leakage of insulating oil medium. Electrical connection in a watertight environment is achieved by mating the plug connector module and the socket connector module.

2. The universal watertight oil-filled connector according to claim 1, characterized in that, Both the plug-side insulator assembly and the socket-side insulator assembly are fitted with O-ring seals (13), which are located in the axial cavity of the oil-filled plug housing (1) and the axial cavity of the oil-filled socket housing (8). The compression of the O-ring seal (13) in the sealing groove is 15%-25% of its own diameter.

3. The universal watertight oil-filled connector according to claim 1, characterized in that, The fit gap between the oil-filled PU tube and the cable bundle is ≤0.5mm, and the fit between the oil-filled PU tube and the tail interface of the oil-filled plug housing (1) is an interference fit with an interference amount of 0.1-0.3mm.

4. An assembly method applicable to the universal watertight oil-filled connector according to any one of claims 1-3, characterized in that, Includes the following steps: S1. Pre-assembly of contact components and insulators: First, press the positioning pin hole (6) and the electrical socket (5) into the preset mounting holes of the front insulator (3) and the rear insulator (4) of the oil-filled plug, respectively. Second, press the positioning pin (12) and the electrical pin (11) into the preset mounting holes of the front insulator (9) and the rear insulator (10) of the oil-filled socket, respectively. At the same time, check the O-ring seal (13) to ensure that it is intact and located in the preset sealing groove, and that the compression of the O-ring seal (13) is between 15% and 25% to form a reliable radial static seal that meets the design requirements. S2. Insulator assembly and core wire welding: Align the front insulator (3) and rear insulator (4) of the oil-filled plug with the contact components installed along the axial reference surface and fix them with fasteners or snap-fit ​​structures to form a plug-side insulator assembly; then use welding process to weld the core wire of the external cable to the tail terminal of the electrical socket (5), and perform continuity test after welding to ensure reliable electrical connection; then align the front insulator (9) and rear insulator (10) of the oil-filled socket with the contact components installed along the axial reference surface and fix them with fasteners or snap-fit ​​structures to form a socket-side insulator assembly; S3. Assembly Installation and Tail-end Processing: Push the plug-side insulator assembly with integrated contact and core wire into the axial cavity of the oil-filled plug housing (1) until its limiting structure is tightly fitted with the inner stop surface of the oil-filled plug housing (1); at the same time, orderly lead out the core wire from the outlet hole at the tail of the oil-filled plug housing (1); then push the socket-side insulator assembly into the axial cavity of the oil-filled socket housing (8) until its limiting structure is tightly fitted with the inner stop surface of the oil-filled socket housing (8); S4. Tail sealing and mechanical fixation: Install an oil-filled PU tube on the lead-out core wire, so that one end of the oil-filled PU tube is tightly fitted with the core wire, and the other end is interference-fitted with the tail interface of the oil-filled plug shell (1); then, screw the oil-filled tail clip (2) so that the oil-filled tail clip (2) generates axial clamping force, causing the oil-filled PU tube to deform radially and form a stress seal. S5. Vacuum oil filling and sealing: Insulating oil medium is injected into the sealed cavity of the assembled plug connector module and socket connector module through the oil filling port on the oil-filled plug shell (1) and the oil-filled socket shell (8) in a vacuum environment. The vacuum degree in the cavity is monitored during the oil filling process. When the vacuum degree is ≤10Pa, the state is maintained and oil filling is continued until oil overflows from the oil filling port. S6. Plug and socket mating test: Position the plug connector module and the socket connector module with positioning pin (12) and then tighten them with oil-filled screw sleeve (7) after mating. Then conduct a water tightness test. Place the mated connector in a water pressure test device, apply the design water pressure and keep it for 24 hours to check for leakage. At the same time, conduct an electrical performance test. S7. Finished Product Inspection and Packaging: Conduct a visual inspection of the assembled and tested connectors to ensure there is no structural damage. After rechecking the insulation, watertightness, and electrical properties, and confirming that they all meet the design requirements, the products are packaged.

5. The assembly method of the universal watertight oil-filled connector according to claim 4, characterized in that, In step S5, the method for determining vacuum oil injection is as follows: when the vacuum degree is >10Pa, continue to evacuate until the vacuum degree is ≤10Pa; start oil injection while maintaining the vacuum degree ≤10Pa, monitor the vacuum degree in real time during the oil injection process, if the vacuum degree is >10Pa, stop oil injection, evacuate again until ≤10Pa, and then continue oil injection; when oil overflows from the oil injection port, stop oil injection and seal the oil injection port, and check the vacuum degree in the cavity again after sealing. If the change in vacuum degree within 1 hour is ≤5Pa, the oil injection is deemed qualified; if the change is >5Pa, the vacuum oil injection step is repeated.

6. The assembly method of the universal watertight oil-filled connector according to claim 4, characterized in that, In step S6, the water tightness test includes: after applying the design water pressure, checking for leakage every 2 hours. If there is no leakage within 24 hours, the water tightness is deemed acceptable. If leakage is found at hour t (t≤24), the leakage location and leakage amount are recorded. The test is then paused, and the connector is removed to check the sealing structure. After replacing the damaged seal, steps S1-S6 are repeated. If there is no leakage within 24 hours of the second water tightness test, the test is deemed acceptable. If there is still leakage, the connector assembly is deemed a failure.

7. The assembly method of the universal watertight oil-filled connector according to claim 4, characterized in that, In step S6, the electrical performance test specifically involves: measuring the contact resistance. If the contact resistance is ≤5mΩ, the electrical performance is qualified. If the contact resistance is >5mΩ, first check if there is a cold solder joint. If there is a cold solder joint, resolder it and measure the contact resistance again. If the contact resistance is ≤5mΩ, it is qualified. If there is no cold solder joint, check if there is deformation or oxidation of the contact component. Replace the contact component, reassemble, and measure the contact resistance until the contact resistance is ≤5mΩ. If the contact resistance is still >5mΩ after three replacements or treatments, the connector assembly is considered a failure.

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