A fully-sealed motor electric control terminal connection structure

Abstract

This utility model relates to the field of motor and electrical control connection technology, and in particular to a fully sealed motor and electrical control terminal connection structure. It includes electrical control terminals for electrical connection between a motor and an electrical control system. The electrical control terminals include: a female terminal, fixed to the electrical control system and mechanically interlocked with a male terminal fixed to the motor frame, used for current conduction; a silicone rubber expansion layer, wrapping and filling the outer periphery and gaps of the female terminal, used to reduce the contact resistance between the female terminal and the mating terminal; and an aluminum alloy housing, in which the female terminal with the pre-installed silicone rubber expansion layer is axially inserted into a mounting cavity. The intelligent thermal expansion characteristics of the silicone rubber expansion layer enable adaptive pressure adjustment, effectively solving the problem of increased contact resistance at high temperatures. Simultaneously, the heat dissipation fins inside the aluminum alloy housing construct an efficient heat dissipation channel, significantly improving reliability under high current conditions and ensuring excellent performance of the connection structure in complex environments.

Description

Technical Field

[0001] This utility model relates to the field of motor and electrical control connection technology, specifically a fully sealed motor and electrical control terminal connection structure. Background Technology

[0002] In fields such as power systems, new energy vehicles, and industrial equipment, the stability of electrical connections directly determines system safety and energy efficiency. As a critical node for current transmission, the stability of the contact resistance of electronic connection terminals is of paramount importance, as contact resistance can vary due to material properties, surface roughness, clamping force, and ambient temperature.

[0003] According to CN105071087B, a method for fixing a motor terminal, a power cord fixing assembly, a motor, and its power cord is disclosed. This technology discloses a method for fixing a motor terminal, a power cord fixing assembly, and its power cord, wherein the motor terminal is used to connect the power cord and the winding lead pin. It includes a base, a pin receiving portion protruding from the base for the winding lead pin to pass through and be positioned, and a connecting portion bent along one side of the base for crimping and fixing with one end of the power cord. The base has a clearance hole for the winding lead pin to pass through the pin receiving portion, and the pin receiving portion has an anti-disengagement plate for engaging with the anti-disengagement slot of the winding lead pin. This technology has the following advantages: "When connecting the power cord and the winding lead pin, the entire connection process does not require drilling or soldering, effectively simplifying the connection process between the power cord and the winding lead pin, and enabling automated connection, thus improving motor production efficiency and reducing labor costs in motor production."

[0004] In high-temperature environments, the difference in thermal expansion of materials and metal creep lead to a decrease in contact pressure, which significantly increases contact resistance and causes overheating damage. Furthermore, high-intensity vibration can cause fretting wear on the terminal contact surface, and the accumulation of wear debris and oxidation corrosion further increase the contact resistance. Secondly, under high-current conditions, heat accumulation is difficult to effectively dissipate, and the poor thermal conductivity of traditional insulating and sealing materials leads to excessively high local temperature rise. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this utility model provides a fully sealed motor control terminal connection structure. It achieves adaptive pressure regulation through the intelligent thermal expansion characteristics of the silicone rubber expansion layer, effectively solving the problem of increased contact resistance at high temperatures. At the same time, it utilizes the heat dissipation fins inside the aluminum alloy shell to construct an efficient heat dissipation channel, significantly improving reliability under high current conditions and enabling the connection structure to maintain excellent performance in complex environments.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a fully sealed motor electrical control terminal connection structure, comprising electrical control terminals for electrical connection between the motor and the electrical control system, wherein the electrical control terminals include:

[0007] The female terminal is fixed to the electrical control system and mechanically interlocked with the male terminal fixed to the motor frame, and is used to conduct current;

[0008] The silicone rubber expansion layer wraps around and fills the outer periphery and gaps of the female terminal and is used to reduce the contact resistance between the female terminal and the mating terminal.

[0009] The aluminum alloy housing has a female terminal with a pre-installed silicone rubber expansion layer axially inserted into the mounting cavity of the aluminum alloy housing, and the silicone rubber expansion layer forms an interference fit with the aluminum alloy housing.

[0010] Preferably, the electrical control terminal further includes heat dissipation fins, which are machined on the inner wall of the aluminum alloy housing and are used to increase the heat exchange area with the silicone rubber expansion layer.

[0011] Preferably, the electrical control terminal further includes mounting holes formed on the female terminal and the aluminum alloy housing, and the female terminal and the aluminum alloy housing are fastened together with bolts through the mounting holes.

[0012] Preferably, the silicone rubber expansion layer is made of addition-type liquid silicone rubber, the interference of the silicone rubber expansion layer covering the female terminal is 0.3 to 0.8 mm, and the initial assembly compression is 15% to 20%.

[0013] Preferably, the compression recovery rate of the silicone rubber expansion layer is ≥95%, and the thermal conductivity is ≥1.2 W / m·K.

[0014] Preferably, the silicone rubber expansion layer contains cerium oxide nanoparticles with a mass fraction of 0.5-2 wt%.

[0015] Preferably, the coefficient of thermal expansion of the silicone rubber expansion layer is 250-350ppm / °C in the range of 20-150°C, and the elastic modulus is 1-5MPa.

[0016] Preferably, the female terminal is made of a chromium-zirconium-copper alloy and has a gold-plated surface. Beneficial effects

[0017] This invention provides a fully sealed motor electrical control terminal connection structure. Compared with the prior art, it has the following advantages:

[0018] 1. Due to the fact that the coefficient of thermal expansion of silicone rubber is much higher than that of metal, when the working temperature rises, the silicone rubber expansion layer generates a significant radial expansion force due to its high thermal expansion characteristics. This expansion force actively acts on the female terminal, accurately offsetting the contact pressure loss caused by the thermal expansion difference of the metal parts. This not only effectively solves the technical problem of increased contact resistance under high temperature environment, but also ensures the reliability of the connection structure under high intensity vibration conditions through continuous and stable clamping force.

[0019] 2. By using addition-cured liquid silicone rubber as the base material for the silicone rubber expansion layer, and through precise control of the interference fit and initial compression design, this liquid silicone rubber forms a sealing structure with excellent elasticity and temperature resistance after curing. Its initial compression ensures sufficient contact pressure during assembly, while the interference fit design reserves space for material expansion when the temperature rises. This allows the silicone rubber layer to dynamically adjust the clamping force under different working conditions, ensuring reliable sealing and electrical contact at room temperature, and further enhancing the clamping effect through thermal expansion at high temperatures. At the same time, the fluidity of the material allows it to perfectly fill the complex gap between the female terminal and the aluminum alloy shell, forming a seamless sealing protection and an efficient heat conduction path. Furthermore, the coefficient of thermal expansion of silicone is higher than that of aluminum alloy. The greater the thickness of the silicone between the gaps, the more it expands at high temperatures, thus further clamping the terminal and reducing contact resistance at high temperatures.

[0020] 3. An efficient heat conduction channel is constructed through an integrated heat dissipation design; the heat dissipation fins on the inner side of the aluminum alloy shell greatly increase the heat exchange area, and the close cooperation with the silicone rubber layer forms a continuous heat dissipation path from the internal heat source to the external environment; this allows the heat generated by the terminal to be quickly and evenly diffused to the entire shell surface, effectively avoiding the problem of local overheating caused by heat accumulation in traditional structures; the optimized heat dissipation performance not only delays material aging, but also significantly improves the reliability of the connector under high current conditions. Attached Figure Description

[0021] Figure 1 This is a three-dimensional structural diagram of the present invention;

[0022] Figure 2 This is a schematic diagram of the aluminum alloy shell in this utility model;

[0023] Figure 3 This is a schematic diagram of the structure of the female terminal in this utility model;

[0024] Figure 4 This is a cross-sectional view of the female terminal in this utility model.

[0025] In the diagram: 1. Electrical control terminal; 11. Female terminal; 12. Silicone rubber expansion layer; 13. Mounting hole; 14. Aluminum alloy housing; 15. Heat dissipation fins. Detailed Implementation

[0026] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings. 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.

[0027] Please see Figure 1 - Figure 4 This utility model provides a technical solution: a fully sealed motor electrical control terminal connection structure, including an electrical control terminal 1 for electrical connection between the motor and the electrical control system, wherein the electrical control terminal 1 includes:

[0028] The female terminal 11 is fixed to the electrical control system and mechanically interlocked with the male terminal fixed to the motor frame for conducting current;

[0029] The silicone rubber expansion layer 12 wraps around and fills the outer periphery and gap of the female terminal 11 and is used to reduce the contact resistance between the female terminal 11 and the mating terminal.

[0030] The female terminal 11 of the aluminum alloy housing 14, which is pre-installed with a silicone rubber expansion layer 12, is axially inserted into the mounting cavity of the aluminum alloy housing 14, and the silicone rubber expansion layer 12 and the aluminum alloy housing 14 form an interference fit.

[0031] In this embodiment, due to the fact that the coefficient of thermal expansion of silicone rubber (CTE≈250-350 ppm / °C) is much higher than that of metal (copper CTE≈17 ppm / °C), when the operating temperature rises, the silicone rubber expansion layer 12 generates a significant radial expansion force due to its high thermal expansion characteristics. This expansion force actively acts on the female terminal 11, precisely offsetting the contact pressure loss caused by the thermal expansion difference of the metal parts. This not only effectively solves the technical problem of increased contact resistance under high temperature conditions, but also ensures the reliability of the connection structure under high-intensity vibration conditions through continuous and stable clamping force. This unique adaptive mechanism can dynamically adjust the clamping force according to temperature changes and automatically match the needs of different load conditions. The entire adjustment process is achieved entirely by relying on the physical properties of the material itself, without relying on any external control system, which simplifies the structural design and improves the system reliability.

[0032] Specifically, the electrical control terminal 1 also includes heat dissipation fins 15, which are machined on the inner wall of the aluminum alloy housing 14 and are used to increase the heat exchange area with the silicone rubber expansion layer 12.

[0033] In this embodiment, the heat dissipation fins 15 significantly increase the contact surface area with the silicone rubber expansion layer 12, effectively improving the efficiency of heat conduction from the inside to the outer shell, so that the heat generated by the terminals can be quickly and evenly diffused to the entire aluminum alloy shell 14.

[0034] Specifically, the electrical control terminal 1 also includes mounting holes 13 formed on the female terminal 11 and the aluminum alloy housing 14, and the female terminal 11 and the aluminum alloy housing 14 are fastened together with bolts through the mounting holes 13.

[0035] In this embodiment, the rigid fixation between the female terminal 11 and the aluminum alloy housing 14 is ensured, effectively resisting relative displacement under vibration conditions; at the same time, the bolt fastening method provides precise and controllable assembly pressure, so that the silicone rubber expansion layer 12 can maintain the best compression state, which ensures both sealing performance and maintains appropriate thermal expansion space.

[0036] Specifically, the silicone rubber expansion layer 12 is made of addition-cured liquid silicone rubber, the interference of the silicone rubber expansion layer 12 covering the female terminal 11 is 0.3 to 0.8 mm, and the initial assembly compression is 15% to 20%.

[0037] In this embodiment, addition-type liquid silicone rubber is used as the base material of the silicone rubber expansion layer 12, and the interference fit and initial compression are precisely controlled. After curing, the liquid silicone rubber forms a sealing structure with excellent elasticity and temperature resistance. Its initial compression ensures sufficient contact pressure during assembly, while the interference fit design reserves space for material expansion when the temperature rises. This allows the silicone rubber layer to dynamically adjust the clamping force under different working conditions, ensuring reliable sealing and electrical contact at room temperature, and further enhancing the clamping effect through thermal expansion at high temperatures. At the same time, the fluidity of the material allows it to perfectly fill the complex gap between the female terminal 11 and the aluminum alloy shell 14, forming a seamless sealing protection and an efficient heat conduction path. Furthermore, the coefficient of thermal expansion of silicone is higher than that of aluminum alloy. The greater the thickness of the silicone between the gaps, the more it expands at high temperatures, thus clamping the terminal more tightly and reducing the contact resistance at high temperatures.

[0038] Specifically, the compression recovery rate of the silicone rubber expansion layer 12 is ≥95%, and the thermal conductivity is ≥1.2 W / m·K.

[0039] In this embodiment, the material can almost completely recover its original shape after repeated compression and deformation, ensuring that it maintains a stable contact pressure during long-term use; at the same time, its good thermal conductivity effectively establishes an efficient heat conduction channel from the female terminal to the aluminum alloy shell, quickly dissipating the Joule heat generated during the power-on process.

[0040] Specifically, cerium oxide nanoparticles are added to the silicone rubber expansion layer 12, with a mass fraction of 0.5-2 wt%.

[0041] In this embodiment, the addition of cerium oxide nanoparticles effectively slows down the thermo-oxidative aging process of the silicone rubber expansion layer 12 under high temperature conditions, and greatly enhances the heat resistance stability of the material; at the same time, the unique catalytic properties of cerium oxide can decompose the active free radicals generated during the rubber aging process, thereby inhibiting the degradation of material performance.

[0042] Specifically, the coefficient of thermal expansion of the silicone rubber expansion layer 12 is 250-350ppm / °C in the range of 20-150℃, and the elastic modulus is 1-5MPa.

[0043] In this embodiment, the silicone rubber expansion layer 12 has specific thermal expansion characteristics and elastic modulus, enabling it to intelligently respond to temperature changes: when the ambient temperature rises, the material will expand significantly, generating a continuous radial clamping force, dynamically compensating for the decrease in contact pressure caused by the thermal expansion difference of the metal terminals; its moderate elastic modulus ensures sufficient rigidity to transmit the clamping force, while also having the necessary flexibility to absorb the impact of mechanical vibration.

[0044] Specifically, the female terminal 11 is made of a chromium-zirconium-copper alloy and has a gold-plated surface.

[0045] In this embodiment, the chromium-zirconium-copper alloy provides excellent mechanical strength and electrical conductivity, ensuring structural stability and low resistance characteristics during high current transmission; the gold plating layer on the surface not only significantly improves the corrosion resistance and oxidation resistance of the terminals, extending their service life in harsh environments, but also ensures the stability of the electrical connection due to the low contact resistance of the gold layer.

[0046] The working principle and usage process of this utility model are as follows: First, the female terminal 11 with the pre-installed silicone rubber expansion layer 12 is axially inserted into the mounting cavity of the aluminum alloy housing 14, and a rigid connection is achieved by tightening bolts. At this time, the silicone rubber layer generates an initial compression to form a seal. When the temperature rises, the silicone rubber expansion layer 12 automatically expands due to the difference in thermal expansion coefficients, continuously compensating for the attenuation of the contact pressure of the metal terminal; at the same time, heat is conducted through the silicone rubber layer to the inner heat dissipation fins 15 of the aluminum alloy housing 14 for rapid diffusion. Throughout the entire working process, the connection structure achieves dynamic pressure regulation and efficient heat dissipation through the inherent properties of the material, ensuring stable electrical connection performance under complex working conditions such as high temperature and vibration without external control.

[0047] Furthermore, by using addition-cured liquid silicone rubber as the base material for the silicone rubber expansion layer 12, and through precise control of the interference fit and initial compression design, the liquid silicone rubber forms a sealing structure with excellent elasticity and temperature resistance after curing. Its initial compression ensures sufficient contact pressure during assembly, while the interference fit design reserves space for material expansion when the temperature rises. This allows the silicone rubber layer to dynamically adjust the clamping force under different working conditions, ensuring reliable sealing and electrical contact at room temperature, and further enhancing the clamping effect through thermal expansion at high temperatures. At the same time, the fluidity of the material allows it to perfectly fill the complex gap between the female terminal 11 and the aluminum alloy shell 14, forming a seamless sealing protection and an efficient heat conduction path. Moreover, the coefficient of thermal expansion of silicone is higher than that of aluminum alloy. The greater the thickness of the silicone between the gaps, the more it expands at high temperatures, thus clamping the terminal more tightly and reducing the contact resistance at high temperatures.

[0048] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0049] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A fully sealed motor electrical control terminal connection structure, characterized in that: Includes an electrical control terminal (1) for electrical connection between the motor and the electrical control system, the electrical control terminal (1) comprising: The female terminal (11) is fixed to the electrical control system and mechanically interlocked with the male terminal fixed to the motor frame for conducting current; The silicone rubber expansion layer (12) wraps around and fills the outer periphery and gap of the female terminal (11) and is used to reduce the contact resistance between the female terminal (11) and the mating terminal; The female terminal (11) of the pre-installed silicone rubber expansion layer (12) of the aluminum alloy housing (14) is axially inserted into the mounting cavity of the aluminum alloy housing (14), and the silicone rubber expansion layer (12) and the aluminum alloy housing (14) form an interference fit.

2. The fully sealed motor electrical control terminal connection structure according to claim 1, characterized in that: The electrical control terminal (1) also includes heat dissipation fins (15), which are machined on the inner wall of the aluminum alloy housing (14) and are used to increase the heat exchange area with the silicone rubber expansion layer (12).

3. The fully sealed motor electrical control terminal connection structure according to claim 1, characterized in that: The electrical control terminal (1) also includes mounting holes (13) on the female terminal (11) and the aluminum alloy housing (14), and the female terminal (11) and the aluminum alloy housing (14) are fastened together with bolts through the mounting holes (13).

4. The fully sealed motor electrical control terminal connection structure according to claim 1, characterized in that: The silicone rubber expansion layer (12) is made of addition-cured liquid silicone rubber. The interference of the silicone rubber expansion layer (12) on the female terminal (11) is 0.3 to 0.8 mm, and the initial assembly compression is 15% to 20%.

5. The fully sealed motor electrical control terminal connection structure according to claim 1, characterized in that: The compression recovery rate of the silicone rubber expansion layer (12) is ≥95%, and the thermal conductivity is ≥1.2 W / m·K.

6. The fully sealed motor electrical control terminal connection structure according to claim 1, characterized in that: The silicone rubber expansion layer (12) contains cerium oxide nanoparticles with a mass fraction of 0.5-2 wt%.

7. The fully sealed motor electrical control terminal connection structure according to claim 1, characterized in that: The coefficient of thermal expansion of the silicone rubber expansion layer (12) is 250-350ppm / °C in the range of 20-150℃, and the elastic modulus is 1-5MPa.

8. The fully sealed motor electrical control terminal connection structure according to claim 1, characterized in that: The female terminal (11) is made of chromium zirconium copper alloy and has a gold-plated surface.

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