A high-voltage distribution box based on a through-cylinder connector

Abstract

The utility model discloses a high pressure distribution box based on wear the cylinder connector relates to new energy automobile technical field, solved the traditional fuse box of prior art usually volume is bigger, vertical occupies size is bigger, is unfavorable to the problem of installation. The utility model discloses a main body subassembly is connected with the upper cover subassembly on, the main body subassembly includes the insulating support, and the insulating support is equipped with the casing, and the casing is threaded and is equipped with the incoming wire harness assembly of installation on the insulating support, and the output terminal assembly and the output wire harness assembly are electrically connected respectively to the output end of incoming wire harness assembly, and the output terminal assembly and the output wire harness assembly all extend the casing, and the high voltage insurance is still equipped with between incoming wire harness assembly and the output wire harness assembly, and the high voltage insurance sets up on the insulating support. The utility model discloses incoming wire harness assembly, output terminal assembly and output wire harness assembly are set up in the casing and the upper cover subassembly through the insulating support, and the volume is small, and the direct motor is on, and the space is small in the whole car.

Description

Technical Field

[0001] This utility model relates to the field of new energy vehicle technology, and in particular to a high-voltage junction box based on a cylinder-through connector. Background Technology

[0002] In the field of new energy electric vehicles, the increasing market share of new energy vehicles has led to a surge in the number and types of onboard electrical components, resulting in increased power consumption in vehicle circuits. Furthermore, the high integration of vehicle load circuits necessitates a gradual increase in the demand for high-power circuits. The entire vehicle's electrical power supply originates from the battery pack, is distributed by wiring harnesses, and then connects to various loads. This high-voltage junction box is an innovation compared to common automotive junction boxes. Traditional high-voltage junction boxes are typically large, occupying significant space within the vehicle, and require wiring harnesses to connect to the motor, thus increasing costs. Additionally, the standard installation of discharge sockets in vehicles now necessitates interfaces for power supply.

[0003] Existing technology, such as the Chinese utility model patent with publication number CN209683615U, discloses a new energy vehicle cable distribution box, including a housing, a cover fastened to the housing, and several connector housings. The connector housings include a first input connector housing and a first output connector housing, which are respectively connected to the housing. The housing includes a protective section and a power conversion section. The protective section includes an insulating partition, which is located inside the housing near the first input and first output connector housings. The power conversion section includes a first shunt converter copper busbar and a second shunt converter copper busbar. Although this patent discloses the function of cable splitting, it is not used for cylinder-through connectors.

[0004] Therefore, it is necessary to develop a high-voltage junction box that is simple in structure, small in size, can be directly connected to the motor, and provides an interface and protection for the vehicle's discharge socket, similar to an IPT connector. Utility Model Content

[0005] To address the shortcomings in the aforementioned background technology, this utility model proposes a high-voltage junction box based on a cylinder connector, which solves the problem that traditional fuse boxes in the prior art are usually large in size and occupy a large vertical dimension, making them inconvenient to install.

[0006] The technical solution of this utility model is implemented as follows: A high-voltage junction box based on a cylinder connector includes a main sub-assembly, a top cover sub-assembly connected to the main sub-assembly, the main sub-assembly including an insulating bracket, a housing provided outside the insulating bracket, an incoming wire harness assembly mounted on the insulating bracket passing through the housing, the output end of the incoming wire harness assembly being electrically connected to an output terminal assembly and an output wire harness assembly respectively, both the output terminal assembly and the output wire harness assembly extending out of the housing, a high-voltage fuse is also provided between the incoming wire harness assembly and the output wire harness assembly, the high-voltage fuse being installed on the insulating bracket.

[0007] Furthermore, the insulating bracket is provided with an embedded conductive sheet one and an embedded conductive sheet two, which are respectively connected to the input wire harness assembly and the output wire harness assembly. The insulating bracket is also provided with a groove that cooperates with the high-voltage fuse.

[0008] Furthermore, both ends of the high-voltage fuse are provided with connecting pieces. The high-voltage fuse is installed in the groove and connected to the embedded conductive sheet and the output wire harness assembly respectively through the connecting pieces.

[0009] Furthermore, the incoming wire harness assembly includes a positive wire harness and a negative wire harness, both of which are provided with a tail cap that mates with the housing.

[0010] Furthermore, the output terminal assembly includes a positive terminal and a negative terminal arranged in parallel. The input end of the positive terminal is provided with a conductive plate one and is connected to the positive wire harness one through the conductive plate one. The input end of the negative terminal is connected with a conductive plate two and is connected to the negative wire harness one through the conductive plate two. Both the positive terminal and the negative terminal are provided with a sheath, and the sheath cooperates with the sealing ring provided on the housing.

[0011] Furthermore, the output harness assembly includes a second positive harness and a second negative harness. The input terminal of the second positive harness is connected to a first embedded conductive plate via a high-voltage fuse. The second negative harness is connected to the first embedded conductive plate. The output terminals of the second positive harness and the second negative harness are connected to connectors, which are mounted on the housing.

[0012] Furthermore, both positive electrode harness one and negative electrode harness one are 50-square wire harnesses, and both positive electrode harness two and negative electrode harness two are 6-square wire harnesses.

[0013] Furthermore, the housing is provided with a mounting groove, and the insulating bracket is installed in the mounting groove.

[0014] Furthermore, the upper cover sub-assembly includes an upper cover, which is bolted to the housing and encapsulates the insulating bracket and the incoming line harness assembly, the output terminal assembly and the output line harness assembly mounted on the insulating bracket within the housing.

[0015] Furthermore, the upper part of the cover is provided with a groove, and a high-voltage identification card is pasted in the groove.

[0016] The beneficial effects of this utility model are as follows: The incoming wire harness assembly is connected to the output terminal assembly and the output wire harness assembly respectively, realizing a one-to-two split function. It is used in new energy vehicles, located within the vehicle's wiring harness, providing protection for the wiring. The incoming wire harness assembly, output terminal assembly, and output wire harness assembly are housed within the housing and top cover sub-assembly via an insulating bracket, resulting in a small size. Directly mounted on the motor, it occupies minimal space within the vehicle. Furthermore, the fuse box achieves an IP67 protection rating, allowing for quick replacement of high-voltage fuses. The top cover sub-assembly is fixed to the main sub-assembly with M5 bolts. The main sub-assembly contains a recessed platform where silicone sealant can be applied. This silicone sealant functions similarly to a sealing ring, reducing costs and achieving a one-to-two split function. It also eliminates the need for a separate wiring harness between the motor and the branch line, improving motor efficiency. Simultaneously, the other path can provide power to the vehicle's in-vehicle discharge socket. The junction box contains a high-voltage fuse, which ensures the safe operation of the vehicle's electrical outlets, improving the overall electrical safety of the vehicle. It solves the problem that traditional fuse boxes are usually large in size and occupy a large vertical dimension, making them inconvenient to install. At the same time, it also solves the problem that high-voltage fuses are easily damaged parts and replacing them is very complicated. The electromagnetic shielding effect of this fuse box is excellent, improving the overall safety of the vehicle. Attached Figure Description

[0017] To more clearly illustrate the embodiments of this utility model, the drawings used in the description of the embodiments 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.

[0018] Figure 1 This is a schematic diagram of the structure of this utility model;

[0019] Figure 2 A schematic diagram of the main sub-assembly structure;

[0020] Figure 3 This is a schematic diagram of the insulating support structure;

[0021] Figure 4 This is a schematic diagram of the embedded conductive sheet structure;

[0022] Figure 5 This is a schematic diagram of the upper cover sub-assembly.

[0023] In the diagram: 1. M5 bolt, 2. Top cover sub-assembly, 3. M6 bolt, 4. Main body sub-assembly, 201. High voltage identification card, 202. Top cover, 401. Sealing ring, 402. Sheath, 403. Output terminal assembly, 404. Insulating bracket, 405. Housing, 406. Output wiring harness assembly, 407. Input wiring harness assembly, 408. High voltage fuse, 409. Conductive plate two, 410. Conductive plate one, 4041. Embedded nut, 4042. Embedded conductive plate one, 4043. Embedded conductive plate two, 40421. Irregularly shaped plate one, 40422. Press-fit blind hole nut, 40431. Irregularly shaped plate two. Detailed Implementation

[0024] 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.

[0025] like Figure 1 As shown in Embodiment 1, a high-voltage junction box based on a cylinder connector includes a main sub-assembly 4, with a top cover sub-assembly 2 connected to the main sub-assembly 4. The main sub-assembly 4 includes an insulating bracket 404, and a housing 405 is provided outside the insulating bracket 404. An input wire harness assembly 407 mounted on the insulating bracket 404 is installed on the housing 405. The output end of the input wire harness assembly 407 is electrically connected to an output terminal assembly 403 and an output wire harness assembly 406, respectively. Both the output terminal assembly 403 and the output wire harness assembly 406 extend out of the housing 405. A high-voltage fuse 408 is also provided between the input wire harness assembly 407 and the output wire harness assembly 406, and the high-voltage fuse 408 is provided on the insulating bracket 404. The incoming wire harness assembly connects to both the output terminal assembly and the output wire harness assembly, achieving a one-to-two split. This device is installed in new energy vehicles, located within the vehicle's wiring harness, and provides protection for the wiring. The incoming wire harness assembly, output terminal assembly, and output wire harness assembly are housed within the housing and top cover sub-assembly via an insulating bracket. It is compact, directly mounted on the motor, and occupies minimal space within the vehicle. The fuse box has an IP67 protection rating, allowing for quick replacement of the high-voltage fuse. The top cover sub-assembly is secured to the main sub-assembly with M5 bolts. The main sub-assembly features a recessed platform for applying silicone sealant, which functions similarly to a sealing ring and reduces costs. This junction box provides a one-to-two split, eliminating the need for wiring between the motor and the branch line, thus improving motor efficiency. Simultaneously, the other branch can supply power to the vehicle's in-vehicle discharge socket. Furthermore, the junction box contains a high-voltage fuse to ensure the safe operation of the in-vehicle discharge socket, enhancing the overall safety of the vehicle's electrical system.

[0026] like Figure 2 and Figure 4 As shown in Embodiment 2, a high-voltage junction box based on a cylinder connector is provided. The insulating bracket 404 contains an embedded conductive sheet 4042 and an embedded conductive sheet 4043. The embedded conductive sheet 4042 and the embedded conductive sheet 4043 are respectively connected to the inlet wiring harness assembly 407 and the outlet wiring harness assembly 406. The insulating bracket 404 also contains a groove that mates with a high-voltage fuse 408. The embedded conductive sheet 4042 includes a shaped sheet 40421 and a press-fit blind hole nut 40422, and the embedded conductive sheet 4043 includes a press-fit blind hole nut 40422 and a shaped sheet 40431. By press-fitting blind hole nuts onto the conductive sheets, the efficiency of injection molding is improved, the design and processing difficulty of the injection mold is reduced, and the precision of the injection mold is improved, achieving cost reduction and efficiency improvement. Embedded nuts 4041, embedded conductive plates 1 4042, embedded conductive plates 2 4043, and insulating brackets 4044 are embedded in the insulating bracket, reducing assembly steps, reducing the volume of the junction box, reducing costs and increasing efficiency, and improving the safety of the junction box.

[0027] In this embodiment, the high-voltage fuse 408 is provided with connecting pieces at both ends. The high-voltage fuse 408 is installed in the groove and connected to the embedded conductive piece 4043 and the output wire harness assembly 406 respectively through the connecting pieces, which facilitates the installation and removal of the high-voltage fuse 408.

[0028] The specific working process: A high-voltage junction box based on a cylinder-through connector has a one-to-two splitting function and can be adapted to 2.5 sq mm, 4 sq mm, and 6 sq mm wire diameters at the output end of the in-vehicle socket. This line is equipped with a high-voltage fuse. In case of an accident and the high-voltage fuse fails, repairs only require removing the top cover assembly, quickly replacing the fuse, and then reassembling the top cover. This structural design solves the problem of traditional junction boxes being typically large in size and occupying significant space, making installation difficult. It also solves the problem of direct connection between the high-voltage junction box and the motor via terminals. This high-voltage junction box has excellent electromagnetic shielding and a high protection level, improving the overall vehicle safety.

[0029] All other structures are the same as in Example 1.

[0030] like Figure 2 and Figure 3As shown in Embodiment 3, a high-voltage junction box based on a cylinder connector is provided. The incoming wire harness assembly 407 includes a positive wire harness one and a negative wire harness one that are not intersecting. Both the positive wire harness one and the negative wire harness one are provided with a tail cap that mates with the housing 405. The tail cap is a conventional structure used to fix the wire harness in conjunction with the housing. The output terminal assembly 403 includes a positive terminal and a negative terminal that are symmetrically arranged. The input end of the positive terminal is provided with a conductive plate one 410 and is connected to the positive wire harness one through the conductive plate one 410. The input end of the negative terminal is connected with a conductive plate two 409 and is connected to the negative wire harness one through the conductive plate two 409. Both the positive terminal and the negative terminal are provided with a sheath 402, and the sheath 402 mates with a sealing ring 401 provided on the housing 405. The output harness assembly 406 includes a second positive harness and a second negative harness symmetrically arranged. The input terminal of the second positive harness is connected to an embedded conductive plate 4042 via a high-voltage fuse 408, and the second negative harness is also connected to the embedded conductive plate 4042. The output terminals of the second positive and second negative harnesses are connected to connectors mounted on the housing 405. Both the first positive and second negative harnesses are 50-square-inch harnesses, and both the second positive and second negative harnesses are 6-square-inch harnesses. The housing 405 has a mounting groove, and an insulating bracket 404 is installed within the mounting groove.

[0031] Specifically, the insulating bracket is bolted to the housing. Then, conductive sheet 410 and conductive sheet 409 are bolted to the insulating bracket 404. Subsequently, the high-voltage fuse 408 is also fixed to the insulating bracket 404. The incoming wire harness assembly 407 is bolted to conductive sheet 409 and conductive sheet 410. Simultaneously, the output wire harness assembly 406 is bolted to the high-voltage fuse 408 and the embedded conductive sheet 410 on the insulating bracket, thus connecting the entire circuit. Due to the use of a split-wire exit method, considering airtightness and electromagnetic shielding, the incoming wire harness assembly 407 includes welded terminals, 50 sq mm inner and outer metal clamps, a 50 sq mm sealing ring, a 50 sq mm shielding ring, and a 50 sq mm tail clip. The output wire harness assembly includes welded terminals, 6 sq mm inner and outer metal clamps, a 6 sq mm sealing ring, a 6 sq mm shielding ring, and a 6 sq mm tail clip. Furthermore, considering that the output wire harness assembly 406 connects to the vehicle's in-vehicle discharge socket, and also considering safety, the positive terminal of this circuit is connected to the high-voltage fuse to ensure normal safety. Meanwhile, the shell has a recessed platform covered with silicone, ensuring a tight seal. This is beneficial for the safe operation of new energy vehicles in complex environments.

[0032] All other structures are the same as in Example 2.

[0033] like Figure 5As shown in Embodiment 4, a high-voltage junction box based on a cylinder connector is provided. The upper cover sub-assembly 2 includes an upper cover 202, which is bolted to a housing 405 and encapsulates an insulating bracket 404 and an inlet wire harness assembly 407, an output terminal assembly 403, and an output wire harness assembly 406 mounted on the insulating bracket 404 within the housing 405. The upper part of the upper cover 202 has a groove in which a high-voltage identification card 201 is affixed. The upper cover sub-assembly 1 includes a high-voltage identification card 201 and an upper cover 202. The high-voltage identification card 201 is affixed to the upper cover 202, which has a groove to ensure proper assembly. Furthermore, the upper cover is stamped, resulting in high flatness and ensuring airtightness.

[0034] All other structures are the same as in Example 3.

[0035] The above description is merely a preferred embodiment of this utility model and is not intended to limit the scope of this utility model. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A high-voltage junction box based on a cylinder connector, characterized in that: The system includes a main sub-assembly (4), on which a top cover sub-assembly (2) is connected. The main sub-assembly (4) includes an insulating bracket (404), and a housing (405) is provided outside the insulating bracket (404). An incoming line harness assembly (407) is installed on the housing (405) and mounted on the insulating bracket (404). The output end of the incoming line harness assembly (407) is electrically connected to an output terminal assembly (403) and an output wire harness assembly (406), respectively. Both the output terminal assembly (403) and the output wire harness assembly (406) extend out of the housing (405). A high-voltage fuse (408) is also provided between the incoming line harness assembly (407) and the output wire harness assembly (406). The high-voltage fuse (408) is located on the insulating bracket (404).

2. The high-voltage junction box based on the cylinder connector according to claim 1, characterized in that: The insulating bracket (404) is provided with an embedded conductive sheet one (4042) and an embedded conductive sheet two (4043). The embedded conductive sheet one (4042) and the embedded conductive sheet two (4043) are respectively connected to the incoming wire harness assembly (407) and the output wire harness assembly (406). The insulating bracket (404) is also provided with a groove that cooperates with the high voltage fuse (408).

3. The high-voltage junction box based on the cylinder connector according to claim 2, characterized in that: Both ends of the high-voltage fuse (408) are provided with connecting pieces. The high-voltage fuse (408) is installed in the groove and connected to the embedded conductive sheet (4043) and the output wire harness assembly (406) respectively through the connecting pieces.

4. The high-voltage junction box based on the cylinder connector according to claim 3, characterized in that: The incoming wire harness assembly (407) includes a positive wire harness and a negative wire harness, both of which are provided with a tail cap that mates with the housing (405).

5. The high-voltage junction box based on the cylinder connector according to claim 4, characterized in that: The output terminal assembly (403) includes a positive terminal and a negative terminal. The input end of the positive terminal is provided with a conductive plate (410) and is connected to the positive wire harness through the conductive plate (410). The input end of the negative terminal is connected with a conductive plate (409) and is connected to the negative wire harness through the conductive plate (409). Both the positive terminal and the negative terminal are provided with a sheath (402). The sheath (402) cooperates with the sealing ring (401) provided on the housing (405).

6. The high-voltage junction box based on the cylinder connector according to claim 4 or 5, characterized in that: The output harness assembly (406) includes a positive harness two and a negative harness two. The input end of the positive harness two is connected to the embedded conductive sheet one (4042) through a high voltage fuse (408). The negative harness two is connected to the embedded conductive sheet one (4042). The output ends of the positive harness two and the negative harness two are connected to connectors, which are installed on the housing (405).

7. The high-voltage junction box based on the cylinder connector according to claim 6, characterized in that: Both positive electrode harness one and negative electrode harness one are 50-square wire harnesses, and both positive electrode harness two and negative electrode harness two are 6-square wire harnesses.

8. The high-voltage junction box based on the cylinder connector according to any one of claims 1 to 5 and 7, characterized in that: The housing (405) is provided with a mounting groove, and the insulating bracket (404) is installed in the mounting groove.

9. The high-voltage junction box based on the cylinder connector according to claim 8, characterized in that: The upper cover sub-assembly (2) includes an upper cover (202), which is bolted to the housing (405) and encapsulates the insulating bracket (404) and the incoming line harness assembly (407), the output terminal assembly (403) and the output line harness assembly (406) mounted on the insulating bracket (404) within the housing (405).

10. The high-voltage junction box based on the cylinder connector according to claim 9, characterized in that: The upper part of the cover (202) is provided with a groove, and the high voltage identification card (201) is pasted in the groove.

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