Deepwater high-voltage large-current connector and butt joint method thereof

Abstract

The invention discloses a deepwater high-voltage large-current connector and a butt joint method thereof. Insulator assemblies of a plug and a socket of the connector adopt inlay plastic compression, and the method comprises the following steps of: constructing multiple high-pressure sealing by adopting a sealing ring with the hardness of 90 and precision interference fit; the butt joint end of the insulator adopts a stepped structure so as to increase the creepage distance in a limited space; misplug prevention is realized through the key and the key slot; and the shell is made of 316L stainless steel and is provided with a butt joint marking line. According to the invention, the technical problems of high-reliability sealing, high-voltage insulation and large-current current carrying under deep sea extreme pressure are systematically solved, so that the connector can meet the harsh requirements of 6000 meters underwater, 65MPa pressure bearing, 12.5 kVDC voltage withstanding and 50A current carrying, and is suitable for full-deep-sea operation.

Description

Technical Field

[0001] This invention relates to the field of electrical connector technology, specifically to a deep-sea high-voltage, high-current connector and its mating method. Background Technology

[0002] With the rapid development of deep-sea exploration, marine resource development, and underwater equipment technology, unprecedented demands have been placed on the reliability and performance of underwater power transmission systems. Traditional underwater connectors are mostly designed for signal transmission or shallow water environments, and their structures are simple, with limited sealing levels and electrical performance.

[0003] In deep-sea environments exceeding 6000 meters, connectors need to withstand hydrostatic pressures of over 60 MPa, posing extreme challenges to their structural strength and sealing reliability. Simultaneously, the power demands of deep-sea operational equipment (such as remotely operated vehicles, deep-sea workstations, and exploration equipment) are increasing, requiring connectors capable of stably transmitting thousands of volts of high voltage and tens of amperes of high current. However, high voltage requires sufficient clearance and creepage distance to prevent breakdown, while high current demands sufficient conductor cross-sectional area and heat dissipation capacity. Deep-sea connectors, limited by installation space and pressure sealing requirements, often have extremely compact internal spaces. Therefore, resolving the contradiction between extreme pressure sealing, high-voltage insulation, and high-current carrying capacity within a limited internal space has become a long-standing technical challenge in this field.

[0004] Existing underwater connector solutions often only address one or two specific issues, lacking an integrated solution that can systematically meet the comprehensive performance requirements of deep water, high pressure, and high current. Therefore, an innovative connector design is urgently needed to overcome these technical bottlenecks. Summary of the Invention

[0005] The present invention aims to provide a deep-sea high-voltage high-current connector and its mating method to solve the technical problem that the existing technology cannot simultaneously achieve high reliability sealing, high voltage insulation and high current carrying capacity under the extreme pressure environment of the deep sea.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: In one aspect, a deep-water high-voltage, high-current connector is provided, comprising a mating plug and a socket.

[0007] The plug includes a plug housing, a socket insulator assembly installed within the plug housing, a first clamping nut for axially fixing the socket insulator assembly, and a tail sealing assembly connected to the tail of the plug housing. The socket insulator assembly uses an inlay molding process to integrally encapsulate multiple conductive sockets within the insulator; the outer periphery of the assembly has an annular groove and is fitted with a first main sealing ring. The hardness of the first main sealing ring is 90.

[0008] The socket includes a square housing, a pin insulator assembly installed within the square housing, a second clamping nut for axially fixing the pin insulator assembly, and a device mounting sealing ring disposed at the flange of the square housing. The pin insulator assembly is also manufactured using an inlay molding process. A second main sealing ring is provided between the inner wall of the mating end of the square housing and the pin insulator assembly.

[0009] The outer periphery of the mating end of the plug housing is provided with at least two keys extending axially, and the mating end of the square housing is provided with keyways that match the number and position of the keys, for guiding and preventing incorrect insertion during the insertion and removal process.

[0010] The plug also includes a connecting nut, which is rotatably fitted onto the outside of the plug housing. The connecting nut has threads on its inner wall for engaging with corresponding threads on the outer periphery of the square housing to lock the plug and socket together.

[0011] Preferably, both the plug housing and the square housing are made of 316L stainless steel.

[0012] Preferably, the first main sealing ring, the second main sealing ring, and other elastic sealing elements in the connector are made of nitrile rubber.

[0013] Preferably, the first main sealing ring and the inner wall of the plug housing are interference fit, with an interference amount of 0.03 mm to 0.07 mm, preferably 0.05 mm.

[0014] Preferably, the mating end faces of the socket insulator assembly and the pin insulator assembly are both of two stepped cylindrical surface configurations with different diameters.

[0015] Preferably, the tail sealing assembly includes a tail sleeve, and the tail sleeve and the tail end of the plug housing are radially sealed by two parallel tail sealing rings with a hardness of 90.

[0016] Preferably, the inner wall of the tail end of the square housing is provided with an annular groove, and the pin insulator assembly is axially limited by a retaining spring.

[0017] Preferably, the outer surface of the square housing is provided with an annular marking line to indicate whether the connecting nut is tightened properly.

[0018] Secondly, a method for mating the aforementioned deep-water high-voltage, high-current connector is provided, characterized by comprising the following steps: Align the key on the plug housing with the keyway on the square housing; Push the plug into the socket axially, then rotate the connecting nut to engage its internal thread with the external thread of the square housing; Continue rotating the connecting nut until its end face or designated reference edge is aligned with the annular mark line on the square disc housing. This indicates that the mating locking force has reached the preset value, the sealing ring is in the optimal compression state, and the mating is complete.

[0019] Beneficial effects: Compared with the prior art, the beneficial effects of the present invention are as follows: This invention, through the synergistic effect of multi-dimensional innovative designs such as high-hardness sealing rings, precision interference tolerances, stepped insulator structures, and inlaid molding processes, integrates for the first time three extreme performance indicators—underwater depth of 6000 meters (withstanding pressure of 65MPa), 12.5kVDC withstand voltage, and 50A current carrying capacity—into a single connector, thus resolving a long-standing technical contradiction.

[0020] Employing nitrile rubber sealing rings with a hardness of 90, combined with a precision interference fit of 0.05mm, the sealing rings maintain sufficient structural strength to resist compression under the ultra-high hydrostatic pressure of the deep sea, while also generating sufficient elastic deformation to fill microscopic gaps. Multiple seals form a redundant barrier, resulting in reliability far exceeding that of traditional underwater connectors using sealing rings with conventional hardness.

[0021] The innovative two-stage stepped insulator mating surface design cleverly extends the surface creepage distance between the high-voltage conductor and the grounding shell without increasing the overall diameter of the connector, thus meeting the stringent insulation distance requirements of 12.5kVDC high voltage within a limited cylindrical space.

[0022] The key and keyway anti-misfit design ensures accurate docking even in low-visibility conditions like the deep sea or when operated by a robotic arm. Marking lines on the outer casing provide a visual indication of reliable locking. The removable design of the insulator assembly facilitates inspection and maintenance, reducing total lifecycle costs.

[0023] The housing is made of 316L stainless steel, providing excellent resistance to seawater corrosion and stress corrosion cracking, ensuring the structural integrity of the connector during long-term deep-sea service. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the axial cross-sectional structure of the plug in an embodiment of the present invention; Figure 2 This is a three-dimensional structural diagram of the plug in an embodiment of the present invention; Figure 3 This is a schematic diagram of the axial cross-sectional structure of the socket in an embodiment of the present invention; Figure 4 This is a three-dimensional structural diagram of the socket in an embodiment of the present invention; In the diagram: 101-Plug housing, 102-Socket insulator assembly, 103-First clamping nut, 104-First main sealing ring, 105-Tail sleeve, 106-Tail sealing ring, 107-Tail clip, 108-Tail nut, 109-Conductive socket, 110-Connecting nut, 111-Key, 112-Clamping washer; 201-Square housing, 202-Pin insulator assembly, 203-Second clamping nut, 204-Second main sealing ring, 205-Equipment mounting sealing ring, 206-Snap ring, 207-Annular clamping washer, 208-Mating end sealing ring, 209-Keyway, 210-Marking line, 211-Conductive pin. Detailed Implementation

[0025] The embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0026] The following specific examples illustrate the implementation of this application. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. This application can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this application. It should be noted that, in the absence of conflict, the following embodiments and features in the embodiments can be combined with each other. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0027] It should be noted that, unless otherwise defined, the technical or scientific terms used in this invention should have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms "first," "second," and similar words used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Words such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects.

[0028] Please see Figures 1 to 4 This invention provides a deep-sea high-voltage, high-current connector, which consists of two main components: a detachable plug and a socket.

[0029] like Figure 1 , Figure 2As shown, the plug includes a plug housing 101. In this embodiment of the invention, the plug housing 101 is made of 316L stainless steel, possessing excellent seawater corrosion resistance and high strength. At least two axially extending protruding keys 111 are uniformly provided on the outer periphery of the mating end of the plug housing 101. A socket insulator assembly 102 is installed inside the plug housing 101. This socket insulator assembly 102 is integrally molded using an inlay molding process. Specifically, multiple conductive sockets 109 made of copper alloy are precisely inlaid and positioned, and then high-performance insulating engineering plastic (such as PEEK) is injected under high temperature and pressure to encapsulate and mold them, thereby firmly bonding the conductive sockets 109 and the insulator into a single unit, ensuring the stability of the electrical connection and mechanical strength.

[0030] The mating end face of the socket insulator assembly 102 is designed as a stepped cylindrical surface with two sections of different diameters, namely a first cylindrical section with a larger diameter and a second cylindrical section with a smaller diameter, forming an annular stepped surface between them. This unique stepped structure can significantly extend the surface creepage distance between the high-voltage conductor (socket) and the grounding shell without increasing the overall radial dimension of the connector, which is a key design feature to meet the insulation requirements of high voltage (12.5kVDC).

[0031] An annular groove is machined on the outer circumferential surface of the socket insulator assembly 102, and a first main sealing ring 104 is fitted inside the groove. The first main sealing ring 104 is made of nitrile rubber with a hardness of 90. The fit between the sealing ring and the inner wall of the plug housing 101 is an interference fit, preferably controlled within the range of 0.03 mm to 0.07 mm, with an optimal value of 0.05 mm. This combination of high hardness and precise interference ensures that under extremely high hydrostatic pressure (65 MPa) in the deep sea, the sealing ring can provide sufficient support strength to resist extrusion deformation, while also generating sufficient elastic rebound force to tightly fill all microscopic gaps, forming a reliable first radial sealing barrier.

[0032] A first clamping nut 103 is screwed into the socket insulator assembly 102 via a threaded connection, and a clamping washer 112 is provided between the socket insulator assembly 102 and the first clamping nut 103. The function of the first clamping nut 103 is to axially fix the socket insulator assembly 102 to prevent axial movement during insertion, removal or under pressure, and at the same time provide a stable pre-compression force for the first main sealing ring 104.

[0033] The plug also includes a tail sealing assembly. This assembly mainly includes a tail sleeve 105 fitted onto the tail end of the plug housing 101. Two tail sealing rings 106 are installed side-by-side between the tail sleeve 105 and the inner wall of the tail end of the plug housing 101. It is understood that the number of tail sealing rings can be greater than two; under permissible conditions, the number of tail sealing rings can be increased to improve the sealing effect. These two sealing rings are also made of nitrile rubber with a hardness of 90. Together, they constitute a second radial seal at the cable entry point, effectively preventing seawater intrusion from the tail. In this embodiment of the invention, a tail clip 107 and a tail nut 108 are also provided at the end of the tail sleeve 105 (away from the mating end). The overall tail structure is designed with a vulcanized shape, allowing for vulcanization treatment with the cable sheath, further enhancing the sealing reliability and tensile strength at this location.

[0034] In addition, a connecting nut 110 is rotatably fitted onto the outside of the mating end near the plug housing 101. The inner wall of the connecting nut 110 is machined with internal threads.

[0035] like Figure 3 , Figure 4 As shown, the socket includes a square housing 201; in this embodiment of the invention, the square housing 201 is also made of 316L stainless steel. The inner wall of the front end (mating end) of the square housing 201 is machined with keyways 209, the same number as the number of plug keys 111, and whose positions and shapes completely correspond. The cooperation between the keys 111 and the keyways 209 achieves precise positioning of the plug and socket in the circumferential direction, providing a clear anti-misinsertion function and ensuring accurate docking during operation in the dark environment of the deep sea.

[0036] Inside the square housing 201, a pin insulator assembly 202 is installed. This assembly is also manufactured using an inlay molding process. It contains conductive pins 211 corresponding to the conductive sockets of the plug, and its mating ends are designed with a stepped cylindrical surface to match the plug structure and ensure sufficient creepage distance. The outer periphery of the pin insulator assembly 202 is sealed to the inner wall of the square housing 201 by a second main sealing ring 204, which is also made of nitrile rubber with a hardness of 90. A second clamping nut 203 is screwed in to axially fix the pin insulator assembly 202.

[0037] To further enhance the fixation of the pin insulator assembly, an annular retaining circlip groove is provided on the inner wall of the tail end of the square housing 201, and a retaining circlip 206 is installed thereon. The retaining circlip 206 engages in the groove, providing auxiliary axial restraint for the pin insulator assembly 202 and preventing it from loosening under extreme operating conditions.

[0038] The square housing 201 is designed with a flange structure, which facilitates its secure installation on the panel of the deep-sea equipment using screws. On the back of the flange, an equipment mounting sealing ring 205 (usually a rubber O-ring) is fitted to achieve a static waterproof seal between the socket and the equipment panel.

[0039] External threads are machined on the outer periphery of the square housing 201 for engaging with the connecting nut 110 of the plug. A clear annular marking line 210 is provided on the housing surface behind the external threads. This marking line visually indicates the final tightening position of the connecting nut 110.

[0040] The socket also includes an annular compression pad 207 (which may be made of elastic materials such as fluororubber) and a mating end sealing ring 208 for sealing the mating joint. When the connecting nut 110 is tightened to fully mate the plug and the socket, the front end face of the plug housing 101 presses against the annular compression pad 207 to form an end face seal.

[0041] Connection method and working principle: The docking process of the connector described in this embodiment of the invention is as follows: First, align the key 111 on the front end of the plug housing 101 with the key groove 209 on the socket housing 201 and insert it to complete the initial guidance and prevent misinsertion.

[0042] Then, rotate the connecting nut 110 clockwise so that its internal thread engages with the external thread on the square housing 201. As the tightening process proceeds, the plug is gradually pulled toward the socket.

[0043] When the front face (or other designated reference edge) of the connecting nut 110 is aligned with the marking line 210 on the surface of the square housing 201, the preset mating locking torque has been reached. Tightening should be stopped immediately to complete the mating process. At this point, the entire connector is in its optimal working condition, specifically as follows: Multiple sealing mechanisms are in place: the inner wall of the plug housing 101 strongly compresses the first main sealing ring 104, forming a core radial dynamic seal. The front end face of the plug housing 101 tightly presses against the annular compression pad 207, forming a reliable metal-elastomer end face seal. The mating end sealing ring 208 is compressed. These three elements together form a redundant sealing system at the plug-socket mating interface. At the same time, the tail sealing ring 106 at the tail end and the equipment mounting sealing ring 205 at the equipment interface ensure static sealing on the cable side and the equipment side, respectively. With the guarantee of high hardness (90) material and precise tolerance (0.05mm interference), these five sealing lines can withstand the extreme hydrostatic pressure of 6000 meters (approximately 65MPa) underwater for a long time, ensuring that the internal cavity is absolutely dry.

[0044] High-voltage insulation is achieved through the synergistic effect of the two-stage stepped mating structure of the socket insulator assembly 102 and the pin insulator assembly 202, which maximizes the creepage distance between the conductor and the housing. This design cleverly resolves the contradiction between the "compact structure" of the deep-sea connector and the "need for distance in high-voltage insulation," enabling it to stably withstand a 12.5kVDC withstand voltage test without the risk of breakdown or flashover.

[0045] Reliable high-current transmission: The inlay molding process ensures high-precision positioning and a firm connection between the conductive pins / holes and the insulator, providing a low-resistance, high-stability electrical path. Optimized current-carrying cross-sectional area and contact design enable the connector to withstand a rated current of 50A for extended periods with controllable temperature rise.

[0046] Reliable and convenient operation: The design of key 111 and keyway 209 eliminates the possibility of mis-insertion; the marking line 210 provides a clear and visual signal of locking completion, avoiding the risk of insufficient sealing due to under-tightening or damage to components due to over-tightening, and greatly improving the reliability and efficiency of operation in complex underwater environments.

[0047] Long-term reliable maintenance: All insulator components are secured with clamping nuts and are removable. This design allows for the testing, replacement, or maintenance of core components without scrapping the entire connector, significantly reducing total life-cycle costs.

[0048] In summary, the connector of this invention systematically integrates and solves three major technical challenges in the deep-sea environment—extreme pressure sealing, high-voltage insulation, and high-current transmission—through a series of innovative structural, material, and process designs. It achieves superior performance in three aspects: deep water (6000 meters / 65MPa), high voltage (12.5kVDC), and high current (50A), providing a highly reliable power interface solution for all-deep-sea operations.

[0049] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, various modifications and variations can be made to the embodiments of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A deep-sea high-voltage, high-current connector, comprising a plug and a socket, characterized in that: The plug includes a plug housing (101), a socket insulator assembly (102) installed in the housing, and a first clamping nut (103) for axially fixing the socket insulator assembly. The socket insulator assembly (102) is integrally formed by an inlay molding process, and a first main sealing ring (104) is provided on its outer periphery. The hardness of the first main sealing ring (104) is 90. The socket includes a square housing (201), a pin insulator assembly (202) installed in the housing, and a second clamping nut (203) for axially fixing the pin insulator assembly. The plug housing (101) has a key (111) at the mating end, and the square housing (201) has a keyway (209) that mates with the key (111). The plug also includes a connecting nut (110), which is rotatably fitted onto the outside of the plug housing (101) and can be screwed into the corresponding thread on the outer periphery of the square housing (201).

2. The deep-sea high-voltage high-current connector according to claim 1, characterized in that: Both the plug housing (101) and the square housing (201) are made of 316L stainless steel.

3. The deep-sea high-voltage high-current connector according to claim 1, characterized in that: The first main sealing ring (104) is made of nitrile rubber.

4. The deep-sea high-voltage high-current connector according to claim 1, characterized in that: The first main sealing ring (104) and the inner wall of the plug housing (101) are interference fit, with an interference amount of 0.03 mm to 0.07 mm.

5. The deep-sea high-voltage high-current connector according to claim 1, characterized in that: The mating end face of the socket insulator assembly (102) is a stepped cylindrical surface with two different diameters.

6. The deep-sea high-voltage high-current connector according to claim 1, characterized in that: The plug also includes a tail sealing assembly, which includes a tail sleeve (105) fitted onto the tail end of the plug housing (101), and the tail sleeve (105) and the plug housing (101) are sealed by at least two tail sealing rings (106) with a hardness of 90.

7. The deep-sea high-voltage high-current connector according to claim 1, characterized in that: The inner wall of the tail end of the square housing (201) is provided with a retaining ring groove, and the retaining ring (206) is used to axially limit the pin insulator assembly (202).

8. The deep-sea high-voltage high-current connector according to claim 1, characterized in that: The outer surface of the square housing (201) is provided with a marking line (210) for indicating whether the connecting nut (110) is tightened in place.

9. The deep-sea high-voltage high-current connector according to claim 1, characterized in that: The socket also includes an annular compression pad (207) disposed inside the square housing (201); when the connecting nut (110) is tightened to make the plug and the socket fully connected, the front end face of the plug housing (101) presses against the annular compression pad (207) to form an end face seal.

10. A method for mating a deep-sea high-voltage, high-current connector as described in any one of claims 1-9, characterized in that, Includes the following steps: Align the key (111) on the plug housing (101) with the keyway (209) on the square housing (201); Rotate the connecting nut (110) to engage with and tighten it on the square housing (201); Observe the marking line (210) on the square housing (201). When the designated part of the connecting nut (110) reaches the position of the marking line (210), stop tightening and complete the docking.

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