A wire harness, terminal block, electrical connector, and electrical equipment.

Abstract

This application relates to the field of wire harness technology, and provides a wire harness, terminal block, electrical connector, and electrical equipment. The wire harness provided in this application includes: a wire harness body; and a connector, the wire harness body being connected to the connector, the connector being adapted to limit and electrically connect with a wire harness to be connected. The wire harness of this application, by providing a connector connected to the wire harness body, achieves limiting and electrical connection between the wire harness and the wire harness to be connected; the connector has a guiding function, which can adaptively adjust the matching position of the wire harness and the wire harness to be connected, absorb mating angle deviations, and ensure the contact area and conductivity between the wire harness and the wire harness to be connected.

Description

Technical Field

[0001] This application relates to the field of wire harness technology, and in particular to a wire harness, terminal block, electrical connector and electrical equipment. Background Technology

[0002] The current connection between the aluminum alloy high-voltage wires of the power battery in new energy vehicles uses an aluminum busbar and copper bolt connection adapter, which has a complex overall structure and the copper plug connection is costly. Bolting the aluminum busbar is difficult to operate and seal. Because aluminum busbars are soft and have a low melting point, poor contact during plug connection can easily lead to damage. Bolting requires tools for tightening, occupies a lot of space, is not conducive to the arrangement of the power battery, and makes it difficult to control the sealing performance. Summary of the Invention

[0003] This application aims to solve the problems in related technologies and proposes a wire harness, terminal block, electrical connector and electrical equipment.

[0004] The first aspect of this application provides a wire harness, comprising:

[0005] Wire harness body:

[0006] A connector is used to connect the wire harness body to the connector, which is suitable for limiting and electrically connecting with the wire harness to be connected.

[0007] In some alternative implementations, the connector is at least partially inserted through a through-hole in the wire harness body;

[0008] And / or, the material of the wire harness body is aluminum alloy.

[0009] In some alternative implementations, the connector is T-shaped or I-shaped;

[0010] And / or, the connector is made of copper;

[0011] And / or, the wiring harness also includes a limiting member, which is connected to the connector and is disposed opposite to the connector.

[0012] In some alternative embodiments, the connector includes a connection contact surface, which is one side of the connector with the wire harness on its back, and the connection contact surface is the surface of the connector that contacts the wire harness to be connected.

[0013] In some alternative implementations, the shape of the connecting contact surface is concave and / or convex;

[0014] And / or, the concave surface is a spherical concave surface, a circular concave surface, and / or a polygonal concave surface, and the convex surface is a spherical convex surface, a circular convex surface, and / or a polygonal convex surface.

[0015] A second aspect of this application provides a terminal block comprising: a housing and a wire harness, the wire harness being connected to the housing, and at least a portion of the wire harness being disposed within the housing.

[0016] In some alternative implementations, an elastic element is also included: one end of the elastic element is connected to the housing; the other end of the elastic element is connected to the wiring harness.

[0017] In some alternative embodiments, a seal is also included: the seal is disposed between the wire harness body and the housing.

[0018] A third aspect of this application provides an electrical connector, comprising: a first terminal block and a second terminal block, wherein the first terminal block includes a first connector and the second terminal block includes a second connector, and the first terminal block and the second terminal block are limited and electrically connected to each other through the first connector and the second connector, wherein the first terminal block is the aforementioned terminal block and the second terminal block is the aforementioned terminal block.

[0019] A fourth aspect of this application provides an electrical device, which includes: the wire harness, or the terminal block, or the electrical connector.

[0020] In summary, this application can achieve at least the following technical effects:

[0021] The wire harness of this application, by setting a connector connected to the wire harness body, achieves the limiting and electrical connection between the wire harness and the wire harness to be connected through the connector; the connector has a guiding function, which can adaptively adjust the matching position of the wire harness and the wire harness to be connected, absorb the misalignment of the mating angle, and ensure the contact area and conductivity between the wire harness and the wire harness to be connected. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the first wiring harness in an embodiment of this application;

[0023] Figure 2 This is a cross-sectional schematic diagram of the second wire harness in an embodiment of this application;

[0024] Figure 3 This is a cross-sectional schematic diagram of the second terminal block in an embodiment of this application;

[0025] Figure 4 This is a cross-sectional schematic diagram of the first terminal block in an embodiment of this application;

[0026] Figure 5 This is a perspective view of the first wiring terminal in an embodiment of this application;

[0027] Figure 6 This is a cross-sectional schematic diagram of the electrical connector in an embodiment of this application.

[0028] Attached image labels:

[0029] 1000. Electrical connectors;

[0030] 100. First terminal block; 110. First wire harness body; 121. First connector; 122. First connecting contact surface; 123. First limiting member; 130. First housing; 140. First elastic member; 150. First sealing member;

[0031] 200. Second terminal block; 210. Second wire harness body; 221. Second connector; 222. Second connection contact surface; 223. Second limiting member; 230. Second housing; 240. Second elastic member; 250. Second sealing member. Detailed Implementation

[0032] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0033] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, 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, and therefore should not be construed as a limitation of this application.

[0034] 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 technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0035] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; 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; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0036] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0037] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0038] In existing vehicles, copper is expensive for super-fast charging connectors for power batteries, and aluminum alloy high-voltage wiring harnesses cannot achieve quick connection. Copper is needed to solve the aforementioned quick-connect conversion problem. For connectors with a charging power of 1000 kW and a charging current of 1000 amps, copper connectors are large in width, and the connection between the aluminum alloy high-voltage busbar and the copper connector is bolted, resulting in a large space occupation, complex structure, and high material cost. Direct insertion of aluminum materials makes it impossible to control the cross-sectional area of ​​the connecting wires, leading to poor durability.

[0039] In traditional technology, the AC / DC charging / discharging wire connector (male terminal) of the power battery and the DC wire connector (female terminal) of the drive motor are connected by bolts. The male terminal is connected to the wire harness by bolts and fixed to the connector housing by a limiting structure. The overall connection structure is complex, and the material and processing costs are high. If aluminum alloy busbars are used to connect directly by bolts, quick plugging cannot be achieved.

[0040] Example 1:

[0041] Embodiment 1 of this application provides a wire harness, including:

[0042] Wire harness body:

[0043] A connector is used to connect the wire harness body to the connector, which is suitable for limiting and electrically connecting with the wire harness to be connected.

[0044] By setting a connector that connects to the wire harness body, the wire harness and the wire harness to be connected are limited and electrically connected through the connector; the connector has a guiding function, which can adaptively adjust the matching position of the wire harness and the wire harness to be connected, absorb the misalignment of the mating angle, and ensure the contact area and conductivity between the wire harness and the wire harness to be connected.

[0045] The wire harness body and connectors can be fixedly connected, detachably connected, and integrally molded. The wire harness body can be an aluminum alloy conductor used for high-voltage, high-current transmission in a power battery system. The connectors can be fixed to the ends of the wire harness body using a cold-press riveting process. The connectors are conductive to achieve electrical connection between the wire harness and the wire harness to be connected; and the connectors are equipped with a limit structure to limit the movement between the wire harness and the wire harness to be connected, thus achieving the dual functions of mechanical locking and electrical conduction. The wire harness to be connected can be one wire harness or multiple wire harnesses.

[0046] In some alternative implementations, the connector is at least partially inserted through a through-hole in the harness body.

[0047] The connector is conductive, enabling an electrical connection between the wire harness and the wire harness to be connected. The connector can be made of conductive metal to ensure an effective electrical connection between the wire harness and the wire harness to be connected; the appropriate conductive metal can be selected based on voltage and current requirements.

[0048] One side surface of the connector is adapted to be connected with a connecting harness for limiting the connection between the harness and the harness to be connected.

[0049] The connector can be designed as a riveted core, such as Figure 1 , Figure 2As shown, the axial through-hole of the riveting core extends through the wire harness body. The diameter of the through-hole is interference-fitted with the outer diameter of the riveting core to ensure that the riveting core can fully fill the through-hole during plastic deformation during the riveting process, thereby improving the reliability of the connection between the connector and the wire harness body.

[0050] In some alternative implementations, the wire harness body is made of aluminum alloy.

[0051] The wire harness body can be made of extruded aluminum alloy wires. The surface of the wires can be treated with a chemical conversion film to improve corrosion resistance. After removing the oxide film from the riveting area with the connector, it is mechanically polished to ensure a clean riveting interface, thereby ensuring the formation of a conductive path.

[0052] The wiring harness body can be made of high-strength aluminum alloy wire, which has higher strength and is suitable for battery pack edge wiring areas that need to withstand mechanical impact. There is no solder between the high-strength aluminum alloy wire and the connector; the metallurgical bond is achieved entirely through mechanical riveting. This avoids the formation of brittle intermetallic compounds during welding, which would significantly reduce the plasticity and toughness of the connection between at least two wiring harnesses, increasing the risk of brittle fracture.

[0053] In some alternative implementations, the connector is T-shaped or I-shaped.

[0054] When the connector adopts a T-shaped structure, the connector includes a first transverse structure and a first longitudinal structure. The first longitudinal structure is perpendicularly connected to one side surface of the first transverse structure. The first transverse structure has a dimension perpendicular to the axial direction that is at least partially larger than the diameter of the through hole of the wire harness body, forming a "cap-shaped" limiting structure. The side surface of the first transverse structure facing the first longitudinal structure fits against the side surface of the wire harness body, generating limiting and pull-out resistance along the axial direction of the through hole between the connector and the wire harness body. The first longitudinal structure passes through the through hole of the wire harness body, and the outer diameter of the first longitudinal structure is larger than the diameter of the through hole, improving the reliability of the connection between the connector and the wire harness body. The T-shaped structure is suitable for unidirectional force scenarios, such as the positive and negative output terminals of a battery module.

[0055] When the connector adopts a T-shaped structure, the connector can be a cold-forged oxygen-free copper rivet. The head of the connector is a spherical concave surface (the spherical concave surface is in contact with at least a portion of the surface of the wire harness to be connected), and the rod of the connector is cylindrical.

[0056] When the connector adopts an I-shaped structure, the connector includes a second transverse structure, a third transverse structure, and a second longitudinal structure. One end of the second longitudinal structure connects to the second transverse structure, and the other end connects to the third transverse structure. The second longitudinal structure passes through a through-hole in the wire harness body. The outer diameter of the first longitudinal structure is larger than the diameter of the through-hole, improving the reliability of the connection between the connector and the wire harness body. Along the axial direction of the through-hole, the inner surfaces of the second and third transverse structures are located on the two sides of the wire harness body, forming double limiting surfaces and creating a "sandwich" mechanical locking, effectively improving shear resistance. The inner surfaces of the second and third transverse structures are opposite each other. The I-shaped structure is suitable for intermediate connection nodes subjected to bidirectional forces or torsional stress, such as busbar branch points in battery packs.

[0057] When the connector adopts an I-shaped structure, the connector includes a first connector 121 and a second connector 221. The first connector 121 is T-shaped, and the second connector 221 is inverted T-shaped. At least one of the T-shaped and / or inverted T-shaped connectors has a limiting hole on its longitudinal structure, thereby limiting the T-shaped and inverted T-shaped connectors to each other, thus forming an I-shaped connector. The materials of the first connector 121 and the second connector 221 can be the same or different. At least one of the first connector 121 and the second connector 221 is made of a conductive material. At least one of the first connector 121 and the second connector 221 is a "rivet". The conductive material of the first connector 121 and the second connector 221 contacts the wire harness to be connected to achieve limiting and electrical connection between the wire harness and the wire harness to be connected; the other of the first connector 121 and the second connector 221 can play a limiting role, limiting the other end of the elastic element, thereby ensuring the precise alignment of the elastic element and preventing displacement of the elastic element.

[0058] By differentiating the shape of the connectors, optimal mechanical matching can be achieved under different stress scenarios.

[0059] If the contact area between the connector and the wire harness body needs to be treated with a chemical conversion film, after the chemical conversion film treatment, the local contact area retains a conductive path, while the remaining area forms a non-conductive passivation layer to avoid local temperature rise due to the blockage of the insulation layer and ensure the continuous and stable current path.

[0060] The "riveting" of wire harnesses to the wire harnesses to be connected is achieved by using rivets. The "riveting" replaces the "screw connection" in related technologies, eliminating the need for fastening bolts and connecting structural materials, and can effectively control the contact area between at least two wire harnesses.

[0061] In some alternative implementations, the connector is made of copper.

[0062] Copper can be used as the conductive metal for connectors. Copper wire has better conductivity than aluminum wire. The conductivity of copper wire is 58 × 10^6 S / m, while that of aluminum wire is 37 × 10^6 S / m. This means that copper wire of the same cross-sectional area can carry a larger current and has higher conductivity. Copper wire of the same cross-sectional area can withstand a larger current. Therefore, copper wire has a relatively higher load capacity. The tensile strength of copper wire is about 1.5 times higher than that of aluminum wire, which means that copper wire is less likely to break under tension. In practical use, copper wire has higher durability. Copper wire has better resistance to oxidation and corrosion, while aluminum wire is relatively poor. Aluminum wire is easily oxidized during use and is prone to corrosion in humid environments, thus reducing its conductivity.

[0063] A gold plating layer can be applied to the copper surface to prevent copper oxidation and reduce the initial contact resistance. In high-humidity, high-salt-spray environments (such as electric vehicles in coastal areas), the gold plating layer can effectively delay corrosion. Local areas of the connector contact surface can use pure gold (thickness ≥ 1 μm) as micro-contact points, while the remaining areas are copper substrates, achieving a balance between cost and performance.

[0064] In extremely cost-sensitive scenarios, copper-clad aluminum can be used, which meets the temperature rise requirements of high-voltage systems while being lighter than pure copper. The connector surface has no insulating coating, ensuring exposed contact surfaces for easy conductivity and preventing contact failure due to insulation aging.

[0065] By using aluminum alloy as the wire harness body and copper connectors to form a cold-pressed riveting structure, a metallurgical bond of dissimilar metals "aluminum alloy-copper" is achieved. This avoids the brittle fracture caused by the formation of Al-Cu intermetallic compounds in traditional welding, while also reducing the amount of copper used and lightening the weight of the wire harness.

[0066] In some alternative embodiments, the wiring harness further includes a limiting member connected to a connector, the limiting member and the connector being disposed opposite to each other.

[0067] The limiting component and the connecting component can be detachably connected, fixedly connected, or integrally molded. The limiting component can be made of the same material as the connecting component, such as integrally molding the limiting component and the connecting component, thereby simplifying the structure and process flow and reducing costs from a process perspective. The limiting component can be made of a different material than the connecting component, such as the limiting component being made of plastic and the connecting component being made of copper. The plastic limiting component and the copper connecting component can be detachably or fixedly connected, thereby reducing the amount of copper used and reducing costs from a material perspective.

[0068] The limiting component can be an annular boss, with an outer diameter larger than the shaft diameter of the connector. The limiting component is located on the side of the wire harness body facing away from the connector, forming a "double-end limiting" structure. During terminal connection, the limiting component acts as a mechanical stop, radially (in the radial direction of the through hole) limiting the other end of the elastic component with the wire harness, ensuring precise alignment of the elastic component and preventing displacement.

[0069] When the connector adopts a T-shaped structure, one end of the first longitudinal structure is connected to the first transverse structure, and the first transverse structure contacts one side surface of the wire harness body. The other end of the first longitudinal structure can be flush with the other side surface of the wire harness body. In this case, a limiting member needs to be set. The limiting member is connected to the first longitudinal structure, and when the terminals are connected, the limiting member acts as a mechanical stop to achieve radial (through-hole radial direction) limiting between the other end of the elastic member and the wire harness, ensuring the precise alignment of the elastic member and preventing displacement. The other end of the first longitudinal structure can protrude from the other side surface of the wire harness body. When the terminals are connected, the protruding first longitudinal structure acts as a mechanical stop to achieve radial (through-hole radial direction) limiting between the other end of the elastic member and the wire harness, ensuring the precise alignment of the elastic member and preventing displacement. However, when the outer diameter of the protruding first longitudinal structure is smaller than the preset size of the inner diameter of the elastic member, a limiting member is set at the other end of the first longitudinal structure. The outer diameter of the limiting member matches the inner diameter of the elastic member, thereby ensuring the stable fixation of the other end of the elastic member.

[0070] In some alternative embodiments, the connector includes a connection contact surface, which is one side of the connector with the wire harness on its back, and the connection contact surface is the surface of the connector that contacts the wire harness to be connected.

[0071] The connecting contact surface is the end face of the connector, designed as a non-planar structure. It directly participates in the electrical connection between the wire harness and the wire harness to be connected, serving as the only effective interface for current conduction. The geometry of the connecting contact surface is designed to match the contact characteristics of the wire harness and the wire harness to be connected. For example, if the contact surface of the wire harness to be connected is a spherical concave surface, the connecting contact surface is designed as a spherical convex surface, forming a surface-to-surface contact transition structure to achieve self-balancing of contact pressure. Under high voltage and high current conditions, this contact surface carries a high current density, effectively reducing temperature rise. This solution, through optimization of the connecting contact surface morphology, breaks through the physical limits of traditional planar contact, improving the current carrying capacity of the electrical connection point between wire harnesses.

[0072] In some alternative implementations, the shape of the connecting contact surface is concave and / or convex.

[0073] The connecting contact surface is concave, with a radius of curvature of 2mm to 5mm, and mates with at least a portion of the surface (convex) of the wire harness to be connected, ensuring micro-contact is maintained even without external force. All connecting contact surfaces can be plated with a nickel-palladium-gold composite layer to inhibit oxidation. All contact surfaces can be laser polished to effectively reduce surface roughness, ensuring stable contact and eliminating localized arcing.

[0074] The connecting contact surface is concave and / or convex, replacing the "planar fit" in related technologies with "concave-convex surface fit". This allows the connecting contact surface of the wire harness to fit with at least a portion of the surface of the wire harness to be connected, thereby providing a guiding function, adaptively adjusting deviations in the matching position, absorbing deviations in the fitting angle, and ensuring sufficient contact area and conductivity of 1000KW and 1000A or more.

[0075] In some alternative embodiments, the concave surface is a spherical concave surface, a circular concave surface, and / or a polygonal concave surface, and the convex surface is a spherical convex surface, a circular convex surface, and / or a polygonal convex surface.

[0076] When the connecting contact surface is a spherical concave surface, at least a portion of the surface of the wire harness to be connected is a spherical convex surface. When the connecting contact surface is a circular concave surface, at least a portion of the surface of the wire harness to be connected is a circular convex surface. When the connecting contact surface is a polygonal concave surface, at least a portion of the surface of the wire harness to be connected is a polygonal convex surface.

[0077] When the connecting contact surface is a spherical convex surface, at least a portion of the surface of the wire harness to be connected is a spherical concave surface. When the connecting contact surface is a circular convex surface, at least a portion of the surface of the wire harness to be connected is a circular concave surface. When the connecting contact surface is a polygonal convex surface, at least a portion of the surface of the wire harness to be connected is a polygonal concave surface.

[0078] A spherical convex surface refers to a spherical surface that curves outwards, with its center of curvature located on the same side as the observer; a spherical concave surface refers to a spherical surface that curves inwards, with its center of curvature located on the opposite side of the observer. The geometric matching of the spherical concave and spherical convex surfaces ensures uniform distribution of contact pressure and avoids stress concentration. Both spherical concave and spherical convex surfaces have a self-aligning function during insertion and removal, automatically compensating for angular deviations and axial displacements, significantly improving insertion reliability.

[0079] A circular convex surface refers to a geometric shape with an outwardly convex surface, whose convex surface (top surface) has a circular outline. A circular concave surface refers to a geometric shape with an inwardly concave surface, whose concave surface (bottom surface) has a circular outline. Circular outlines include circles, ellipses, semicircles, semi-ellipses, crescent shapes, etc. Circular concave surfaces (e.g., diameter φ=6mm) and circular convex surfaces (e.g., diameter φ=6.05mm) are used for fixed busbar connections. An interference fit locating pin achieves axial alignment, suitable for low-frequency vibration environments.

[0080] A polygonal convex surface refers to a geometric shape with an outwardly convex surface, whose convex surface (top surface) presents a polygonal outline. A polygonal concave surface refers to a geometric shape with an inwardly concave surface, whose concave surface (bottom surface) presents a polygonal outline. Polygonal outlines include triangles, quadrilaterals, pentagons, hexagons, octagons, etc. A combination of polygonal concave surfaces (e.g., hexagons) and polygonal convex surfaces (e.g., hexagons) is used at the lateral cable outlet. Its angular structure restricts relative rotation, preventing slippage of the contact surface due to torque. It is suitable for compact modules with limited space. Multi-point contact through the edges reduces single-point pressure and improves vibration fatigue resistance.

[0081] Example 2:

[0082] Embodiment 2 of this application provides a terminal block, including: a housing and the wire harness, the wire harness being connected to the housing, and at least part of the wire harness being disposed inside the housing.

[0083] The housing can be made of high-strength engineering plastics and has an independent internal chamber that houses at least a portion of the wiring harness. The housing has excellent flame retardancy and strength.

[0084] The housing has a guide groove, and the wire harness body is positioned in the guide groove. The housing also has an electrical connection hole, through which the connection contact surface of the wire harness connector is exposed.

[0085] The housing has an internal mounting cavity, and the connector is positioned inside the mounting cavity.

[0086] In some alternative implementations, an elastic element is also included: one end of the elastic element is connected to the housing; the other end of the elastic element is connected to the wiring harness.

[0087] The elastic element can be a spring, and the spring can be made of stainless steel. A helical compression spring is another example.

[0088] One end of the spring is fixed to the inner wall of the housing, and the other end of the spring presses against the opposite surface of the connection contact surface on the wire harness. For example, the other end of the spring presses against one side surface of the wire harness body, or the other end of the spring presses against one side surface of the connector and the other end of the spring presses against one side surface of the limiting member. After installation, the spring is in a compressed state, and the spring's restoring force generates outward pressure on the connector of the wire harness, thereby causing the wire harness to generate pressure facing the wire harness to be connected at the position of the connector.

[0089] In another embodiment, such as Figure 3 , Figure 4 As shown, the elastic element can be a disc spring or a wave spring, used in scenarios with limited space and height. Its compression characteristics are steeper, providing a more stable force-displacement curve. An insulating gasket can be provided between the elastic element and the housing to prevent current from forming a circuit through the housing, ensuring electrical isolation.

[0090] The pressure of the elastic element causes the connection contact surface of the wire harness to automatically fit with the connection contact surface of the wire harness to be connected, absorbing the positional deviation between the terminal (male or female) and the terminal (female or male) to be connected, effectively controlling the contact area, and ensuring conductivity of 1000 kW and 1000 amps or more.

[0091] Terminal blocks achieve electrical connection of wire harnesses within two interconnected terminals by using "spring compression" instead of "bolt fastening". This ensures compression durability and absorbs misalignment between the male and female terminals through the compression of the elastic element, while also maintaining durability.

[0092] In some alternative implementations, a seal is also included: the seal is disposed between the wiring harness and the housing.

[0093] The wiring harness is secured to the housing by a seal, ensuring that the sealing ring is compressed to form a double seal when the wiring harness passes through the housing, preventing moisture and dust from entering.

[0094] The seal can be an insulating bushing, such as a silicone rubber O-ring. The seal can be a double-lip seal structure, with the inner lip fitting the wire harness and the outer lip fitting the housing, forming a pressure relief cavity in between to prevent internal pressure buildup due to temperature changes. The wire harness body is sealed to the housing via an interference fit with the sealing ring.

[0095] Example 3:

[0096] Embodiment 3 of this application provides an electrical connector 1000, a first terminal block 100 and a second terminal block 200. The first terminal block 100 includes a first connector 121, and the second terminal block 200 includes a second connector 221. The first terminal block 100 and the second terminal block 200 are limited and electrically connected through the first connector 121 and the second connector 221. The first terminal block 100 and the second terminal block 200 are the aforementioned terminal blocks.

[0097] The first terminal 100 is the aluminum alloy output wire inside the power battery module, and the first connector 121 is a spherical concave rivet. The second terminal 200 is the aluminum alloy input wire of the high-voltage cable outside the battery pack, and the first connector 121 is a spherical convex rivet. The first terminal 100 (male) and the second terminal 200 (female) are electrically connected through the concave-convex fit of the spherical concave rivet and the spherical convex rivet. When the first terminal 100 and the second terminal 200 are connected, the convex surface inserts into the concave surface, and the contact surfaces automatically align, forming a stable conductive path. This structure enables the connection of aluminum alloy wire harnesses, reduces the use of copper materials, reduces weight, and shortens assembly time.

[0098] The engagement of the first connector 121 and the second connector 221 does not rely on bolt tightening, but rather on the application of continuous axial pressure by an elastic element, causing the concave surface to form an adaptive surface contact with the opposite convex surface, achieving stable conduction with low contact resistance. Specifically, the first terminal 100 also includes a first housing 130 and a first elastic element 140. One end of the first elastic element 140 is connected to the first housing 130, and the other end of the first elastic element 140 is connected to the side where the first limiting member 123 of the first connector 121 is located, thereby generating outward pressure through the restoring force of the first elastic element 140. The second terminal 200 also includes a second housing 230 and a second elastic element 240. One end of the second elastic element 240 is connected to the second housing 230, and the other end of the second elastic element 240 is connected to the side where the second limiting member 223 of the second connector 221 is located, thereby generating outward pressure through the restoring force of the second elastic element 240. When the first connecting contact surface 122 of the first connector 121 is in contact with the second connecting contact surface 222 of the second connector 221, the first elastic element 140 and the second elastic element 240 apply pressure on the outside, thereby making the first connecting contact surface 122 and the second connecting contact surface 222 fit more tightly, thus achieving stable electrical conduction.

[0099] This design completely eliminates the traditional copper transition terminal and bolt fastening structure, solving long-term reliability problems such as interface peeling, accelerated oxidation, and increased contact resistance caused by the difference in thermal expansion coefficients of copper and aluminum.

[0100] The connection between the aluminum alloy wires is made by using a concave-convex spherical mating and spring force to compress the aluminum alloy wires, replacing the bolt connection; the aluminum alloy wire strip overlap is riveted with copper rivets, replacing the connection between the copper wire strip and the aluminum alloy wire strip, realizing the supercharging aluminum alloy quick connector for the power battery, replacing the existing copper quick connector, which can significantly reduce material costs and vehicle costs, and reduce connection space and weight.

[0101] Example 4:

[0102] Embodiment 4 of this application provides an electrical device, which includes: the wire harness, or the terminal block, or the electrical connector 1000.

[0103] It should be noted that the aforementioned electronic devices can be any conventional device that requires electricity, such as, but not limited to, vehicles, batteries, skateboard chassis, ships, drones, mobile phones, computers, air conditioners, refrigerators, washing machines, microwave ovens, printers, fax machines, etc.

[0104] For example, the electrical connector 1000 is used in an 800V high-voltage power battery system as a main circuit connector between modules or between a module and a high-voltage junction box. Within the battery pack, multiple electrical connectors 1000 are arranged longitudinally along the module, with each connection structure being independently sealed and independently elastically compressed, achieving modular assembly.

[0105] In the power battery of new energy vehicles, the first terminal 100 (AC / DC charging / discharging terminal) and the second terminal 200 (DC drive motor terminal) are connected by a spring clamp. By replacing traditional copper connectors with aluminum alloy plugs, rapid connection between aluminum alloy wires is achieved. The relatively fixed AC / DC copper wires / copper busbars throughout the vehicle can be completely replaced by aluminum alloy busbars, significantly reducing the material cost of high-voltage wiring harnesses in new energy vehicles, facilitating production and after-sales maintenance, and ensuring the performance and durability of high-voltage and high-current transmission.

[0106] like Figure 1 As shown, the DC terminal of the drive motor uses aluminum alloy wire as the first wire harness body 110, and a copper spherical concave surface as the first connector 121 to control the contact surface of the charging and discharging AC / DC terminals and ensure conductivity. Figure 4 , Figure 5As shown, the other end of the first wiring harness body 110 (the end connected to the drive motor) is bent downwards at 135 degrees to ensure that the first connector 121 can pass through the first seal 150 from inside the battery pack. The first wiring harness body 110 is sealed to the first housing 130 through the first seal 150 via an interference fit. Simultaneously, the charging / discharging AC / DC terminals are connected to the aluminum alloy DC busbar to form a 90-degree angle or a horizontal 180-degree angle for compatibility. A 45-degree tilt connection forms a structural guide insertion, solving the problem of interference if the aluminum alloy busbar is not easily deformed. An insulating bushing is used to fix and support the top contact end position of the aluminum alloy busbar, ensuring that the spherical concave surface of the female end corresponds to the spherical convex surface of the male end. The added fit of the spherical concave and convex surfaces provides a guiding function, adaptively adjusting the matching position, absorbing the deviation of the fitting angle, and ensuring the contact area and conductivity of over 1000 kW and 1000 amps.

[0107] The charging and discharging AC / DC terminals use aluminum alloy wires as the second wiring harness body 210, such as... Figure 2 As shown, a spherical concave surface made of copper is used as the second connector 221 to control the contact surface of the AC / DC charging and discharging terminals. This controls the contact area of ​​the aluminum alloy wire, ensuring the resistance of the second connector 221 matches the overall wire resistance. This prevents damage during operation due to an insufficiently small second connection contact surface 222, thus ensuring conductivity. Figure 3 As shown.

[0108] The charging and discharging AC / DC terminals are bent backward at 135 degrees at the other end of the second wiring harness body 210 (the end connected to the battery pack) to ensure that the copper spherical surface in the second wiring harness body 210 and the second connector 221 can pass through the second seal 250. The second wiring harness body 210 is sealed with the second housing 230 by interference fit through the second seal 250. The second wiring harness body 210 is connected to the aluminum alloy busbar plug of the battery pack at a 90-degree angle. The DC busbar is installed on the vehicle body at a 45-degree angle first. During the assembly process of the battery pack with the vehicle body, the 45-degree angle of the plug-in forms a guiding function, so that the male connector can be smoothly inserted into the female end of the battery pack. This solves the problem that the aluminum alloy busbar is not easy to deform. If there is interference in the insertion, the aluminum alloy busbar needs to be deformed and avoided during the assembly process.

[0109] The second elastic element 240 is fixed to the second housing 230 by the second insulating element, ensuring insulation between the second elastic element 240 and the second housing 230. The second wire harness body 210 and the second housing 230 have a reserved range of motion to absorb positional deviations between the concave and convex spherical surfaces of the first terminal 100 (charging / discharging AC / DC terminal) and the second terminal 200 (drive motor DC terminal). Under the relative pressure of the second elastic element 240 and the first elastic element 140, the spherical concave surface of the second connector 221 tightly fits against the spherical convex surface of the first connector 121, realizing the connection between the charging / discharging AC / DC terminal and the drive motor DC terminal. This achieves a direct compression connection between aluminum alloy wire harnesses, replacing copper connector connections. Figure 6 As shown.

[0110] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A wire harness, characterized in that, include: Wire harness body: A connector is provided, wherein the wire harness body is connected to the connector, and the connector is adapted to limit and electrically connect with the wire harness to be connected.

2. The wire harness as described in claim 1, characterized in that, The connector is at least partially inserted through a through hole in the wire harness body; And / or, the material of the wire harness body is aluminum alloy.

3. The wire harness as described in claim 2, characterized in that, The shape of the connector is T-shaped or I-shaped; And / or, the connector is made of copper; And / or, the wiring harness further includes a limiting member connected to the connector, the limiting member being disposed opposite to the connector.

4. The wire harness as described in claim 2, characterized in that, The connector includes a connecting contact surface, which is the side of the connector facing away from the wire harness, and is the surface of the connector that contacts the wire harness to be connected.

5. The wire harness as described in claim 4, characterized in that, The shape of the connecting contact surface is concave and / or convex; And / or, the concave surface is a spherical concave surface, a circular concave surface, and / or a polygonal concave surface, and the convex surface is a spherical convex surface, a circular convex surface, and / or a polygonal convex surface.

6. A terminal block, characterized in that, include: The housing and the wiring harness as described in any one of claims 1-5, wherein the wiring harness is connected to the housing and at least a portion of the wiring harness is disposed within the housing.

7. The terminal block as described in claim 6, characterized in that, It also includes an elastic element: one end of the elastic element is connected to the housing; the other end of the elastic element is connected to the wire harness.

8. The terminal block as described in claim 6, characterized in that, It also includes a seal: the seal is disposed between the wire harness body and the housing.

9. An electrical connector (1000), characterized in that, include: A first terminal block (100) and a second terminal block (200), wherein the first terminal block (100) includes a first connector (121) and the second terminal block (200) includes a second connector (221), wherein the first terminal block (100) and the second terminal block (200) are limited and electrically connected to each other through the first connector (121) and the second connector (221), wherein the first terminal block (100) is a terminal block as described in any one of claims 6-8 and the second terminal block (200) is a terminal block as described in any one of claims 6-8.

10. An electrical appliance, characterized in that, The electrical equipment includes: a wire harness as described in any one of claims 1-5, or a terminal block as described in any one of claims 6-8, or an electrical connector (1000) as described in claim 9.

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