Integrated sealed insulated high-voltage conductive connection strip for electric vehicles

Abstract

This invention relates to the field of conductive connection technology for electric vehicles, and discloses an integrated sealed and insulated high-voltage conductive connector for electric vehicles, comprising an insulating shell, a sealing ring, and a conductor. The conductor is embedded inside the insulating shell, and the sealing ring is fitted into the slot of the conductor. A sealant is sprayed between the sealing ring and the slot of the conductor. The surface of the conductor is electroplated with a tin layer. Blind bolt holes for interlocking with matching parts are provided at the center of both ends of the conductor. The insulating shell is made of polybutylene terephthalate. This integrated sealed and insulated high-voltage conductive connector for electric vehicles utilizes the interference fit between the sealing ring and the conductor slot, along with the sealant spraying structure, to achieve a tight fit between the conductor and the sealing ring. Combined with the full-coverage protection of the insulating shell, it significantly improves the overall sealing performance, effectively preventing external environmental erosion of the internal structure and ensuring the stability and durability of the sealing effect.

Description

Technical Field

[0001] This invention relates to the field of conductive connection technology for electric vehicles, specifically to an integrated sealed and insulated high-voltage conductive connector for electric vehicles. Background Technology

[0002] High-voltage conductive connectors for electric vehicles are key connectors that enable power transmission between high-voltage core components such as battery packs and controllers in electric vehicles. Their conductivity, sealing and insulation properties, and structural adaptability directly affect the operational stability, safety, and service life of the high-voltage system in electric vehicles, and they are widely used in the field of new energy electric vehicles.

[0003] In existing high-voltage conductive busbars, the conductive copper busbars and sealing and insulation components are independent. Typically, during installation, additional sealing gaskets and insulating washers are added at the joints, and then bolts are tightened to achieve sealing and insulation. This separate assembly method is not only cumbersome, but also prone to inconsistent sealing due to variations in manual installation, making it difficult to guarantee stable sealing performance. Furthermore, over long-term use, problems such as loose bolts and aging / deformed sealing gaskets can easily lead to seal failure. External impurities such as moisture, salt spray, and dust can easily penetrate the connection points, causing conductor oxidation and increased contact resistance. This not only reduces conductivity but also easily leads to safety hazards such as excessive temperature rise, insulation breakdown, and flashover, seriously affecting the operational reliability of the high-voltage system. Summary of the Invention

[0004] Technical problems to be solved To address the shortcomings of existing technologies, this invention provides an integrated sealed and insulated high-voltage conductive connector for electric vehicles. This solves the problem of separate designs for conductive copper busbars and sealing / insulating components, which require additional sealing gaskets and insulating pads for assembly and bolt fastening, resulting in cumbersome assembly procedures and poor consistency of sealing components.

[0005] (II) Technical Solution To achieve the above objectives, the present invention provides the following technical solution: an integrated sealed and insulated high-voltage conductive connector for electric vehicles, comprising an insulating shell, a sealing ring, and a conductor. The conductor is embedded inside the insulating shell, the sealing ring is fitted into the slot of the conductor, and sealant is sprayed between the sealing ring and the slot of the conductor. The surface of the conductor is electroplated with a tin-plated layer, and blind bolt holes for overlapping with the opposite parts are provided at the center of both ends of the conductor.

[0006] Preferably, the insulating shell is made of polybutylene terephthalate and is integrally formed by injection molding; the conductor is made of electrolytic copper; and the sealing ring is made of methyl vinyl silicone.

[0007] Preferably, the slot of the conductor has a square structure, the sealing ring has a square cross-section structure adapted to the slot, the slot and the sealing ring are interference fit, and the inner diameter of the sealing ring is tightly sealed to the conductor and the inner wall surface of the slot.

[0008] Preferably, the external structure of the insulating housing is customized according to the installation environment, meets ergonomic requirements, and enables convenient installation of the high-voltage conductive connection bar.

[0009] Preferably, a wire threaded insert is embedded in the blind bolt hole to ensure the torque requirement for bolt lap tightening, the cross-sectional area of ​​the conductor is adapted to the working condition of continuous high current, and the temperature rise of the conductor is controlled within a reasonable range.

[0010] Preferably, the sealing ring and the conductor are embedded together inside the insulating shell, and the insulating shell protects the sealing ring and the conductor from damage by external salt spray, temperature and humidity environments.

[0011] Preferably, the sharp corners of the sealing ring are chamfered to prevent cracks or tears from forming when the sealing ring is subjected to external forces.

[0012] Preferably, the insulating shell adopts a flat wrapping design, and an insulating layer is formed by injection molding around the sealing ring embedded in the groove, which ensures both insulation and support strength, and meets the sealing performance requirements.

[0013] Preferably, the sealing performance of the insulating shell meets the protection level requirements for dustproof, waterproof and high-pressure water spray, the insulation withstand voltage performance meets the technical requirements of no breakdown and no flashover under high voltage DC voltage, and the conductivity of the conductor meets the standard requirements for the conductivity of pure copper.

[0014] (III) Beneficial Effects Compared with the prior art, the present invention provides an integrated sealed and insulated high-voltage conductive connector for electric vehicles, which has the following advantages: 1. This integrated sealed and insulated high-voltage conductive connector for electric vehicles utilizes an interference fit between the sealing ring and the conductor slot, along with the application of sealant, to achieve a tight fit between the conductor and the sealing ring. Combined with the full protection of the insulating shell, this significantly improves the overall sealing performance, effectively preventing external environmental erosion of the internal structure and ensuring the stability and durability of the sealing effect.

[0015] 2. This integrated sealed and insulated high-voltage conductive connector for electric vehicles utilizes a structure where the conductor, sealing ring, and insulating shell are integrally injection molded, integrating conductivity, insulation, and sealing functions into one unit. This replaces the traditional separate installation method of bolts and sealing gaskets, simplifying the assembly process and enabling convenient installation and disassembly. At the same time, it makes the overall structure more compact, significantly saving installation space and adapting to the confined installation conditions of electric vehicles.

[0016] 3. This integrated sealed and insulated high-voltage conductive connector for electric vehicles utilizes a tin-plated layer on the conductor surface and the selection of specialized materials to ensure excellent conductivity. Combined with the pressure-resistant insulation design of the insulating shell, the connector achieves efficient conductivity while meeting insulation requirements under high-voltage conditions, balancing conductivity efficiency and safety, and is suitable for the high-voltage power consumption scenarios of electric vehicles. Attached Figure Description

[0017] Figure 1 This is a schematic diagram showing the overall structure of the present invention broken down; Figure 2 This is a schematic diagram of the sealing ring structure of the present invention; Figure 3 This is a schematic diagram of the conductor structure of the present invention.

[0018] In the diagram: 1. Insulating shell; 2. Sealing ring; 3. Conductor; 4. Tin plating layer; 5. Blind hole bolt hole; 6. Groove; 7. Sealant. Detailed Implementation

[0019] 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.

[0020] Please see Figure 1 - Figure 3 As shown, an integrated sealed and insulated high-voltage conductive connector for electric vehicles includes an insulating housing 1, a sealing ring 2, and a conductor 3. The conductor 3 is embedded inside the insulating housing 1. The sealing ring 2 is fitted into the slot 6 of the conductor 3, and sealant 7 is sprayed between the sealing ring 2 and the slot 6 of the conductor 3. The surface of the conductor 3 is electroplated with a tin-plated layer 4. Blind bolt holes 5 for overlapping with the hands are opened at the center of both ends of the conductor 3.

[0021] First, the insulating shell 1 is made of polybutylene terephthalate and is integrally molded using injection molding. The conductor 3 is made of electrolytic copper, and the sealing ring 2 is made of methyl vinyl silicone. By selecting polybutylene terephthalate and electrolytic copper for the conductor 3 with a tin-plated layer 4, high conductivity is achieved while improving corrosion resistance. The sealing ring 2 is made of methyl vinyl silicone rubber, which ensures good flexibility, adhesion, and resistance to aging, corrosion, and temperature and humidity changes, making it suitable for the complex operating environment of electric vehicles.

[0022] Secondly, the slot 6 of conductor 3 has a square structure, and the sealing ring 2 has a square cross-section structure that is adapted to the slot 6. The slot 6 and the sealing ring 2 are interference-fitted, and the inner diameter of the sealing ring 2 is tightly sealed to the inner wall of conductor 3 and slot 6. Through the square adaptation structure of slot 6 and sealing ring 2 + 0.1mm interference fit design, the sealing ring 2 is firmly fixed in the slot 6 of conductor 3, preventing it from loosening during use. Through the tight sealing fit between the inner diameter of the sealing ring 2 and the inner wall of slot 6, the primary seal between conductor 3 and sealing ring 2 is achieved, blocking the medium leakage channel.

[0023] Furthermore, the external structure of the insulating housing 1 is customized according to the installation environment and meets ergonomic requirements, enabling convenient installation of the high-voltage conductive connection bar. By customizing the external shape of the insulating housing 1 according to the installation environment and following the ergonomic design of the operation and assembly structure of the insulating housing 1, the installation space requirements of electric vehicle battery packs and controllers are met, while reducing the difficulty of installation operations, improving on-site assembly efficiency, and reducing installation time.

[0024] Furthermore, a wire thread insert is embedded in the blind bolt hole 5 to ensure the torque requirement for bolt lap tightening. The cross-sectional area of ​​conductor 3 is adapted to the working condition of continuous high current, and the temperature rise of conductor 3 is controlled within a reasonable range. By embedding a wire thread insert in the No. 6 blind bolt hole 5 of conductor 3, the torque bearing capacity during bolt tightening can be improved, while preventing the threads of blind bolt hole 5 from stripping or wearing, thus achieving the firmness and conductivity stability of the connection between the conductive connector and the component.

[0025] Furthermore, the sealing ring 2 and the conductor 3 are embedded together inside the insulating shell 1. The insulating shell 1 protects the sealing ring 2 and the conductor 3 from damage caused by external salt spray, temperature and humidity. By precisely designing the cross-sectional area of ​​the conductor 3 and matching it with the high conductivity of T2 copper, the temperature control requirement of the conductor 3 being ≤30 Kelvin is achieved under the condition of continuous energization of 300A high current. This avoids the aging of the insulating shell 1, the failure of the sealing performance of the sealing ring 2, and the decline in the conductivity of the conductor 3 due to excessive temperature rise.

[0026] Furthermore, the sharp corners of the sealing ring 2 are chamfered to prevent cracks or tears from forming under external forces. By embedding the sealing ring 2 and conductor 3 into the injection-molded structure of the insulating shell 1, the insulating shell 1 provides full-dimensional physical protection for the sealing ring 2 and conductor 3, isolating them from the erosion of harsh environmental factors such as salt spray, sudden changes in temperature and humidity, and dust, thus achieving long-term stability of sealing and conductivity performance and extending the product's service life.

[0027] Furthermore, the insulating shell 1 adopts a flat wrapping design, and an insulating layer is formed by injection molding around the sealing ring 2 embedded in the groove 6. This ensures both insulation and support strength, while also meeting the sealing performance requirements. By optimizing the sharp corners of the sealing ring 2 cross-section with a chamfered R-angle structure, the stress concentration at the sharp corners can be eliminated, preventing damage such as cracks or tears in the sealing ring 2 under external pressure or tension during injection molding, installation, or use. This ensures the integrity of the sealing structure and the continuity of the sealing effect.

[0028] Finally, the sealing performance of the insulating shell 1 meets the protection level requirements for dustproof, waterproof and high-pressure water spray, the insulation withstand voltage performance meets the technical requirements of no breakdown and no flashover under high voltage DC voltage, and the conductivity of the conductor 3 meets the standard requirements for the conductivity of pure copper.

[0029] In summary, this integrated sealed and insulated high-voltage conductive connector for electric vehicles, when in use, achieves the coordinated realization of three major functions—conductivity, sealing, and insulation—through the integrated structural design and manufacturing process of conductor 3, sealing ring 2, and insulating shell 1. Simultaneously, relying on the structural compatibility and material characteristics of each component, it ensures stable operation under the high-voltage conditions of electric vehicles. The conductivity function is realized by conductor 3 as the core carrier. Conductor 3 is made of electrolytic copper with a conductivity of not less than 95%, meeting the high-voltage, high-current transmission requirements of electric vehicles. A tin plating layer 4 is electroplated on the surface of conductor 3, which effectively prevents oxidation of conductor 3. To prevent increased contact resistance and ensure stable conductivity, conductor 3 is designed with a cross-sectional area for high-current operation. Under continuous 300A operation, the temperature rise is ≤30 Kelvin, preventing excessive temperature rise from affecting conductivity and surrounding components. Each end of conductor 3 has a No. 6 blind bolt hole 5 at its center, with a steel wire thread insert embedded inside. This allows for connection to components such as electric vehicle battery packs and controllers via bolts, with a tightening torque ≥9 N·m. This ensures reliable connection between conductor 3 and external high-voltage components, achieving stable power transmission. The two blind bolt holes 5 at both ends guarantee symmetrical connection and balanced conductivity.

[0030] The sealing function is achieved through the combined action of the sealing ring 2, the conductor 3 slot 6, and the sealant 7, along with the protective enclosure of the insulating shell 1. The sealing performance reaches IP6K7K and IP6K9K levels, effectively preventing the intrusion of external moisture, salt spray, dust, and other impurities. A square slot 6 is formed on the conductor 3, and the sealing ring 2 is designed with a square cross-section to fit the slot 6. The slot 6 and the sealing ring 2 form a 0.1mm interference fit. The inner diameter of the sealing ring 2 (13.9mm) tightly seals against the inner wall diameter of the conductor 3 slot 6 (14.4mm), ensuring the sealing ring 2 is securely embedded within the slot 6, forming the first line of defense. The sealing ring 2 is made of methyl vinyl silicone, possessing excellent flexibility and adhesion, allowing it to fully conform to the inner wall of the slot 6, preventing gaps. Before the sealing ring 2 is inserted into the slot 6 of the conductor 3, a layer of sealant 7 is sprayed into the slot 6 to ensure that the sealing ring 2 and the slot 6 of the conductor 3 are in full contact and adhered, eliminating any minor gaps that may exist in the interference fit, further enhancing the sealing effect, and forming a second sealing barrier. The sealing ring 2 and the conductor 3 are embedded together inside the insulating shell 1. The insulating shell 1 is injection molded to form a 2mm thick insulating layer around the sealing ring 2, completely encasing and protecting the sealing ring 2 from damage caused by external salt spray, temperature and humidity changes, and external forces, while also preventing the sealing ring 2 from aging and deformation, ensuring the durability of the sealing effect. In addition, the sharp corners of the sealing ring 2 are chamfered to prevent cracks or tears caused by injection molding or installation forces, ensuring the structural integrity of the sealing component.

[0031] The insulation function is achieved with the insulating shell 1 as the core. The insulation withstand voltage meets the technical requirements of 3KVDC 60S without breakdown or flashover, providing reliable insulation protection for high-voltage conduction processes and avoiding safety hazards such as leakage and short circuits. The insulating shell 1 is made of polybutylene terephthalate (PET), which has a small difference in thermal expansion coefficient with the conductor 3, effectively reducing concentrated stress after injection molding and preventing insulation layer cracking. The insulating shell 1 is integrally molded using an injection molding process, embedding and encapsulating the conductor 3 (containing a tin-plated layer 4) and the sealing ring 2 within it, completely isolating the conductor 3 from external metal parts and the shell, forming an integral insulation barrier. The insulating shell 1 adopts a flat, enclosed design, ensuring structural strength while adapting to the limited installation space of electric vehicles. For high-voltage operating conditions, the insulation... The injection molding thickness around the conductor 3 and sealing ring 2 in housing 1 is precisely controlled, ensuring both insulation performance and sufficient support strength to prevent insulation layer damage due to structural deformation. The shape and structure of the insulating housing 1 are customized according to the actual installation environment of electric vehicle battery packs and controllers, meeting ergonomic requirements. This facilitates installation while preventing bumps and scratches to the insulating housing 1 during installation, ensuring the integrity of the insulation layer. At the same time, the full-enclosure design of the insulating housing 1 can prevent external environmental factors from corroding the conductor 3 and sealing ring 2, indirectly protecting the stability of insulation performance. This high-voltage conductive connector integrates the insulating housing 1, conductor 3, and sealing ring 2 into a single unit through injection molding, replacing the traditional separate installation method of bolts and sealing washers. In practical use, one end of the connector is connected to the inside of the electric vehicle battery pack or controller, and the other end extends to the outside. Through the cooperation of the sealing ring 2 in the middle of the conductor 3 and the insulating shell 1, the inside of the battery pack / controller is isolated and sealed from the outside. The conductor 3 completes the transmission of high-voltage electrical energy, the insulating shell 1 provides insulation protection and mechanical support for the entire conductive and sealing structure, and the sealing ring 2 achieves sealing and isolation at the core position. At the same time, auxiliary structures such as the tin-plated layer 4, the sealant 7, and the blind bolt hole 5 work together with the core components: the tin-plated layer 4 ensures the stable performance of the conductive core, the sealant 7 enhances the sealing effect, and the blind bolt hole 5 enables reliable connection between the connector and the external components. Ultimately, the entire connector achieves efficient conductivity while having stable sealing and insulation performance, making it suitable for the complex operating conditions of electric vehicle high-voltage systems.

[0032] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

Claims

1. An integrated sealed and insulated high-voltage conductive connector for electric vehicles, comprising an insulating housing (1), a sealing ring (2), and a conductor (3), characterized in that: The insulating housing (1) is inlaid with a conductor (3), a sealing ring (2) is fitted into the slot (6) of the conductor (3), and a sealant (7) is sprayed between the sealing ring (2) and the slot (6) of the conductor (3). The surface of the conductor (3) is electroplated with a tin plating layer (4), and blind bolt holes (5) for connecting with the opposite parts are opened at the center of both ends of the conductor (3).

2. The integrated sealed and insulated high-voltage conductive connector for electric vehicles according to claim 1, characterized in that: The insulating shell (1) is made of polybutylene terephthalate and is integrally formed by injection molding. The conductor (3) is made of electrolytic copper and the sealing ring (2) is made of methyl vinyl silicone.

3. The integrated sealed and insulated high-voltage conductive connector for electric vehicles according to claim 1, characterized in that: The slot (6) of the conductor (3) is a square structure, and the sealing ring (2) is a square cross-section structure that is adapted to the slot (6). The slot (6) and the sealing ring (2) are interference fit, and the inner diameter of the sealing ring (2) is tightly sealed to the inner wall of the conductor (3) and the slot (6).

4. The integrated sealed and insulated high-voltage conductive connector for electric vehicles according to claim 1, characterized in that: The external structure of the insulating housing (1) is customized according to the installation environment and meets the requirements of ergonomics, so as to realize the convenient installation of the high voltage conductive connection bar.

5. The integrated sealed and insulated high-voltage conductive connector for electric vehicles according to claim 1, characterized in that: The blind bolt hole (5) is inlaid with a wire thread sleeve to ensure the torque requirement for bolt lap tightening. The cross-sectional area of ​​the conductor (3) is adapted to the working condition of continuous high current, and the temperature rise of the conductor (3) is controlled within a reasonable range.

6. The integrated sealed and insulated high-voltage conductive connector for electric vehicles according to claim 1, characterized in that: The sealing ring (2) and the conductor (3) are embedded together inside the insulating shell (1). The insulating shell (1) protects the sealing ring (2) and the conductor (3) from damage caused by external salt spray, temperature and humidity.

7. The integrated sealed and insulated high-voltage conductive connector for electric vehicles according to claim 1, characterized in that: The sharp corners of the cross section of the sealing ring (2) are chamfered to prevent cracks or tears from forming when the sealing ring (2) is subjected to external forces.

8. The integrated sealed and insulated high-voltage conductive connector for electric vehicles according to claim 1, characterized in that: The insulating shell (1) adopts a flat wrapping design, and an insulating layer is formed by injection molding around the sealing ring (2) embedded in the slot (6), which ensures both insulation and support strength, and meets the sealing performance requirements.

9. The integrated sealed and insulated high-voltage conductive connector for electric vehicles according to claim 1, characterized in that: The sealing performance of the insulating shell (1) meets the protection level requirements of dustproof, waterproof and high-pressure water spray, the insulation withstand voltage performance meets the technical requirements of no breakdown and no flashover under high voltage DC voltage, and the conductivity of the conductor (3) meets the standard requirements of pure copper conductivity.

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