A high and low voltage integrated three-phase cylinder connector

Abstract

This utility model relates to the field of connector technology, specifically to a high- and low-voltage integrated three-phase cylinder connector, which solves the problems of poor dimensional accuracy and uneven injection molding wall thickness in existing technologies. It includes a connector housing, on which a high-voltage connection component and a low-voltage connection component are provided. The high-voltage connection component includes a high-voltage housing, which is integrally injection molded with the connector housing. A copper busbar is provided on the high-voltage housing, extending from both ends. The advantages are: the copper busbar is first assembled onto the high-voltage housing to form the high-voltage connection component, and then the high-voltage connection component is embedded into the connector housing using an integral injection molding process, improving the positional accuracy of the high-voltage connection component on the connector housing; the low-voltage housing uses integral injection molding to fix and install the pins, improving the installation accuracy of the pins on the connector housing and preventing the pins from bending during injection molding with the connector housing; and improving the overall dimensional accuracy of the product structure.

Description

Technical Field

[0001] This utility model relates to the field of connector technology, and in particular to a high and low voltage integrated three-phase cylinder connector. Background Technology

[0002] With increasing global focus on environmental protection and energy sustainability, the new energy vehicle industry is experiencing explosive growth. Among the core technologies of new energy vehicles, the motor and electronic control system is crucial, and its development trend is towards integration and intelligence. Integration can effectively reduce system size, weight, and cost, while improving overall system performance; intelligence helps achieve more precise control and higher energy efficiency. Hybrid vehicles, as transitional products in the electrification process of new energy vehicles, also adopt integrated solutions for their motors and electronic control systems to meet their complex power requirements and limited space. Against this backdrop, a three-phase integrated connector for hybrid vehicle motors and electronic control systems has emerged, becoming one of the key components driving the development of hybrid vehicle technology.

[0003] In this technical field, there are currently many similar products on the market, among which the most common solution is to use copper busbars or copper pillars integrally coated with rubber injection molding. For example, Chinese patent CN220963807U discloses a high- and low-voltage wiring integrated connector. This connector includes a body, a high-voltage connection component, and a low-voltage connection component. The high-voltage connection component is inserted into the body, and its two ends extend outwards to both sides of the body to form a first high-voltage interface and a second high-voltage interface. The high-voltage connection component uses a copper busbar and is fixed at the first high-voltage interface and the second high-voltage interface by pin riveting.

[0004] However, the above-mentioned existing technical solutions have shortcomings. The manufacturing method of directly connecting the copper busbar to the main body and integrally encapsulating it with plastic injection molding has its drawbacks. During the encapsulation injection molding process, the plastic particles melt into a fluid, wrap around the copper busbar, and then cool. If the wrapping is too strong, internal stress will be generated, which will cause defects such as warping and deformation of the product, affecting dimensional accuracy and stability. In other words, when the copper busbar and the main body are integrally injection molded, if the injection wall thickness is too thick or unevenly distributed, it will aggravate the unevenness of thermal shrinkage. It may also cause defects such as pores and shrinkage marks due to differences in cooling rate, further increasing the probability of residual internal stress. Utility Model Content

[0005] This invention proposes a high- and low-voltage integrated three-phase cylinder connector, which solves the problems of poor product dimensional accuracy and uneven injection molding wall thickness in the prior art.

[0006] The technical solution of this utility model is implemented as follows:

[0007] A high- and low-voltage integrated three-phase cylinder connector includes a connector housing, on which a high-voltage connection assembly and a low-voltage connection assembly are mounted. The high-voltage connection assembly includes a high-voltage housing, which is integrally injection molded with the connector housing. Copper busbars are mounted on the high-voltage housing, extending from both ends. The copper busbars are first assembled onto the high-voltage housing to form the high-voltage connection assembly, and then the high-voltage connection assembly is embedded into the connector housing using an integral injection molding process. The high-voltage housing has a positioning structure to improve the installation accuracy of the copper busbars on the connector housing, improve the dimensional accuracy of the overall product structure, and ensure the stability of the overall product structure.

[0008] The copper busbar is equipped with a positioning groove and a bending section. The positioning groove is located on the side of the copper busbar, and the bending section is located in the middle of the copper busbar. A copper busbar mounting hole is provided inside the high-voltage housing. A positioning clip and a positioning bevel are provided inside the mounting hole. The positioning groove engages with the positioning clip, and the bending section engages with the positioning bevel. The positioning bevel and the positioning clip work together to axially limit the copper busbar, ensuring its installation stability within the mounting hole. Even in the complex vibration environment of a vehicle, this ensures the copper busbar remains in place and maintains a good electrical connection.

[0009] The high-voltage housing has a high-pressure potting groove on its side, which communicates with the copper busbar mounting hole; the connector housing has a housing potting groove, which communicates with the high-pressure potting groove. After the connector housing is injection molded, sealant is introduced into the copper busbar mounting hole through the housing potting groove and the high-pressure potting groove to ensure the sealing between the copper busbar and the high-voltage housing, and between the copper busbar and the connector housing.

[0010] The connector housing is equipped with a connecting flange, and a track adhesive is applied to one side of the connecting flange. During connector installation, the connecting flange is connected to the motor housing, and the track adhesive seals the gap between the connecting flange and the motor housing, ensuring the connector's airtightness after installation.

[0011] The connector housing is provided with an electrically controlled sealing groove, and the electrically controlled sealing groove is provided with an electrically controlled sealing ring. When the connectors are mated, the electrically controlled sealing ring ensures the sealing between the two mating connectors and prevents airtight leakage during the mating process.

[0012] The connector housing has a slot, and the electrically controlled sealing groove communicates with the slot. A locking key is connected to the electrically controlled sealing ring, and the locking key engages with the slot. The engagement of the slot and the locking key secures the electrically controlled sealing ring within the electrically controlled sealing groove, preventing radial rotation and axial displacement of the sealing ring. This avoids the need for adhesive fixation, simplifies the installation process, improves production efficiency, and ensures the stability of the sealing performance.

[0013] The connector housing is provided with a high-pressure sealing groove, and a high-pressure sealing ring is installed inside the high-pressure sealing groove. The high-pressure sealing groove corresponds to the position of the high-pressure connection assembly. The high-pressure sealing ring further enhances the sealing performance of the high-pressure connection part.

[0014] The connector housing is provided with a low-pressure sealing groove, and a low-pressure sealing ring is installed in the low-pressure sealing groove. The low-pressure sealing groove corresponds to the position of the low-pressure connection component. The low-pressure sealing ring further enhances the sealing performance of the low-pressure connection part.

[0015] The low-voltage connection assembly includes a low-voltage housing with pins inside. The low-voltage housing and the connector housing are integrally injection molded together. The pins are fixedly installed in the low-voltage housing through integral injection molding, improving the dimensional accuracy of the pins within the connector housing, resulting in more stable and reliable low-voltage signal transmission and reduced signal distortion. Simultaneously, the pins undergo a secondary injection molding process to prevent bending during the injection molding process with the connector housing.

[0016] A metal skeleton is embedded in the connector housing. The metal skeleton fits into the connecting flange, and the metal skeleton and track adhesive are located on both sides of the connecting flange, respectively. The metal skeleton can enhance the overall strength of the connector, reduce the warping deformation of the plastic parts, ensure stability, ensure the structural stability of the connector under complex working conditions, and improve its vibration and pressure resistance.

[0017] The beneficial effects of this invention are as follows: The connector integrates high and low voltage settings, enabling three-phase power connection between the motor and electronic control system, as well as low-voltage signal transmission. This results in high space utilization, fewer parts, and effective cost reduction. It also better achieves functional mating and supply-demand integrity. The copper busbar is first assembled onto the high-voltage housing to form a high-voltage connection assembly, which is then embedded into the connector housing using an integral injection molding process, improving the positional accuracy of the high-voltage connection assembly on the connector housing. The low-voltage housing uses an integral injection molding method to fix and install the pins, improving the installation accuracy of the pins on the connector housing and preventing bending of the pins during injection molding. This improves the dimensional accuracy of the overall product structure and ensures its stability.

[0018] By using a secondary encapsulation process to assemble the copper busbars and pins within the connector housing, the uniformity of the plastic wall thickness can be controlled more precisely, reducing localized stress concentration and lowering the risk of defects caused by differences in material thermal expansion, thereby improving the stability of product dimensional accuracy.

[0019] After the electronically controlled sealing ring is assembled into the electronically controlled sealing groove on the connector housing, the locking key on the electronically controlled sealing ring engages with the locking groove on the connector housing. After assembly, the electronically controlled sealing ring is fixed in place, preventing radial rotation and axial displacement of the electronically controlled sealing ring when the connector is mated, thus avoiding the use of adhesive fixing process.

[0020] Using potting compound and track adhesive for secondary sealing achieves sealing of high and low voltage integrated products, ensuring overall airtightness, improving sealing performance, ensuring the stability and safety of the entire component, and preventing failure; reducing the risk of airtight failure caused by aging of the sealing ring and reduced adhesion between the shell and terminals during high-temperature thermal aging, thermal shock and other environmental processes. Attached Figure Description

[0021] 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.

[0022] Figure 1 This is a schematic diagram of a high- and low-voltage integrated three-phase cylinder connector according to the present invention.

[0023] Figure 2 This is a schematic diagram of the shell assembly structure;

[0024] Figure 3 This is a schematic diagram of the high-voltage connection assembly structure;

[0025] Figure 4 This is a schematic diagram of the copper busbar structure;

[0026] Figure 5 Schematic diagram of low-voltage connection component structure;

[0027] Figure 6 This is a schematic diagram of the structure of the electronically controlled sealing ring.

[0028] In the diagram: 1. Connector housing; 2. Metal frame; 3. High-voltage connection assembly; 4. High-voltage sealing ring; 5. Low-voltage connection assembly; 6. Low-voltage sealing ring; 7. Track adhesive; 8. Electrically controlled sealing ring; 11. High-voltage sealing groove; 12. Low-voltage sealing groove; 13. Electrically controlled sealing groove; 14. Housing potting groove; 15. Slot; 31. High-voltage housing; 32. Copper busbar; 321. Positioning groove; 322. Bending section; 33. High-voltage potting groove; 34. Positioning clip; 51. Low-voltage housing; 52. Pin; 81. Locking key. Detailed Implementation

[0029] 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.

[0030] Example 1, as Figure 1 As shown, a high- and low-voltage integrated three-phase cylinder connector includes a connector housing 1, on which a high-voltage connection component 3 and a low-voltage connection component 5 are provided, such as... Figure 3 As shown, the high-voltage connection assembly 3 includes a high-voltage housing 31, which is integrally injection molded with the connector housing 1. A copper busbar 32 is provided on the high-voltage housing 31, extending from both ends of the high-voltage housing 31. During connector manufacturing, the copper busbar 32 is first assembled onto the high-voltage housing 31 to form the high-voltage connection assembly 3. Then, the high-voltage connection assembly 3 is embedded into the connector housing 1 through integral injection molding, improving the dimensional accuracy of the copper busbar 32 within the connector housing 1 and ensuring the stability of the overall product structure. Furthermore, the connector integrates high and low voltage settings, enabling three-phase power connection between the motor and electronic control system, as well as low-voltage signal transmission. This results in high space utilization, fewer parts, effectively reducing costs, and better achieving functional mating and supply-demand integrity.

[0031] Furthermore, such as Figure 3 , Figure 4 As shown, the copper busbar 32 is provided with a positioning groove 321 and a bending portion 322. The positioning groove 321 is located on the side of the copper busbar 32, and the bending portion 322 is located in the middle of the copper busbar 32. The high-voltage housing 31 is provided with a copper busbar mounting hole. The inner side of the copper busbar mounting hole is provided with a positioning clip 34 and a positioning bevel. The positioning groove 321 engages with the positioning clip 34, and the bending portion 322 engages with the positioning bevel. The positioning bevel and the positioning clip 34 work together to axially limit the copper busbar 32, ensuring the installation stability of the copper busbar 32 in the copper busbar mounting hole.

[0032] Furthermore, such as Figure 2 , Figure 3 As shown, the high-voltage housing 31 has a high-pressure potting groove 33 on its side, which communicates with the copper busbar mounting hole; the connector housing 1 has a housing potting groove 14, which communicates with the high-pressure potting groove 33. After the connector housing 1 is injection molded, sealant is introduced into the copper busbar mounting hole through the housing potting groove 14 and the high-pressure potting groove 33 to ensure the sealing between the copper busbar 32 and the high-voltage housing 31, and between the copper busbar 32 and the connector housing 1, thus ensuring the sealing of the connector's interior.

[0033] Furthermore, the connector housing 1 is provided with a connecting flange, and a track adhesive 7 is provided on one side of the connecting flange. During connector installation, the connecting flange is connected to the motor housing, and the track adhesive 7 seals the gap between the connecting flange and the motor housing, ensuring the sealing performance of the connector after installation; in addition, through holes are provided at the four corners of the connecting flange, and bolts pass through the through holes to connect to the motor housing during connector installation, ensuring the connector is stably installed on the motor housing.

[0034] Example 2, based on Example 1, provides a high- and low-voltage integrated three-phase cylinder connector. The connector housing 1 has an electrically controlled sealing groove 13, and the electrically controlled sealing groove 13 has an electrically controlled sealing ring 8. The electrically controlled sealing ring 8 is located on the electrically controlled side of the connecting flange, achieving a seal on the electrically controlled side of the connector. The electrically controlled sealing groove 13 axially positions the electrically controlled sealing ring 8. Figure 2 , Figure 6 As shown, the connector housing 1 has a slot 15, and the electrically controlled sealing groove 13 communicates with the slot 15. A locking key 81 is connected to the electrically controlled sealing ring 8, and the locking key 81 engages with the slot 15. When installing the electrically controlled sealing ring 8, the locking key 81 is aligned with the slot 15, allowing it to smoothly engage within the electrically controlled sealing groove 13. The engagement between the slot 15 and the locking key 81 secures the electrically controlled sealing ring 8 within the electrically controlled sealing groove 13, preventing radial rotation of the electrically controlled sealing ring 8. During connector mating, this prevents radial rotation and axial movement of the electrically controlled sealing ring 8, avoiding the use of adhesive for fixation. Simultaneously, the electrically controlled sealing ring 8 ensures a tight seal between the two mating connectors.

[0035] Furthermore, the connector housing 1 is provided with a high-pressure sealing groove 11, within which a high-pressure sealing ring 4 is installed. The high-pressure sealing groove 11 corresponds to the position of the high-pressure connecting assembly 3. The connector housing 1 is also provided with a low-pressure sealing groove 12, within which a low-pressure sealing ring 6 is installed. The low-pressure sealing groove 12 corresponds to the position of the low-pressure connecting assembly 5. Both the high-pressure sealing ring 4 and the low-pressure sealing ring 6 are located on the motor side of the connector's connecting flange, achieving a seal on the motor side of the connector.

[0036] Furthermore, such as Figure 5 As shown, the low-voltage connection assembly 5 includes a low-voltage housing 51, within which pins 52 are disposed. The low-voltage housing 51 is integrally injection molded with the connector housing 1. The low-voltage housing 51 is fixedly installed with the pins 52 through integral injection molding, improving the dimensional accuracy of the pins 52 within the connector housing 1 and making the low-voltage signal transmission more stable and reliable.

[0037] Furthermore, a metal skeleton 2 is embedded in the connector housing 1. The metal skeleton 2 is fitted to the connecting flange, and the metal skeleton 2 and the track adhesive 7 are located on both sides of the connecting flange, respectively. The metal skeleton 8 can enhance the overall strength of the connector, reduce the warping deformation of the plastic parts, and effectively resist external forces such as vibration and impact during vehicle operation, thus ensuring the structural stability of the connector.

[0038] 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 high-low voltage integrated three-phase through-bolt connector comprising a connector housing (1), characterized in that, The connector housing (1) is provided with a high-voltage connection assembly (3) and a low-voltage connection assembly (5). The high-voltage connection assembly (3) includes a high-voltage housing (31). The high-voltage housing (31) is integrally injection molded with the connector housing (1). The high-voltage housing (31) is provided with a copper busbar (32). The copper busbar (32) extends out of both ends of the high-voltage housing (31).

2. The high-low pressure integrated three-phase through-bolt connector of claim 1, wherein, The copper busbar (32) is provided with a positioning groove (321) and a bending part (322). The positioning groove (321) is located on the side of the copper busbar (32), and the bending part (322) is located in the middle of the copper busbar (32). The high-voltage housing (31) is provided with a copper busbar mounting hole. The copper busbar mounting hole is provided with a positioning clip (34) and a positioning slope. The positioning groove (321) is engaged with the positioning clip (34), and the bending part (322) is engaged with the positioning slope.

3. The high-low pressure integrated three-phase through-bolt connector of claim 1 or 2, wherein, The high-pressure housing (31) has a high-pressure potting groove (33) on its side, which is connected to the copper busbar mounting hole; the connector housing (1) has a housing potting groove (14), which is connected to the high-pressure potting groove (33).

4. The high-low pressure integrated three-phase through-bolt connector of claim 3, wherein, The connector housing (1) is provided with a connecting flange, and a track adhesive (7) is provided on one side of the connecting flange.

5. The high-low pressure integrated three-phase through-bolt connector of claim 1 or 4, wherein, The connector housing (1) is provided with an electrical control sealing groove (13), and the electrical control sealing groove (13) is provided with an electrical control sealing ring (8).

6. The high-low pressure integrated three-phase through-bolt connector of claim 5, wherein, The connector housing (1) is provided with a slot (15), the electrical control sealing groove (13) is connected to the slot (15), and the electrical control sealing ring (8) is connected with a locking key (81), which engages with the slot (15).

7. The high-low pressure integrated three-phase through-bolt connector of claim 6, wherein, The connector housing (1) is provided with a high-pressure sealing groove (11), and a high-pressure sealing ring (4) is provided in the high-pressure sealing groove (11). The high-pressure sealing groove (11) corresponds to the position of the high-pressure connection assembly (3).

8. The high and low voltage integrated three-phase cylinder connector according to claim 6, characterized in that, The connector housing (1) is provided with a low-pressure sealing groove (12), and a low-pressure sealing ring (6) is provided in the low-pressure sealing groove (12). The low-pressure sealing groove (12) corresponds to the position of the low-pressure connection assembly (5).

9. The high-low pressure integrated three-phase through-bolt connector of any one of claims 1, 7, 8, wherein, The low-pressure connection assembly (5) includes a low-pressure housing (51), a pin (52) is provided inside the low-pressure housing (51), and the low-pressure housing (51) is integrally injection molded with the connector housing (1).

10. The high-low pressure integrated three-phase through-bolt connector of claim 9, wherein, A metal frame (2) is embedded in the connector housing (1).

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