90-degree plastic quick-plug type shielding and sealing new energy cable hose connector

Abstract

The invention provides a 90-degree plastic quick-plug type shielding and sealing new energy cable hose connector, and belongs to the technical field of new energy automobile connectors. The connector comprises a 90-degree connector shell made of an insulating reinforced plastic material, a sealing assembly, a tail cover hasp and a shielding stretching elastic sheet, the shielding stretching elastic sheet is directly sleeved and crimped on the cable shielding layer, and the annular elastic sheet end of the shielding stretching elastic sheet is directly contacted and conducted with the box body, so that short-path shielding connection is established, and conduction through the shell is not needed; and the tail cover hasp adopts a'boss-pit 'mechanical interlocking structure, so that the axial tension of the hose is effectively resisted. Integrated preassembling of the connector on the cable is achieved, the assembling procedures of terminal clients are greatly reduced, meanwhile, the connector has the advantages of being light in weight, good in sealing performance, low in shielding contact resistance, high in mechanical strength and the like, and the problems that an existing metal connector is heavy and tedious in assembling are solved.

Description

Technical Field

[0001] This invention belongs to the field of new energy vehicle connector technology, specifically relating to a 90° plastic quick-connect shielded and sealed new energy cable hose connector mainly used in automotive power transmission scenarios. Background Technology

[0002] With the rapid development of the new energy vehicle industry, especially the evolution of vehicle architecture towards higher voltage (such as 800V high-voltage platforms) and higher current, extremely stringent requirements have been placed on the insulation withstand voltage rating, electromagnetic shielding effectiveness, and waterproof sealing performance of high-voltage wiring harness connectors. As the lifeline and artery of energy transmission in the three-electric system of new energy vehicles, the reliability of high-voltage power cables directly affects the stability of vehicle power output and driving safety. Therefore, optimizing assembly processes and improving the reliability of connection structures while ensuring the safety of high-voltage electrical connections (excellent shielding and sealing) has become a pressing technical challenge for the industry.

[0003] Currently, most new energy vehicle power cables use metal-shielded waterproof cable connectors. Their typical structure involves a threaded connection to a sealed housing, with the cable secured by a round nut on the connector tightening and compressing the sealing bushing. Finally, a metal spring connects the cable shielding layer, connector, and housing to achieve conductive shielding. This typically includes components such as a metal shell, threaded locking mechanism, independent sealing bushing, and metal shielding spring, requiring multiple assembly steps at the terminal site, including cable insertion, shielding treatment, nut tightening, and sealing crimping. Its disadvantages include: 1. The assembly process is complicated and depends on the operator's skills, which can easily lead to problems such as inadequate sealing and poor shielding contact; 2. The weight is relatively large, which is not conducive to the overall vehicle lightweighting; 3. Hose and connector are usually separate, requiring additional hose to be installed at the terminal, thus disrupting the process; 4. It has many structural parts, resulting in higher costs.

[0004] Based on the inventor's extensive practical experience in the design and manufacturing of high-voltage connection systems for new energy vehicles, and addressing the pain points of existing technologies such as cumbersome assembly of discrete components and unclear responsibility boundaries, the inventor conducted in-depth structural innovation and repeated prototype testing to provide an integrated, pre-installable solution. This solution, through structural optimization, moves the previously dispersed shielding and sealing processes to the wiring harness supplier (second-tier supplier) for centralized completion, allowing end users to perform only simple insertion positioning and screw tightening operations. This design not only clarifies the quality responsibility of the supply chain but also significantly improves the assembly efficiency, connection reliability, and product consistency of the vehicle production line through standardized pre-installation processes, thus completing the creation of this invention. Summary of the Invention

[0005] Purpose of the invention: The main purpose of this invention is to provide a 90° plastic quick-connect shielded and sealed new energy cable hose connector, which aims to achieve integrated pre-installation of the product on the cable, significantly reducing the installation process for end customers; at the same time, under the premise of using lightweight plastic material for the main body, the invention ensures excellent cable shielding contact conductivity, reliable sealing performance, and sufficient fixing strength to resist the axial tensile force of the hose through structural innovation, thereby solving the technical problems of existing metal connectors being heavy, cumbersome to assemble, and having dispersed supply chain responsibilities.

[0006] Technical Solution: To solve the above-mentioned technical problems, the present invention provides a 90° plastic quick-connect shielded sealed new energy cable hose connector, including a 90° connector housing, a sealing component installed in the housing, a tail cap buckle, and a shielding tension spring; the 90° connector housing is made of insulating reinforced plastic material; the shielding tension spring is an integrally formed metal component, including a crimping cylinder, a middle stepped surface, and an annular contact spring; the crimping cylinder is crimped and fixed and connected to the cable shielding layer; the middle stepped surface is positioned on the end face of the 90° connector housing to form an axial stop structure, used to withstand the axial tension of the cable to prevent cable displacement; the annular contact spring is designed with a multi-convex circular structure, used to directly and elastically contact the inner wall of the housing hole when the connector is inserted into the housing mounting hole to achieve shielding conduction.

[0007] Furthermore, the tail cap latch is used to connect the protective corrugated hose to the 90° connector housing; the tail cap latch adopts a hinge and double snap-fit ​​structure; at least two protrusions are designed on the movable half of the tail cap latch, and corresponding recesses are provided on the main body of the tail cap latch; when the half latch is engaged, the protrusions fit into the recesses to form an axially reinforced fixing structure to disperse and resist the axial tensile force transmitted by the hose.

[0008] Furthermore, the 90° connector housing has a boss housing structure at its tail end, and the tail cover buckle has a square recess at its tail end. The square recess is adapted to be installed on the boss housing to fix the tail cover buckle to the housing.

[0009] Furthermore, the sealing assembly includes a wire seal located inside the 90° connector housing and a lip seal located outside the tail end of the 90° connector housing; the wire seal is used to seal the gap between the cable and the housing, and the lip seal is used to seal the gap between the housing and the customer's mounting hole.

[0010] Furthermore, the 90° connector housing consists of an injection-molded housing and a screw-hole bushing fitting press-fitted into a pre-drilled hole. The screw-hole bushing fitting is used to lock the connector onto the housing with screws.

[0011] The assembly process of this invention is divided into two stages, clarifying the responsibilities of the supply chain: Phase 1: Pre-installation by Tier 2 suppliers (completed by the wire harness factory) Step 1: Pass the high-voltage shielded cable through the protective corrugated hose and the finished product (including the assembled shell, sealing body seal, tail cap buckle, and lip seal) in sequence.

[0012] Step 2: Remove the outer insulation layer from the cable end to expose the shielding layer and turn it outwards.

[0013] Step 3: Insert the shielding stretch spring and cover the outward-facing shielding layer. Use a special crimping die to perform hexagonal crimping to ensure the spring is tightly fixed to the cable shielding layer.

[0014] Step 4: Insert the corrugated hose into the mounting teeth of the tail cap latch 1, fasten the latch, and use the above-mentioned "boob-recess" structure to lock the hose.

[0015] Phase Two: Installation by End Customers (Completed by OEM) Step 5: The customer directly inserts the pre-installed wiring harness assembly into the mounting hole of the enclosure.

[0016] Step Six: At this point, the lip seal is compressed to achieve a seal between the housing and the connector; at the same time, the annular spring of the shielding tension spring is compressed and maintains a constant contact pressure with the housing hole wall to achieve electromagnetic shielding conduction.

[0017] Step 7: Use screws to pass through the screw hole bushing fitting to lock the connector onto the housing.

[0018] Beneficial effects: The assembly process is significantly simplified: most of the assembly of the connector can be completed during the wire harness production stage (cable sealing and fixing, hose connection, and pre-installation of shielding springs). The terminal only needs to be inserted and locked. The installation time is reduced from minutes to seconds, significantly improving efficiency and eliminating the risk of human error in on-site assembly.

[0019] High performance and high reliability of shielded connection: The integrated shielding stretching spring directly presses the shielding layer and elastically contacts the enclosure, eliminating the accumulation of contact resistance between multiple parts, establishing a shorter and more stable shielding grounding path, with low shielding conduction resistance and good vibration resistance.

[0020] Integrated and lightweight design: Using a plastic shell as the main body and combining key functional metal parts, while meeting the IP67 / IP69K protection level and sufficient mechanical strength, it achieves a weight reduction of more than 60% compared to all-metal joints, which is beneficial to the improvement of vehicle energy efficiency.

[0021] Balancing structural strength and convenience: The tail cap buckle features a unique "hinge buckle + boss-recess interlocking" design, which enables quick fastening and disassembly of the hose, while effectively bearing axial tension through the mechanical interlocking structure, thus solving the reliability problem of plastic parts under long-term stress.

[0022] Cost and error-proofing advantages: Reduced number of parts and optimized assembly process lower overall costs. Multi-color exterior design provides intuitive error-proofing identification, enhancing system security. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall structure of the 90° plastic quick-connect shielded and sealed new energy cable hose connector in an embodiment of the present invention; Figure 2 yes Figure 1 Overall sectional view; Figure 3 yes Figure 1 Explosion-decomposition diagram; Figure 4 This is a cross-sectional view of the present invention assembled on a customer's enclosure according to an embodiment of the invention; Figure 5 This is a schematic diagram of the engagement state of the tail cap buckle and the protective corrugated hose in an embodiment of the present invention; Figure 6 yes Figure 1 Enlarged view of the tailgate latch; Figure 7 yes Figure 1 The shielding tension spring before crimping; Figure 8 yes Figure 1 The shielding tension spring before crimping; Explanation of reference numerals in the attached drawings: 1. Tail cover buckle; 2. Sealing body seal; 3. 90° connector housing; 4. Lip seal; 5. Shielding tension spring; 10. Protective corrugated hose; 11. New energy cable; 12. Housing; 13. Set screw. Detailed Implementation

[0024] Example 1: like Figure 1-3 As shown, the 90° plastic quick-connect shielded and sealed new energy cable hose connector of this embodiment is mainly composed of a tail cap buckle 1, a sealing body seal 2, a 90° connector housing 3, a lip seal 4, and a shielding tension spring 5.

[0025] Main Structure and Materials: The 90° connector housing 3 serves as the main carrier and is injection molded from insulating reinforced plastic (such as high-strength engineering plastics like PA66+GF), resulting in a compact structure. To ensure installation strength, the 90° connector housing 3 consists of an injection-molded housing and a metal threaded bushing fitting, which is press-fitted into the pre-drilled hole.

[0026] Shielding conductive structures: such as Figure 7 and Figure 8 As shown, the shielding tension spring 5 is one of the core components of this invention, and it is made of a highly conductive metal material (such as copper alloy). Unlike existing technologies that rely on the shell for conductivity, the shielding tension spring 5 of this invention is directly sleeved on the shielding layer of the new energy cable; Fixed end: One end of the spring contact is pressed together with the outward-facing cable shielding layer using a hexagonal crimping process. This satisfies both the need for tight contact and conductivity between the spring contact and the cable shielding layer, and also secures the spring contact and cable as a single unit.

[0027] like Figure 6 As shown, the shielding tension spring 5 is a metal component formed by stamping. Its axial structure mainly includes three parts: the upper pressing cylinder, the middle positioning step, and the lower multi-convex annular contact.

[0028] Crimping cylinder (connection end): The upper end is designed as a cylindrical structure, which is fitted onto the outward-facing shielding layer of the cable. Through a hexagonal crimping process, the cylinder undergoes plastic deformation, tightly wrapping and gripping the cable shielding layer, achieving the dual function of electrical conduction and mechanical fixation.

[0029] Positioning Step (Anchoring End): A radially enlarged intermediate step surface is designed between the crimping cylinder and the lower contact. This intermediate step surface directly abuts (positions) axially against (positions) the inner end face of the 90° connector housing 3. This fit forms a rigid axial limiting structure. When the cable is subjected to an outward pulling force, the force is transmitted through the crimping cylinder to the intermediate step surface and blocked by the 90° connector housing 3. Therefore, the shielding tension spring 5 also functions as a cable anchoring device, effectively preventing cable displacement and successfully replacing the traditional connector structure that relies on the compression of a sealing bushing to fix the cable, simplifying the design.

[0030] Multi-convex circular contact (contact end): The lower end is designed as a ring-shaped (multi-convex circular) spring structure, that is, several outwardly protruding elastic contacts are evenly distributed on the circumference of the ring base (as shown in the figure). When the connector is inserted into the mounting hole of the enclosure, these convex circular contacts undergo elastic deformation under pressure, directly and tightly adhering to the inner wall of the enclosure. The point contact structure allows for smooth installation, movement, and rotation without significant resistance, satisfying both tight contact and convenient installation and use. The high-stress multi-point contact maintained on the inner wall of the enclosure ensures shielded conduction with low contact resistance.

[0031] like Figure 4 As shown, the above combination establishes a direct short path from the cable shielding layer to the shielding tension spring and then to the customer housing, without passing through the connector housing, thus allowing the 90° connector housing 3 to be made of plastic.

[0032] Hoses fixing and tensile structures: such as Figure 5 and Figure 6 As shown, the tail cap buckle 1 is used to secure the protective corrugated hose 10. Its main body adopts a hinge and double-buckle fastening structure.

[0033] To address the issue of plastic buckles easily breaking apart when subjected to axial tension from the corrugated tube, this embodiment features two rectangular protrusions on the movable half-hook and a recess at the corresponding position on the main body of the tail cap buckle 1.

[0034] Working principle: When the half-fastener is closed, the boss engages with the recess, forming a mechanical interlock. When the hose generates axial tension, this force is transmitted and dispersed through the contact surface between the boss and the side wall of the recess, preventing the force from acting directly on the fragile hinge or buckle cantilever, thus significantly improving the axial tension resistance.

[0035] Performance comparison data and test report summary Example 2: The assembly process of this invention is divided into two stages to clarify supply chain responsibilities: Phase 1: Pre-installation by Tier 2 suppliers (completed by the wire harness factory) Step 1: Press the metal screw hole bushing fitting into the 90° connector injection molded housing to form the 90° connector housing 3. Step 2: Install the sealing body seal 2 and the lip seal 4 into the corresponding positions of the 90° connector housing 3 in sequence. Step 3: Press the tail cap latch 1 onto the protrusion of the 90° connector housing 3 to complete the pre-assembly of the connector body. Step 4: Pass the high-voltage shielded cable through the protective corrugated hose 10 and through the pre-installed connector, so that the cable extends from the front. Step 5: Insert the hose into the toothed buckle of the tail cap latch 1 and lock it in place. Step 6: Peel off the outer insulation layer at the designated position at the front of the cable and turn the exposed shielding layer outward. Step 7: Place the five shielding stretch spring clips onto the outward-facing shielding layer and use a dedicated hexagonal crimping tool to crimp and secure them. The crimping force ensures that the inner wall structure of the spring clips tightly engages with the shielding layer.

[0036] The subsequent standard procedures include crimping and heat shrinking of the cable terminals. At this point, a complete, deliverable modular "cable-hose-connector" assembly is ready.

[0037] Phase Two: Installation by End Customers (Completed by OEM) Step 8: Insert the above modular components directly into the mounting holes on the housing 12, so that the lip seal 4 enters the hole and the annular spring of the shielding tension spring 5 contacts the wall of the housing hole. Step 9: First, fix the cable terminals to the corresponding positions on the enclosure with screws. Step 10: Then, use the set screw 13 to pass through the mounting hole of the 90° connector housing 3 and fasten it to the housing 12. After installation, the sealing element 2 achieves radial sealing of the cable, the lip seal 4 achieves axial sealing of the enclosure hole, and the shielding tension spring 5 achieves electrical connection between the shielding layer and the enclosure.

Claims

1. A 90° plastic quick-connect shielded sealed new energy cable hose connector, comprising a 90° connector housing (3), a sealing assembly installed within the 90° connector housing (3), a tail cap buckle (1) for connecting a protective corrugated hose (10), and a shielding tension spring (5); characterized in that: The 90° connector housing (3) is made of insulating reinforced plastic material; The shielding tension spring (5) is an integrally formed metal component, including a crimping cylinder, an intermediate stepped surface, and an annular contact spring; the crimping cylinder is crimped and fixed to the cable shielding layer; the intermediate stepped surface is positioned on the end face of the 90° connector housing (3) to form an axial stop structure, which is used to withstand the axial tension of the cable to prevent cable displacement; the annular contact spring is designed with a multi-convex circular structure, which is used to directly and elastically contact the inner wall of the housing when the connector is inserted into the housing mounting hole to achieve shielding conduction.

2. The 90° plastic quick-connect shielded sealed new energy cable flexible conduit joint according to claim 1, characterized in that: The tail cap buckle (1) adopts a hinge and double buckle fastening structure; at least two protrusions are designed on the movable half buckle of the tail cap buckle (1), and a corresponding recess is provided on the main body of the tail cap buckle (1); when the tail cap buckle (1) is fastened, the protrusions are fitted into the recesses to form an axially reinforced fixing structure to disperse and resist the axial tension transmitted by the hose.

3. The 90° plastic quick-connect shielded sealed new energy cable flexible conduit joint according to claim 1, characterized in that: The tail of the 90° connector housing (3) is provided with a boss housing structure, and the tail cover buckle (1) is provided with a square recess at the tail. The square recess is adapted to be installed on the boss housing structure to realize the fixation of the tail cover buckle (1) and the 90° connector housing (3).

4. The 90° plastic quick-connect shielded sealed new energy cable flexible conduit joint according to claim 1, characterized in that: The sealing assembly includes a sealing body seal (2) located inside the 90° connector housing (3) and a lip seal (4) located outside the tail end of the 90° connector housing (3); the sealing body seal (2) is used to seal the gap between the cable and the 90° connector housing (3), and the lip seal (4) is used to seal the gap between the 90° connector housing (3) and the housing mounting hole.

5. A 90° plastic quick-connect shielded sealed new energy cable flexible conduit connector according to claim 1, characterized in that: The 90° connector housing (3) consists of an injection-molded housing and a screw hole bushing fitting pressed into a reserved hole, wherein the screw hole bushing fitting is made of metal.

6. The 90° plastic quick-connect shielded sealed new energy cable flexible conduit joint according to claim 1, characterized in that: The shielding stretching spring (5) is pressed into a hexagonal irregular shape by pressing the pressing cylinder body.

7. A method for assembling and using a 90° plastic quick-connect shielded sealed new energy cable flexible conduit joint as described in any one of claims 1 to 6, characterized in that: Including the pre-installation steps by the wire harness supplier: Step 1: Pass the high-voltage shielded cable through the protective corrugated hose (10) and the pre-assembled connector in sequence. The pre-assembled connector includes an assembled 90° connector housing (3), a sealing body seal (2), a tail cap buckle (1), and a lip seal (4). Step 2: Remove the outer insulation layer from the cable end to expose the shielding layer and turn it outwards; Step 3: Insert the shielding tension spring (5) and cover the outward-facing shielding layer, then press the shielding tension spring (5) to make it tightly fixed to the cable shielding layer; Step 4: Insert the protective corrugated hose (10) into the mounting teeth of the tail cap buckle (1), and fasten the buckle to lock the hose, forming a wire harness assembly.

8. The assembly and usage method according to claim 7, characterized in that, It also includes the OEM installation steps: Step 5: Insert the pre-assembled wiring harness assembly into the mounting holes of the enclosure; Step 6: Compress the lip seal (4) to seal the box and the connector, and at the same time compress the shielding stretching spring (5) to achieve electromagnetic shielding conduction between the cable shielding layer and the box hole wall; Step 7: Use screws to pass through the screw hole bushing fitting to tighten the connector onto the housing.

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