Integrated clamping wire-to-row electric connector

Abstract

The invention discloses an integrated clamping wire-to-row electric connector, relates to the technical field of electric connectors, and solves the problem that mechanical damage and chemical corrosion are easy to occur when a flexible wire is switched to a rigid flat cable in the prior art. The cable comprises a wire and a flat cable, the wire and the flat cable are welded into an integrated structure, a wire bar welding portion of the wire and the flat cable is sleeved with a sheath body, the wire is sleeved with a wire sealing plug, and the flat cable is provided with a flat cable sealing plug. The wire sealing plug and the flat cable sealing plug are located on the two sides of the wire row welding portion of the wire and the flat cable and matched with the sheath body to form a sealing cavity for sealing the wire row connecting portion, one end of the sheath body is provided with a wire tail clamp used for limiting the wire sealing plug, and the other end of the sheath body is provided with a flat cable tail clamp used for limiting the flat cable sealing plug. The wire is fixedly connected with the flat cable, reliable switching between the flexible wire and the rigid flat cable is realized, the welding spot is sealed in the sheath, fully-closed protection is carried out on the welded welding spot, and the influence of mechanical damage and chemical corrosion is avoided.

Description

Technical Field

[0001] This invention relates to the field of electrical connector technology, and in particular to an integrated card-mounted wire-to-wire electrical connector. Background Technology

[0002] In power distribution, automotive electronics, and high-power electrical equipment, ribbon cables are widely used due to their excellent conductivity, high mechanical strength, and cost advantages. Especially in the field of new energy vehicles, where the demand for high-current charging is increasing, the application of aluminum ribbon cables has gradually become one of the effective solutions for automakers to reduce costs and increase efficiency in high-current connections. However, due to space constraints on vehicle platforms and assembly sequences, the application of aluminum ribbon cables in high-current automotive wiring harnesses is limited because the rigidity of all-aluminum ribbon cable harnesses is much greater than that of traditional wires, making them difficult to bend. However, a rigid-flexible combination solution that reliably transfers flexible wires to rigid ribbon cables (i.e., "wire-to-ribbon") significantly lowers the barrier to ribbon cable application. However, the corresponding ribbon cable fixing and connection point protection solutions are significantly lagging behind, restricting the engineering application and reliability of this technology.

[0003] In existing technologies, the connection and fixation of line-to-bus connectors mostly adopts screw locking: by drilling through holes at the end of the cable, crimping or welding open terminals to the conductor ends, and then connecting the aluminum bus and conductors together with screws and nuts. This method has obvious drawbacks: First, drilling holes in the cable weakens its effective current-carrying cross-section and creates stress concentration around the holes, which may cause cracking at the openings during long-term operation or vibration; second, the installation process is cumbersome, and the crimping or welding of terminals to the conductor ends and the subsequent bolting process are inefficient; third, if the cable is used as an aluminum bus, the copper-aluminum interface is still a macroscopic physical contact between two materials, which is susceptible to mechanical damage and chemical corrosion.

[0004] The aforementioned fixing methods reveal a core problem: they are all "passive" mechanical fixations separated from electrical connection functions, and the attenuation of bolt torque significantly impacts the reliability of electrical performance. Existing solutions cannot provide adequate contact for busbar connections.

[0005] 1. Reliable electrical connection performance: Under the impact of environmental thermal shock, as well as vibration during vehicle operation and wire movement on the bolt fastening torque, torque attenuation will lead to a gradual deterioration of connection resistance.

[0006] 2. Integrated sealing protection: to isolate air and moisture and prevent electrochemical corrosion, the bolt fastening brings additional openings that are not directly necessary.

[0007] 3. Convenient installation experience: Enables quick positioning and secure fixing of cabling, simplifying the final assembly process.

[0008] Therefore, there is an urgent need in this field for an innovative fixing structure that not only eliminates the drawbacks of drilling and screwing, but also integrates the fixing of the ribbon cable with the sealing and protection of the connection point, forming a highly reliable and highly integrated "wire-to-ribbon" adapter solution. Developing an efficient and highly reliable clamping fixing structure has become crucial for promoting the widespread application of wires and ribbon cables in the new energy vehicle industry. Summary of the Invention

[0009] To address the shortcomings in the aforementioned background technology, this invention proposes an integrated card-mounted wire-to-bus connector, which solves the problem of mechanical damage and chemical corrosion that easily occur when flexible wires are transferred to rigid cables in the prior art.

[0010] The technical solution of the present invention is implemented as follows: An integrated card-mounted wire-to-bus connector includes a wire and a busbar. The wire and the busbar are welded into an integral structure. A sheath body is provided over the welded portion of the wire and the busbar. A wire sealing plug is provided on the wire, and a busbar sealing plug is provided on the busbar. The wire sealing plug and the busbar sealing plug are located on both sides of the welded portion of the wire and the busbar and cooperate with the sheath body to form a sealing cavity for sealing the welded portion of the busbar. One end of the sheath body is provided with a wire tail clip for limiting the wire sealing plug, and the other end of the sheath body is provided with a busbar tail clip for limiting the busbar sealing plug.

[0011] A further preferred embodiment has a PLR inside the sheath body.

[0012] In a further preferred embodiment, the PLR ​​includes a substrate, a circular hole in the center of the substrate that mates with a wire, and baffles symmetrically arranged on both sides of the circular hole on the limiting surface of the substrate. The baffles are provided with baffle springs and support ribs.

[0013] More preferably, the ribbon cable includes a ribbon cable conductor, a ribbon cable sheath is provided on the ribbon cable conductor, a ribbon cable welding part is provided at the end of the ribbon cable conductor for welding with the wire, grooves are provided on both sides of the ribbon cable welding part, a positioning surface is provided on the side of the groove near the end face of the ribbon cable, and a ribbon cable guide surface is provided on both sides of the end face of the ribbon cable.

[0014] In a further preferred embodiment, the sheath body is provided with a conductor sealing part, a wire transition part and a wire sealing part in sequence, and the sheath body is also provided with a retaining part located inside the wire transition part. The wire transition part is also provided with a wire stop surface that mates with the end face of the wire.

[0015] In a further preferred embodiment, the retaining part includes a snap-fit ​​tongue, one side of which forms a support cavity with the inner wall of the sheath body, and the other side of the snap-fit ​​tongue facing the central axis of the sheath body is provided with a boss.

[0016] More preferably, the wire sealing part includes a wire sealing cavity, and a sealing end face II is provided inside the wire sealing cavity; the cable sealing part includes a cable sealing cavity, and a sealing end face I is provided inside the cable sealing cavity.

[0017] In a further preferred embodiment, the outer wall of the sheath body is provided with a sheath mounting platform I that cooperates with the cable tail clip and a sheath mounting platform II that cooperates with the conductor tail clip. Two side ribs are symmetrically arranged between sheath mounting platform I and sheath mounting platform II, and the two side ribs form a side groove with the sheath body. Two limiting ribs are also symmetrically arranged on the outer wall side adjacent to the outer wall side where the sheath body and the side ribs are located, and the two limiting ribs cooperate with the sheath body to form a slot.

[0018] In a further preferred embodiment, the cable end clip is provided with a end clip ring groove, and the cable end clip is provided with a end clip spring tongue I that engages with the sheath mounting platform I; the conductor end clip is provided with a end clip round groove, and the conductor end clip is provided with a end clip spring tongue II that engages with the sheath mounting platform II.

[0019] More preferably, the wire includes a wire conductor, the wire conductor is covered with a wire sheath, and the end of the wire conductor is provided with a wire welding part that is welded to the ribbon cable welding part.

[0020] The beneficial effects of this invention are as follows: This invention achieves welding connection between conductors and ribbon cables, and realizes rapid fixing of ribbon cables through a snap-fit ​​design, sealing the solder joints within the sheath, thereby improving the reliability and durability of the connection. It achieves efficient and reliable transfer between flexible conductors and rigid ribbon cables. The overall structure eliminates the drawbacks of traditional screw locking, and has advantages such as rapid assembly, stable fixing, and strong adaptability. Through the integrated welding design and the sealing structure combining the sealing plug, sheath, and tail clip, the stability of current transmission and sealing reliability are improved, avoiding problems such as weakening of the current-carrying cross-section and torque attenuation. The snap-fit ​​spring and PLR work together to achieve dual locking, combined with a multi-position installation structure, taking into account rapid assembly, stable fixing, and scene adaptability. The overall integration is high and the vibration resistance is strong. Attached Figure Description

[0021] To more clearly illustrate the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the structure of the present invention;

[0023] Figure 2 This is a schematic diagram of the wire bar welding part of the present invention;

[0024] Figure 3 This is a cross-sectional view of the main body of the sheath of the present invention;

[0025] Figure 4 This is a schematic diagram of the structure of the PLR ​​of the present invention;

[0026] Figure 5 This is a schematic diagram of the fixing and side fixing of the wire-to-bus connector bracket in this invention.

[0027] In the diagram: 1. Sheath body; 11. Cable sealing part; 111. Cable sealing cavity; 112. Sealing end face I; 12. Holding part; 13. Cable transition part; 18. Cable stop surface; 14. Conductor sealing part; 141. Conductor sealing cavity; 142. Sealing end face II; 15. Support cavity; 16. Clip-on spring; 161. Boss; 10. Sheath mounting platform II; 19. Sheath mounting platform I; 101. Side rib; 102. Limiting rib; 103. Side groove; 104. Slot; 2. Conductor; 21. Conductor sheath; 22. Conductor; 23. 3. Wire welding part, 31. Wire tail clip, 32. Tail clip round groove, 33. Tail clip spring tongue II, 4. Wire sealing plug, 5. PLR, 51. Base plate, 52. Round hole, 53. Baffle, 531. Support rib, 532. Baffle spring tongue, 54. Limiting surface, 6. Ribbon cable, 61. Ribbon cable sheath, 62. Ribbon cable conductor, 63. Ribbon cable welding part, 64. Ribbon cable end face, 65. Ribbon cable guide surface, 66. Groove, 661. Stop surface, 7. Ribbon cable tail clip, 71. Tail clip ring groove, 72. Tail clip spring tongue I, 8. Ribbon cable sealing plug, 9. Wire strip welding part. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] like Figure 1As shown in Embodiment 1, the integrated card-mounted wire-to-bus connector includes a wire 2, a busbar 6, a sheath body 1, a wire sealing plug 4, a busbar sealing plug 8, a wire tail clip 3, and a busbar tail clip 7. The wire 2 is made of flexible copper wire, and the busbar 6 is made of rigid aluminum busbar. The two are ultrasonically welded to form an integrated structure. The welded portion 9 of the busbar is the core area for current transmission. Employing a single-cavity welding process, compared to traditional multi-cavity segmented welding, the welding operation is concentrated within a single sealed cavity containing the wire strip welding section 9. This eliminates the need for individual positioning and welding of multiple cavities, resulting in higher welding positioning accuracy, a simplified operation process, and significantly improved welding efficiency. Simultaneously, the single-cavity welding structure allows for seamless welding of the conductor 2 and the ribbon cable 6 without cavity space limitations. It can flexibly accommodate conductors 2 and ribbon cables 6 with different diameters and cross-sectional areas, eliminating the need to replace adapter components due to cavity specifications. This greater structural flexibility meets diverse electrical connection adaptation needs. Furthermore, the integrated single-cavity sealing design ensures the welded joint is completely enclosed and sealed, reducing weak points compared to multi-cavity welding and simultaneously improving the overall integrity and reliability of the sealing protection. The sheath body 1 has a hollow cylindrical structure and is fitted onto the outside of the wire strip welding section 9, providing basic protection and an installation carrier for the welded joint. The conductor sealing plug 4 and the ribbon cable sealing plug 8 are respectively fitted onto the conductor 2 and the ribbon cable 6, and are distributed on both sides of the wire strip welding section 9. When the conductor sealing plug 4 and the cable sealing plug 8 are attached to the inner wall of the sheath body 1, the three together form a closed sealing cavity, and the cable welding part 9 is completely placed in the sealing cavity, thus achieving preliminary sealing protection for the welding joint.

[0030] The sheath body 1 is fitted with a wire tail clip 3 and a cable tail clip 7 at both ends, which are fixed to the sheath body 1 by a snap-fit ​​structure. The wire tail clip 3 is fitted outside the wire 2, and its inner wall fits tightly against the wire sheath 21, which can restrict the wire sealing plug 4 from moving axially along the wire 2; similarly, the cable tail clip 7 is fitted outside the cable 6, which restricts the axial displacement of the cable sealing plug 8, thereby ensuring the stability of the sealing cavity. This design abandons the cumbersome structure of traditional screw-locked wire-to-cable connectors, improves the stability of current transmission through a welded integrated structure, and achieves integrated sealing protection of the welded joint by using the combination structure of the sealing plug, sheath, and tail clip. This avoids the problems of reduced current-carrying cross-section and torque attenuation caused by bolt locking in traditional structures. Moreover, the overall structure has a high degree of integration, laying the foundation for subsequent rapid snap-fit ​​assembly.

[0031] like Figure 1As shown in Embodiment 2, the integrated card-mounted wire-to-line connector, based on Embodiment 1, adds a PLR5 inside the sheath body 1. This PLR5 is fitted onto the wire 2 and completely located within the cavity of the wire tail clip 3. Its axial position is limited by the cooperation between the wire tail clip 3 and the sheath body 1, preventing it from moving axially along the wire 2. A circular hole 52, matching the outer diameter of the wire 2, is opened at the center of the PLR5. During assembly, the wire 2 passes through this hole 52, keeping the PLR5 and wire 2 relatively fixed. Simultaneously, one side of the PLR5 is in contact with the end face of the wire sealing plug 4, providing axial support and further improving the sealing stability of the plug. The PLR5 achieves a dual function: firstly, it accurately positions the relative position of the wire 2 and the sheath body 1, preventing the wire 2 from shifting due to its flexibility and causing stress on the welded joint; secondly, it provides rigid support for the wire sealing plug 4, preventing deformation and failure under vibration, and also provides an installation base for the subsequent secondary locking structure, improving the overall structure's holding power.

[0032] like Figure 4 As shown, in a preferred embodiment, the PLR5 includes a substrate 51 and baffles 53. The substrate 51 is a rectangular plate with a circular hole 52 in its center. The inner diameter of the hole 52 is clearance-fitted with the outer diameter of the wire sheath 21 of the wire 2, ensuring that the wire 2 passes through smoothly while avoiding excessive relative wobbling. The limiting surface 54 of the substrate 51 is the end face facing the inside of the sheath body 1. Two baffles 53 are symmetrically arranged on this end face, located on both sides of the circular hole 52 and integrally formed perpendicularly to the substrate 51. Each baffle 53 has two parallel supporting ribs 531, which can improve the bending strength of the baffle 53. The free end of the baffle 53 has an inwardly inclined baffle spring tongue 532, which has a certain elastic deformation capability, making it easy to embed into the corresponding structure during assembly. The precise positioning of PLR5 and wire 2 is achieved through the cooperation of base plate 51 and circular hole 52. The support rib 531 on baffle 53 strengthens the structural rigidity and prevents baffle 53 from breaking under vibration. The elastic structure of baffle spring tongue 532 provides a structural basis for secondary locking, so that PLR5 not only has positioning function, but can also participate in the locking and fixing of the overall structure, improving connection reliability.

[0033] As another preferred embodiment, the PLR5 has a split structure, consisting of two or more substrates, with baffles installed on the corresponding substrates of the PLR5. The split structure effectively disperses stress, improves structural reliability under vibration conditions, and facilitates later maintenance and replacement, reducing maintenance costs and operational complexity. Its flexible adaptability and expandability allow for the design of different specifications of wires and connectors. It significantly improves assembly tolerance and spatial adaptability. The separate configuration of the substrates and baffles achieves functional modularity and synergistic reinforcement. The positioning and support functions of the PLR ​​are distributed to two or more substrates, each of which can be designed differently according to stress requirements. Multiple substrates work together to form multi-point radial positioning and axial support for the wire 2, resulting in more precise positioning and more stable support compared to a single-substrate integrated structure.

[0034] All other structures are the same as in Example 1.

[0035] like Figure 2 As shown in Embodiment 3, the integrated card-mounted wire-to-bus connector, based on Embodiment 2, includes a bus 6 comprising a conductor 62 and a sheath 61. The conductor 62 is preferably made of aluminum, and the sheath 61 is preferably made of PVC, serving as insulation and protection. A portion of the sheath 61 is removed from the end of the conductor 62, exposing a welding portion 63 for easy welding to the conductor welding portion 23. Symmetrical grooves 66 are formed on both sides of the welding portion 63. The grooves 66 are trapezoidal, with a stop surface 661 on the side of the groove 66 closest to the end face 64 of the bus 63. The stop surface 661 is perpendicular to the center plane of the bus 63, forming a planar contact structure. The end face 64 is the free end face of the welding portion 63, with chamfers on both sides forming a guide surface 65. The chamfer angle is preferably 30 degrees, facilitating the embedding of the bus 6 into the sheath body 1. The trapezoidal groove 66 and the stop surface 661 are designed to precisely match the clamping structure of the sheath body 1, achieving axial positioning of the ribbon cable 6. The ribbon cable guide surface 65 reduces the assembly difficulty of the ribbon cable 6 and the sheath body 1, enabling rapid positioning and assembly, while avoiding scratching the ribbon cable conductor 62 during assembly. Compared with the traditional open structure, it does not damage the integrity of the ribbon cable conductor 62, ensuring the current-carrying cross-section and structural strength. The conductor 2 includes a conductor 22 and a conductor sheath 21. The conductor 22 is a multi-strand copper wire stranded structure with a cross-sectional area adapted to the ribbon cable conductor 62 to ensure current transmission matching. The conductor sheath 21 is preferably made of flame-retardant material, covering the outside of the conductor 22, and has insulation, wear resistance, and high and low temperature resistance.

[0036] Specifically, part of the conductor sheath 21 is removed from the end of the conductor 22, exposing the conductor welding portion 23. This portion is tin-plated to improve welding wettability and oxidation resistance. During welding, the conductor welding portion 23 and the ribbon cable welding portion 63 are stacked and ultrasonically welded to form a strong weld joint, meeting the requirements of high current transmission. The multi-strand copper conductor 22 has good flexibility, which can adapt to the complex installation space inside new energy vehicles, forming a rigid-flexible connection solution with the rigid aluminum ribbon cable. The tin plating treatment of the conductor welding portion 23 improves welding reliability and corrosion resistance. Compared with traditional crimp terminal connections, it reduces intermediate connecting parts, lowers contact resistance, and reduces the risk of failure.

[0037] like Figure 3 As shown in Embodiment 4, the integrated snap-fit ​​wire-to-bus connector, based on Embodiment 3, has a wire sealing part 14, a busbar transition part 13, and a busbar sealing part 11 arranged axially inside the sheath body 1. These three parts are coaxially arranged and their inner cavities are interconnected, forming a complete assembly channel. The inner diameter of the wire sealing part 14 is interference-fitted with the outer diameter of the wire sealing plug 4 to ensure a sealing effect; similarly, the inner diameter of the busbar sealing part 11 is interference-fitted with the outer diameter of the busbar sealing plug 8 to achieve sealing at both ends. The busbar transition part 13 is located in the middle of the sheath body 1, and its inner diameter is slightly larger than the outer diameter of the busbar welding part 9, providing space for the welding joint. The retaining parts 12 are symmetrically arranged on the inner walls of both sides of the busbar transition part 13, integrally formed with the sheath body 1, and used to snap-fit ​​and fix the busbar 6. The busbar transition part 13 also has a busbar stop surface 18, which is an annular plane that fits against the busbar end face 64, restricting the busbar 6 from moving inward along the axial direction of the sheath body 1. The inner wall partition structure enables the sheath body 1 to simultaneously perform sealing, containment, fixing and limiting functions. The integrated molding structure improves the structural rigidity and sealing performance of the sheath body 1, avoiding weak sealing points caused by splicing multiple parts. The cooperation between the cable stop surface 18 and the cable end face 64 further strengthens the axial positioning of the cable 6, enabling the cable 6 to remain stable in a vibration environment and improving the vibration resistance of the overall connection.

[0038] In this embodiment, the retaining part 12 includes a snap-fit ​​spring 16, which is an elastic structure integrally formed on the inner wall of the sheath body 1. It adopts a cantilever beam design, has good elastic deformation capability, and can withstand the deformation stress of repeated assembly. A support cavity 15 is formed between one side of the snap-fit ​​spring 16 and the inner wall of the sheath body 1. The support cavity 15 is a rectangular cavity used to accommodate the baffle spring 532 of PLR5. A boss 161 is provided on the other side of the snap-fit ​​spring 16 facing the central axis of the sheath body 1. The boss 161 is a semi-circular structure that is adapted to the groove 66 of the ribbon cable 6.

[0039] During assembly, the ribbon cable 6 is pushed into the sheath body 1 along the ribbon cable guide surface 65. The ribbon cable welding part 63 presses the locking spring 16 to deform it towards the support cavity 15. When the ribbon cable end face 64 is in contact with the ribbon cable stop surface 18, the boss 161 is embedded in the groove 66, and the locking spring 16 is reset, realizing the locking and fixing of the ribbon cable 6. The boss 161 contacts the stop surface 661 to provide axial holding force. The cantilever beam locking spring 16 realizes the quick locking and fixing of the ribbon cable 6 without additional tools, and the assembly efficiency is improved compared with traditional screw locking. The precise fit between the boss 161 and the groove 66 ensures the reliability of locking. The support cavity 15 provides installation space for the secondary locking of the PLR5, so that the retaining part 12 has both the initial locking function and can work with the PLR5 to achieve double locking, improving the structural stability.

[0040] In this embodiment, the wire sealing part 14 includes a wire sealing cavity 141. The inner diameter of the wire sealing cavity 141 is adapted to the wire sealing plug 4 and can completely accommodate the sealing part of the wire sealing plug 4. A sealing end face II142 is provided inside the wire sealing cavity 141. This end face is an annular plane that fits against the end face of the wire sealing plug 4 to form an axial sealing surface, and at the same time limits the axial position of the wire sealing plug 4.

[0041] During assembly, one end of the wire sealing plug 4 is fitted with the sealing end face II142, and the other end is fitted with the end face of the base plate 51 of the PLR5, forming a bidirectional limiting in the axial direction. At the same time, the outer wall of the wire sealing plug 4 is interference-fitted with the inner wall of the wire sealing cavity 141, forming a radial seal, thus achieving an all-round seal between the wire 2 and the sheath body 1. The combined sealing structure of the axial sealing surface and the radial interference fit significantly improves the sealing performance between the wire 2 and the sheath body 1, effectively preventing air, moisture, and dust from entering the sealing cavity. The sealing end face II142 also has a limiting function, simplifying the structural design, avoiding the need for additional limiting components, and improving the integration of the sheath body 1.

[0042] In this embodiment, the cable sealing part 11 includes a cable sealing cavity 111, which is a cylindrical cavity at the other end of the sheath body 1. The inner diameter of the cavity is adapted to the cable sealing plug 8, and it can completely accommodate the sealing part of the cable sealing plug 8. A sealing end face I112 is provided inside the cable sealing cavity 111. This end face is an annular plane that fits against the end face of the cable sealing plug 8 to form an axial sealing surface, restricting the cable sealing plug 8 from moving into the sealing cavity. The outer wall of the cable sealing plug 8 is press-fitted with the inner wall of the cable sealing cavity 111 to form a radial seal. At the same time, after the cable tail clip 7 is assembled, its inner wall fits against the other end face of the cable sealing plug 8 to form an axial pressing force, further improving the sealing reliability and preventing the sealing plug from loosening under vibration. The sealing structure forms a symmetrical design with the sealing structure of the wire sealing part 14, ensuring the consistency of the sealing performance at both ends of the sheath body 1 and realizing the full-closure protection of the sealing cavity. The combination design of axial pressing and radial press-fit gives the sealing structure good vibration resistance.

[0043] like Figure 5 As shown in Embodiment 5, the integrated card-mounted cable-to-bus connector, based on Embodiment 4, has a sheath mounting platform I19 and a sheath mounting platform II10 on the outer wall of the sheath body 1. Both are annular protrusions, integrally formed with the sheath body 1, and are used to fix the cable tail clip 7 and the wire tail clip 3, respectively. The sheath mounting platform I19 is located at one end near the cable sealing part 11, and the sheath mounting platform II10 is located at one end near the wire sealing part 14. Two side ribs 101 are symmetrically arranged between them. The side ribs are rectangular protrusions, and the two side ribs 101 and the outer wall of the sheath body 1 enclose a side groove 103.

[0044] In this embodiment, two symmetrically arranged limiting ribs 102 are also provided on the outer wall of the sheath body 1. The limiting ribs are rectangular protrusions, and the two limiting ribs 102 and the outer wall of the sheath body 1 enclose a slot 104, which is adapted to the snap-fit ​​structure on the car body. The slot 104 and the side slot 103 have the same width and are symmetrically arranged along the central axis of the sheath body 1, so that adjacent connectors can achieve three installation postures: face-to-face, in the same direction, and back-to-back, that is, the distance between adjacent cables can be reduced from large to small. The sheath mounting structure provides a reliable fixing carrier for the tail clip, ensuring the stability of the tail clip after assembly; the design of the side slot and the slot allows multiple connectors to be quickly fixed, and the multi-posture installation function improves the adaptability of the connector to different vehicle installation environments, expands the application range, and significantly improves the installation flexibility compared to the traditional fixing structure.

[0045] One end face of the cable tail clip 7 is provided with a tail clip ring groove 71. The inner diameter of the tail clip ring groove 71 is interference-fitted with the outer diameter of the cable sheath 61, which can circumferentially limit the cable sheath 61 and prevent the cable 6 from rotating relative to the cable tail clip 7. The two sides of the cable tail clip 7 are provided with symmetrically arranged tail clip springs I72. The tail clip springs I72 are elastic protrusion structures that can be elastically deformed during assembly and embedded in the slot of the sheath mounting platform I19 to realize the fastening and fixing of the cable tail clip 7 and the sheath body 1, thereby restricting the movement of the cable sealing plug 8.

[0046] One end face of the wire tail clip 3 is provided with a tail clip groove 31. The inner diameter of the tail clip groove 31 is interference-fitted with the outer diameter of the wire sheath 21 to achieve circumferential limiting of the wire 2. The two sides of the wire tail clip 3 are provided with symmetrically arranged tail clip springs II 32, whose structure is the same as that of the tail clip spring I 72. During assembly, they are embedded into the slots of the sheath mounting platform II 10 to achieve the snap-fit ​​fixation between the wire tail clip 3 and the sheath body 1, restricting the movement of the wire sealing plug 4. The snap-fit ​​connection between the tail clip and the sheath body 1 enables quick assembly and disassembly, which is convenient for later maintenance. The tail clip ring groove 71 and the tail clip groove 31 respectively provide circumferential limiting of the ribbon cable 6 and the wire 2, preventing the wire and ribbon cable from twisting and causing stress on the welding joint. The symmetrical design of the double springs ensures the stability of the tail clip fixation, prevents the tail clip from loosening under vibration, and further ensures the reliability of the sealing structure.

[0047] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An integrated card-mounted wire-to-electrical connector, characterized in that, The device includes a conductor (2) and a ribbon cable (6). The conductor (2) and the ribbon cable (6) are welded together as a single structure. The ribbon cable weld (9) of the conductor (2) and the ribbon cable (6) is covered with a sheath body (1). The conductor (2) is covered with a conductor sealing plug (4). The ribbon cable (6) is covered with a ribbon cable sealing plug (8). The conductor sealing plug (4) and the ribbon cable sealing plug (8) are located on both sides of the ribbon cable weld (9) of the conductor (2) and the ribbon cable (6) and cooperate with the sheath body (1) to form a sealing cavity for sealing the ribbon cable weld (9). One end of the sheath body (1) is provided with a conductor tail clip (3) for limiting the conductor sealing plug (4), and the other end of the sheath body (1) is provided with a ribbon cable tail clip (7) for limiting the ribbon cable sealing plug (8).

2. The integrated card-mount wire-to-electric connector according to claim 1, characterized in that, The sheath body (1) is equipped with PLR (5).

3. The integrated card-mount wire-to-electric connector according to claim 2, characterized in that, The PLR ​​(5) includes a substrate (51), a circular hole (52) that mates with the wire (2) is provided in the middle of the substrate (51), and baffles (53) symmetrically arranged on both sides of the circular hole (52) are provided on the limiting surface (54) of the substrate (51). The baffles (53) are provided with baffle springs (532) and support ribs (531).

4. The integrated card-mount wire-to-disk connector according to any one of claims 1 to 3, characterized in that, The ribbon cable (6) includes a ribbon cable conductor (62), a ribbon cable sheath (61) is provided on the ribbon cable conductor (62), a ribbon cable welding part (63) is provided at the end of the ribbon cable conductor (62) to be welded to the wire (2), a groove (66) is provided on both sides of the ribbon cable welding part (63), a stop surface (661) is provided on the side of the groove (66) near the ribbon cable end face (64), and a ribbon cable guide surface (65) is provided on both sides of the ribbon cable end face (64).

5. The integrated card-mount wire-to-electrical connector according to claim 4, characterized in that, The sheath body (1) is provided with a conductor sealing part (14), a wire transition part (13) and a wire sealing part (11) in sequence. The sheath body (1) is also provided with a retaining part (12), which is located in the wire transition part (13). The wire transition part (13) is also provided with a wire stop surface (18) that cooperates with the wire end face (64).

6. The integrated card-mount wire-to-electrical connector according to claim 5, characterized in that, The retaining part (12) includes a snap-fit ​​tongue (16), one side of the snap-fit ​​tongue (16) forms a support cavity (15) with the inner wall of the sheath body (1), and the other side of the snap-fit ​​tongue (16) facing the central axis of the sheath body (1) is provided with a boss (161).

7. The integrated card-mount wire-to-electrical connector according to claim 6, characterized in that, The wire sealing part (14) includes a wire sealing cavity (141), and a sealing end face II (142) is provided inside the wire sealing cavity (141); the cable sealing part (11) includes a cable sealing cavity (111), and a sealing end face I (112) is provided inside the cable sealing cavity (111).

8. The integrated card-mount wire-to-disk connector according to claim 5, 6, or 7, characterized in that, The outer wall of the sheath body (1) is provided with a sheath mounting platform I (19) that cooperates with the cable end clip (7) and a sheath mounting platform II (10) that cooperates with the conductor end clip (3). There are two symmetrically arranged side ribs (101) between the sheath mounting platform I (19) and the sheath mounting platform II (10). The two side ribs (101) and the sheath body (1) form a side groove (103). The outer wall side adjacent to the outer wall side where the sheath body (1) and the side ribs (101) are located is also provided with two symmetrically arranged limiting ribs (102). The two limiting ribs (102) and the sheath body (1) cooperate to form a slot (104).

9. The integrated card-mount wire-to-electric connector according to claim 8, characterized in that, The cable end clip (7) is provided with a end clip ring groove (71), and the cable end clip (7) is provided with a end clip spring tongue I (72) that is engaged with the sheath hanging platform I (19); the conductor end clip (3) is provided with a end clip round groove (31), and the conductor end clip (3) is provided with a end clip spring tongue II (32) that is engaged with the sheath hanging platform II (10).

10. The integrated card-mount wire-to-disk connector according to claim 9, characterized in that, The wire (2) includes a wire conductor (22), the wire conductor (22) is covered with a wire sheath (21), and the end of the wire conductor (22) is provided with a wire welding part (23) that is welded to the wiring welding part (63).

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