An electric vehicle wire harness connector with a sealed state visualization function

Abstract

The application discloses a kind of electric vehicle wire harness connectors with sealing state visualization function, including male end shell, female end shell, sealing ring at the butt joint and internal signal terminal.Sealing ring is elastic complex, internally embedded with the electrochromic functional film layer integrally formed with it, which includes flexible net-like upper and lower electrodes, electrochromic active layer and hygroscopic swelling solid electrolyte layer stacked in turn;Female end shell is provided with special driving electrode, and the elastic contact terminal of flexible conductive lead end is only conducted with driving electrode to form electric field when butt joint.Electrochromic active layer is in first optical state when dry, and solid electrolyte layer swells to change ion mobility after water penetration, triggering electrochromic reaction to become second optical state that can be distinguished by naked eye.Sealing state visualization is realized, without special equipment, intuitive judgment, butt joint power on, separate power off, zero static power consumption, simple structure, improve maintenance efficiency and driving safety.

Description

Technical Field

[0001] This invention relates to the field of electrical connection components for electric vehicles, specifically to an electric vehicle wiring harness connector with a function for visualizing the sealing status. Background Technology

[0002] Electric vehicle wiring harness connectors are the core hub for signal and current transmission in a vehicle's electrical system, and their sealing performance directly determines the overall safety and reliability of the vehicle. Because electric vehicles often operate in complex and humid environments such as rain, wading, and high-pressure washing, the sealing rings at the interface between the male and female terminals are prone to aging, deformation, or assembly misalignment. This can lead to water seepage, causing short circuits, leakage, or even serious malfunctions such as limited power at the signal terminals, endangering driving safety.

[0003] The sealing rings of existing electric vehicle wiring harness connectors only provide basic sealing and cannot visually indicate their sealing status. When a seal fails and water seepage occurs, the initial amount of water seeping in is small and highly concealed, making it difficult to detect through visual inspection. Traditional methods for testing airtightness and liquid tightness require specialized equipment and can only be used during production sampling or troubleshooting. They cannot achieve real-time monitoring during vehicle operation, resulting in the potential for seal failure not being detected in time. This can easily lead to the escalation of the fault, increasing maintenance costs and safety risks.

[0004] Currently, there is no technical solution that can provide real-time feedback on the sealing status of the sealing ring through visualization during the operation of the connector. This cannot meet the high-precision and real-time monitoring requirements of electric vehicles for connector sealing reliability. Therefore, developing an electric vehicle wiring harness connector that can intuitively judge the sealing status and provide timely warnings of potential water leakage has become an urgent technical problem to be solved. Summary of the Invention

[0005] To address the shortcomings in the prior art, the present invention provides an electric vehicle wiring harness connector with a sealing status visualization function.

[0006] The technical solution adopted in this invention is: an electric vehicle wiring harness connector with a sealing status visualization function, including a male end shell, a female end shell, a sealing ring disposed at the joint of the male end shell and the female end shell, and a signal terminal disposed inside the male end shell and the female end shell. The sealing ring is an elastic composite with radial compression deformation capability, and an electrochromic functional film layer is embedded inside it. The electrochromic functional film layer and the sealing ring are co-vulcanized or co-injection molded into an integral structure.

[0007] The electrochromic functional film layer includes a lower electrode, an electrochromic active layer, a solid electrolyte layer and an upper electrode stacked in sequence. The lower electrode and the upper electrode are both flexible mesh conductive structures. The solid electrolyte layer is a gel-state ionic conductor with hygroscopic expansion characteristics, which maintains the electrochromic active layer in a stable state in a reduced or oxidized state under dry conditions.

[0008] The mating surface of the female end shell is provided with a dedicated driving electrode corresponding to the electrochromic functional film layer.

[0009] The dedicated driving electrode includes a first electrode and a second electrode. The first electrode is electrically connected to the positive terminal of the connector's operating voltage, and the second electrode is electrically connected to the negative terminal of the connector's operating voltage.

[0010] The flexible conductive leads on the flexible mesh conductive structure are provided with elastic contact terminals at their ends. The two elastic contact terminals are electrically connected to the first electrode and the second electrode respectively only when the connector is mated, and an electric field is formed between the upper electrode and the lower electrode.

[0011] When the sealing ring is in a dry and sealed state, the electrochromic active layer presents a first optical state; when water seeps into the sealing ring and liquid water penetrates into the solid electrolyte layer, the solid electrolyte layer undergoes local swelling and changes its ion mobility. Under the action of the electric field applied by the working voltage, the redox reaction of the electrochromic active layer is triggered, causing it to change from the first optical state to the second optical state, making the second optical state and the first optical state distinguishable to the naked eye.

[0012] Furthermore, the electrochromic functional film layer is divided into at least four independent detection areas, each detection area having an independent flexible mesh electrode and an independent flexible conductive lead, and the four detection areas respectively correspond to the four side walls of the female end shell, and the side walls of the female end shell are provided with observation windows for observing the sealing ring.

[0013] The solid electrolyte layers in each detection area are physically isolated from each other. When water seeps into the sealing part corresponding to a certain detection area, only the solid electrolyte layer in that area swells locally and triggers an electrochromic reaction, while other detection areas remain in their first optical state, thereby achieving precise circumferential positioning of the leak point.

[0014] Furthermore, the electrochromic active layer is a tungsten trioxide / polyaniline nanocomposite film, wherein the mass fraction of tungsten trioxide is 60%-80%, the mass fraction of polyaniline is 20%-40%, the film thickness is 1-3μm, and the porosity is controlled at 15%-30% to allow water molecule diffusion.

[0015] The solid electrolyte layer is a polyethylene oxide gel electrolyte containing lithium perchlorate, wherein the molar ratio of lithium perchlorate to polyethylene oxide is 1:8 to 1:12, the gel thickness is 40-60 μm, and the moisture absorption expansion rate is greater than 150%.

[0016] The lower electrode is an indium tin oxide conductive film, and the upper electrode is a porous gold electrode with a pore size of 50-200 nm and a porosity of 40%-60%, which is used to enhance the uniformity of the electric field and the permeation rate of water molecules.

[0017] Furthermore, one end of the male end housing is provided with an insertion section, and the outer wall of the insertion section is integrally provided with a clamping ring. One end of the female end housing is provided with a socket that is inserted and mated with the insertion section. The bottom wall of the socket is provided with an annular groove for embedding a sealing ring. The insertion section is inserted into the clamping ring, and the clamping ring presses and holds the sealing ring in the annular groove.

[0018] The outer walls on both sides of the clamping ring are provided with fitting bosses, and the side walls on both sides of the insertion hole are provided with fitting openings that match the fitting bosses.

[0019] The dedicated driving electrode is embedded in the bottom wall of the annular groove. When the clamping ring presses the sealing ring, the elastic contact terminal forms a reliable electrical contact with the dedicated driving electrode.

[0020] Furthermore, the sealing ring is an elastic composite with a gradient modulus structure, comprising, from the inside out:

[0021] Inner elastic matrix: made of silicone rubber or fluorosilicone rubber, with a Shore A hardness of 40-60;

[0022] Intermediate functional layer: The electrochromic functional film layer is embedded in this layer, and the mesh opening ratio of the flexible mesh electrode is greater than 70% to allow elastic deformation;

[0023] Outer hydrophobic barrier: composed of modified silicone rubber with a surface energy of less than 25 mN / m and a thickness of 0.1-0.3 mm, used to delay the penetration of liquid water and provide a response time window for the electrochromic reaction;

[0024] The inner elastic matrix, the middle functional layer, and the outer hydrophobic barrier are chemically bonded through a co-sulfurization process, ensuring that the electrical connection and optical properties of the electrochromic functional film remain stable within the radial compression deformation range of 20%-40% of the sealing ring.

[0025] Furthermore, the ionic conductivity and hygroscopic properties of the solid electrolyte layer are synergistically regulated by the lithium perchlorate concentration and the polyethylene oxide molecular weight to form a color change threshold with humidity gradient response characteristics.

[0026] When the sealing ring is slightly leaking, the seeping water forms a local low ion concentration area in the solid electrolyte layer, triggering the electrochromic active layer to exhibit the second optical state; when the sealing ring is severely leaking, the water completely wets the solid electrolyte layer, forming a high ion concentration area, triggering the electrochromic active layer to exhibit the third optical state.

[0027] The second and third optical states are different shades of the same color system or completely different color systems, thereby achieving a visual grading indication of the severity of water seepage.

[0028] Furthermore, it also includes an impedance monitoring circuit, which monitors the volume resistivity change of the solid electrolyte layer in real time through the flexible conductive lead;

[0029] When the solid electrolyte layer absorbs moisture and expands, causing its volume resistivity to decrease by more than 50%, the impedance monitoring circuit triggers an early warning signal from the vehicle system and sends a sealing status warning containing leakage location information to the vehicle controller via the wireless communication module, thus achieving redundant backup of visual indication and electronic monitoring.

[0030] The impedance monitoring circuit includes a microprocessor, a signal conditioning circuit, and a wireless communication module. The microprocessor determines the water leakage status by measuring the impedance change between the upper and lower electrodes. When the impedance value is lower than a preset threshold, it is determined to be a sealing failure.

[0031] Furthermore, the flexible conductive lead is a spiral or wavy extended structure with an elongation rate greater than 150% of the maximum working deformation of the sealing ring, ensuring the reliability of the electrical connection during connector insertion and removal and under vibration.

[0032] The elastic contact terminal is a gold-plated spring pin or a conductive elastomer. The elastic contact terminal is located on the inner wall of the sealing ring, with a contact stroke of 2-3 mm. Its contact pressure is 0.5-2 N when the connector is mated. It automatically disconnects the electrical connection when the connector is separated, thus preventing the electrochromic functional film from undergoing an undesirable electrochemical reaction when the connector is not in operation.

[0033] Furthermore, the flexible conductive leads corresponding to each detection area are coded with different resistance values ​​or different impedance characteristics. The impedance monitoring circuit distinguishes the signals of different detection areas by identifying the differences in the electrical characteristics of each lead, thereby realizing automatic identification and electronic reporting of the leakage location.

[0034] Furthermore, the electrochromic functional film layer is distributed in a continuous ring or in segments in the circumferential direction of the sealing ring. When the segmented distribution is adopted, the spacing between each segment is less than 5mm, ensuring that there are no blind spots in the leakage monitoring of the sealing ring in the entire circumference.

[0035] The first optical state of the electrochromic active layer is transparent or light gray, which has no significant impact on the appearance of the connector in a dry state; the second optical state is dark blue, dark purple or black, which forms a high-contrast visual warning in a water-permeable state.

[0036] The beneficial effects of this invention are:

[0037] 1. A visual indication of the sealing status has been implemented, improving maintenance efficiency.

[0038] By integrating an electrochromic functional film layer inside the sealing ring, when water seeps into the sealing ring, the moisture penetrates to the solid electrolyte layer, triggering a redox reaction in the electrochromic active layer, causing the sealing ring to change from transparent / light-colored (first optical state) to blue / dark-colored (second optical state). This color change is directly observable with the naked eye, without the need to disassemble the connector or use testing instruments, significantly improving the efficiency and convenience of checking the sealing condition and achieving a "one-click" maintenance experience.

[0039] 2. Zero power consumption when the connector is disconnected, reducing system energy consumption.

[0040] By incorporating flexible contact terminals at the ends of the flexible conductive leads, and ensuring these terminals only form an electrical connection with a dedicated drive electrode on the female housing when the connector is mated, a mechanical automatic switching on / off mechanism for the electrochromic circuit is achieved. When the connector is disconnected, the flexible contact terminals automatically disconnect from the dedicated drive electrode, completely de-energizing the electrochromic functional film layer, resulting in zero static power consumption. When the connector is mated, the electrical connection is automatically established through the insertion and removal action, eliminating the need for additional electronic switches or control circuits. This design eliminates long-term standby power consumption, which helps extend the driving range of electric vehicles.

[0041] 3. Directly utilizes the operating voltage for driving, simplifying the system architecture.

[0042] This invention utilizes the connector's normal operating voltage (12V or 48V) as the sole driving source for the electrochromic functional film layer (the driving electrode is electrically connected to the working circuit). An electric field is directly applied between the upper and lower electrodes through the first electrode (connected to the positive terminal) and the second electrode (connected to the negative terminal) of the dedicated driving electrode. This design eliminates the need for DC-DC conversion circuits, dedicated driving chips, or complex power management circuits, significantly reducing system complexity, cost, and potential failure points, while improving reliability.

[0043] 4. Adapts to sealing ring compression deformation, maintaining stable electrical connection.

[0044] By employing a flexible mesh conductive structure as the upper and lower electrodes, and using flexible conductive leads with a spiral or wavy extended structure, the electrochromic functional film can adapt to 20%-40% radial compression deformation of the sealing ring. The flexible mesh electrode has a mesh opening ratio of more than 70%, maintaining electrical continuity even under compression. The elongation of the flexible conductive leads is greater than 150% of the maximum working deformation of the sealing ring, ensuring reliable electrical connection during insertion / removal and under vibration conditions, thus solving the technical problem of rigid electrodes being prone to breakage under compression deformation.

[0045] In addition to the objectives, features, and advantages described above, the present invention has other objectives, features, and advantages. The invention will now be described in further detail with reference to the accompanying drawings. Attached Figure Description

[0046] Figure 1 This is a schematic diagram of the structure of the present invention.

[0047] Figure 2 This is an exploded view of the present invention.

[0048] Figure 3 This is a schematic diagram of the circuit connection of the present invention.

[0049] Figure 4 This is a schematic diagram of the radial layering of the sealing ring.

[0050] Figure 5 This is a schematic diagram of the microstructure of the electrochromic functional film.

[0051] Figure 6 This is a schematic diagram showing the humidity gradient and color grading indicators.

[0052] Figure 7 A schematic diagram of the impedance monitoring circuit (I).

[0053] Figure 8 Connection diagram of impedance monitoring circuit (II)

[0054] Figure 1-8 In the middle: 1. Male end shell; 2. Female end shell; 3. Sealing ring; 4. First electrode; 5. Second electrode; 6. Flexible contact terminal; 7. Observation window; 8. Insertion section; 9. Clamping ring; 10. Insertion hole; 11. Annular groove; 12. Fitting boss; 13. Fitting opening. Detailed Implementation

[0055] 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.

[0056] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0057] In addition, the instruction manual is attached Figure 7 and attached Figure 8 It is a complete image that is connected from left to right.

[0058] This invention provides an electric vehicle wiring harness connector with a sealing status visualization function.

[0059] In this embodiment, refer to Figure 1-8 The electric vehicle wiring harness connector with a sealing status visualization function includes a male end shell 1, a female end shell 2, a sealing ring 3 disposed at the joint of the male end shell and the female end shell, and a signal terminal disposed inside the male end shell and the female end shell. The sealing ring is an elastic composite with radial compression deformation capability, and an electrochromic functional film layer is embedded inside it. The electrochromic functional film layer and the sealing ring are co-vulcanized or co-injection molded into an integral structure.

[0060] The electrochromic functional film layer includes a lower electrode, an electrochromic active layer, a solid electrolyte layer and an upper electrode stacked in sequence. The lower electrode and the upper electrode are both flexible mesh conductive structures. The solid electrolyte layer is a gel-state ionic conductor with hygroscopic expansion characteristics, which maintains the electrochromic active layer in a stable state in a reduced or oxidized state under dry conditions.

[0061] The mating surface of the female end shell is provided with a dedicated driving electrode corresponding to the electrochromic functional film layer.

[0062] The dedicated driving electrode includes a first electrode 4 and a second electrode 5. The first electrode 4 is electrically connected to the positive terminal of the connector's working voltage, and the second electrode 5 is electrically connected to the negative terminal of the connector's working voltage.

[0063] The flexible conductive leads on the flexible mesh conductive structure are provided with elastic contact terminals 6 at their ends. The two elastic contact terminals 6 are electrically connected to the first electrode and the second electrode respectively only when the connector is mated, and an electric field is formed between the upper electrode and the lower electrode.

[0064] When the sealing ring is in a dry and sealed state, the electrochromic active layer presents a first optical state; when water seeps into the sealing ring and liquid water penetrates into the solid electrolyte layer, the solid electrolyte layer undergoes local swelling and changes its ion mobility. Under the action of the electric field applied by the working voltage, the redox reaction of the electrochromic active layer is triggered, causing it to change from the first optical state to the second optical state, making the second optical state and the first optical state distinguishable to the naked eye.

[0065] The above technical solution is based on the synergistic effect of electrochromic effect and elastic deformation of sealing ring. Tungsten trioxide (WO3) in the electrochromic functional film undergoes a reversible redox reaction under the action of an electric field: when moisture permeates into the solid electrolyte layer, the electrolyte layer absorbs moisture and expands, causing a change in ion mobility. Under the action of the electric field formed by the upper and lower electrodes, Li⁺ ions are embedded into the WO3 lattice to form tungsten bronze (Li⁺). x WO3), causing the color to change from transparent / light to blue / dark. Simultaneously, utilizing the mechanical contact circuit switching principle, the connector achieves automatic power-on in the mating state and complete power-off in the disconnected state through the physical contact / separation of the elastic contact terminals and the dedicated drive electrode.

[0066] This allows for direct assessment of the sealing status through visually perceptible color changes, without the need for disassembly or instruments. The circuit is completely disconnected when the connector is detached, resulting in no static power consumption. Dedicated drive electrodes are directly connected to the vehicle's operating voltage (12V / 48V), eliminating the need for a dedicated DC-DC converter. The flexible contact terminals only conduct when mated, preventing electrode wear during non-operational periods, extending the lifespan of the electrochromic component, and ensuring the monitoring function is activated only when the connector is in operation, thus enhancing the targeting of monitoring efforts.

[0067] The sealing ring is integrally formed with the electrochromic functional film and the silicone rubber substrate using a co-vulcanization process. First, the lower electrode (ITO conductive film) is deposited on a flexible substrate, and then a WO3 / polyaniline composite film (1-3 μm thick), a LiClO4 / PEO gel electrolyte (40-60 μm thick), and an upper electrode (porous gold electrode) are sequentially coated to form a flexible functional film.

[0068] The functional membrane is embedded in a silicone rubber mold, liquid silicone rubber is injected, and it is vulcanized at 150-180℃ and 10-15MPa to form a chemical bond between the functional membrane and the sealing ring.

[0069] Specifically, the electrochromic functional film layer is divided into at least four independent detection areas, each detection area has an independent flexible mesh electrode and an independent flexible conductive lead, and the four detection areas correspond to the four side walls of the mother end shell respectively. The side walls of the mother end shell are provided with observation windows 7 for observing the sealing ring.

[0070] The solid electrolyte layers in each detection area are physically isolated from each other. When water seeps into the sealing part corresponding to a certain detection area, only the solid electrolyte layer in that area swells locally and triggers an electrochromic reaction, while other detection areas remain in their first optical state, thereby achieving precise circumferential positioning of the leak point.

[0071] In this embodiment, the electrochromic functional film layer is divided into at least four independent detection areas. Each area is equipped with an independent flexible mesh electrode and a flexible conductive lead. Each detection area corresponds to one of the four side walls of the mother end shell. At the same time, an observation window is provided on the side wall of the mother end shell. The solid electrolyte layer of each detection area is physically isolated to ensure that when water seeps into a single area, only the solid electrolyte layer of that area swells and triggers the electrochromic reaction, while other areas maintain a stable optical state. Combined with the observation window, the leakage location can be intuitively located.

[0072] This enables precise circumferential positioning of leak points, addressing the limitation of existing visual monitoring systems that can only determine whether water is leaking but cannot pinpoint the exact location of the leak. Multiple independent detection areas cover the four side walls of the mother-end casing, and with the observation window, staff can quickly locate the area where the seal has failed, significantly improving maintenance efficiency and reducing maintenance time.

[0073] Specifically, the electrochromic active layer is a tungsten trioxide / polyaniline nanocomposite film, wherein the mass fraction of tungsten trioxide is 60%-80%, the mass fraction of polyaniline is 20%-40%, the film thickness is 1-3μm, and the porosity is controlled at 15%-30% to allow water molecule diffusion.

[0074] The solid electrolyte layer is a polyethylene oxide gel electrolyte containing lithium perchlorate, wherein the molar ratio of lithium perchlorate to polyethylene oxide is 1:8 to 1:12, the gel thickness is 40-60 μm, and the moisture absorption expansion rate is greater than 150%.

[0075] The lower electrode is an indium tin oxide conductive film, and the upper electrode is a porous gold electrode with a pore size of 50-200 nm and a porosity of 40%-60%, which is used to enhance the uniformity of the electric field and the permeation rate of water molecules.

[0076] In this embodiment, the WO3 / polyaniline composite film combines the electrochromic properties of WO3 (high coloring efficiency and high contrast) with the conductivity and flexibility of polyaniline to form a nanocomposite structure, thereby improving the mechanical strength and ion insertion / extraction rate of the film. The LiClO4 / PEO gel electrolyte utilizes the chain segment movement characteristics of polyethylene oxide to provide ion conduction channels, while lithium perchlorate provides the Li⁺ ion source. The gel expands in volume after absorbing moisture, changing the ion mobility and thus regulating the electrochromic response threshold.

[0077] Preparation of electrochromic active layer:

[0078] WO3 / polyaniline composite films were prepared using the sol-gel method. Tungstic acid (H2WO4) was dissolved in hydrogen peroxide (H2O2, 30%) to form a peroxytungstic acid solution, and then polyaniline emulsion (10% solid content) was added, controlling the mass ratio of WO3 to polyaniline to be 7:3.

[0079] A thin film was coated on an ITO conductive film using a spin coating method (3000 rpm, 30 s). After drying at 80°C, the film was annealed at 200°C for 2 hours to form a porous film with a porosity of 20%.

[0080] Preparation of solid electrolyte layer:

[0081] LiClO4 and PEO (molecular weight 600,000) were dissolved in acetonitrile solvent at a molar ratio of 1:10, with a solid content of 15%, and stirred at 60°C for 6 hours to form a homogeneous solution.

[0082] A gel layer with a thickness of 50 μm was coated on the electrochromic active layer using a blade coating method and then vacuum dried at 60 °C for 12 hours to form a flexible gel electrolyte.

[0083] Fabrication of porous gold electrodes:

[0084] A gold film was deposited on the surface of the gel layer by magnetron sputtering with a sputtering power of 100W, an argon gas pressure of 0.5Pa, a time of 10 minutes, and a film thickness of 100nm.

[0085] A gold film was treated with sulfuric acid solution (0.5M) by anodizing at 2V for 30 seconds to form a porous structure with a pore size of 100nm and a porosity of 50%.

[0086] Specifically, one end of the male end housing is provided with an insertion section 8, and the outer wall of the insertion section 8 is integrally provided with a clamping ring 9. One end of the female end housing is provided with a socket 10 that is inserted and mated with the insertion section. The bottom wall of the socket is provided with an annular groove 11 for embedding the sealing ring. The insertion section is inserted into the clamping ring, and the clamping ring presses and holds the sealing ring in the annular groove.

[0087] The outer walls on both sides of the clamping ring are provided with fitting bosses 12, and the side walls on both sides of the insertion hole are provided with fitting openings 13 that are adapted to the fitting bosses.

[0088] The dedicated driving electrode is embedded in the bottom wall of the annular groove. When the clamping ring presses the sealing ring, the elastic contact terminal forms a reliable electrical contact with the dedicated driving electrode.

[0089] In this embodiment, the male end housing is provided with an insertion section and a clamping ring, while the female end housing is provided with a matching socket and an annular groove. After the insertion section is inserted into the socket, the clamping ring tightly presses the sealing ring into the annular groove, ensuring reliable sealing. A dedicated drive electrode is embedded in the bottom wall of the annular groove. Utilizing the insertion action of the male end insertion section, the clamping ring presses the sealing ring, and the elastic contact terminals on the sealing ring are pushed towards the dedicated drive electrode to achieve precise docking and form reliable electrical contact, ensuring the stable establishment of the electric field of the electrochromic functional film layer. The circuit is switched on and off simultaneously with the insertion and removal of the connector, requiring no additional operation.

[0090] Specifically, the sealing ring is an elastic composite with a gradient modulus structure, comprising, from the inside out:

[0091] Inner elastic matrix: made of silicone rubber or fluorosilicone rubber, with a Shore A hardness of 40-60;

[0092] Intermediate functional layer: The electrochromic functional film layer is embedded in this layer, and the mesh opening ratio of the flexible mesh electrode is greater than 70% to allow elastic deformation;

[0093] Outer hydrophobic barrier: composed of modified silicone rubber with a surface energy of less than 25 mN / m and a thickness of 0.1-0.3 mm, used to delay the penetration of liquid water and provide a response time window for the electrochromic reaction;

[0094] The inner elastic matrix, the middle functional layer, and the outer hydrophobic barrier are chemically bonded through a co-sulfurization process, ensuring that the electrical connection and optical properties of the electrochromic functional film remain stable within the radial compression deformation range of 20%-40% of the sealing ring.

[0095] In this embodiment, functional zoning is achieved through a gradient distribution of material hardness: the inner soft matrix provides the main elastic sealing force, the middle functional layer accommodates the electrochromic film and allows for moderate deformation, and the outer hard hydrophobic barrier delays moisture penetration. The three layers are chemically bonded through co-sulfurization, ensuring that the interfaces do not separate during compression deformation. At the same time, the difference in modulus between the layers ensures a reasonable stress distribution, preventing excessive stress on the electrochromic functional film layer.

[0096] Three-layer material formula:

[0097] Inner elastic matrix: methyl vinyl silicone rubber (MVQ, vinyl content 0.5%), with added fumed silica (30 phr) as a reinforcing agent, Shore hardness A50;

[0098] Intermediate functional layer: Same substrate as the inner layer, but with the addition of a small amount (5 phr) of chopped glass fiber to improve dimensional stability, Shore hardness A55;

[0099] Outer hydrophobic barrier: Fluorosilicone rubber (FVMQ, fluorine content 20%), surface energy 22mN / m, with added polytetrafluoroethylene micro powder (10phr) to reduce the coefficient of friction, Shore hardness A 75.

[0100] Molding process:

[0101] The process employs a three-layer co-extrusion + compression molding vulcanization. First, the three rubber compounds are plasticized separately and then extruded into a tubular semi-finished product (inner layer thickness 1.5mm, middle layer thickness 1mm, outer layer thickness 0.2mm) through a three-layer co-extrusion die.

[0102] The semi-finished product is placed in a mold, and an electrochromic functional film layer is embedded in it. It is then vulcanized at 170℃ and 15MPa for 10 minutes to cross-link and bond the three layers of rubber, while simultaneously forming a chemical bond with the functional film layer.

[0103] Achieve the following effect:

[0104] The gradient modulus structure balances the sealing performance, elastic deformation capability, and monitoring function stability of the sealing ring. The inner elastic matrix ensures the reliability of the seal, while the outer hydrophobic barrier slows down the seepage rate and prevents the leakage from expanding rapidly.

[0105] The outer hydrophobic barrier provides a response time window for the electrochromic reaction, ensuring that staff have sufficient time to detect potential leaks and address them promptly, further reducing the risk of failure.

[0106] The three-layer structure has a tight chemical bond, and the electrical connection and optical performance of the electrochromic functional film remain stable within the radial compression deformation range of 20%-40% of the sealing ring, making it suitable for connector mating and deformation requirements in the vibration environment of electric vehicles.

[0107] 4. The electrode grid opening ratio of the intermediate functional layer is optimized so as not to affect the elastic deformation of the sealing ring, and to ensure the electric field uniformity of the electrochromic component, thus balancing practicality and reliability.

[0108] Specifically, the ionic conductivity and hygroscopic properties of the solid electrolyte layer are synergistically regulated by the lithium perchlorate concentration and the polyethylene oxide molecular weight to form a color change threshold with humidity gradient response characteristics.

[0109] When the sealing ring is slightly leaking, the seeping water forms a local low ion concentration area in the solid electrolyte layer, triggering the electrochromic active layer to exhibit the second optical state; when the sealing ring is severely leaking, the water completely wets the solid electrolyte layer, forming a high ion concentration area, triggering the electrochromic active layer to exhibit the third optical state.

[0110] The second and third optical states are different shades of the same color system or completely different color systems, thereby achieving a visual grading indication of the severity of water seepage.

[0111] In this embodiment, based on the coupling principle of electrolyte layer ion concentration and conductivity, the ionic conductivity of the solid electrolyte layer changes nonlinearly with the amount of moisture absorbed: During slight water seepage, water locally dissolves LiClO4 to form a low-concentration ion region, resulting in a slight increase in conductivity, a moderate electrochromic reaction rate, and a light color; during heavy water seepage, water completely wets the area, forming a high-concentration ion region, leading to a significant increase in conductivity, a fast reaction rate, and a deep color. By adjusting the LiClO4 concentration and PEO molecular weight, the degree of color change corresponding to different humidity thresholds can be set.

[0112] Thus achieving:

[0113] 1. Tiered warning: The severity of water seepage (minor / serious) is distinguished by the intensity of the color.

[0114] 2. Trend prediction: The gradual change from light to dark color indicates the trend of water seepage.

[0115] 3. Adjustable threshold: The material ratio can be adjusted to meet different protection level requirements.

[0116] Material ratio adjustment:

[0117] The first threshold (>100ppm) is set as follows: the molar ratio of LiClO4 to PEO is 1:10, and the molecular weight of PEO is 400,000. At this point, the gel begins to absorb moisture significantly at a relative humidity of 30%, the conductivity increases by 2 times, and the electrochromic layer is triggered to turn light blue (optical density OD=0.3).

[0118] Second threshold (>500ppm): Under the same ratio, when the relative humidity is 70%, the gel is fully swollen, the conductivity increases by 10 times, and the electrochromic layer turns deep blue (OD=1.2).

[0119] Color contrast control:

[0120] Second optical state (light blue): RGB(100,150,200), transmittance 60%;

[0121] Third optical state (deep blue): RGB(30,50,100), transmittance 20%;

[0122] The two colors are from the same color family, making it easy to visually judge the increasing severity.

[0123] Specifically, it also includes an impedance monitoring circuit, which monitors the volume resistivity change of the solid electrolyte layer in real time through the flexible conductive lead;

[0124] When the solid electrolyte layer absorbs moisture and expands, causing its volume resistivity to decrease by more than 50%, the impedance monitoring circuit triggers an early warning signal from the vehicle system and sends a sealing status warning containing leakage location information to the vehicle controller via the wireless communication module, thus achieving redundant backup of visual indication and electronic monitoring.

[0125] The impedance monitoring circuit includes a microprocessor, a signal conditioning circuit, and a wireless communication module. The microprocessor determines the water leakage status by measuring the impedance change between the upper and lower electrodes. When the impedance value is lower than a preset threshold, it is determined to be a sealing failure.

[0126] In this embodiment, based on the principle of parallel impedance monitoring, the electrochromic functional film exhibits high impedance (>10MΩ) in a dry state. Water seepage increases the ionic conductivity of the solid electrolyte layer, resulting in a decrease in overall impedance. An impedance monitoring circuit is connected in parallel with the electrochromic functional film through a flexible conductive lead. A small AC signal (frequency 1kHz, amplitude 100mV) is applied to the electrode, and the impedance amplitude and phase changes are measured. When the impedance decreases by more than 50% (corresponding to significant swelling of the electrolyte layer due to water seepage), it is determined to be a seal failure.

[0127] Thus achieving:

[0128] 1. Redundancy Backup: Dual protection of electronic monitoring and visual indicators enhances reliability;

[0129] 2. Remote early warning: Sends early warnings to the vehicle system via wireless communication to achieve real-time monitoring;

[0130] 3. Quantitative judgment: The percentage change in impedance can quantify the degree of water seepage, which is more accurate than visual inspection.

[0131] Impedance monitoring circuit design:

[0132] Microprocessor: Uses STM32L4 series low-power MCU, with built-in 12-bit ADC and DAC;

[0133] Signal conditioning circuit: includes a sine wave generator (generating a 1kHz excitation signal), an instrumentation amplifier (AD620, 100x gain) and a phase-sensitive detector to measure the real and imaginary parts of the impedance;

[0134] Wireless communication module: CAN bus transceiver (TJA1043) or low-power Bluetooth module (nRF52840) to send monitoring data to the vehicle gateway.

[0135] Monitoring algorithm:

[0136] Calibration phase: Record the reference impedance Z0 under dry conditions.

[0137] Monitoring phase: Measure the impedance Z in real time and calculate the rate of change ΔZ = (Z0 - Z) / Z0;

[0138] Judgment logic: When ΔZ>50% lasts for more than 5 seconds, an early warning signal is triggered, which includes a timestamp and location code.

[0139] Installation method:

[0140] The impedance monitoring circuit can be integrated into the PCB board inside the male terminal housing, and connected in parallel with the sealing ring electrode through a flexible conductive lead. The PCB board is then sealed and protected with epoxy resin.

[0141] Specifically, the flexible conductive lead is a spiral or wavy extended structure with an elongation rate greater than 150% of the maximum working deformation of the sealing ring, ensuring the reliability of the electrical connection during connector insertion and removal and under vibration.

[0142] The elastic contact terminal is a gold-plated spring pin or a conductive elastomer. The elastic contact terminal is located on the inner wall of the sealing ring, with a contact stroke of 2-3 mm. Its contact pressure is 0.5-2 N when the connector is mated. It automatically disconnects the electrical connection when the connector is separated, thus preventing the electrochromic functional film from undergoing an undesirable electrochemical reaction when the connector is not in operation.

[0143] In this embodiment, based on the design principle of flexible and extensible structures, the spiral or wavy lead structure can elastically extend (spiral unfolding or wave flattening) when under tension and contract (spiral tightening or wave deepening) when under compression. Its effective length change rate can reach over 200%, far exceeding that of straight leads (<5%). This structure provides length compensation when the sealing ring is compressed, preventing lead breakage or electrode peeling. The gold-plated spring pin uses the pre-compression force of the spring to maintain contact pressure, ensuring stable contact resistance under vibration.

[0144] Specifically, the flexible conductive leads corresponding to each detection area are coded with different resistance values ​​or different impedance characteristics. The impedance monitoring circuit distinguishes the signals of different detection areas by identifying the differences in the electrical characteristics of each lead, thereby realizing automatic identification and electronic reporting of the leakage location.

[0145] In this embodiment, based on the principle of resistance coding identification, precision resistors of different resistance values ​​are connected in series in the flexible conductive leads of each detection area (e.g., 1kΩ in region 1, 2kΩ in region 2, and so on). The impedance monitoring circuit applies a test voltage to all leads, measures the total current and the current distribution of each branch, and calculates the resistance value of the leads in each region according to Ohm's law, thereby identifying the regions where impedance changes occur. This coding method does not require additional address lines or communication lines and can achieve multi-region identification using only two existing power lines.

[0146] Thus achieving:

[0147] 1. Reduced wiring: No need to run separate cables to the monitoring module for each area, reducing the number of leads;

[0148] 2. Automatic positioning: The system automatically calculates and reports the specific area, eliminating the need for manual judgment;

[0149] 3. High expandability: More areas can be expanded by increasing the resistance level.

[0150] Specifically, the electrochromic functional film layer is distributed in a continuous ring or in segments in the circumferential direction of the sealing ring. When the segmented distribution is adopted, the spacing between each segment is less than 5mm, ensuring that there are no blind spots in the leakage monitoring of the sealing ring in the entire circumference.

[0151] The first optical state of the electrochromic active layer is transparent or light gray, which has no significant impact on the appearance of the connector in a dry state; the second optical state is dark blue, dark purple or black, which forms a high-contrast visual warning in a water-permeable state.

[0152] In this embodiment, based on the principle of full-coverage monitoring, the electrochromic functional film layer is continuously distributed in a ring or densely distributed in segments along the circumference, ensuring that any water seepage at any location along the circumference of the sealing ring can be detected within a 5mm range. Continuous distribution is suitable for simple seal monitoring, while segmented distribution is suitable for scenarios requiring precise positioning, with segment spacing <5mm ensuring no blind spots.

[0153] Please note to all technical personnel: Although the present invention has been described according to the specific embodiments above, the ideas of the present invention are not limited to this invention. Any modifications that utilize the ideas of the present invention will be included within the scope of protection of this patent.

Claims

1. An electric vehicle wiring harness connector with a sealing status visualization function, comprising a male end housing, a female end housing, a sealing ring disposed at the mating point of the male end housing and the female end housing, and a signal terminal disposed within the male end housing and the female end housing, characterized in that: The sealing ring is an elastic composite with radial compression deformation capability, and an electrochromic functional film layer is embedded inside it. The electrochromic functional film layer and the sealing ring are co-vulcanized or co-injection molded into an integral structure. The electrochromic functional film layer includes a lower electrode, an electrochromic active layer, a solid electrolyte layer and an upper electrode stacked in sequence. The lower electrode and the upper electrode are both flexible mesh conductive structures. The solid electrolyte layer is a gel-state ionic conductor with hygroscopic expansion characteristics, which maintains the electrochromic active layer in a stable state in a reduced or oxidized state under dry conditions. The mating surface of the female end shell is provided with a dedicated driving electrode corresponding to the electrochromic functional film layer. The dedicated driving electrode includes a first electrode and a second electrode. The first electrode is electrically connected to the positive terminal of the connector's operating voltage, and the second electrode is electrically connected to the negative terminal of the connector's operating voltage. The flexible conductive leads on the flexible mesh conductive structure are provided with elastic contact terminals at their ends. The two elastic contact terminals are electrically connected to the first electrode and the second electrode respectively only when the connector is mated, and an electric field is formed between the upper electrode and the lower electrode. When the sealing ring is in a dry and sealed state, the electrochromic active layer presents a first optical state; when the sealing ring leaks water and liquid water penetrates into the solid electrolyte layer, the solid electrolyte layer undergoes local swelling and changes its ion mobility. Under the action of the electric field applied by the working voltage, the redox reaction of the electrochromic active layer is triggered, causing it to change from the first optical state to the second optical state, making the second optical state and the first optical state distinguishable to the naked eye. The electrochromic functional film is divided into at least four independent detection areas. Each detection area has an independent flexible mesh electrode and an independent flexible conductive lead. The four detection areas correspond to the four side walls of the female end shell, and the side walls of the female end shell are provided with observation windows for observing the sealing ring. The solid electrolyte layers in each detection area are physically isolated from each other. When water seeps into the sealing part corresponding to a certain detection area, only the solid electrolyte layer in that area swells locally and triggers an electrochromic reaction, while other detection areas maintain the first optical state, thereby achieving precise circumferential positioning of the leak point. The ionic conductivity and hygroscopic properties of the solid electrolyte layer are synergistically regulated by the lithium perchlorate concentration and the polyethylene oxide molecular weight to form a color change threshold with humidity gradient response characteristics. When the sealing ring is slightly leaking, the seeping water forms a local low ion concentration area in the solid electrolyte layer, triggering the electrochromic active layer to exhibit the second optical state; when the sealing ring is severely leaking, the water completely wets the solid electrolyte layer, forming a high ion concentration area, triggering the electrochromic active layer to exhibit the third optical state. The second and third optical states are different shades of the same color system or completely different color systems, thereby achieving a visual grading indication of the severity of water seepage.

2. The electric vehicle wiring harness connector with sealing status visualization function according to claim 1, characterized in that: The electrochromic active layer is a tungsten trioxide / polyaniline nanocomposite film, wherein the mass fraction of tungsten trioxide is 60%-80%, the mass fraction of polyaniline is 20%-40%, the film thickness is 1-3μm, and the porosity is controlled at 15%-30% to allow water molecule diffusion. The solid electrolyte layer is a polyethylene oxide gel electrolyte containing lithium perchlorate, wherein the molar ratio of lithium perchlorate to polyethylene oxide is 1:8 to 1:12, the gel thickness is 40-60 μm, and the moisture absorption expansion rate is greater than 150%. The lower electrode is an indium tin oxide conductive film, and the upper electrode is a porous gold electrode with a pore size of 50-200 nm and a porosity of 40%-60%, which is used to enhance the uniformity of the electric field and the permeation rate of water molecules.

3. The electric vehicle wiring harness connector with sealing status visualization function according to claim 1, characterized in that: One end of the male end housing is provided with an insertion section, and a clamping ring is integrally provided on the outer wall of the insertion section. One end of the female end housing is provided with a socket that is inserted into the insertion section. The bottom wall of the socket is provided with an annular groove for embedding a sealing ring. The insertion section is inserted into the clamping ring, and the clamping ring presses and holds the sealing ring in the annular groove. The outer walls on both sides of the clamping ring are provided with fitting bosses, and the side walls on both sides of the insertion hole are provided with fitting openings that match the fitting bosses. The dedicated driving electrode is embedded in the bottom wall of the annular groove. When the clamping ring presses the sealing ring, the elastic contact terminal forms a reliable electrical contact with the dedicated driving electrode.

4. The electric vehicle wiring harness connector with sealing status visualization function according to claim 1, characterized in that: The sealing ring is an elastic composite with a gradient modulus structure, comprising, from the inside out: Inner elastic matrix: made of silicone rubber or fluorosilicone rubber, with a Shore A hardness of 40-60; Intermediate functional layer: The electrochromic functional film layer is embedded in this layer, and the mesh opening ratio of the flexible mesh electrode is greater than 70% to allow elastic deformation; Outer hydrophobic barrier: composed of modified silicone rubber with a surface energy of less than 25 mN / m and a thickness of 0.1-0.3 mm, used to delay the penetration of liquid water and provide a response time window for the electrochromic reaction; The inner elastic matrix, the middle functional layer, and the outer hydrophobic barrier are chemically bonded through a co-sulfurization process, ensuring that the electrical connection and optical properties of the electrochromic functional film remain stable within the radial compression deformation range of 20%-40% of the sealing ring.

5. The electric vehicle wiring harness connector with sealing status visualization function according to claim 1, characterized in that: It also includes an impedance monitoring circuit, which monitors the volume resistivity change of the solid electrolyte layer in real time through the flexible conductive lead; When the solid electrolyte layer absorbs moisture and expands, causing its volume resistivity to decrease by more than 50%, the impedance monitoring circuit triggers an early warning signal from the vehicle system and sends a sealing status warning containing leakage location information to the vehicle controller via the wireless communication module, thus achieving redundant backup of visual indication and electronic monitoring. The impedance monitoring circuit includes a microprocessor, a signal conditioning circuit, and a wireless communication module. The microprocessor determines the water leakage status by measuring the impedance change between the upper and lower electrodes. When the impedance value is lower than a preset threshold, it is determined to be a sealing failure.

6. The electric vehicle wiring harness connector with sealing status visualization function according to claim 1, characterized in that: The flexible conductive lead has a spiral or wavy extended structure with an elongation rate greater than 150% of the maximum working deformation of the sealing ring, ensuring the reliability of the electrical connection during connector insertion and removal and under vibration. The elastic contact terminal is a gold-plated spring pin or a conductive elastomer. The elastic contact terminal is located on the inner wall of the sealing ring, with a contact stroke of 2-3 mm. Its contact pressure is 0.5-2 N when the connector is mated. It automatically disconnects the electrical connection when the connector is separated, thus preventing the electrochromic functional film from undergoing an undesirable electrochemical reaction when the connector is not in operation.

7. The electric vehicle wiring harness connector with sealing status visualization function according to claim 5, characterized in that: Each detection area is coded with a different resistance value or a different impedance characteristic. The impedance monitoring circuit distinguishes the signals of different detection areas by identifying the differences in the electrical characteristics of each lead, thereby realizing the automatic identification and electronic reporting of the leakage location.

8. The electric vehicle wiring harness connector with sealing status visualization function according to claim 1, characterized in that: The electrochromic functional film layer is distributed in a continuous ring or in segments in the circumferential direction of the sealing ring. When the segmented distribution is adopted, the spacing between each segment is less than 5mm, ensuring that there are no blind spots in the leakage monitoring of the sealing ring in the entire circumference. The first optical state of the electrochromic active layer is transparent or light gray, which has no significant impact on the appearance of the connector in a dry state; the second optical state is dark blue, dark purple or black, which forms a high-contrast visual warning in a water-permeable state.

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