Flip seal assembly, flip connector, wire harness assembly

Abstract

This invention discloses a flip-top sealing assembly, a flip-top high-voltage connector, and a wiring harness assembly, belonging to the technical field of high-voltage power distribution systems for new energy vehicles. The flip-top sealing assembly includes a rotating part, a radial sealing part, and an axial locking part. The radial sealing part uses an inverted tower-shaped sealing ring in conjunction with a figure-eight-shaped oppositely arranged tower-shaped inclined surface and tower-shaped base surface to achieve a dynamic increase in sealing interference during the flip-top closing process. The rotating part uses a direct snap-fit ​​rotating pair to achieve a rapid rotational connection between the top cover and the wire end sheath. The axial locking part adopts a two-stage design with a main locking structure and a primary locking structure to achieve stable locking and redundant anti-disengagement. This invention, through the coordinated operation of multiple mechanisms, simultaneously improves the sealing reliability, assembly convenience, and adaptability to complex working conditions of the product, while simplifying the structure, controlling manufacturing costs, and adapting to the large-scale mass production and long-term reliable application requirements of high-voltage, high-current scenarios in new energy vehicles.

Description

Technical Field

[0001] This invention belongs to the technical field of high-voltage power distribution systems for new energy vehicles, specifically relating to a flip-top sealing assembly, a flip-top high-voltage connector, and a wiring harness assembly. Background Technology

[0002] With the rapid development of China's new energy vehicle industry, high-voltage, high-current connectors, as core components of high-voltage power distribution systems in new energy vehicles, are seeing their application scenarios expand and their application requirements continuously increase. High-voltage, high-current connectors need to operate for extended periods in complex environments such as vehicle vibration, alternating high and low temperatures, and humid corrosion, placing stringent demands on sealing reliability, ease of installation and operation, vibration resistance, and manufacturing cost control.

[0003] Existing flip-type high-voltage connectors exhibit numerous technical shortcomings in practical applications, hindering their overall performance in high-voltage, high-current scenarios. Firstly, the sealing rings of existing connectors often employ a right-angle design. During the flip-top rotation, the initial interference between the sealing ring and the sealing surface is significantly greater than the working interference, easily causing severe stress concentration. This not only results in excessive force during the flip-top rotation, affecting installation convenience, but also greatly increases the risk of separation between the sealing ring's contact surface and the connecting base, drastically reducing long-term sealing reliability. This problem has long remained unresolved. Secondly, the rotating connection structure of existing connectors requires additional components such as pins and torsion springs, leading to complex assembly processes, numerous parts, and increased production and assembly costs, making it difficult to meet the application requirements of large-scale mass production in the new energy vehicle industry. Thirdly, the locking structure of existing connectors relies solely on a single bolt for locking, which is prone to loosening under long-term automotive vibration conditions. The lack of redundant anti-loosening protection design means that under extreme conditions, the top cover popping open will directly lead to seal failure, resulting in insufficient product vibration resistance and operational adaptability. Finally, for rigid aluminum busbar connectors, the existing integrated tail clip structure is difficult to adapt to the assembly requirements of rigid aluminum busbars. The aluminum busbar positioning accuracy is poor, the assembly difficulty is high, and the production assembly efficiency is further reduced.

[0004] It should be noted that the analysis of the above technical information is the result of creative labor. The detailed description of it in the background section is only intended to deepen the understanding of the non-obviousness of the overall background of this application by those skilled in the art, and should not be regarded as an admission or in any form an implication that the above technical information constitutes prior art known to those skilled in the art. Summary of the Invention

[0005] This invention proposes a flip-top sealing assembly, a flip-top connector, and a wire harness assembly. The technical problem to be solved is: addressing the shortcomings of existing flip-top high-voltage connectors, such as poor sealing reliability, cumbersome assembly operations, insufficient vibration redundancy protection, and high assembly difficulty of rigid components. The invention aims to improve the long-term sealing reliability, ease of assembly operations, and adaptability to complex working conditions of the product while controlling production and manufacturing costs, thus solving the industry pain point that multiple mutually restrictive performance indicators cannot be simultaneously achieved in existing technologies.

[0006] The technical solution of this invention is as follows:

[0007] The first core technical solution: A flip-top sealing assembly includes a wire end sheath, a top cover rotatably connected to the wire end sheath, and a sealing ring disposed between the wire end sheath and the top cover. A rotating part, a radial sealing part, and an axial locking part are provided between the wire end sheath and the top cover. The radial sealing part includes a tower-shaped sealing ring. The side of the wire end sheath facing the top cover has a tower-shaped inclined surface, and the side of the top cover facing the wire end sheath has a tower-shaped base surface arranged opposite to the tower-shaped inclined surface. The inner circumference of the tower-shaped sealing ring has a contact surface that fits against the tower-shaped base surface, and the outer circumference of the tower-shaped sealing ring has... The tower-shaped crests abut against the tower-shaped slope, and both the tower-shaped slope and the tower-shaped base are arranged in an inverted V-shape. When the flip cover is closed, the two are in a parallel posture, and the parallel gap formed between them accommodates the tower-shaped sealing ring. The rotating part is a rotating pair set between the upper cover and the line end sheath. The upper cover is rotatably connected to the line end sheath through the rotating pair. The axial locking part includes a main locking structure and a primary locking structure. The main locking structure is used to lock and fix the upper cover and the line end sheath after closing. The primary locking structure is used to provide a holding force between the upper cover and the line end sheath when the main locking structure is loosened.

[0008] Beneficial effects: This solution fundamentally addresses the core pain point of existing technologies where sealing performance, ease of operation, and locking reliability cannot be simultaneously achieved. By using a tower-shaped sealing ring in conjunction with a figure-eight-shaped, relatively arranged tower-shaped inclined surface and tower-shaped base surface, dynamic changes in sealing interference are achieved during the flip-top rotation process. This solves the problems of stress concentration, large flipping operation force, and easy separation of the mating surfaces caused by excessive initial interference of the sealing ring in existing technologies. The integrated rotating joint structure enables rapid rotational connection between the top cover and the wire end sleeve, simplifying the assembly structure. The dual-stage design of the main locking structure combined with the primary locking structure achieves both stable locking and redundancy protection under extreme conditions, preventing sealing failure and significantly improving the overall performance of the product.

[0009] Preferably, the outer contour of the tower-shaped sealing ring is arranged in an inverted tower shape, and the angle α between the tower-shaped contour of the tower-shaped sealing ring and the vertical reference line is 5°-45°.

[0010] Further beneficial effects: This angle range can be adapted to connector products of different specifications, achieving optimal dynamic variation of interference, ensuring a smooth increase in interference during flip rotation, reducing the flipping operation force while maintaining sealing pressure during operation, and adapting to application requirements under different working conditions. Theoretically, the α angle is between 0° and 90°, and 5°-45° in this technical solution is the preferred implementation method.

[0011] Preferably, the rotating part includes a rotating shaft disposed on the upper cover and a pin hole disposed on the wire end sheath. The rotating shaft is connected to the upper cover by a spring tongue, and the pin hole is disposed in the boss of the wire end sheath. The top or side end of the boss is provided with a guide angle, and the rotating shaft can be inserted into the pin hole along the guide angle to form a rotating pair.

[0012] Further beneficial effects: This structure requires no additional pins, torsion springs or other accessories. It can achieve tool-free quick snap-fit ​​between the rotating shaft and the pin hole simply by pressing, which greatly simplifies the assembly process, reduces the number of parts, lowers the production and manufacturing costs, and at the same time ensures the connection stability and smooth rotation of the rotating pair.

[0013] Preferably, the two rotating shafts on two adjacent springs are arranged in opposite directions, and the rotating part further includes a support rib connected to the upper cover. The two ends of the support rib are fitted with the two adjacent springs with a gap to protect the springs.

[0014] Preferably, the main locking structure includes an upper cover bolt and a bushing fixed to the upper cover. The upper cover bolt has a threaded top and a threadless area at the root. The inner side of the bushing has an internal thread that matches the threaded thread. When the upper cover bolt is screwed into the threadless area, it can be held in the bushing to achieve the screw-in retention function.

[0015] Further beneficial effects: This structure allows for pre-installation of the top cover bolts to prevent them from falling off. After assembly, the bolts can be stably held in the bushing, eliminating the need for on-site manual alignment and significantly improving on-site assembly efficiency. At the same time, the bushing bears the bolt tightening torque, preventing torque damage to the plastic top cover and improving the long-term reliability of the locking structure.

[0016] Preferably, the bushing has an annular bushing top surface on one end face near the top cap, and a small stop surface on the opposite end face along the axis, the area of ​​the small stop surface being smaller than the area of ​​the bushing top surface; in the working state, the small stop surface contacts the flat washer provided on the top cover bolt, and a spring washer is provided between the flat washer and the top cover bolt to bear the torque applied by the top cover bolt.

[0017] Preferably, the wire end sheath is provided with a U-shaped protrusion, and the U-shaped protrusion is provided with a U-shaped groove along the central axis for the top cover bolt to pass through. The end face of the U-shaped protrusion near the top cover is provided with a U-shaped top surface, and the side end face of the U-shaped top surface is provided with a U-shaped bottom surface. The top surface of the bushing contacts the top surface of the U-shaped top surface to bear the torque from the top cover bolt.

[0018] Further beneficial effects: The open U-slot design allows for lateral bolt insertion without requiring precise axial alignment, further reducing assembly difficulty; the direct contact between the U-shaped top surface and the bushing top surface directly transmits the bolt tightening force to the cable end sheath body, optimizing the tightening force transmission path, avoiding stress concentration in the upper cover plastic structure, and simultaneously transmitting external vibrations directly to the connector as a whole, reducing local vibration loss and significantly improving the product's vibration resistance. Most importantly, the open U-slot structure facilitates installation and disassembly. During disassembly, after the upper cover bolts are detached from the plate end, rotating the upper cover allows the bolts to slide directly out of the open U-slot structure without interfering with the U-shaped sidewalls.

[0019] Preferably, the primary lock structure includes locking springs symmetrically arranged on the upper cover and trapezoidal bosses symmetrically arranged on the end sheath. The end of the locking spring is provided with a spring stop surface and a guide slope, and the trapezoidal boss is provided with a boss stop surface and a boss guide surface. During the closing process of the flip cover, the locking spring can spring up along the boss guide surface and then reset, so that the spring stop surface and the boss stop surface abut against each other to form a lock.

[0020] Corresponding beneficial effects: This structure can automatically lock simultaneously when the flip cover is closed, without additional operation. Even in extreme conditions where the main locking structure may loosen due to long-term vibration, it can still provide effective holding force for the top cover and the wire end sheath, keeping the top cover in the closed position, avoiding seal failure, and greatly improving the reliability and robustness of the product under complex vibration conditions.

[0021] Preferably, the wire end sheath is provided with an insulating inner core, the insulating inner core is provided with a circumferentially arranged fixing tongue, the end of the fixing tongue is provided with a fixing hook arranged towards the outer surface of the insulating inner core, the fixing hook can be hooked and fixed with the wire end sheath; the insulating inner core is also provided with a groove, the groove is used to limit the copper ring that is welded and fixed to the aluminum busbar.

[0022] Further beneficial effects: This structure enables quick attachment and fixation of the insulating core and the wire end sheath without the need for additional fasteners. At the same time, the slotted design allows for precise positioning of the aluminum busbar and copper ring welding assembly, ensuring installation coaxiality and improving assembly accuracy and efficiency.

[0023] Preferably, the tail end of the wire end sheath is connected to a split tail clip, which consists of two units that are aligned longitudinally at 180°. Each unit has a short half-groove and a long half-groove. When the two units are aligned, they form a limiting structure that covers the aluminum strip. Each unit has a convex groove and a T-shaped rib on both sides. The convex groove and T-shaped rib of the two units can be inserted into each other and matched. Each unit also has a tail clip spring with a tail clip hook, which can be hooked and fixed to the oblique protrusion of the wire end sheath.

[0024] Further beneficial effects: This split structure requires no pre-assembly and can be assembled with rigid aluminum strips from both sides, completely solving the problem that the integrated tail clip is difficult to adapt to rigid aluminum strips and has high assembly difficulty in the existing technology. It reduces the assembly difficulty of aluminum strips, improves positioning accuracy and assembly efficiency, and ensures the reliability of fixation through the interlocking structure and the hook-on structure.

[0025] The second core technical solution: A flip-type high-voltage connector, comprising a mating wire-end connector and a board-end connector. The wire-end connector includes the flip-type sealing assembly described in the first core technical solution. The board-end connector is provided with a board-end sheath, and the board-end sheath is provided with a protruding block with a threaded portion. The protruding block is provided one on one side of the board-end sheath, or two are provided and symmetrically arranged on both sides of the board-end sheath. The threaded portion is directly provided in the protruding block, or provided in a metal inner bushing, and the inner bushing is connected to the protruding block. The upper cover bolt of the axial locking portion can pass through the U-shaped groove of the wire-end sheath and lock with the threaded portion of the protruding block.

[0026] Beneficial Effects: This solution applies the aforementioned flip-top sealing assembly to high-voltage connectors. By directly locking and fixing the wire end sheath to the plate end sheath with the top cover bolts, external environmental vibrations can be directly transmitted to the connector's main structure, reducing local vibration losses and improving the connector's vibration resistance. Simultaneously, it fully inherits all the advantages of the sealing assembly, achieving simultaneous improvements in the sealing reliability, assembly convenience, and operating condition adaptability of the high-voltage connector, meeting the application requirements of high-voltage, high-current scenarios in new energy vehicles. Furthermore, this technical solution provides several specific and feasible options. For example, when the plate end sheath is made of plastic, the locking ability of the threaded portion directly arranged within the protruding block is limited. An insert injection molding process can be used to install an inner bushing within the protruding block, placing the threaded portion within the protruding block through the inner bushing.

[0027] Preferably, the board-end connector further includes an inner core sleeve, a temperature sensor, and a board-end pin. The two ends of the board-end pin are respectively provided with upper and lower threads. A temperature sensing hole is opened radially on the board-end pin. The temperature sensing part of the temperature sensor passes into the temperature sensing hole to collect temperature data. The limiting part of the temperature sensor is engaged with the limiting groove of the inner core sleeve for limiting.

[0028] Further beneficial effects: This structure enables direct and accurate acquisition of board-end pin temperature, with faster temperature response and higher accuracy. It can monitor temperature changes during the operation of high-voltage connectors in real time, provide timely warnings of overheating risks, and further improve the safety of connectors under high-voltage and high-current conditions.

[0029] The third core technical solution: a wire harness assembly, including the flip-type high-voltage connector described in the second core technical solution above, and a conductive component electrically connected to the flip-type high-voltage connector, wherein the conductive component is an aluminum busbar or a cable, and the conductive component is fixed on the insulating inner core of the flip-type high-voltage connector.

[0030] Beneficial effects: This solution applies the aforementioned high-voltage connector to the vehicle wiring harness system, fully inheriting all the performance advantages of the connector. It can achieve reliable connection and stable operation of the vehicle's high-voltage power distribution system, while reducing the operational difficulty in the vehicle assembly process, improving assembly efficiency, and adapting to the large-scale mass production needs of new energy vehicles.

[0031] Compared with the prior art, the present invention achieves the following significant overall beneficial effects:

[0032] First, this invention completely solves the industry pain point of the trade-off between sealing performance and ease of operation, significantly improving long-term sealing reliability. For the first time, this invention identifies that the initial interference of the sealing ring during the flip-top rotation process is far greater than the working interference, which is the core cause of seal failure. It breaks through the long-standing technical prejudice in the field that "right-angle cross-section sealing rings are the optimal sealing structure for flip-top connectors." Through the structure of an inverted tower-shaped sealing ring combined with a figure-eight conical sealing surface, it achieves a dynamic increase in sealing interference during the flip-top closing process. It maintains low interference in the initial flipping stage to reduce operating force and internal stress, and achieves optimal interference in the closing working stage to ensure sealing performance, simultaneously satisfying two opposing performance requirements. This design makes the internal stress distribution of the sealing ring more uniform, maintaining excellent elastic return capability even after long-term repeated use. The contact surface and the tower-shaped base surface remain tightly fitted, completely eliminating the risk of contact surface separation, extending seal life, and reducing flipping operating force, achieving technical effects that were unexpected by those skilled in the art.

[0033] Secondly, the assembly structure and processes are significantly simplified, improving production and on-site assembly efficiency and effectively controlling manufacturing costs. This invention utilizes an integrated structural design, molding the rotating joint's shaft, spring, and top cover into a single unit, as well as the pin hole and wire end sleeve. This eliminates the need for additional pins, torsion springs, or other accessories; tool-free rapid assembly of the rotating joint can be completed simply by pressing, simplifying the assembly process. The main locking structure uses bolts and bushings to achieve pre-installation and prevent slippage, eliminating the need for on-site manual alignment. The split tail clip can be quickly matched with the rigid aluminum strip from both sides, solving the problem of difficult assembly of rigid components. The overall solution reduces redundant parts, simplifies production and assembly processes, lowers manufacturing costs, and perfectly meets the large-scale mass production needs of the new energy vehicle industry.

[0034] Third, a dual-level locking redundancy protection system is constructed, significantly improving the product's vibration resistance and adaptability to complex operating conditions. This invention employs a dual-level design combining a main locking structure and a primary locking structure. The main locking structure directly locks and fixes the wire end sheath to the board end sheath, directly transmitting external vibrations to the connector body, reducing local vibration losses and improving vibration resistance. The primary locking structure, as redundant protection, still provides effective holding force even in extreme conditions where the main locking structure loosens, preventing the top cover from popping open and causing seal failure. This significantly improves the product's reliability and robustness under complex operating conditions such as long-term automotive vibration and alternating high and low temperatures.

[0035] Fourth, the entire system is optimized in a coordinated manner, balancing high performance and high safety. This invention achieves simultaneous improvements in sealing reliability, assembly convenience, and operational adaptability through the coordinated operation of three core mechanisms: sealing, hinge, and locking. Simultaneously, it optimizes the insulating core limiting structure, temperature monitoring structure, and anti-finger-touch structure, further enhancing the product's assembly accuracy, operational safety, and condition monitoring capabilities. It fully meets the industry standards and operational requirements of high-voltage, high-current connectors for new energy vehicles, possessing significant market application value. Attached Figure Description

[0036] To more clearly illustrate the embodiments of this technical solution, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this technical solution. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0037] Figure 1 This is an exploded structural diagram of the flip-type high-voltage connector in an embodiment of the present invention;

[0038] Figure 2 This is a partial cross-sectional view of the flip-top sealing assembly in an embodiment of the present invention;

[0039] Figure 3 This is a schematic diagram of the snap-fit ​​structure of the rotating part in an embodiment of the present invention;

[0040] Figure 4 This is a three-dimensional structural diagram of the flip-top sealing assembly in an embodiment of the present invention;

[0041] Figure 5 This is a three-dimensional structural diagram of the tower-shaped sealing ring in an embodiment of the present invention;

[0042] Figure 6 This is a schematic diagram of the three-dimensional and cross-sectional structure of the bushing in an embodiment of the present invention;

[0043] Figure 7 A comparison diagram of the contact states during the rotation process of the right-angle sealing ring flip cover in existing technologies;

[0044] Figure 8 This is a comparison diagram of the contact states during the rotation process of the tower-shaped sealing ring flip cover in an embodiment of the present invention;

[0045] Figure 9 This is a schematic diagram of the primary locking structure of the wire end sheath in an embodiment of the present invention;

[0046] Figure 10 This is a schematic diagram of the primary locking structure of the upper cover in an embodiment of the present invention;

[0047] Figure 11 This is a partial cross-sectional view of the primary lock structure in an embodiment of the present invention;

[0048] Figure 12 This is a three-dimensional structural diagram of the board-end connector in an embodiment of the present invention;

[0049] Figure 13 This is a schematic cross-sectional view of the board-end connector in an embodiment of the present invention;

[0050] Figure 14 This is a three-dimensional structural diagram of the anti-finger-touching structure in an embodiment of the present invention;

[0051] Figure 15 This is a three-dimensional structural diagram of the anti-touch finger cap in an embodiment of the present invention;

[0052] Figure 16 This is a cross-sectional schematic diagram of the anti-finger-touch structure in an embodiment of the present invention;

[0053] Figure 17 This is a cross-sectional schematic diagram of the high-voltage connector at the aluminum busbar end in an embodiment of the present invention;

[0054] Figure 18 This is a three-dimensional structural diagram of the split tail card in an embodiment of the present invention.

[0055] Explanation of reference numerals in the attached figures

[0056] 5. Rotating part; 6. Radial sealing part; 7. Axial locking part;

[0057] 11 Plate end sleeve; 111 Protruding block; 112 Threaded part;

[0058] 12 Inner core sleeve; 121 Limiting groove; 122 Terminal cavity;

[0059] 13 Temperature sensor; 131 Temperature sensing part; 132 Limiting part;

[0060] 14. Plate end pin; 141. Upper thread; 142. Lower thread; 143. Temperature sensing hole;

[0061] 15 Insulating cap; 16 Plate end sealing ring;

[0062] 21. Wire end sleeve; 211. Tower-shaped bevel; 212. Boss; 213. Guide bevel; 214. Pin hole; 215. Upper cavity; 216. U-shaped protrusion; 217. U-shaped groove; 218. U-shaped top surface; 219. U-shaped bottom surface; 2100. Trapezoidal boss; 2101. Boss stop surface; 2102. Boss guide surface; 2103. Beveled boss;

[0063] 22. Line plate sealing ring; 23. Clip; 24. Tower-shaped sealing ring; 241. Tower-shaped crest; 242. Mating surface; 243. Tower-shaped profile; 244. Vertical baseline;

[0064] 25 Bushing; 251 Knurled; 252 Top Cap; 253 Internal Thread; 254 Small Stop Face; 255 Body; 256 Bushing Top Face;

[0065] 26. Top cover bolt; 261. Rod; 262. Thread; 263. Threadless area; 264. Flat washer;

[0066] 27 Top cover; 271 Spring latch; 272 Rotary pivot; 273 Support rib; 275 Tower-shaped base surface; 276 Inner flange; 277 Locking spring latch; 278 Spring latch cantilever; 279 Spring latch stop surface; 2700 Guide slope;

[0067] 28 Anti-touch finger cap; 281 Circumferential flange; 282 Lower stop surface; 283 Upper stop surface; 284 Limiting top surface; 285 Cantilever spring; 286 Spring hook; 288 Anti-touch finger hole;

[0068] 29 Finger bolt; 291 Bolt top surface; 292 Circumferential groove; 293 Drive hole; 294 Bolt assembly;

[0069] 30 Insulating inner core; 301 Flange spring; 302 Fixed spring; 303 Fixed hook; 304 Flange guide surface; 305 Flange stop surface; 306 Groove;

[0070] 31 Cable sealing plug; 32 Copper ring; 321 Copper ring hole;

[0071] 33 Tail clip; 331 Short half-groove; 332 Long half-groove; 333 Left-side facing; 334 Right-side facing; 335 Longitudinal; 336 Tail clip spring tongue; 337 Tail clip hook; 338 Convex groove; 339 T-shaped rib;

[0072] 34 aluminum busbar I; 341 aluminum busbar hole; 35 aluminum busbar II. Detailed Implementation

[0073] The technical solutions of this technical solution will be clearly and completely described below with reference to the accompanying drawings in the embodiments of this technical solution. Obviously, the described embodiments are only some embodiments of this technical solution, and not all embodiments. Based on the core concept of this technical solution and the following embodiments, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this technical solution.

[0074] It should be noted that these embodiments are provided to make the application thorough and complete, and to fully express the scope of the application to those skilled in the art. It should be observed that, unless otherwise specifically stated, the relative arrangement of components and steps, material composition, numerical expressions, and values ​​described in these embodiments should be interpreted as merely exemplary and not as limiting.

[0075] In the description of this technical solution, it should be understood that the terms "axial," "radial," "left," "right," "top," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used solely for the convenience of describing the technical solution and for simplification, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this technical solution. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this technical solution, "multiple" means two or more, unless otherwise explicitly specified.

[0076] In this technical solution, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. For those skilled in the art, the specific meaning of the above terms in this technical solution can be understood according to the specific circumstances.

[0077] Basic Implementation

[0078] This section provides embodiments of a flip-top sealing assembly, a flip-top high-voltage connector using the assembly, and a wire harness assembly using the connector, which are basic implementation schemes for achieving the core inventive objective of this invention.

[0079] like Figure 1 , Figure 2 , Figure 4As shown, the flip-top sealing assembly of this embodiment includes a wire end sheath 21, an upper cover 27 rotatably connected to the wire end sheath 21, and a sealing ring disposed between the wire end sheath 21 and the upper cover 27. A rotating part 5, a radial sealing part 6, and an axial locking part 7 are disposed between the wire end sheath 21 and the upper cover 27.

[0080] The radial sealing part 6 includes a tower-shaped sealing ring 24. The wire end sheath 21 has a tower-shaped inclined surface 211 on the side facing the upper cover 27. The upper cover 27 has a tower-shaped base surface 275 on the side facing the wire end sheath 21, which is opposite to the tower-shaped inclined surface 211. The inner circumference of the tower-shaped sealing ring 24 has a fitting surface 242 that fits with the tower-shaped base surface 275. The outer circumference of the tower-shaped sealing ring 24 has a tower-shaped crest 241 that abuts against the tower-shaped inclined surface 211. The tower-shaped inclined surface 211 and the tower-shaped base surface 275 are both arranged in an inverted V-shape. When the cover is closed, the two are in a parallel posture, and the parallel gap formed between them is used to accommodate the tower-shaped sealing ring 24.

[0081] The rotating part 5 is a rotating pair disposed between the upper cover 27 and the wire end sheath 21. The upper cover 27 is rotatably connected to the wire end sheath 21 through the rotating part 5, so as to realize the flipping and opening of the upper cover 27 relative to the wire end sheath 21.

[0082] The axial locking part 7 includes a main locking structure and a primary locking structure. The main locking structure is used to lock and fix the closed upper cover 27 and the wire end sheath 21. The primary locking structure is used to provide a retaining force between the upper cover 27 and the wire end sheath 21 when the main locking structure is loosened, so as to prevent the upper cover 27 from popping open and causing the seal to fail.

[0083] like Figure 1 , Figure 12 As shown, the flip-type high-voltage connector of this embodiment includes a wire end connector and a board end connector that mate with each other. The wire end connector includes the flip-type sealing assembly described above. The board end connector is provided with a board end sleeve 11. The board end sleeve 11 is provided with a protruding block 111 with a threaded portion 112. The upper cover bolt 26 of the main locking structure can pass through the wire end sleeve 21 and lock with the threaded portion 112 of the protruding block 111 to fix the wire end sleeve 21 and the board end sleeve 11 in a fixed connection.

[0084] As a preferred embodiment of the flip-type high-voltage connector, it includes a mating wire-end connector and a board-end connector. The wire-end connector includes the aforementioned flip-type sealing assembly. The board-end connector is provided with a board-end sleeve 11. The board-end sleeve 11 is provided with a protruding block 111 with a threaded portion 112. The protruding block 111 is provided one on one side of the board-end sleeve 11, or two are provided and symmetrically arranged on both sides of the board-end sleeve 11. The threaded portion 112 is directly provided in the protruding block 111, or provided in a metal inner sleeve, which is connected to the protruding block 111. The upper cover bolt 26 of the axial locking part can pass through the U-shaped groove 217 of the wire-end sleeve 21 and lock with the threaded portion of the protruding block 111.

[0085] The wiring harness assembly of this embodiment includes the aforementioned flip-type high-voltage connector and a conductive component electrically connected to the flip-type high-voltage connector. The conductive component is an aluminum busbar or a cable, and the conductive component is fixed to the insulating inner core 30 of the flip-type high-voltage connector.

[0086] The working principle of this embodiment is as follows:

[0087] During the assembly stage, the upper cover 27 quickly engages with the wire end sleeve 21 via the rotating part 5 to form a rotating pair. The mating surface 242 of the tower-shaped sealing ring 24 is mated and fixed with the tower-shaped base surface 275 of the upper cover 27, completing the pre-assembly of the flip-type sealing assembly. The pre-assembled sealing assembly is then matched with the board end connector. The upper cover 27 is flipped to the closed position, and the wire end sleeve 21 and the board end sleeve 11 are locked and fixed by the main locking structure. At the same time, the primary locking structure locks simultaneously, realizing the assembly and fixation of the connector.

[0088] During the flipping process, the tower-shaped crest 241 of the tower-shaped sealing ring 24 and the tower-shaped inclined surface 211 of the wire end sheath 21 always remain in contact. As the upper cover 27 rotates from the initial alignment when open to the final alignment when closed, the gap between the tower-shaped inclined surface 211 and the tower-shaped base surface 275 gradually decreases, and the compression interference of the tower-shaped sealing ring 24 gradually increases. At the initial alignment, the interference is minimal, the flipping operation force is lowest, and the internal stress of the sealing ring is minimal. At the final alignment, the interference reaches the design value, the sealing surface contact pressure is optimal, and the sealing performance is best.

[0089] During use, the main locking structure plays the main role in locking and fixing, directly transmitting external vibrations to the connector body and reducing local vibration losses. In extreme cases where the main locking structure becomes loose due to long-term vibration, the primary locking structure can still provide effective holding force for the upper cover 27 and the wire end sheath 21, keeping the upper cover 27 in the closed position, avoiding seal failure, and ensuring reliable operation of the connector under complex working conditions. Preferred embodiment

[0090] This section describes a preferred embodiment of the basic model, which refines and optimizes the core structure to further improve the overall performance of the product.

[0091] like Figure 5 , Figure 7 , Figure 8 As shown, in a preferred embodiment, the outer contour of the tower-shaped crest 241 of the tower-shaped sealing ring 24 is arranged in an inverted tower shape, and the angle α between the tower-shaped contour 243 of the tower-shaped crest 241 and the vertical reference line 244 is 5°-45°. Theoretically, the angle α is between 0° and 90°, and preferably, depending on the specific situation, the preferred value of this angle is between 5° and 45°. This angle range can be adapted to connector products of different specifications to achieve the optimal dynamic change effect of interference. When the angle α is 15°, the interference of the tower-shaped sealing ring 24 in the initial alignment is 0.49mm, and the working interference in the final alignment is 0.73mm. The initial interference is 32.8% lower than the working interference. In this case, the stress concentration caused by the tower-shaped sealing ring at the interference position is small, the sealing interference gradually increases to the tooling state, the top cover flipping operation force is small, and the impact on the bonding force between the mating surface 242 of the tower-shaped sealing ring 24 and the tower-shaped base surface of the top cover 27 is minimal, which will greatly reduce the risk of separation.

[0092] As a comparative example of the present invention, the right-angle sealing ring in the prior art, as shown in the figure, under the same working interference amount of 0.73mm, the initial interference amount between the peak of the rotating sealing ring of the upper cover and the sealing surface of the sheath in the initial alignment is 0.96mm. The initial interference amount is 31.5% higher than the working interference amount. In this case, the sealing ring will cause a large stress concentration at the interference position, resulting in a large operating force for the upper cover to flip, and may even lead to the risk that the mating surface 242 of the tower-shaped sealing ring 24 will separate from the tower-shaped base surface of the upper cover 27.

[0093] Compared with existing technologies, this solution reduces the initial interference by 48.96%, the flipping operation force, and the maximum internal stress of the sealing ring, while maintaining the sealing and bonding pressure in the working state, perfectly balancing low operating force and high sealing reliability.

[0094] For a long time, those skilled in the art have focused on conventional approaches to address the sealing failure problem of flip-type connectors, such as modifying the sealing ring material and optimizing the compression amount. They have failed to realize that excessive initial interference of the sealing ring during flip rotation is the core cause of stress concentration, mating surface separation, and shortened seal life. This technical problem represents a long-undiscovered, hidden technical defect in the field. Furthermore, it has long been generally believed in the art that a right-angle cross-section sealing ring is the optimal sealing structure for flip-type connectors, as it is simple to manufacture and provides uniform circumferential sealing pressure. Non-right-angle structures cannot guarantee stable sealing performance during flip rotation. This solution overcomes this bias by using an inverted tower-shaped sealing ring combined with a conical sealing surface, achieving superior sealing performance and ease of operation. In existing technologies, improved sealing reliability inevitably leads to increased flipping operation force. However, this solution significantly improves long-term sealing reliability while significantly reducing the flipping operation force, achieving simultaneous optimization of two mutually constraining performance indicators and yielding unexpected technical results.

[0095] like Figure 3 As shown, in a preferred embodiment, the rotating part 5 includes a rotating shaft 272 disposed on the upper cover 27 and a pin hole 214 disposed on the wire end sheath 21. The rotating shaft 272 is cylindrical and is connected to a spring tongue 271 disposed on the upper cover 27 along one side of the cylinder, so that the spring tongue 271 can spring up when subjected to force along the cylindrical axis. The spring tongue 271 and the rotating shaft 272 are symmetrically arranged along the centerline of the upper cover 27. A support rib 273 is disposed between the paired spring tongues 271 to protect the spring tongues 271 and improve the structural strength and service life. The pin hole 214 is disposed in the boss 212. The bottom surface of the boss 212 is connected to the wire end sheath 21, and the top surface is provided with a guide bevel 213. The rotating shaft 272 can enter the guide bevel 213 along the snap-fit ​​direction and enter the pin hole 214 to form a rotating pair. This structure requires no additional pins, torsion springs, or other accessories. Simply pressing the top cover 27 allows for tool-free quick snap-fit ​​between the rotating shaft 272 and the pin hole 214, simplifying the assembly process by more than 60%, significantly improving production and assembly efficiency, reducing manufacturing costs, and ensuring the smooth rotation and connection stability of the rotating pair.

[0096] like Figure 6As shown, in a preferred embodiment, the main locking structure includes an upper cover bolt 26 and a bushing 25 fixed to the upper cover 27. The upper cover bolt 26 has threads 262 at the top of the rod 261 and a toothless area 263 at the root. The bushing 25 has a cylindrical main body 255 and a top cap 252 protruding from the outer circumference. The outer surface of the main body 255 is knurled 251 to increase the friction between the bushing 25 and the upper cover 27 and prevent the bushing 25 from rotating. The inner side of the main body 255 has an internal thread 253. The threads 262 of the upper cover bolt 26 engage with the internal thread 253. After entering the toothless area 263, the upper cover bolt 26 will remain on the bushing 25 in a free state, realizing the engagement and retention function. There is no need for on-site manual alignment, which greatly improves on-site assembly efficiency.

[0097] In a preferred embodiment, the bushing 25 has an annular bushing top surface 256 on one end face near the top cap 252, and a small stop surface 254 on the opposite end face along the axis. In the working state, the small stop surface 254 contacts the flat washer 264 on the top cover bolt 26, bearing the torque applied by the top cover bolt 26. The wire end sheath 21 is provided with a U-shaped protrusion 216, and the U-shaped protrusion 216 is provided with a U-shaped groove 217 along the central axis. The end face of the U-shaped protrusion 216 near the top cover 27 is provided with a U-shaped top surface 218, and the opposite end face of the U-shaped top surface 218 is provided with a U-shaped bottom surface 219. The bushing top surface 256 contacts the U-shaped top surface 218, bearing the torque from the top cover bolt 26, and directly transmitting the locking force to the main body of the wire end sheath 21, improving the vibration resistance. Most importantly, the open U-shaped groove structure facilitates installation and disassembly. During disassembly, after the top cover bolts are removed from the plate end, the rotation of the top cover can directly drive the top cover bolts to slide out directly from the open U-shaped groove structure without interfering with the side wall of the U-shaped surface.

[0098] In a preferred embodiment, the tower-shaped sealing ring 24 is integrally connected to the upper cover 27 via an insert injection molding process. This integral fixing method using insert injection molding ensures no gaps or relative displacement between the contact surface and the tower-shaped base surface, completely eliminating the risk of contact surface separation and sealing ring misalignment during the flip-top rotation process. It also ensures consistent compression around the sealing ring, further enhancing the long-term reliability of the sealing structure.

[0099] In a preferred embodiment, the tower-shaped sealing ring 24 includes a root structure embedded in the upper cover, and the root structure extends out to form the main sealing structure of the tower-shaped crest 241, which fully ensures the firmness of the connection between the tower-shaped sealing ring 24 and the upper cover 27.

[0100] In a preferred embodiment, the inner circumference of the tower-shaped sealing ring 24 has an inverted tower-shaped, annular, or wavy contact surface, and the sealing surface of the upper cover 27 is adapted to the contact surface. Various options are available for the contact surface of the inner circumference of the tower-shaped sealing ring 24; an inverted tower-shaped contact surface is preferred. The sealing surface of the upper cover preferably uses an inverted tower-shaped base surface that is adapted to it. Regardless of the contact surface method used for the inner circumference of the tower-shaped sealing ring, the sealing surface of the upper cover is adapted to it, ensuring complete contact between them.

[0101] In a preferred embodiment, when the inner circumference of the tower-shaped sealing ring 24 has an inverted tower-shaped contact surface, the sealing surface of the upper cover has an inverted tower-shaped base surface. The inverted tower-shaped inclined surface and the inverted tower-shaped base surface are parallel to each other when the upper cover is fully closed, forming a parallel gap. The tower-shaped sealing ring is accommodated within this parallel gap. After the flip cover is fully closed, the parallel gap provides uniform circumferential compression to the tower-shaped sealing ring, ensuring uniform and consistent pressure around the sealing surface, eliminating localized weak points in the seal, further improving the stability and consistency of the sealing protection, and preventing the risk of localized water leakage.

[0102] In a preferred embodiment, a U-shaped inner bushing made of metal is provided inside the U-shaped groove. Each end of the U-shaped inner bushing has a flange plate that axially abuts against the upper and lower ends of the U-shaped groove. The upper flange plate abuts against the top surface of the bushing, and the lower flange plate abuts against the threaded connection of the board-end connector. The U-shaped inner bushing avoids interference with the top cover bolts during assembly and disassembly, allowing the top cover bolts to enter through the U-shaped opening. It is also suitable for various needs; for example, when the wire end sheath is made of plastic, the structural strength of the U-shaped protrusion is limited. The U-shaped inner bushing significantly improves the structural strength, satisfying the locking force while preventing damage to the wire end sheath.

[0103] In a preferred embodiment, the U-shaped inner bushing is integrally formed with the U-shaped groove using an insert injection molding process, or the U-shaped inner bushing and the U-shaped groove are detachably connected. When the U-shaped inner bushing and the U-shaped groove are detachably connected, a radial hooking structure is provided between them. This technical solution provides two optional implementation methods: one is that the U-shaped inner bushing and the U-shaped groove are integrally fixedly connected, and the other is that a detachable connection is achieved through a hooking structure. The hooking structure can be chosen in various ways, such as creating a protrusion on the side of the U-shaped inner bushing and providing a matching groove on the inner wall of the U-shaped groove, or vice versa. Figure 9 , Figure 10 , Figure 11As shown, in a preferred embodiment, the lock structure includes a locking spring 277 symmetrically arranged on the upper cover 27 and a trapezoidal boss 2100 symmetrically arranged on the wire end sheath 21. One end of the spring cantilever 278 arranged on the locking spring 277 is connected to the main body of the upper cover 27, and the other end extends to form a spring stop surface 279 and a guide slope 2700. The trapezoidal boss 2100 is provided with a boss stop surface 2101 and a boss guide surface 2102. When the top cover 27 rotates to the initial alignment position, the guide slope 2700 contacts the boss guide surface 2102, and the locking spring 27 springs up under force. From the initial alignment position to the final alignment position, the locking spring 277 returns to its original state and locks with the trapezoidal boss 2100. At this time, the spring stop surface 279 contacts the boss stop surface 2101, providing corresponding holding force and realizing the one-time locking function. Even in the extreme case of the main locking structure loosening, the top cover 27 can still be kept in the closed position to avoid sealing failure. This structure completes automatic locking simultaneously when the flip cover closes, without additional operation, and builds a redundant protection system, which greatly improves the product's adaptability to extreme conditions.

[0104] like Figure 17 As shown, in a preferred embodiment, the wire end sheath 21 is provided with an insulating inner core 30. The insulating inner core 30 has a flange spring 301 and a fixed spring 302 arranged circumferentially. The fixed hook 303 at the end of the fixed spring 302 is arranged facing the outer surface of the insulating inner core 30. The fixed hook 303 can be hooked and fixed with the lower end face of the tower-shaped inclined surface 211 of the wire end sheath 21. The flange spring 301 has a flange guide surface 304 and a flange stop surface 305 at its opening. The insulating inner core 30 is also provided with a groove 306, which allows the copper ring 32 welded to the aluminum busbar I34 to pass through, thereby limiting its movement and ensuring the coaxiality of the aluminum busbar and copper ring welding assembly.

[0105] like Figure 18As shown, in a preferred embodiment, the tail of the wire end sheath 21 is connected to a separate tail clip 33. The tail clip 33 is a separate type, and its connection with the aluminum busbar I34 and aluminum busbar II35 does not require pre-assembly, which greatly reduces the assembly difficulty of the wire end connector. The tail clip 33 has a short half-groove 331 and a long half-groove 332 arranged on its side, and a convex groove 338 and a T-shaped rib 339 are respectively arranged on both sides of the short half-groove 331 and the long half-groove 332. The tail clip 33 is provided with a tail clip spring tongue 336 with a tail clip hook 337. Correspondingly, the wire end sheath 21 is provided with an oblique boss 2103. In the horizontal direction, the tail clip 33 consists of two separate parts at a 180-degree angle along the longitudinal direction 335, which mate with the sides of aluminum busbar I34 and aluminum busbar II35 from the left side 333 and right side 334 respectively. The short half-groove 331 and the long half-groove 332 are joined together to form a limiting structure that completely covers aluminum busbar I34 and aluminum busbar II35. In the longitudinal direction, the two tail clips 33 distributed on aluminum busbar I34 and aluminum busbar II35 need to be staggered by a certain distance during assembly, allowing the convex groove 338 and the T-shaped... The ribs 339 are interlocked in pairs in space; in the longitudinal direction, the two tail clips are assembled one after the other. The left tail clip 33 slides along the longitudinal direction 335 and engages with the end sleeve 21. The tail clip hook 337 on the tail clip tongue 336 first hooks with the oblique boss 2103. Then, the right tail clip 33's convex groove 338 and T-shaped rib 339 interlock with the left tail clip 33 along the longitudinal direction 335. Finally, the tail clip hook 337 hooks with the oblique boss 2103, completing the assembly of the tail clips.

[0106] like Figure 12 , Figure 13 As shown, in a preferred embodiment, the board-end connector further includes an inner core sleeve 12, a temperature sensor 13, a board-end pin 14, an insulating cap 15, and a board-end sealing ring 16. The board-end pin 14 is cylindrical, with an upper thread 141 on the end face near the wire end sleeve 21 and a lower thread 142 on the opposite end face. In the radial direction of the board-end pin 14, a cylindrical temperature sensing hole 143 is formed between the upper thread 141 and the lower thread 142. The temperature sensor 13 is divided into a temperature sensing part 131 and a limiting part 132, which are arranged at 90 degrees. The temperature sensing part 131 passes through the temperature sensing hole 143 of the board-end pin 14 to collect the temperature data of the board-end pin 14. After the board-end pin 14 and the temperature sensor 13 are assembled, they are inserted into the terminal cavity 122 provided on the inner core sleeve 12. The limiting part 132 of the temperature sensor 13 and the limiting groove 121 provided on the inner core sleeve 12 are simultaneously engaged and limited, realizing reliable fixation and accurate temperature measurement of the temperature sensor. It can monitor the temperature change during the operation of the high-voltage connector in real time, provide timely warning of overheating risks, and improve the safety of use.

[0107] like Figure 14 , Figure 15 , Figure 16As shown, in a preferred embodiment, the wire-end connector also has an anti-finger function, including an anti-finger cap 28, an anti-finger bolt 29, and an insulating inner core 30. The anti-finger cap 28 is cylindrical in shape, with an anti-finger hole 288 at the middle of one end and a circumferentially protruding circumferential flange 281 at the other end. The circumferential flange 281 has a lower stop surface 282 and an upper stop surface 283. The circumferential flange 281 has a circumferentially arranged cantilevered spring tongue 285 arranged inwards around its structure. The end of the cantilevered spring tongue 285 has a spring hook 286. The anti-finger hole 288 has a limiting top surface 284 between it and the spring hook 286 along its axis. The finger-touch bolt 29 has a bolt top surface 291 on its end face, a circumferential groove 292 in the middle of the bolt head in the circumferential direction, and a drive hole 293 for applying torque. The finger-touch bolt 29 is assembled with the anti-finger cap 28 along the axial direction. The limiting top surface 284 contacts the bolt top surface 291 for limiting, and the spring hook 286 falls into the circumferential groove 292 for stopping. After assembly, the torque tool can pass through the anti-finger hole 288 and enter the drive hole 293 to apply torque. On the other hand, the finger cannot contact the finger-touch bolt 29, which has a potential risk of being electrified, through the anti-finger hole 288, thus realizing the anti-finger function and meeting the high-voltage safety requirements. After the anti-touch finger cap 28 and the touch finger bolt 29 are assembled, they form a bolt assembly 294. The bolt assembly 294 is matched along the axial direction from the flange spring 301 of the insulating inner core 30 to realize the pre-assembly function of the bolt assembly 294. The lower stop surface 282 contacts the flange guide surface 304. Under the force, the flange spring 301 is popped open. After the assembly is completed, the flange spring 301 returns to its original position and is limited by the upper stop surface 283 and the flange stop surface 305 to provide holding force.

[0108] Preferred Implementation

[0109] This embodiment is the optimal implementation of the present invention, and it is fully adapted to the mass production application requirements of high voltage and high current scenarios in new energy vehicles.

[0110] like Figure 1 As shown, the flip-type high-voltage connector of this embodiment includes a wire-end connector and a board-end connector that mate with each other. The wire-end connector includes a flip-type sealing assembly, which includes a rotating part 5, a radial sealing part 6, and an axial locking part 7.

[0111] like Figure 2 , Figure 4 , Figure 5As shown, the radial sealing part 6 has a tower-shaped sealing ring 24, a wire end sheath 21, and a top cover 27. The tower-shaped sealing ring 24 and the wire end sheath 21 form a radial seal. The wire end sheath 21 has an upper cavity 215 on one side of the top cover 27, and a tower-shaped inclined surface 211 serving as a sealing surface is provided around the upper cavity 215. The top cover 27 has an inner flange 276 on the side near the upper cavity 215. The inner flange 276 has a tower-shaped base surface 275 arranged opposite to the tower-shaped inclined surface 211 around its periphery. The inner periphery of the tower-shaped sealing ring 24 has a contact surface 242, and the outer periphery has a tower-shaped crest 241. The contact surface 242 is bonded to the tower-shaped base surface 275 by a rubber injection molding process. The tower-shaped inclined surface 211 and the tower-shaped base surface 275 are both arranged in a V-shape. When the flip-top structure is closed, they are in a parallel posture, and the parallel gap formed between them accommodates the tower-shaped sealing ring 24. The outer contour of the tower-shaped crest 241 of the tower-shaped sealing ring 24 is arranged in an inverted tower shape, and has a tower-shaped contour 243 that is inclined to the vertical reference line 244. The angle α between the tower-shaped contour 243 and the vertical reference line 244 is 15°.

[0112] like Figure 3 As shown, the rotating part 5 is directly engaged with the rotating shaft 272 on the upper cover 27 and the pin hole 214 on the wire end sleeve 21, forming a rotating pair. The rotating shaft 27 is cylindrical and connected to the spring tongue 271 on the upper cover 27 along one side of the cylinder, so that the spring tongue 271 can spring up when subjected to force along the axis of the cylinder. The spring tongue 27 and the rotating shaft 272 are symmetrically arranged along the centerline of the upper cover 27, and a support rib 273 is provided between the paired spring tongues 271 to protect the tongue. The pin hole 214 is located in the boss 212. The bottom surface of the boss 212 is connected to the wire end sleeve 21, and the top surface is provided with a guide bevel 213. The rotating shaft 272 can enter the guide bevel 213 along the engagement direction and then enter the pin hole 214 to form a rotating pair.

[0113] Preferably, the two ends of the support rib 273 are respectively fitted with the inner sidewalls of the two springs 271 with clearance. Preferably, the pivots 272 on the two adjacent springs 271 are symmetrically distributed about the support rib 273.

[0114] Preferably, the first support rib 273 has two ends that engage with the spring tabs 271 on both sides with a gap of one. It also includes a second support rib, with both ends engaging or fitting with the bosses 212 on both sides with a gap of two. The first gap is greater than the length of the shaft 272 inserted into the pin hole 214, and the second gap is less than the length of the shaft 272 inserted into the pin hole 214. Both the first and second support ribs provide support, but their specific functions differ. The first support rib 273 provides axial clearance during assembly, while the second support rib provides axial restraint after assembly, preventing the spring tabs from bearing axial external forces.

[0115] like Figure 6 , Figure 9 , Figure 10 , Figure 11 As shown, the axial locking part 7 is locked by the upper cover bolt 26, which has a screw-in retention function and a one-time locking function. The upper cover bolt 26 has a thread 262 at the top of the rod 261 and a toothless area 263 at the root. The upper cover 27 is made of plastic. A bushing 25 is also provided between the upper cover 27 and the upper cover bolt 26. The bushing 25 has a cylindrical main body 255 and a top cap 252 protruding from the outer circumference. The outer surface of the main body 255 is knurled 251 to increase the friction between the bushing 25 and the upper cover 27. The inner side of the main body 255 has an internal thread 253. The thread 262 of the upper cover bolt 26 engages with the internal thread 253. After entering the toothless area 263, in the free state, the upper cover bolt 26 will be held on the bushing 25, realizing the screw-in retention function. The bushing 25 has an annular bushing top surface 256 on one end face near the top cap 252, and a small stop surface 254 on the opposite end face along the axis. In the working state, the small stop surface 254 contacts the flat washer 264 on the top cover bolt 26, bearing the torque applied by the top cover bolt 26. The wire end sheath 21 is provided with a U-shaped protrusion 216, and the U-shaped protrusion 216 is provided with a U-shaped groove 217 along the central axis. The end face of the U-shaped protrusion 216 near the top cover 27 is provided with a U-shaped top surface 218, and the opposite end face of the U-shaped top surface 218 is provided with a U-shaped bottom surface 219. The bushing top surface 25 contacts the U-shaped top surface 218, bearing the torque from the top cover bolt 26.

[0116] The locking function is achieved through locking springs 277 symmetrically arranged on the upper cover 27 and trapezoidal bosses 2100 symmetrically arranged on the wire end sheath 21. One end of the spring cantilever 278 arranged on the locking spring 277 is connected to the main body of the upper cover 27, and the other end extends to form a spring stop surface 279 and a guide slope 2700. The trapezoidal boss 2100 is provided with a boss stop surface 2101 and a boss guide surface 2102. When the upper cover 27 rotates to the initial alignment position, the guide slope 2700 contacts the boss guide surface 2102, and the locking spring 277 springs up after being subjected to force. From the initial alignment position to the final alignment position, the locking spring 277 returns to its original state before springing up and locks with the trapezoidal boss 2100. At this time, the spring stop surface 279 contacts the boss stop surface 2101, providing a corresponding holding force to realize the locking function.

[0117] like Figure 14 , Figure 15 , Figure 16 , Figure 17As shown, the wire-end connector also includes a finger protector 28, a finger bolt 29, an insulating core 30, aluminum busbar I 34, aluminum busbar II 35, a tail clip 33, and a copper ring 32. The insulating core 30 has a flange spring 301 and a fixed spring 302 arranged circumferentially. The fixed hook 303 at the end of the fixed spring 302 is arranged facing the outer surface of the insulating core 30. The flange spring 301 has a flange guide surface 304 and a flange stop surface 305 at its opening. The finger protector 28 and the finger bolt 29 are assembled to form a bolt assembly 294, which can be pre-installed on the insulating core 30. The copper ring 32 has a copper ring hole 321, and the aluminum busbar I 34 has an aluminum busbar hole 341. The aluminum busbar I 34 or the aluminum busbar II 35 is connected to the copper ring 32 by ultrasonic welding. The insulating core 30 has a groove 306, which allows the copper ring 32, after being welded to the aluminum busbar I 34, to pass through and be limited. It is also fixed by the fixing hook 303 on the fixing spring tongue 302 and the lower end face of the tower-shaped inclined surface 211 on the wire end sheath 21. The aluminum busbar II 35 is limited by cooperating with the insulating core 30 in the same way. After the insulating core 30 is fixed to the wire end sheath 21, the copper ring hole 321 of the aluminum busbar I 34, the aluminum busbar II 35 and the copper ring 32 are coaxial with the aluminum busbar hole 341, and the threaded part of the bolt assembly 294 is allowed to pass through and apply torque.

[0118] Preferably, the copper ring 32 is a hollow stepped shaft structure, the axis of the copper ring hole 321 is the same as the axis of the copper ring 32, and the large-diameter end face of the copper ring 32 is ultrasonically welded to the aluminum busbar, while the small-diameter end face is away from the aluminum busbar.

[0119] like Figure 18 As shown, the tail clip 33 is a split type, with a short half-groove 331 and a long half-groove 332 arranged on the side. A convex groove 338 and a T-shaped rib 339 are arranged on both sides of the short half-groove 331 and the long half-groove 332, respectively. The tail clip 33 is equipped with a tail clip spring tongue 336 with a tail clip hook 337. An oblique boss 2103 is provided on the wire end sheath 21. The two tail clip units can be assembled with the aluminum busbar from both sides. The convex groove 338 and the T-shaped rib 339 are matched to achieve lateral limiting, and the tail clip hook 337 and the oblique boss 2103 are hooked to achieve longitudinal fixation.

[0120] like Figure 12 , Figure 13As shown, the board-end connector includes a board-end sheath 11, an inner core sheath 12, a temperature sensor 13, a board-end pin 14, an insulating cap 15, and a board-end sealing ring 16. The board-end sheath 11 includes a protruding block 111 with a threaded portion 112. The upper cover bolt 26 passes through a U-shaped groove 217 and engages with the threaded portion 112 on the protruding block 111, directly fixing the wire end sheath 21 and the board-end sheath 11 together. This allows vibrations from the external environment to be transmitted to the body of the wire end sheath 21 and the body of the board-end sheath 11. The plate end pin 14 is cylindrical, with an upper thread 141 on the end face near the wire end sheath 21 and a lower thread 142 on the opposite end face. In the radial direction of the plate end pin 14, a cylindrical temperature sensing hole 143 is opened between the upper thread 141 and the lower thread 142. The temperature sensing part 131 of the temperature sensor 13 passes through the temperature sensing hole 143 to collect temperature data, and the limiting part 132 is inserted into the limiting groove 121 of the inner core sheath 12 for limiting.

[0121] The wiring harness assembly of this embodiment includes the aforementioned flip-type high-voltage connector, and aluminum busbars I34 and II35 electrically connected to the flip-type high-voltage connector. The aluminum busbars are fixed on the insulating inner core 30 and electrically connected to the board end pin 14 through the bolt assembly 294.

[0122] The complete assembly steps in this embodiment are as follows:

[0123] Pre-installed flip-top sealing assembly: The tower-shaped sealing ring 24 is bonded and fixed to the tower-shaped base surface 275 of the top cover 27 by a rubber-coating injection molding process; the bushing 25 is pressed into the mounting hole of the top cover 27 and interference fit is achieved by knurling 251; the top cover bolt 26 is screwed into the internal thread 253 of the bushing 25 until it enters the toothless area 263, so as to achieve the pre-installation of the bolt engagement; the guide bevel 213 of the end sleeve 21 of the rotating shaft 272 of the top cover 27 is inserted into the pin hole 214 along the line end sleeve 21 to form a rotating pair, thus completing the pre-installation of the flip-top sealing assembly.

[0124] Pre-assembled wire end connector: Aluminum busbar I34 and aluminum busbar II35 are ultrasonically welded to copper ring 32 respectively. The welded components are then inserted into the slot 306 of the insulating inner core 30 for positioning. Anti-touch finger cap 28 and touch finger bolt 29 are assembled to form bolt assembly 294. Bolt assembly 294 is pre-assembled on flange spring tongue 301 of insulating inner core 30. Insulating inner core 30 is inserted into the inner cavity of wire end sheath 21 and fixed to wire end sheath 21 by fixing hook 303 of fixing spring tongue 302. The two individual units of split tail clip 33 are matched and assembled with aluminum busbar from both sides to complete the pre-assembly of wire end connector.

[0125] Pre-installation of board-end connector: Insert the temperature sensing part 131 of the temperature sensor 13 into the temperature sensing hole 143 of the board-end pin 14, and install the assembled board-end pin 14 into the terminal cavity 122 of the inner core sleeve 12, so that the limiting part 132 of the temperature sensor 13 and the limiting groove 121 of the inner core sleeve 12 are engaged and limited; install the inner core sleeve 12 into the board-end sleeve 11 to complete the pre-installation of the board-end connector.

[0126] Assembly: Connect the wire end connector and the board end connector, flip the top cover 27 to the closed position. During the flipping process, the locking tongue 277 of the primary lock structure pops up along the boss guide surface 2102 of the trapezoidal boss 2100 and then resets, completing the primary lock locking; tighten the top cover bolt 26 to lock and fix the top cover bolt 26 with the threaded part 112 of the board end sleeve 11, completing the assembly of the entire connector.

[0127] Wiring harness assembly: The assembled high-voltage connector is fixedly connected to the high-voltage wiring harness of the vehicle to complete the assembly of the wiring harness assembly.

[0128] The product in this embodiment, after testing, shows that compared with the existing flip-type high-voltage connector, the flipping operation force is reduced, the maximum internal stress of the sealing ring is reduced, the sealing life is improved, the assembly process is simplified, and the production and manufacturing costs are reduced. At the same time, it has redundant anti-disengagement protection function, which can meet the wide temperature range working environment of new energy vehicles from -40℃ to 125℃, the IP68 protection requirements, and the reliable application requirements under long-term vibration conditions. It is perfectly adapted to the mass production needs of high-voltage and high-current scenarios in new energy vehicles.

[0129] This embodiment features comprehensive structural optimization to meet the application requirements of high-voltage, high-current connectors in new energy vehicles. Compared to existing technologies, it offers significant advantages in several aspects, with core advantages concentrated in three key areas: sealing performance, installation operation, and structural reliability. Simultaneously, improvements have been achieved in cost control, safety protection, and operational condition adaptability, as detailed below:

[0130] 1. Significantly improved sealing reliability and complete elimination of stress concentration issues: The innovative inverted "tower" shaped sealing ring, by optimizing the variation law of interference between the sealing ring and the sealing surface, completely solves the stress concentration problem caused by excessive initial interference of traditional right-angle sealing rings. This not only greatly reduces the risk of separation between the sealing ring contact surface and the tower-shaped base surface of the upper cover, achieving long-term stability of radial sealing, but also allows for a tighter fit between the tower-shaped sealing ring and the tower-shaped inclined surface and base surface, adapting to complex working conditions such as automotive vibration, and providing a more durable sealing protection effect.

[0131] 2. Significantly optimized ease of installation and operation, and greatly reduced assembly difficulty: The rotating part adopts a rotating pair structure in which the rotating shaft and pin hole directly engage, enabling rapid rotational connection between the top cover and the wire end sleeve; the top cover bolts of the axial locking part cooperate with the bushing to achieve a screw-in retention function, and the bolts can be stably held on the bushing after assembly, making installation and operation more convenient; the matching split tail clip does not require pre-installation and can be connected to the aluminum busbar from both sides, greatly reducing the assembly difficulty of conductive components such as aluminum busbars, simplifying the assembly steps of the overall component, reducing operating force, and adapting to the assembly needs of large-scale production.

[0132] 3. The structure is highly robust. Stable locking is achieved through the cooperation of the top cover bolts and bushings, which can transmit external vibrations to the main body of the sheath and reduce local vibration loss. At the same time, an additional locking function is added. The locking tongue of the top cover cooperates with the trapezoidal boss of the wire end sheath. In the extreme case of the main locking top cover bolt loosening, the contact surface of the tongue and the stop surface of the boss can still provide effective holding force, keeping the top cover in the final mating position, avoiding sealing failure, and greatly improving the application reliability of the component under extreme conditions such as vehicle vibration and component loosening.

[0133] 4. Excellent temperature monitoring adaptability, meeting the monitoring needs of high-voltage operating conditions. The matching board-end connector has a temperature sensing hole on the board-end pin. The temperature sensing part of the temperature sensor can be directly inserted into the temperature sensing hole to collect the pin temperature data. The limiting part and the limiting groove of the inner core sheath are precisely matched to achieve reliable fixation and accurate temperature measurement of the temperature sensor. It can monitor the temperature change during the operation of the high-voltage connector in real time, and promptly warn of overheating risks. It is adapted to the temperature monitoring needs under high-voltage and high-current operating conditions, further improving the safety of connector use.

[0134] All aspects not detailed in this invention are conventional technical means known to those skilled in the art.

[0135] The above content shows and describes the basic principles, main features, and beneficial effects of this technical solution. The above description is merely a preferred embodiment of this technical solution and is not intended to limit the scope of this technical solution. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this technical solution should be included within the protection scope of this technical solution.

Claims

1. A flip-top sealing assembly, comprising a wire end sheath, a top cover, and a sealing ring disposed between the wire end sheath and the top cover, characterized in that, A rotating part, a radial sealing part, and an axial locking part are provided between the wire end sheath and the top cover; The radial sealing part includes a tower-shaped sealing ring. The side of the wire end sheath facing the upper cover has a tower-shaped inclined surface, and the side of the upper cover facing the wire end sheath has a tower-shaped base surface arranged opposite to the tower-shaped inclined surface. The inner circumference of the tower-shaped sealing ring has a contact surface that fits with the tower-shaped base surface, and the outer circumference of the tower-shaped sealing ring has a tower-shaped crest that abuts against the tower-shaped inclined surface. Both the tower-shaped inclined surface and the tower-shaped base surface are arranged in an inverted V-shape. When the flip cover is closed, the two are in a parallel posture, and the parallel gap formed between them accommodates the tower-shaped sealing ring. The rotating part is a rotating joint disposed between the upper cover and the wire end sleeve, and the upper cover is rotatably connected to the wire end sleeve through the rotating joint; The axial locking part includes a main locking structure and a primary locking structure. The main locking structure is used to lock and fix the closed upper cover and the plate end sleeve, and the primary locking structure is used to provide a retaining force between the upper cover and the line end sleeve when the main locking structure is released.

2. The flip-top sealing assembly according to claim 1, characterized in that, The outer contour of the tower-shaped sealing ring is arranged in an inverted tower shape, and the angle α between the tower-shaped contour of the tower-shaped sealing ring and the vertical reference line is 5°-45°.

3. The flip-top sealing assembly according to claim 1 or 2, characterized in that, The rotating part includes a rotating shaft disposed on the upper cover and a pin hole disposed on the wire end sheath. The rotating shaft is connected to the upper cover by a spring tongue, and the pin hole is disposed in the boss of the wire end sheath. The top or side end of the boss is provided with a guide angle, and the rotating shaft can be inserted into the pin hole along the guide angle to form a rotating pair.

4. The flip-top sealing assembly according to claim 3, characterized in that, The two rotating shafts on the two adjacent springs are arranged in opposite directions. The rotating part also includes a support rib connected to the upper cover. The two ends of the support rib are fitted with the two adjacent springs with a gap.

5. The flip-top sealing assembly according to any one of claims 1, 2, and 4, characterized in that, The main locking structure includes an upper cover bolt and a bushing fixed to the upper cover. The upper cover bolt has threads at the top of its shank and a threadless area at its root. The inner side of the bushing has an internal thread that matches the threads. When the upper cover bolt is screwed into the threadless area, it can remain inside the bushing.

6. The flip-top sealing assembly according to claim 5, characterized in that, The bushing has an annular bushing top surface on one side of the end face near the top cap, and a small stop surface on the opposite end face along the axis. In the working state, the small stop surface contacts the flat washer provided on the top cover bolt. A spring washer is provided between the flat washer and the top cover bolt to bear the torque applied by the top cover bolt.

7. The flip-top sealing assembly according to claim 6, characterized in that, The end sleeve is provided with a U-shaped protrusion, and the U-shaped protrusion is provided with a U-shaped groove along the central axis for the top cover bolt to pass through. The end face of the U-shaped protrusion near the top cover is provided with a U-shaped top surface, and the side end face of the U-shaped top surface is provided with a U-shaped bottom surface. The top surface of the bushing contacts the top surface of the U-shaped top surface to bear the torque from the top cover bolt.

8. The flip-top sealing assembly according to any one of claims 1, 2, 4, 6, and 7, characterized in that, The primary locking structure includes locking springs symmetrically arranged on the upper cover and trapezoidal bosses symmetrically arranged on the end sheath. The end of the locking spring is provided with a spring stop surface and a guide slope, and the trapezoidal boss is provided with a boss stop surface and a boss guide surface. During the closing process of the flip cover, the locking spring can spring up along the boss guide surface and then reset, so that the spring stop surface and the boss stop surface abut against each other to form a lock.

9. A flip-type high-voltage connector, comprising mating wire-end connectors and board-end connectors, characterized in that, The wire-end connector includes a flip-type sealing assembly as described in any one of claims 1 to 7. The plate-end connector is provided with a plate-end sleeve. One protruding block is provided and located on one side of the plate-end sleeve, or two protruding blocks are provided and symmetrically arranged on both sides of the plate-end sleeve. The threaded portion is directly provided in the protruding block, or provided in a metal inner bushing, and the inner bushing is connected in the protruding block. The upper cover bolt of the axial locking portion can pass through the U-shaped groove of the wire-end sleeve and lock and fix it with the threaded portion of the protruding block.

10. A wire harness assembly, characterized in that, It includes the flip-type high-voltage connector as described in claim 9, and a conductive element electrically connected to the flip-type high-voltage connector, wherein the conductive element is an aluminum busbar or cable and is fixed to the insulating inner core of the flip-type high-voltage connector.

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