A bolted high voltage connector structure

Abstract

The utility model relates to new energy automobile high -voltage electrical connection technical field especially is a kind of bolt connection high -voltage connector structure, solve the problem of many connector spare parts, low assembly efficiency in prior art, including shell half assembly, shell half assembly is equipped with bolt connection hole, bolt assembly is detachably connected in bolt connection hole, bolt assembly is rotatably matched with bolt connection hole.The utility model has the beneficial effect that: in connector production and manufacture, bolt assembly is integrated on shell half assembly, pre-assembly of bolt assembly is realized by hanging structure, effectively reduce the number of spare parts, avoid shell half assembly and bolt assembly in the state of spare parts in production circulation, improve the installation efficiency of connector when using;And bolt assembly can rotate on shell half assembly, do not affect the use of connector when wiring.

Description

Technical Field

[0001] This utility model relates to the field of high-voltage electrical connection technology for new energy vehicles, and in particular to a bolt-connected high-voltage connector structure. Background Technology

[0002] Due to the high-frequency operation of electric motors in new energy vehicles, their vibration levels are relatively high. Under these conditions, traditional quick-connect high-voltage connectors are prone to failure risks such as terminal loosening, increased contact resistance, and even arcing due to insufficient structural vibration resistance, which seriously affects the safety of high-voltage systems. Therefore, bolt-connected high-voltage connectors are widely used due to their high reliability. For example, patent CN110994269A discloses a high-voltage connector for new energy vehicles, including a copper busbar, a metal housing, a metal cover, an insulating shell, an insulating cover, metal terminals, a shielding mechanism, and a rear cover. The metal housing and the metal cover form a first receiving cavity. The side wall and bottom of the metal housing are respectively provided with a first opening and a second opening. The insulating shell and the insulating cover are fastened together to form a second receiving cavity. The copper busbar is located in the second receiving cavity and protrudes from the insulating shell. The copper busbar extends outward from the first opening and is perpendicular to the metal housing. The shielding mechanism and the rear cover are sleeved on the high-voltage wiring harness and connected to the copper busbar through the metal terminals. The shielding mechanism is fixed to the metal housing through the rear cover.

[0003] The copper busbars and metal terminals in the above-mentioned connectors are connected by metal bolts. However, this conventional bolt-connected connector has obvious shortcomings: the connectors are circulated between the wire harness factory and the vehicle factory in the form of loose parts, which complicates the supply chain management; in addition, there are many independent parts, the assembly process is cumbersome and prone to errors, which affects work efficiency. Utility Model Content

[0004] This utility model proposes a bolt-connected high-pressure connector structure, which solves the problems of numerous loose parts and low assembly efficiency in the prior art connectors.

[0005] The technical solution of this utility model is implemented as follows:

[0006] A bolted high-voltage connector structure includes a housing semi-assembly with bolt connection holes. A bolt assembly is detachably connected to the bolt connection holes, and the bolt assembly rotatably engages with the bolt connection holes. The bolt assembly is integrated onto the housing semi-assembly, meaning the bolts are pre-installed during the housing semi-assembly manufacturing process. The bolt assembly can rotate on the housing semi-assembly without affecting the connector's wiring functionality, preventing the housing semi-assembly and bolt assembly from circulating as separate parts during production and reducing the number of individual parts. When installing terminals within the connector, the bolt assembly is first removed from the housing semi-assembly, and after terminal assembly, the bolt assembly is reinstalled onto the housing semi-assembly.

[0007] The bolt assembly includes a bolt cap and a bolt head, which are connected by a first injection molded part. A second injection molded part is connected to the outside of the first injection molded part, and the second injection molded part is hooked to the housing semi-assembly. The bolt assembly is formed by a two-stage injection molding process. The bolt cap provides electromagnetic shielding and resistance to torque. The first and second injection molded parts isolate the bolt cap and bolt head, providing a barrier function. The bolt head is used to connect to and fix the terminal at the board wire end, achieving stable power transmission at the board wire end.

[0008] The second injection molded part has an annular bolt holder on its lower side, and an elastic hook on the lower side of the bolt connection hole, which is connected to the bolt holder. The bolt holder provides a snap-fit ​​structure for the pre-installation of the bolt assembly, and the annular bolt holder ensures that the bolt assembly will not separate from the housing half-assembly when it rotates on the housing half-assembly, thus ensuring the stability of the bolt assembly during use.

[0009] The first injection molded part has a strip-shaped groove on its outer side, and the second injection molded part has a strip-shaped boss on its inner side. The positioning groove mates with the positioning boss. The strip-shaped groove and the strip-shaped boss are arranged along the axial direction of the bolt assembly.

[0010] The first and second injection molded parts mate to form a sealing groove, within which a bolt sealing ring is fitted. The bolt sealing ring engages with the inner wall of the bolt connection hole. The bolt sealing ring seals the gap between the bolt connection hole and the bolt assembly, ensuring the connector's airtightness.

[0011] The bolt cap has an internal hexagonal hole at its top center. This allows workers to easily rotate the bolt cap using an internal hexagonal wrench when using the connector.

[0012] A tail cap is attached to the housing semi-assembly. A wire harness sealing assembly is located inside the tail end of the housing semi-assembly. The tail cap cooperates with the housing semi-assembly to limit the position of the wire harness sealing assembly. The wire harness sealing ring seals the gap between the wire harness and the housing semi-assembly, ensuring the sealing performance of the connector.

[0013] The wire harness sealing assembly includes a wire harness sealing ring and a wire clamp, with the wire harness sealing ring connected to the wire clamp. The wire clamp and the wire harness sealing ring are connected as a single unit by overmolding, reducing the number of parts.

[0014] The wire clamp has a positioning boss on its side, and a positioning groove is provided on the housing semi-assembly. The positioning boss and the positioning groove cooperate with each other. The cooperation between the positioning boss and the positioning groove can ensure that the wire harness sealing assembly is accurately installed in the housing semi-assembly, prevent the wire harness sealing ring from moving forward excessively, and also realize the visualization of the wire harness sealing ring assembly confirmation.

[0015] The tail cover includes a tail cover body, the end face of which mates with the end face of the wire clamp; tail cover hooks are provided on both sides of the tail cover body, and a housing mounting platform is provided on the housing semi-assembly, with the tail cover hooks connected to the housing mounting platform.

[0016] The beneficial effects of this utility model are: 1. During the manufacturing of connectors, the bolt assembly is integrated on the housing semi-assembly, and the bolt assembly is pre-assembled through the hanging structure, which effectively reduces the number of loose parts and avoids the housing semi-assembly and bolt assembly circulating in the production process as loose parts, thus reducing the number of loose parts; and the bolt assembly can rotate on the housing semi-assembly without affecting the use of the connector when wiring.

[0017] 2. The combination of the elastic hook and the bolt holder enables a detachable connection between the bolt assembly and the housing semi-assembly. The hook structure ensures the detachability of the bolt assembly. When installing the terminals inside the connector, the bolt assembly is first removed from the housing semi-assembly. After the terminals are assembled, the bolt assembly is then installed back onto the housing semi-assembly, ensuring smooth assembly of the terminals within the housing semi-assembly. In addition, if the bolt assembly malfunctions, it can be removed from the housing semi-assembly for quick partial replacement without scrapping the entire part.

[0018] 3. Compared to the existing technology where three parts—the sealing ring, the baffle, and the wire clamp—are fitted onto the wire harness and mate with the tail end of the housing semi-assembly, this technology reduces the number of baffle parts by integrating the function of the baffle parts onto the wire clamp. Furthermore, the wire harness sealing ring and wire clamp at the tail end of the housing semi-assembly are connected as a single unit through overmolding, further reducing the number of parts. Additionally, the locating boss on the wire clamp and the locating groove on the housing semi-assembly mate to ensure accurate installation of the wire harness sealing assembly within the housing semi-assembly, preventing the wire harness sealing ring from shifting forward excessively. This also allows for visualization of the wire harness sealing ring's assembly confirmation. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of a bolt-connected high-pressure connector structure according to the present invention;

[0021] Figure 2 This is a partial exploded view of the line end where the sealing assembly is located;

[0022] Figure 3 This is a partial exploded view of the line end where the bolt assembly is located;

[0023] Figure 4 This is a schematic diagram of the bolt assembly structure;

[0024] Figure 5 Sectional view of the bolt assembly mounted on the housing plate assembly;

[0025] Figure 6 This is a schematic diagram of the sealing assembly structure;

[0026] Figure 7 A schematic diagram of the wiring harness structure for installing high-voltage connectors.

[0027] In the diagram: 1. Housing semi-assembly, 2. Bolt assembly, 3. Tail cap, 4. Wiring harness sealing assembly, 5. Bolt sealing ring, 11. Positioning groove, 12. Bolt connection hole, 13. Housing mounting platform, 14. Elastic hook, 21. Bolt cap, 22. First injection molded part, 23. Second injection molded part, 24. Bolt head, 211. Socket hexagon hole, 221. Sealing groove, 231. Bolt mounting platform, 31. Tail cap body, 32. Tail cap hook, 41. Wiring harness sealing ring, 42. Wire clamp, 43. Positioning boss. Detailed Implementation

[0028] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0029] Example 1, as Figure 1 , Figure 7 As shown, a bolted high-voltage connector structure includes a housing semi-assembly 1 with a bolt connection hole 12. A bolt assembly 2 is detachably connected to the bolt connection hole 12, and the bolt assembly 2 is rotatably engaged with the bolt connection hole 12. When the connector is manufactured, the bolt assembly 2 can be integrated onto the housing semi-assembly 1 and transported from the wiring harness factory to the vehicle assembly factory. Specifically, the bolt assembly 2 is installed into the bolt connection hole 12, and a hook-and-loop structure enables pre-assembly of the bolt assembly 2 on the housing semi-assembly 1. This avoids the housing semi-assembly 1 and bolt assembly 2 being transferred between the wiring harness factory and the vehicle assembly factory as separate parts, reducing the number of loose parts. When installing terminals within the connector, the bolt assembly 2 is first removed from the housing semi-assembly 1. After the terminals are assembled, the bolt assembly 2 is then reinstalled onto the housing semi-assembly 1, ensuring smooth assembly of the terminals within the housing semi-assembly 1. Furthermore, the bolt assembly 2 can rotate on the housing semi-assembly 1 without affecting the connector's use during wiring.

[0030] Furthermore, such as Figure 3 , Figure 4 As shown, the bolt assembly 2 includes a bolt cap 21 and a bolt head 24. The bolt cap 21 and the bolt head 24 are connected by a first injection molded part 22. A second injection molded part 23 is connected to the outside of the first injection molded part 22, and the second injection molded part 23 is hooked to the housing semi-assembly 1. The bolt assembly 2 is formed by a two-stage injection molding process. Specifically, in the first injection molding, the first injection molded part 22 is injection molded to connect the bolt cap 21 and the bolt head 24. In the second injection molding, the second injection molded part 23 is injection molded. The bolt cap 21 is a metal bolt cap, which can provide electromagnetic shielding and resist torque. The first injection molded part 22 and the second injection molded part 23 are used to isolate the bolt cap 21 and the bolt head 24, thus playing an isolation role. The bolt head 24 is used to connect and fix the terminal of the board wire end to achieve stable power transmission at the board wire end.

[0031] In addition, the upper part of the bolt head 24 and the lower part of the bolt cap 21 are respectively provided with prism structures. The prism structures are embedded in the first injection molded part 22. When the bolt assembly is connected to the terminal of the plate line, the lower part of the bolt head 24 is threadedly connected to the nut. At this time, the prism structure can better transmit torque.

[0032] Furthermore, the lower side of the second injection molded part 23 is provided with an annular bolt mounting bracket 231, and the lower side of the bolt connection hole 12 is provided with an elastic hook 14, which is connected to the bolt mounting bracket 231. In this embodiment, there are four elastic hooks 14, and each elastic hook 14 is evenly arranged in the circumferential direction of the bolt connection hole 12 to ensure the stability of the bolt assembly 2 and the housing half assembly 1. The bolt mounting bracket 231 provides a snap-fit ​​structure for the pre-installation of the bolt assembly 2, and the annular bolt mounting bracket 231 can ensure that the bolt assembly 2 will not separate from the housing half assembly 1 when it rotates on the housing half assembly 1, thus ensuring the stability of the bolt assembly 2 when the connector is in use.

[0033] In addition, the elastic hook 14 is an elastic structure that ensures the detachability of the bolt assembly 2. When the bolt assembly 2 has a problem, it can be removed from the housing semi-assembly 1 for quick partial replacement without scrapping the entire part.

[0034] Furthermore, the outer side of the first injection molded part 22 is provided with a strip-shaped groove, and the inner side of the second injection molded part 23 is provided with a strip-shaped boss, with the positioning groove cooperating with the positioning boss. The strip-shaped groove and the strip-shaped boss are arranged along the axial direction of the bolt assembly 2, and the strip-shaped groove and the strip-shaped boss correspond one-to-one, ensuring the connection stability between the first injection molded part 22 and the second injection molded part 23.

[0035] Furthermore, such as Figure 5As shown, the first injection molded part 22 and the second injection molded part 23 cooperate to form a sealing groove 221. A bolt sealing ring 5 is installed in the sealing groove 221, and the bolt sealing ring 5 mates with the inner wall of the bolt connection hole 12. The bolt sealing ring 5 seals the gap between the bolt connection hole 12 and the bolt assembly 2, ensuring the sealing performance of the connector.

[0036] Furthermore, the bolt cap 21 has an internal hexagonal hole 211 at its top center. This allows workers to easily rotate the bolt cap 21 using an internal hexagonal wrench during connector use, thereby enabling the bolt assembly 2 to rotate.

[0037] Example 2, based on Example 1, provides a bolted high-pressure connector structure, such as... Figure 2 As shown, a tail cap 3 is attached to the housing semi-assembly 1. A wire harness sealing assembly 4 is located inside the tail end of the housing semi-assembly 1. The tail cap 3 cooperates with the housing semi-assembly 1 to limit the movement of the wire harness sealing assembly 4. The tail cap 3 includes a tail cap body 31, the end face of which mates with the end face of the wire clamp 42. Tail cap hooks 32 are located on both sides of the tail cap body 31. A housing mounting platform 13 is provided on the housing semi-assembly 1, and the tail cap hooks 32 are connected to the housing mounting platform 13. The wire harness sealing assembly 4 seals the gap between the wire harness and the housing semi-assembly 1, ensuring the sealing performance of the connector tail.

[0038] Furthermore, such as Figure 6 As shown, the wire harness sealing assembly 4 includes a wire harness sealing ring 41 and a wire clamp 42, with the wire harness sealing ring 41 connected to the wire clamp 42. The wire clamp 42 and the wire harness sealing ring 41 are connected as a single unit by overmolding, reducing the number of parts in the connector.

[0039] Furthermore, the wire clamp 42 has a positioning boss 43 on its side, and the housing semi-assembly 1 has a positioning groove 11, with the positioning boss 43 engaging with the positioning groove 11. The engagement of the positioning boss 43 and the positioning groove 11 ensures that the wire harness sealing assembly 4 is accurately installed within the housing semi-assembly 1, preventing the wire harness sealing ring 41 from shifting forward excessively, and also enabling visualization of the wire harness sealing ring 41's assembly confirmation.

[0040] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A bolted high-voltage connector structure, comprising a housing semi-assembly (1), characterized in that, The housing semi-assembly (1) is provided with a bolt connection hole (12), and a bolt assembly (2) is detachably connected in the bolt connection hole (12), and the bolt assembly (2) is rotatably engaged with the bolt connection hole (12).

2. The bolted high-pressure connector structure according to claim 1, characterized in that, The bolt assembly (2) includes a bolt cap (21) and a bolt head (24). The bolt cap (21) and the bolt head (24) are connected by a first injection molded part (22). A second injection molded part (23) is connected to the outside of the first injection molded part (22). The second injection molded part (23) is hooked to the housing semi-assembly (1).

3. The bolted high-pressure connector structure according to claim 2, characterized in that, The second injection molded part (23) has an annular bolt bracket (231) on its lower side, and an elastic hook (14) is provided on the lower side of the bolt connection hole (12). The elastic hook (14) is connected to the bolt bracket (231).

4. The bolted high-pressure connector structure according to claim 3, characterized in that, The outer side of the first injection molded part (22) is provided with a strip groove, and the inner side of the second injection molded part (23) is provided with a strip boss. The positioning groove and the positioning boss cooperate.

5. The bolt-connected high-pressure connector structure according to any one of claims 2 to 4, characterized in that, The first injection molded part (22) and the second injection molded part (23) cooperate to form a sealing groove (221). A bolt sealing ring (5) is installed in the sealing groove (221), and the bolt sealing ring (5) cooperates with the inner wall of the bolt connection hole (12).

6. The bolted high-pressure connector structure according to claim 5, characterized in that, The top center of the bolt cap (21) has an internal hexagonal hole (211).

7. The bolted high-pressure connector structure according to claim 1 or 6, characterized in that, A tail cap (3) is attached to the housing semi-assembly (1). A wire harness sealing assembly (4) is provided inside the tail end of the housing semi-assembly (1). The tail cap (3) cooperates with the housing semi-assembly (1) to limit the wire harness sealing assembly (4).

8. The bolted high-pressure connector structure according to claim 7, characterized in that, The wire harness sealing assembly (4) includes a wire harness sealing ring (41) and a wire clamp (42), with the wire harness sealing ring (41) connected to the wire clamp (42).

9. The bolted high-pressure connector structure according to claim 8, characterized in that, The side of the wire clamp (42) is provided with a positioning boss (43), and the housing semi-assembly (1) is provided with a positioning groove (11), and the positioning boss (43) and the positioning groove (11) cooperate.

10. The bolted high-pressure connector structure according to claim 9, characterized in that, The tail cap (3) includes a tail cap body (31), the end face of the tail cap body (31) is matched with the end face of the wire clamp (42); tail cap hooks (32) are provided on both sides of the tail cap body (31), and a housing mounting platform (13) is provided on the housing semi-assembly (1), and the tail cap hooks (32) are connected to the housing mounting platform (13).

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