Encapsulated terminal
By designing the insulated terminal and adopting an integrated sealing structure for the terminal body, the problem of insufficient airtightness of traditional terminals is solved, and the high airtightness and tensile strength are improved, making it suitable for electrical connectors in new energy vehicles.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- DONGGUAN HONGSHENG RUBBER PROD CO LTD
- Filing Date
- 2025-06-24
- Publication Date
- 2026-07-14
Smart Images
Figure CN224502463U_ABST
Abstract
Description
[Technical Field]
[0001] This application relates to the field of electrical connector technology, and more particularly to an overmolded terminal. [Background Technology]
[0002] New energy vehicles refer to automobiles that use unconventional vehicle fuels as their power source (or use conventional vehicle fuels and employ new onboard power devices), integrating advanced technologies in vehicle power control and drive, resulting in vehicles with advanced technical principles and new technologies and structures. New energy vehicles include pure electric vehicles, range-extended electric vehicles, hybrid electric vehicles, fuel cell electric vehicles, and hydrogen engine vehicles. Compared to conventional vehicles, the electrical systems of new energy vehicles are more complex, and the sealing requirements for high-voltage wiring harnesses are also higher. Traditional terminals have lower airtightness and cannot meet the sealing requirements of new energy vehicles.
[0003] Therefore, how to improve the airtightness of terminals is a problem that urgently needs to be solved by those skilled in the art. [Utility Model Content]
[0004] To address the aforementioned issues, this application provides an overmolded terminal, comprising: a terminal body formed by stamping and rolling to create a receiving cavity; a first sealing member received within the receiving cavity; and a second sealing member sleeved on the terminal body and forming an integral structure with the first sealing member.
[0005] In some embodiments, the terminal body is further provided with a notch that connects the receiving cavity to the external space.
[0006] In some embodiments, the inner wall of the receiving cavity is provided with a fastening part, which is disposed adjacent to the notch, and the fastening part is an array of groove structures.
[0007] In some embodiments, the first seal includes a connecting portion and two opposing sealing portions, the sealing portions being fixedly connected as an integral structure via the connecting portion, the size of the connecting portion being smaller than the size of the sealing portions.
[0008] In some embodiments, the outer surface of the sealing portion is provided with ribs, and the ribs are interference-fitted with the inner wall of the receiving cavity.
[0009] In some embodiments, several limiting blocks are also included, which are disposed on the inner wall of the receiving cavity.
[0010] In some embodiments, the limiting block includes a first sidewall and a second sidewall disposed opposite to each other, the first sidewall being inclined to the inner wall of the receiving cavity, and the second sidewall being perpendicular to the inner wall of the receiving cavity.
[0011] In some embodiments, the first seal is made of silicone.
[0012] In some embodiments, the second seal is made of silicone.
[0013] In some embodiments, the first seal and the second seal are formed into an integral structure by injection molding.
[0014] Compared with terminals provided by related technologies, the insulated terminal provided in this application has a simple overall structure and is provided with a notch for adapting crimping tools, which facilitates crimping of wires while retaining more current-carrying area to meet high-current application scenarios; it has a fastening part with a groove structure, which improves the tensile strength between the insulated terminal and the wire, and at the same time alleviates the heat generation problem; the first sealing element and the second sealing element form an integral structure, which improves the airtight performance of the terminal. [Attached Image Description]
[0015] Figure 1 This is a three-dimensional structural diagram of the insulated terminal provided in one embodiment of this application.
[0016] Figure 2 for Figure 1 The diagram shows an exploded view of the three-dimensional structure of the insulated terminal.
[0017] Figure 3 for Figure 1 The diagram shows a three-dimensional structure of the first seal.
[0018] Figure 4 for Figure 1 The diagram shows a cross-sectional view of the insulated terminal.
Detailed Implementation Methods
[0019] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments.
[0020] In the description of the embodiments of this application, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.
[0021] Furthermore, if the embodiments of this application involve descriptions such as "first" or "second," such descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features.
[0022] Please refer to the following: Figure 1 and Figure 2 , Figure 1 This is a three-dimensional structural diagram of the insulated terminal provided in one embodiment of this application. Figure 2 for Figure 1 The diagram shows an exploded three-dimensional structure of the insulated terminal 10. The insulated terminal 10 is used to conduct high current; specifically, it can be mounted on electrical connectors used in new energy vehicles, or on charging guns for new energy vehicles.
[0023] The overmolded terminal 10 includes a terminal body 11, a first sealing element 13, and a second sealing element 15. The terminal body 11 is formed into a receiving cavity 17 by stamping and rolling. The first sealing element 13 is received in the receiving cavity 17 and is interference-fitted with the inner wall of the receiving cavity 17. The second sealing element 15 is sleeved on the outer surface of the terminal body 11 corresponding to the position of the first sealing element 13. The first sealing element 13 and the second sealing element 15 are integrally formed by injection molding to improve the airtightness of the overmolded terminal 10.
[0024] Specifically, one end of the terminal body 11 is a plug-in end 111, which is the end where the insulated terminal 10 is plugged in and mated with other electrical components (such as sockets or plugs). The other end of the terminal body 11, relative to the plug-in end 111, is a wiring end 113, which is the end where the insulated terminal 10 is crimped with a wire. The direction from the plug-in end 111 to the wiring end 113 is defined as the first direction D. Near the plug-in end 111, the receiving cavity 17 communicates with the external space through a first opening 171, the centerline of which is parallel to the first direction; near the wiring end 113, the receiving cavity 17 communicates with the external space through a second opening 173, the centerline of which is parallel to the first direction.
[0025] The terminal body 11 also has a notch 115, the center line of which intersects the first direction, and the notch 115 connects the receiving cavity 17 to the external space. The shape and size of the notch 115 are adapted to the jaw shape of the crimping tool, facilitating the crimping tool to enter the receiving cavity 17 through the notch 115 for crimping operations. In this embodiment, there are two notches 115, which are arranged sequentially along the first direction and spaced apart. In other embodiments, the number of notches 115 may be more or less, depending on the actual application requirements, and no specific limitation is made here.
[0026] The inner wall of the receiving cavity 17 is provided with a fastening part 175, which is disposed adjacent to the notch 115. The fastening part 175 can be a groove structure of a square grid array or a groove structure of a wedge grid array, or other structures that can increase the contact area. In this embodiment, the fastening part 175 is a groove structure of a square grid array, which is located between the two notches 115. The fastening part 175 can improve the mechanical engagement effect between the terminal body 11 and the wire by increasing the friction, thereby enhancing the tensile strength of the assembly. Furthermore, the fastening part 175 can increase the contact area and reduce the current density per unit contact area, which is of great significance for heat dissipation requirements in high-current scenarios.
[0027] Please see Figure 3 , Figure 3 for Figure 1 The diagram shows a three-dimensional structural schematic of the first sealing element. The first sealing element 13 is made of a waterproof soft material, specifically, in this embodiment, it can be made of silicone. The first sealing element 13 is a blind-plug structure, specifically, in this embodiment, it is a dumbbell-shaped blind-plug structure, including a connecting part 131 and two opposing sealing parts 133. The sealing parts 133 are fixedly connected to each other as an integral structure through the connecting part 131, and the size of the connecting part 131 is smaller than the size of the sealing part 133. The outer surface of the sealing part 133 is provided with ribs 1331, and the ribs 1331 are arc-shaped and protrude outwards. The ribs 1331 can strengthen the connection between the first sealing element 13 and the inner wall of the receiving cavity 17, and prevent deformation or relative displacement at the contact point between the two.
[0028] Please refer to the following: Figure 3 and Figure 4 , Figure 4 for Figure 1The diagram shows a cross-sectional view of the insulated terminal. The sealing part 133 is interference-fitted with the inner wall of the receiving cavity 17, and the connecting part 131 is fitted with the inner wall of the receiving cavity 17 to form a receiving groove 135. The terminal body 11 is provided with a through hole 117, which extends from the outer surface of the terminal body 11 to the receiving cavity 17 to connect the receiving cavity 17 with the external space.
[0029] To facilitate the assembly of the terminal body 11 with the first sealing member 13, the rubber-coated terminal 10 further includes several limiting blocks 19, which are disposed on the inner wall of the receiving cavity. Using plane A, perpendicular to the first direction D and containing the center line of the through hole 117, as the boundary, the inner walls of the receiving cavity on both sides opposite to plane A are provided with the limiting blocks 19. The first sidewall 191 of the limiting block 19, away from plane A, is inclined to the inner wall of the receiving cavity. Thus, when the first sealing member 13 enters the receiving cavity 17 through the first opening 171 or the second opening 173, the first sidewall induces deformation in the first sealing member 13, facilitating its installation. Simultaneously, opposite to the first sidewall, the second sidewall 193 of the limiting block 19 is perpendicular to the inner wall of the receiving cavity. Thus, the second sidewall prevents the first sealing member 13 from exiting the receiving cavity 17 through the first opening 171 or the second opening 173.
[0030] Please refer to the following: Figure 4 The second sealing element 15 is integrally formed with the first sealing element 13 through injection molding. Specifically, ejector pins and expansion sleeves are used as auxiliary assembly tools. The ejector pins abut against the connecting part of the first sealing element 13 to maintain the positional correspondence between the receiving groove 135 and the through hole 117. Thus, the receiving groove 135, the through hole 117, the receiving cavity 17, and the external injection mold (not shown) cooperate to form an injection cavity. High-temperature injection molding material fills the injection cavity, cools to form the second sealing element 15, and the second sealing element 15 is sleeved on the outer surface of the terminal body 11 and fixedly connected to the first sealing element 13. At this time, the ejector pins are removed. The first sealing element 13 and the second sealing element 15 form an integral structure, completely blocking the exchange of aerosols between the terminal 113 and the plug-in terminal 111 with plane A as the boundary, achieving a good sealing effect.
[0031] The second seal 15 is a waterproof soft material. In this embodiment, the second seal 15 can be made of silicone. The second seal 15 can be integrated with the first seal 13 through liquid silicone injection molding (LSR).
[0032] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.
Claims
1. A type of insulated terminal, characterized in that, include: The terminal body is formed into a receiving cavity by stamping and rolling; A first sealing element is housed within the receiving cavity; and The second sealing element is sleeved on the terminal body and forms an integral structure with the first sealing element.
2. The insulated terminal according to claim 1, characterized in that, The terminal body is also provided with a notch, which connects the receiving cavity to the external space.
3. The insulated terminal according to claim 2, characterized in that, The inner wall of the receiving cavity is provided with a fastening part, which is arranged adjacent to the notch, and the fastening part is an array of groove structures.
4. The insulated terminal according to claim 1, characterized in that, The first sealing element includes a connecting portion and two opposing sealing portions, which are fixedly connected as an integral structure by the connecting portion, and the size of the connecting portion is smaller than the size of the sealing portion.
5. The insulated terminal according to claim 4, characterized in that, The outer surface of the sealing part is provided with ribs, and the ribs are interference-fitted with the inner wall of the receiving cavity.
6. The insulated terminal according to claim 1, characterized in that, It also includes several limiting blocks, which are disposed on the inner wall of the receiving cavity.
7. The insulated terminal according to claim 6, characterized in that, The limiting block includes a first sidewall and a second sidewall disposed opposite to each other. The first sidewall is inclined to the inner wall of the receiving cavity, and the second sidewall is perpendicular to the inner wall of the receiving cavity.
8. The insulated terminal according to claim 1, characterized in that, The first seal is made of silicone.
9. The insulated terminal according to claim 1, characterized in that, The second seal is made of silicone.
10. The insulated terminal according to claim 1, characterized in that, The first seal and the second seal are formed into an integral structure through injection molding.