Wiring structure of unmanned aerial vehicle controller

Abstract

The invention discloses a wiring structure of an unmanned aerial vehicle controller. The wiring structure comprises an insulating base body, a conductive terminal, a cable assembly and a protection assembly, the conductive terminal comprises a contact part used for electrical connection and an embedded part used for fixation. The insulating base body wraps and fixes the embedding part of the conductive terminal; wherein a first sealing curing material layer is filled between the embedding part of the conductive terminal and the wrapping interface of the insulating substrate; the cable assembly comprises at least one internal conductor and an insulating layer wrapping the internal conductor, one end of the internal conductor is electrically connected with the contact part of the conductive terminal, and the other end of the cable assembly extends out of the second end of the insulating base body; the protection assembly comprises an outer sheath wrapping the insulating layer and a packaging body which fixes the outer sheath and the end part of the cable assembly in the insulating substrate through injection molding. The technical effect of ensuring the reliability of the two wiring ends of the unmanned aerial vehicle controller is achieved.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of unmanned aerial vehicle controller wiring, and more particularly to an unmanned aerial vehicle controller wiring structure. BACKGROUND

[0002] In the field of unmanned aerial vehicle controller wiring, the traditional wiring structure is usually composed of a metal connector (including multiple copper sheets as wiring terminals) at one end and a cable connection at the other end. In actual application, due to the significant difference in material properties (such as thermal expansion coefficient, shrinkage rate) between the copper sheet and the plastic part (usually a connector base) embedded below it, gaps are easily generated at the interface between the two during injection molding or long-term use. These gaps not only reduce the stability and conductivity of electrical connections, but also may cause poor contact, signal attenuation, and even short circuit risk due to the invasion of moisture and dust, seriously affecting the reliable transmission of unmanned aerial vehicle control signals. At the same time, if the cable part of the wiring is directly exposed or improperly fixed, the insulation layer of the cable is prone to wear and tear under the action of frequent movement, vibration, and external stress of the unmanned aerial vehicle, and the internal wires may break, leading to wiring failure. SUMMARY

[0003] To solve the problems of gaps between the metal connector and the connector base at one end of the unmanned aerial vehicle controller and the wear and tear of the insulation layer of the cable at the other end, the application aims to provide an unmanned aerial vehicle controller wiring structure, which includes an insulating base, a conductive terminal, a cable assembly, and a protective assembly. The conductive terminal includes a contact part for electrical connection and an embedded part for fixation. The insulating base wraps and fixes the embedded part of the conductive terminal. A first sealing and curing material layer is filled between the embedded part of the conductive terminal and the wrapping interface of the insulating base. The cable assembly includes at least one internal conductor and an insulation layer wrapping the internal conductor. One end of the internal conductor is electrically connected to the contact part of the conductive terminal, and the other end of the cable assembly extends out of the second end of the insulating base. The protective assembly includes an outer sheath wrapping the outside of the insulation layer and an encapsulation body fixing the outer sheath and the end of the cable assembly in the insulating base by injection molding.

[0004] Compared with the prior art, the technical effects achieved by the technical scheme are: by filling the first sealing and curing material layer between the embedding part of the conductive terminal and the wrapping interface of the insulating base body, the gap that may be formed between the conductive terminal and the insulating base body due to material differences can be avoided, thereby improving the connection stability, sealing performance and long-term electrical conductivity reliability between the conductive terminal and the insulating base body. By providing the composite protection structure composed of the outer sheath and the injection molded package at the cable assembly, multiple mechanical protection against tension, bending and wear is provided for the cable assembly, effectively preventing damage to the cable assembly, significantly prolonging the service life of the entire wiring structure under harsh working conditions, and further ensuring the reliability of the two ends of the controller wiring of the unmanned aerial vehicle.

[0005] Further, the conductive terminal is an integrally formed metal piece, the wiring terminal includes a crimping section, a transition section and a connecting section; the crimping section is used to fixedly connect the internal conductor of the cable assembly; the connecting section is provided with an interface structure for realizing detachable electrical connection with an external circuit; the transition section is connected between the crimping section and the connecting section and is used to disperse mechanical stress between the crimping section and the connecting section.

[0006] Compared with the prior art, the technical effects achieved by the technical scheme are: by setting the conductive terminal as an integrally formed metal piece, the structural strength thereof can be improved. By setting the conductive terminal as an integrally formed crimping section, transition section and connecting section, the cable assembly can be connected through the crimping section, the external circuit can be connected through the connecting section, and the mechanical stress can be dispersed through the transition section, thereby avoiding problems such as fracture or connection failure of the conductive terminal caused by stress concentration.

[0007] Further, the crimping section is a hollow cylindrical sleeve; the connecting section is a connecting plate with a square-hole-shaped through hole, forming a contact part of the conductive terminal; and the transition section is an inclined shrinkage section connected between the crimping section and the connecting section.

[0008] Compared with the prior art, the technical effects achieved by the technical scheme are: the hollow cylindrical sleeve can directly and firmly crimp the cable assembly; the inclined shrinkage section connected between the crimping section and the connecting section can play a role in stress transition and improve the structural strength. The connecting plate with the through hole provides a reliable interface for bolt connection.

[0009] Further, the embedding part of the conductive terminal has a non-smooth surface structure; and / or the cavity of the insulating base body wrapping and fixing the embedding part has a non-smooth surface structure.

[0010] Compared with existing technologies, the technical effects achieved by this solution are as follows: By creating a non-smooth surface structure in the cavity where the conductive terminal is embedded and the insulating substrate is wrapped and fixed, the mechanical engagement area and bonding force between the conductive terminal and the insulating substrate, as well as between both and the subsequently injected first sealing and curing material layer, can be increased. This design not only prevents the conductive terminal from detaching from the insulating substrate, but also ensures that the sealing material adheres and fills more firmly, further eliminating potential micro-gaps and enhancing the vibration resistance, pull-out resistance, and long-term stability of the entire UAV controller wiring structure.

[0011] Furthermore, the first sealing and curing material layer is one or more composite materials selected from potting compound, silicone gel, epoxy resin or polyurethane adhesive.

[0012] Compared with existing technologies, the technical advantages achieved by this solution are as follows: the potting compound, silicone gel, epoxy resin, and polyurethane adhesive all possess excellent flowability and adhesion, enabling better and stronger bonding of metals and plastics through fine gaps; they also exhibit moderate elasticity or rigidity after curing, good insulation, moisture resistance, temperature resistance, and aging resistance. Using these materials reliably achieves gap sealing, stress buffering, and environmental protection functions, ensuring the connection stability, sealing performance, and long-term conductivity reliability between the conductive terminals and the insulating substrate.

[0013] Furthermore, the outer sheath is a braided mesh tube, a spiral wound tube, a heat shrink tube, or a molded elastic sleeve.

[0014] Compared to existing technologies, the technical advantages achieved by this solution are as follows: braided tubing provides high-strength tensile and cut-resistant protection; spiral wound tubing offers excellent flexibility and bend retention; heat-shrink tubing tightly wraps the cable to form a uniform protective layer; and molded elastic sheaths, such as rubber, provide excellent shock absorption and abrasion resistance. These structures provide preliminary and effective mechanical reinforcement and protection for the cable before injection molding, working in conjunction with the subsequent injection-molded encapsulation to form a gradient protection.

[0015] Furthermore, a first sealing ring is provided at the end of the insulating substrate near the cable assembly, and two second sealing rings are provided at the end of the insulating substrate near the conductive terminal; wherein, the size of the first sealing ring is larger than that of the second sealing ring.

[0016] Compared with existing technologies, the technical effects achieved by this solution are as follows: The first sealing ring, located at the end of the insulating substrate near the cable assembly, serves as both a primary seal and a stress reliever. Due to its larger size and elasticity, it can absorb and disperse mechanical stresses from bending, torsion, and tension in the cable, preventing these forces from being directly transmitted to the internal precision crimping or welding points, thus protecting the internal electrical connections from damage. The two second sealing rings, located at the end of the insulating substrate near the conductive terminals, serve as auxiliary seals and provide installation positioning. When the UAV controller wiring structure is inserted into the matching housing, these two small sealing rings form a tight fit with the inner wall of the housing, creating a more complete sealed cavity and providing a secondary sealing barrier to further improve the long-term reliability of the electrical connections.

[0017] Furthermore, the first sealing ring has a rectangular cross-section, while the second sealing ring has a circular cross-section.

[0018] Compared with existing technologies, the technical advantages achieved by this solution are as follows: Circular cross-section sealing rings provide stable and reliable radial compression seals, forming a static seal within the housing; rectangular cross-section sealing rings, due to their larger bearing area and structural volume, provide excellent sealing while possessing stronger elastic deformation capabilities, more effectively buffering and dispersing axial forces and bending moments from the cable, thereby achieving dynamic stress relief. Compared to single-specification sealing rings, the combination of circular rings for static sealing and rectangular rings for dynamic sealing and stress relief achieves better sealing performance and mechanical reliability at a lower cost and with a more compact structure. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the wiring structure of a drone controller provided by the present invention; Figure 2 yes Figure 1 Schematic diagram of the structure of the conductive terminal; Figure 3 yes Figure 1 A schematic diagram of the wiring structure of a Chinese unmanned aerial vehicle (UAV) controller without a sealing ring installed; Figure 4 yes Figure 1 Schematic diagram of the structure of the first and second sealing rings; Figure 5 yes Figure 4 Cross-sectional view of the first and second sealing rings; Figure 6 This is a cross-sectional view of the cable assembly.

[0020] In the picture: 100. Wiring structure of UAV controller; 10. Insulating substrate; 11. First sealing groove; 12. Second sealing groove; 20. Conductive terminal; 21. Crimping section; 22. Transition section; 23. Connecting section; 231. Through hole; 30. Cable assembly; 31. Inner conductor; 32. Insulating layer; 40. Outer sheath; 51. First sealing ring; 52. Second sealing ring. Detailed Implementation

[0021] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments. The embodiments of the present invention are given for illustrative and descriptive purposes only, and are not intended to be exhaustive or to limit the invention to the forms disclosed. Many modifications and variations will be apparent to those skilled in the art. The embodiments were chosen and described to better illustrate the principles and practical application of the invention, and to enable those skilled in the art to understand the invention and design various embodiments with various modifications suitable for a particular purpose.

[0022] See Figure 1 This is a schematic diagram of a wiring structure 100 for a drone controller provided by the present invention. Combined with... Figures 1 to 6 The drone controller wiring structure 100 includes, for example, an insulating substrate 10, conductive terminals 20, cable assemblies 30, and a protective component. The conductive terminals 20 include a contact portion for electrical connection and an embedding portion for fixing. The insulating substrate 10 encloses and fixes the embedding portion of the conductive terminals 20. A first sealing and curing material layer is filled between the embedding portion of the conductive terminals 20 and the enclosing interface of the insulating substrate 10. The cable assembly 30 includes at least one internal conductor 31 and an insulating layer 32 enclosing the internal conductor 31. One end of the internal conductor 31 is electrically connected to the contact portion of the conductive terminals 20, and the other end of the cable assembly 30 extends out of the second end of the insulating substrate 10. The protective component includes an outer sheath 40 enclosing the insulating layer 32 and an encapsulation body that fixes the outer sheath 40 and the end of the cable assembly 30 within the insulating substrate 10 by injection molding. For example, the drone controller wiring structure 100 includes three conductive terminals 20 and three cable assemblies 30. The conductive terminals 20 are made of copper, and the insulating substrate 10 is made of plastic.

[0023] In one specific embodiment, adhesive is injected between the embedded portion of the conductive terminal 20 and the insulating substrate 10, that is, a first sealing and curing material layer is filled to improve the connection stability, sealing performance, and long-term conductivity reliability between the conductive terminal 20 and the insulating substrate 10. At the other end of the insulating substrate 10, an outer sheath 40 is initially wrapped around the cable assembly 30, and the outer sheath 40 and the cable assembly 30 are simultaneously injection molded into the plastic insulating substrate 10 to prevent damage to the cable assembly 30. The cable assembly 30 may contain one or more internal conductors 31; this is not limited here.

[0024] It is understandable that by filling the interface between the embedded portion of the conductive terminal 20 and the encapsulation interface of the insulating substrate 10 with a first sealing and curing material layer, gaps that may form between the conductive terminal 20 and the insulating substrate 10 due to material differences can be avoided, thereby improving the connection stability, sealing performance, and long-term conductivity reliability between the conductive terminal 20 and the insulating substrate 10. By setting a composite protective structure consisting of an outer sheath 40 and an injection-molded encapsulation body at the cable assembly 30, multiple mechanical protections against tension, bending, and abrasion are provided for the cable assembly 30, effectively preventing damage to the cable assembly 30, significantly extending the service life of the entire wiring structure under harsh working conditions, and thus ensuring the reliability of both ends of the UAV controller wiring.

[0025] Furthermore, the conductive terminal 20 is a one-piece molded metal part, and the terminal includes a crimping section 21, a transition section 22, and a connecting section 23; wherein, the crimping section 21 is used to fix the internal conductor 31 of the connecting cable assembly 30; the connecting section 23 is provided with an interface structure for detachable electrical connection with an external circuit; the transition section 22 is connected between the crimping section 21 and the connecting section 23 to disperse the mechanical stress between the crimping section 21 and the connecting section 23.

[0026] It is understandable that by making the conductive terminal 20 a one-piece metal part, its structural strength can be improved. By making the conductive terminal 20 a one-piece crimping section 21, transition section 22 and connecting section 23, the cable assembly 30 can be connected through the crimping section 21, the external circuit can be connected through the connecting section 23, and the mechanical stress can be dispersed through the transition section 22, avoiding problems such as breakage of the conductive terminal 20 or connection failure caused by stress concentration.

[0027] Furthermore, the crimping section 21 is a hollow cylindrical sleeve; the connecting section 23 is a connecting plate with a square or circular through hole 231, forming the contact part of the conductive terminal 20; wherein, the transition section 22 is an inclined shrinking section connecting the crimping section 21 and the connecting section 23.

[0028] Understandably, the hollow cylindrical sleeve can directly and firmly crimp the cable assembly 30; the inclined contraction section connecting the crimping section 21 and the connecting section 23 can play a role in stress transition and improve structural strength. The connecting plate with through hole 231 provides a reliable interface for bolt connection.

[0029] Furthermore, the embedded portion of the conductive terminal 20 has a non-smooth surface structure; and / or the cavity of the insulating substrate 10 that encloses and fixes the embedded portion has a non-smooth surface structure.

[0030] It is understandable that by providing a non-smooth surface structure in the cavity of the embedded portion of the conductive terminal 20 and the insulating substrate 10 that wraps around and fixes the embedded portion, the mechanical engagement area and bonding force between the conductive terminal 20 and the insulating substrate 10, as well as between both and the subsequently injected first sealing and curing material layer, can be increased. This arrangement not only prevents the conductive terminal 20 from detaching from the insulating substrate 10, but also ensures that the sealing material can adhere and fill more firmly, further eliminating potential micro-gaps and enhancing the vibration resistance, pull-out resistance, and long-term stability of the entire UAV controller wiring structure 100.

[0031] Furthermore, the first sealing and curing material layer is one or more composite materials selected from potting compound, silicone gel, epoxy resin or polyurethane adhesive.

[0032] Understandably, potting compounds, silicone gels, epoxy resins, and polyurethane adhesives all possess excellent flowability and adhesion, enabling them to better bond metals and plastics in minute gaps. They also exhibit moderate elasticity or rigidity after curing, along with good insulation, moisture resistance, temperature resistance, and aging resistance. Using these materials reliably achieves gap sealing, stress buffering, and environmental protection functions, ensuring the connection stability, sealing performance, and long-term conductivity reliability between the conductive terminal 20 and the insulating substrate 10.

[0033] Furthermore, the outer sheath 40 is a braided mesh tube, a spiral wound tube, a heat shrink tube, or a molded elastic sleeve.

[0034] Understandably, braided tubing provides high-strength tensile and cut-resistant protection; spiral wound tubing offers good flexibility and flexural retention; heat-shrink tubing tightly wraps the cable to form a uniform protective layer; and molded elastic sheaths, such as rubber, provide excellent shock absorption and abrasion resistance. These structures all provide initial, effective mechanical reinforcement and protection for the cable before injection molding, working in conjunction with the subsequent injection-molded encapsulation to form a gradient of protection.

[0035] Furthermore, the insulating substrate 10 has a first sealing ring 51 at one end near the cable assembly 30, and two second sealing rings 52 at the other end near the conductive terminal 20; wherein the first sealing ring 51 is larger than the second sealing rings 52. For example, the insulating substrate 10 includes a trapezoidal base plate and a flat boss, with a first sealing groove 11 and two second sealing grooves 12 formed on the periphery of the boss for mounting the first sealing ring 51 and the second sealing ring 52.

[0036] Understandably, the first sealing ring 51, located at the end of the insulating substrate 10 near the cable assembly 30, serves as both a primary seal and a stress reliever. Due to its large size and elasticity, it can absorb and disperse mechanical stresses from bending, torsion, and tension in the cable, preventing these forces from being directly transmitted to the internal precision crimping or welding points, thereby protecting the internal electrical connections from damage. The two second sealing rings 52, located at the end of the insulating substrate 10 near the conductive terminal 20, serve as auxiliary seals and provide installation positioning. When the UAV controller wiring structure 100 is inserted into the matching housing, these two small sealing rings form a tight fit with the inner wall of the housing, creating a more complete sealing cavity and providing a secondary sealing barrier to further improve the long-term reliability of the electrical connections.

[0037] Furthermore, the first sealing ring 51 has a rectangular cross-section, while the second sealing ring 52 has a circular cross-section.

[0038] Understandably, circular cross-section sealing rings provide stable and reliable radial compression seals, forming a static seal within the housing. Rectangular cross-section sealing rings, due to their larger pressure-bearing area and structural volume, offer excellent sealing while possessing stronger elastic deformation capabilities, more effectively buffering and dispersing axial forces and bending moments from the cable, thus achieving dynamic stress relief. Compared to a single-specification sealing ring, the combination of circular rings for static sealing and rectangular rings for dynamic sealing and stress relief achieves better sealing performance and mechanical reliability at a lower cost and with a more compact structure.

[0039] In the description of this invention, it should be understood that the indicated orientation or positional relationship is based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description, and is not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0040] Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art and related fields based on the embodiments of the present invention without inventive effort should fall within the scope of protection of the present invention. Structures, devices, and operating methods not specifically described and explained in the present invention, unless otherwise specified or limited, shall be implemented according to conventional means in the art.

Claims

1. A wiring structure for an unmanned aerial vehicle (UAV) controller, characterized in that, The unmanned aerial vehicle (UAV) controller wiring structure (100) includes: an insulating substrate (10), a conductive terminal (20), a cable assembly (30), and a protective component; the conductive terminal (20) includes a contact portion for electrical connection and an embedding portion for fixing; the insulating substrate (10) wraps around and fixes the embedding portion of the conductive terminal (20); wherein, a first sealing and curing material layer is filled between the embedding portion of the conductive terminal (20) and the wrapping interface of the insulating substrate (10); the cable assembly (30) includes at least one inner conductor (31) and an insulating layer (32) wrapping the inner conductor (31), one end of the inner conductor (31) is electrically connected to the contact portion of the conductive terminal (20), and the other end of the cable assembly (30) extends out of the second end of the insulating substrate (10); the protective component includes an outer sheath (40) wrapped around the outside of the insulating layer (32) and an encapsulation body that fixes the outer sheath (40) and the end of the cable assembly (30) within the insulating substrate (10) by injection molding.

2. The wiring structure for the UAV controller according to claim 1, characterized in that, The conductive terminal (20) is a one-piece metal part. The terminal includes a crimp section (21), a transition section (22) and a connecting section (23). The crimp section (21) is used to fix the internal conductor (31) of the cable assembly (30). The connecting section (23) is provided with an interface structure for detachable electrical connection with the external circuit. The transition section (22) is connected between the crimp section (21) and the connecting section (23) to disperse the mechanical stress between the crimp section (21) and the connecting section (23).

3. The wiring structure for the UAV controller according to claim 2, characterized in that, The crimping section (21) is a hollow cylindrical sleeve; the connecting section (23) is a connecting plate with a square or round through hole (231) forming the contact part of the conductive terminal (20); wherein, the transition section (22) is an inclined shrinking section connected between the crimping section (21) and the connecting section (23).

4. The wiring structure of the UAV controller according to claim 2 or 3, characterized in that, The embedded portion of the conductive terminal (20) has a non-smooth surface structure; and / or the cavity of the insulating substrate (10) that encloses and fixes the embedded portion has a non-smooth surface structure.

5. The wiring structure for the UAV controller according to claim 1, characterized in that, The first sealing and curing material layer is one or more composite materials selected from potting compound, silicone gel, epoxy resin or polyurethane adhesive.

6. The wiring structure for the UAV controller according to claim 1, characterized in that, The outer sheath (40) is a braided mesh tube, a spiral wound tube, a heat shrink tube, or a molded elastic sleeve.

7. The wiring structure for the UAV controller according to claim 1, characterized in that, The insulating substrate (10) is provided with a first sealing ring (51) at one end near the cable assembly (30), and two second sealing rings (52) are provided at one end of the insulating substrate (10) near the conductive terminal (20); wherein the size of the first sealing ring (51) is larger than that of the second sealing ring (52).

8. The wiring structure for the UAV controller according to claim 7, characterized in that, The first sealing ring (51) has a rectangular cross-section; the second sealing ring (52) has a circular cross-section.

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