A multi-wire diameter adaptive sealed vehicle power distribution box assembly

Abstract

This utility model discloses a multi-wire diameter adaptive sealed vehicle-mounted power distribution box assembly, relating to the field of power distribution equipment technology. It includes: a box body with a first sealed chamber containing a circuit; the side wall of the box body has several through holes communicating with the first sealed chamber, each through hole containing a sealing sleeve; several cables connected to the circuit within the first sealed chamber pass through a corresponding sealing sleeve, and the inner diameter of the sealing sleeve is compatible with the corresponding cable; the plurality of sealing sleeves includes at least two different inner diameters. Using this solution, the sealed vehicle-mounted power distribution box can adapt to various cable diameters, achieving sealing within the box cavity, eliminating dust accumulation and conductive contaminants such as metal shavings, and mitigating the risk of short circuits caused by water ingress during car washing.

Description

Technical Field

[0001] This utility model relates to the field of power distribution equipment technology, specifically to a multi-wire diameter adaptive sealed vehicle power distribution box assembly. Background Technology

[0002] In recent years, traditional vehicle electrical systems have faced systemic technical challenges in the new energy era. The reason for this is the upgrade of the voltage platform: from the 12V system of fuel vehicles to the 400V / 800V high-voltage system of new energy vehicles. High-power devices such as electric compressors have led to a continuous increase in single-circuit current, thus creating an urgent need for sealed distribution boxes.

[0003] Traditional power distribution boxes have an open design, which leads to dust accumulation and insufficient creepage distance (potentially causing breakdown when the distance is less than 8mm). Furthermore, open-type power distribution boxes do not block conductive contaminants such as metal shavings, potentially causing short circuits (increasing the failure rate by 40% in industrial settings). Open-type power distribution boxes lack waterproofing, making them susceptible to short circuits during high-pressure washing. Additionally, open-type boxes cause condensation buildup, leading to PCB corrosion (copper foil etching rate increases threefold when humidity is greater than 85%). Moreover, the exposed and oxidized copper busbars in open-type power distribution boxes cause a 15% annual increase in contact resistance, increasing the box's own power consumption and causing more severe overheating. Utility Model Content

[0004] To address the shortcomings of existing technologies, this invention aims to provide a multi-wire diameter adaptive sealed vehicle power distribution box assembly. By adopting this solution, the sealed vehicle power distribution box can adapt to various cable diameters to achieve sealing inside the box cavity, eliminate conductive contaminants such as dust accumulation and metal shavings, and mitigate the risk of short circuits caused by water ingress during car washing.

[0005] This utility model is achieved through the following technical solution:

[0006] A multi-wire diameter adaptive sealed vehicle power distribution box assembly, comprising:

[0007] The box has a first sealed chamber inside, and the circuit is distributed in the first sealed chamber.

[0008] The side wall of the box has several through holes that communicate with the first sealed chamber, and each through hole is provided with a sealing sleeve; several cables connected to the circuit inside the first sealed chamber pass through a corresponding sealing sleeve, and the inner diameter of the sealing sleeve is compatible with the corresponding cable.

[0009] The plurality of the aforementioned sealing sleeves includes at least two sealing sleeves with different inner diameters.

[0010] Compared to existing technologies, open-type distribution boxes suffer from problems such as dust accumulation, lack of protection against conductive contaminants like metal shavings, and rapid corrosion of conductive components and control boards within the box. This invention provides a multi-cable diameter adaptive sealed vehicle distribution box assembly. Using this solution, the sealed vehicle distribution box can accommodate various cable diameters, achieving internal sealing, eliminating dust accumulation and conductive contaminants like metal shavings, and mitigating the risk of short circuits caused by water ingress during car washing. Specifically, the solution includes a box body with a sealed chamber. The box body is a one-piece die-cast aluminum alloy structure with an anodized surface. The first sealed chamber inside is used for installing the distribution circuit. Thus, the sealed space isolates the external environment, eliminating the risks of dust accumulation, conductive contaminants like metal shavings, and short circuits caused by water ingress during car washing. In addition, several through holes are provided on the side wall of the box, and a flexible sealing sleeve is installed at each through hole. In this way, the internal cables can pass through the inside of the sealing sleeve flexibly and form a certain sealing effect. The inner diameter of the sealing sleeve can be set in various specifications to accommodate the passage of cables of several different diameters.

[0011] Further optimization, for ease of disassembly and maintenance, also includes a cover plate, the top surface of the box being open, the cover plate being used to close the first sealed chamber from the open.

[0012] To further optimize the design and achieve a sealed opening, a stepped stop is provided at the circumferential end of the opening on the top surface of the box, and a sealing groove is provided circumferentially on the side of the cover for insertion of the stepped stop. In this design, the cover can be made of aluminum alloy sheet, with a stepped stop structure (i.e., an upward-protruding stepped ridge) on the top circumferential surface of the box, which is used to insert into the sealing groove to form a double labyrinth seal, preventing water and dust from penetrating inward. Additionally, several heat dissipation grooves can be evenly distributed on the surface of the cover.

[0013] Further optimization, for ease of assembly and disassembly, allows one side of the cover to be rotatably connected to the box body via a hinge, or the four corners of the cover to be connected to the box body via screws. In this design, the cover can be connected to the box body via screws at the four corners, and the screws can be knurled heads to prevent them from coming loose; when there is sufficient space to lift it up, one side of the cover can be rotatably connected to the box body via a hinge, while the other side is connected via screws.

[0014] Further optimization includes a clamping plate to facilitate the replacement of cables and sealing sleeves and to tighten the sealing sleeves. The side wall of the housing has a longitudinal notch, and the clamping plate is adapted to and detachably connected to the longitudinal notch. Several semi-circular holes are respectively formed on the opposite surfaces of the clamping plate and the longitudinal notch, spaced apart along their respective lengths. A through hole is formed between the semi-circular holes on the clamping plate and the corresponding semi-circular holes on the longitudinal notch. In this design, the clamping plate is made of aluminum alloy, allowing for a tight fit with the periphery of the housing at the longitudinal notch. When installing the sealing sleeve and cables, the sealing sleeve can be inserted into the semi-circular holes at the longitudinal notch. The sealing sleeve has large-diameter ends at both ends and a small-diameter section in the middle; the small-diameter section is inserted, while the large-diameter ends are used for sliding. Then, the clamping plate is placed in, and the sealing sleeve is tightened through the semi-circular holes on the clamping plate, thereby fixing the internal cables and reducing gaps.

[0015] Further optimization involves fixing the clamping plate and reducing the gap below it. A connecting hole for bolts to pass through is provided between adjacent semicircular holes on the clamping plate. A matching threaded hole is provided between adjacent semicircular holes on the longitudinal notch. The bolt passes through the connecting hole and the threaded hole for connection, and a washer is fitted on the bolt between the clamping plate and the longitudinal notch. The washer seals the gap between adjacent through holes. In this design, fixing can be achieved with bolts. A groove is provided at the top of the clamping plate to facilitate the insertion of the bolt head. The bolt passes through the connecting hole from the groove and connects with the threaded hole below, thus fixing the clamping plate. Additionally, a flexible washer is fitted in the middle of the bolt, facilitating the downward pressure of the clamping plate and reducing the gap between adjacent through holes. The through holes can also have different inner diameters to accommodate sealing sleeves of different inner diameters.

[0016] To further optimize the installation of the clamping plate, vertical grooves are provided on the sides of the box on both sides of the longitudinal notch, and the two ends of the clamping plate are used to slide and connect with the vertical grooves.

[0017] To further optimize the design and prevent cables from being cut by the housing while providing flexible protection for internal cables, the sealing sleeve comprises a protective layer, a memory foam layer, and an elastic layer arranged coaxially from the outside to the inside. The sealing sleeve employs a sandwich composite structure in an I-shape, with an inner layer of silicone rubber as the elastic layer, a middle layer of memory foam, and an outer corrugated protective layer. Rubber sleeves with different inner diameters are manufactured to meet varying wire diameter requirements. Several rubber sleeves of the same specification are made with different outer diameters to seal cables of different diameters when passing through the housing. The front and rear ends of the I-shape are secured at the cable exit point of the housing, protecting the cable from being cut by the housing during movement.

[0018] To further optimize the system and reduce the impact of vehicle vibration on the distribution box, several lugs are evenly distributed around the bottom outer side of the box, each lug being connected to a buffer foot. In this design, perforations are provided on the lugs, and the buffer foot includes a buffer sleeve and a buffer pad. The buffer sleeve has the same shape as the sealing sleeve, with large-diameter ends and a small-diameter section in the middle. The size of the small-diameter section matches the size of the perforation and is located within the perforation. The lower end of the buffer sleeve extends beyond the lower side of the box for support. The buffer pad is inserted inside the buffer sleeve to reinforce it. The buffer foot is used to reduce the impact vibration of vehicle vibration on the distribution box, providing shock absorption and support functions.

[0019] Furthermore, the housing includes a second sealed chamber for housing a relay, and the side wall of the housing also has an aviation connector communicating with the second sealed chamber. The relay is an actuator used to intelligently switch the circuit on and off; the aviation connector is mounted on the housing and used to control the relay signal transmission.

[0020] As a redundancy solution, an insulating mounting plate, made of fabric-reinforced phenolic resin board, is installed at the bottom of the first sealed chamber of the box to achieve electrical isolation and mechanical support for the conductive bolts. The conductive plate, made of copper, is a core component for efficient current distribution, reduced contact resistance, and optimized thermal performance in the distribution box. Its surface is nickel-plated and organically passivated, effectively improving its oxidation resistance and reducing impedance. The automotive fuse in the middle provides overload protection for the vehicle's electrical components through rapid melting. The conductive plate and fuse are fixed by several internal bolts, which can be tin-plated copper bolts and nuts. These bolts also ensure conductive connections for the electrical components within the distribution box. Made of brass, the surface is tin-plated to increase the brass's oxidation resistance and effectively reduce impedance.

[0021] Compared with the prior art, this utility model has the following advantages and beneficial effects:

[0022] 1. This utility model provides a multi-wire diameter adaptive sealed vehicle power distribution box assembly. By adopting this solution, the sealed vehicle power distribution box can adapt to various cable diameters to achieve sealing inside the box cavity, eliminate conductive contaminants such as dust accumulation and metal shavings, and mitigate the risk of short circuits caused by water ingress during car washing.

[0023] 2. The present invention provides a multi-wire diameter adaptive sealed vehicle power distribution box assembly. With this solution, the cover plate and the clamping plate make it easy to disassemble and assemble, convenient to maintain, and have a low cost. Attached Figure Description

[0024] The accompanying drawings, which are included to provide a further understanding of the embodiments of the present invention and form part of this application, do not constitute a limitation thereof. In the drawings:

[0025] Figure 1 A schematic diagram of the structure of the multi-wire diameter adaptive sealed vehicle power distribution box assembly provided by this utility model;

[0026] Figure 2 A cross-sectional view of the sealing sleeve provided by this utility model.

[0027] The attached diagram shows the markings and corresponding component names:

[0028] 1-Box body, 2-Sealing sleeve, 201-Protective layer, 202-Memory foam layer, 203-Elastic layer, 3-Cover plate, 4-Pressure plate, 5-Cable, 6-Relay, 7-Aircraft plug, 8-Insulating mounting plate, 9-Conductive plate, 10-Screw, 11-Automotive fuse, 12-Buffer foot support, 13-Internal bolt. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the embodiments and accompanying drawings. The illustrative embodiments and descriptions of this utility model are only used to explain this utility model and are not intended to limit this utility model.

[0030] Example:

[0031] This embodiment provides a multi-wire diameter adaptive sealed vehicle power distribution box assembly, such as... Figures 1-2 As shown, it includes:

[0032] Box 1, which has a first sealed chamber, and the first sealed chamber contains circuitry;

[0033] The side wall of the box 1 has several through holes that communicate with the first sealed chamber, and each through hole is provided with a sealing sleeve 2; several cables 5 connected to the circuit in the first sealed chamber pass through a corresponding sealing sleeve 2, and the inner diameter of the sealing sleeve 2 is compatible with the corresponding cable 5.

[0034] The plurality of sealing sleeves 2 include at least two sealing sleeves 2 with different inner diameters.

[0035] Compared to existing technologies, open-type distribution boxes suffer from problems such as dust accumulation, lack of protection against conductive contaminants like metal shavings, and rapid corrosion of conductive components and control boards within the box 1. This invention provides a multi-cable diameter adaptive sealed vehicle distribution box assembly. Using this solution, the sealed vehicle distribution box can accommodate various cable diameters, achieving internal sealing of the box 1 cavity, eliminating dust accumulation and conductive contaminants like metal shavings, and mitigating the risk of short circuits caused by water ingress during car washing. Specifically, the solution includes a box 1 with a sealed chamber. The box 1 is an integral die-cast aluminum alloy structure with an anodized surface. The first sealed chamber inside is used for installing the distribution circuit. Thus, the sealed space isolates the external environment, eliminating the risks of dust accumulation, conductive contaminants like metal shavings, and short circuits caused by water ingress during car washing. In addition, several through holes are provided on the side wall of the box 1, and a flexible sealing sleeve 2 is installed at each through hole. In this way, the cable 5 inside can pass through the inside of the sealing sleeve 2 flexibly and form a certain sealing effect. The inner diameter of the sealing sleeve 2 can be set in various specifications to accommodate the passage of several different diameter cables 5.

[0036] In some embodiments, for ease of disassembly and maintenance, a cover plate 3 is also included, with the top surface of the box body 1 being open, and the cover plate 3 is used to close the first sealed chamber from the open.

[0037] In some embodiments, to achieve a seal on the open side, a stepped stop is provided at the circumferential end of the open top surface of the box body 1, and a sealing groove is provided circumferentially on the side of the cover plate 3 for the stepped stop to be inserted. In this embodiment, the cover plate 3 can be made of aluminum alloy sheet, and a stepped stop structure, i.e., an upwardly protruding stepped ridge, is provided on the top circumferential surface of the box body 1. This ridge is used to insert into the sealing groove to form a double labyrinth seal, preventing water and dust from penetrating inward. In addition, several heat dissipation grooves can be evenly distributed on the surface of the cover plate 3.

[0038] In some embodiments, for ease of assembly and disassembly, one side of the cover plate 3 is rotatably connected to the box body 1 via a hinge, or the four corners of the cover plate 3 are connected to the box body 1 via screws 10. In this solution, the cover plate 3 can be connected to the box body 1 via screws 10 at the four corners, and the screws 10 can be knurled head screws that do not come loose; when there is sufficient space to lift up, one side of the cover plate 3 can be rotatably connected to the box body 1 via a hinge, while the other side is connected via screws 10.

[0039] In some embodiments, to facilitate the replacement of the cable 5 and the sealing sleeve 2, and to achieve the clamping of the sealing sleeve 2, a clamping plate 4 is also included. A longitudinal notch is provided on the side wall of the housing 1. The clamping plate 4 is adapted to the longitudinal notch and is detachably connected to it. A plurality of semi-circular holes are respectively provided on the opposite surfaces of the clamping plate 4 and the longitudinal notch, and are spaced apart along their respective length directions. A through hole is formed between the semi-circular holes on the clamping plate 4 and the corresponding semi-circular holes on the longitudinal notch. In this embodiment, the clamping plate 4 is made of aluminum alloy and can fit tightly with the periphery of the housing 1 at the longitudinal notch. When installing the sealing sleeve 2 and the cable 5, the sealing sleeve 2 can be inserted into the semi-circular hole at the longitudinal notch. The sealing sleeve 2 has large-diameter ends at both ends and a small-diameter section in the middle; the small-diameter section is inserted, and the large-diameter ends are used for sliding. Then, the clamping plate 4 is placed in, and the sealing sleeve 2 is clamped through the semi-circular hole on the clamping plate 4, thereby fixing the internal cable 5 and reducing gaps.

[0040] In some embodiments, to fix the clamping plate 4 and reduce the gap below the clamping plate 4, a connecting hole for bolts to pass through is provided between adjacent semicircular holes on the clamping plate 4; a matching threaded hole is provided between adjacent semicircular holes on the longitudinal notch; the bolt is used to pass through the connecting hole and the threaded hole for connection, and a washer is fitted on the bolt between the clamping plate 4 and the longitudinal notch, the washer being used to seal the gap between adjacent through holes. In this solution, fixing can be achieved by bolts, a groove is provided on the top of the clamping plate 4 to facilitate the insertion of the bolt head, the bolt passes through the connecting hole from the groove and connects with the threaded hole below, thereby fixing the clamping plate 4; in addition, a washer is fitted in the middle of the bolt, the washer being flexible, which facilitates the downward pressing of the clamping plate 4 and reduces the gap between adjacent through holes. The through holes can also be provided with different inner diameters to accommodate sealing sleeves 2 with different inner diameters; (the bolt in the figure is slightly through the mold, but this does not affect its function).

[0041] In some embodiments, to facilitate quick installation of the clamping plate 4, vertical grooves are also provided on the sides of the box 1 on both sides of the longitudinal notch, and the two ends of the clamping plate 4 are used to slide and connect with the vertical grooves.

[0042] In some embodiments, to prevent the cable 5 from being cut by the housing 1 and to flexibly protect the internal cable 5, the sealing sleeve 2 includes a protective layer 201, a memory foam layer 202, and an elastic layer 203 arranged coaxially from the outside to the inside. The sealing sleeve 2 adopts a sandwich composite structure, in the shape of an I-beam. The inner layer uses silicone rubber as the elastic layer 203, the middle layer uses memory foam 202, and the outer layer is a corrugated protective layer 201. Rubber sleeves with different inner diameters are made according to different wire diameter requirements. Several rubber sleeves of the same specification are made according to the size of the inner diameter, used for sealing when cables 5 of different diameters pass through the housing 1. The front and rear ends of the I-beam shape are engaged at the cable 5 outlet of the housing 1, protecting the cable 5 from being cut by the housing 1 when it shakes.

[0043] In some embodiments, to reduce the impact of vehicle body vibration on the distribution box, several lugs are evenly distributed around the bottom outer side of the box 1, and each lug is connected to a buffer foot 12. In this embodiment, a through hole is provided on the lug, and the buffer foot 12 includes a buffer sleeve and a buffer pad. The shape of the buffer sleeve is the same as that of the sealing sleeve 2, with large-diameter ends at both ends and a small-diameter section in the middle. The size of the small-diameter section is adapted to the size of the through hole and is located inside the through hole. The lower end of the buffer sleeve extends beyond the lower side of the box 1 to provide support. The buffer pad is inserted inside the buffer sleeve to reinforce the buffer sleeve. The buffer foot 12 is used to reduce the impact vibration of vehicle body vibration on the distribution box and has shock absorption and support functions.

[0044] In some embodiments, the housing 1 has a second sealed chamber for housing a relay 6, and the side wall of the housing 1 also has a connector 7 communicating with the second sealed chamber. The relay 6 is an actuator for intelligently switching the circuit on and off; the connector 7 is mounted on the housing 1 and is used to control the signal transmission of the relay 6.

[0045] As a redundancy solution, an insulating mounting plate 8, made of fabric-reinforced phenolic resin board, is installed at the bottom of the first sealed chamber of box 1 to achieve electrical isolation and mechanical support for the conductive bolts. The conductive plate 9, made of copper, is a core component for efficient current distribution, reduced contact resistance, and optimized thermal performance in the distribution box. Its surface is nickel-plated and organically passivated, effectively improving its oxidation resistance and reducing impedance. The automotive fuse 11 in the middle provides overload protection for the vehicle's electrical components through rapid melting. The conductive plate 9 and fuse are fixed by several internal bolts 13. These internal bolts 13 can be tin-plated copper bolts and nuts, which also ensure conductive connections for the electrical components within the distribution box. Made of brass, the surface is tin-plated to increase the brass's oxidation resistance and effectively reduce impedance.

[0046] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of this utility model. It should be understood that the above description is only a specific embodiment of this utility model and is not intended to limit the scope of protection of this utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the scope of protection of this utility model.

Claims

1. A multi-wire diameter adaptive sealed on-board power distribution box assembly, comprising: include: The box (1) has a first sealed chamber inside, and the first sealed chamber contains circuitry. The side wall of the box (1) has several through holes that communicate with the first sealed chamber, and each through hole is provided with a sealing sleeve (2); several cables (5) connected to the circuit in the first sealed chamber pass through one of the corresponding sealing sleeves (2), and the inner diameter of the sealing sleeve (2) is compatible with the corresponding cable (5); The plurality of the sealing sleeves (2) include at least two sealing sleeves (2) with different inner diameters.

2. The multi-wire diameter self-adapting sealed in-vehicle power distribution box assembly of claim 1, wherein, It also includes a cover plate (3), the top surface of the box body (1) is open, and the cover plate (3) is used to close the first sealed chamber from the opening.

3. The multi-wire diameter self-adapting sealed in-vehicle power distribution box assembly of claim 2, wherein, The box body (1) has a stepped stop at the circumferential end of the top opening, and the cover plate (3) has a sealing groove on the side circumferentially for the stepped stop to be inserted.

4. The multi-wire diameter self-adapting sealing vehicle power distribution box assembly of claim 2, wherein, One side of the cover plate (3) is rotatably connected to the box body (1) by a hinge, or the four corners of the cover plate (3) are connected to the box body (1) by screws (10).

5. The multi-wire diameter self-adapting sealing vehicle power distribution box assembly of any one of claims 1-4, wherein, It also includes a clamping plate (4), the side wall of the box body (1) has a longitudinal notch, the clamping plate (4) is adapted to the longitudinal notch, and is detachably connected to the longitudinal notch; A plurality of semicircular holes are respectively provided on the opposite surfaces of the pressing plate (4) and the longitudinal notch, and are arranged at intervals along their respective length directions; the through hole is formed between the semicircular holes on the pressing plate (4) and the semicircular holes on the corresponding longitudinal notch.

6. The multi-wire diameter adaptive sealed vehicle power distribution box assembly according to claim 5, characterized in that, On the clamping plate (4), a connecting hole for bolts to pass through is provided between adjacent semicircular holes; On the longitudinal notch, a matching threaded hole is provided between adjacent semicircular holes; The bolt is used to connect through the connecting hole and the threaded hole, and a washer is fitted on the bolt between the clamping plate (4) and the longitudinal notch, the washer being used to seal the gap between adjacent through holes.

7. The multi-wire diameter self-adapting seal in-vehicle power distribution box assembly of claim 5, wherein, Vertical grooves are provided on the sides of the box body (1) on both sides of the longitudinal notch, and the two ends of the clamping plate (4) are used to slide and connect with the vertical grooves.

8. The multi-wire diameter self-adapting sealing vehicle power distribution box assembly of any one of claims 1-4, wherein, The sealing sleeve (2) includes a protective layer (201), a memory foam layer (202), and an elastic layer (203) arranged coaxially from the outside to the inside.

9. The multi-wire diameter self-adapting sealing vehicle power distribution box assembly of any one of claims 1-4, wherein, The outer bottom of the box (1) is evenly distributed with several lugs, and each lug is connected to a buffer foot support (12).

10. The multi-wire diameter self-adapting sealing vehicle power distribution box assembly of any one of claims 1-4, wherein, The box (1) is provided with a second sealed chamber, which is used to install a relay (6), and the side wall of the box (1) is also provided with a flight plug (7) that communicates with the second sealed chamber.

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