A new energy vehicle high-voltage cable electromagnetic shielding joint

Abstract

The utility model relates to the technical field of automobile manufacturing, specifically relates to a new energy automobile high -voltage cable electromagnetic shielding joint, including joint main part, force nut and shielding ring connection structure, shielding ring connection structure is coaxially built -in in joint main part in detachable mode, and is same time with high -voltage cable's metal shielding layer, joint main part and force nut form electrically conductive communication, force nut and joint main part between realize axial locking through screw pair, shielding ring connection structure includes cap pressure -welding ring, boss washer and annular metal wire net shielding gasket, cap pressure -welding ring is installed on high -voltage cable's metal shielding layer outer surface and is pressure -welding fixed, boss washer is coaxially attached to the axial end surface of cap pressure -welding ring, metal wire net shielding gasket is set up in annular step at the outer periphery of boss washer, and under the axial pressure effect of force nut, is elastically compressed between cap pressure -welding ring and boss washer, can complete mechanical fixation, waterproof sealing and double electromagnetic shielding simultaneously.

Description

Technical Field

[0001] This utility model relates to the field of automobile manufacturing technology, specifically to an electromagnetic shielding connector for high-voltage cables in new energy vehicles. Background Technology

[0002] With the rapid development of new energy vehicles, the market demands increasingly higher electromagnetic compatibility (EMC) performance from the entire vehicle. As core components of new energy vehicles, the drive motor and MCU (Microcontroller Unit) generate significant electromagnetic emission energy from their internal high-frequency IGBT power modules. To confine this electromagnetic energy within the electric drive subsystem formed by the MCU, high-voltage cables, and drive motor, and to reduce interference with surrounding vehicle controllers, the overall shielding effectiveness of the electric drive subsystem is crucial. Metal waterproof cable connectors, as a standard connection method for high-voltage cables, directly affect the shielding effectiveness of the entire electric drive subsystem through their effective connection with the cable shielding layer.

[0003] Existing technology involves using metal structures such as triangular springs, shielding clasps, and stamped springs to achieve a loop connection between the cable shielding layer and the metal cable connector.

[0004] Looping with the high-voltage cable shielding layer is achieved through contact. The high-voltage cable shielding layer requires pre-treatment with copper foil wrapping or copper tube crimping. During installation, the looping metal structure is threaded onto the high-voltage cable shielding layer. However, due to factors such as the dimensional accuracy of the high-voltage cable and mechanical vibration, the looping metal structure may detach from the shielding layer during use. Furthermore, the shielding circlip, stamped spring, and metal cable joint loop are limited by installation gaps, allowing only point contact and not a complete loop. This inability to achieve a loop connection results in electromagnetic interference from within the electric drive subsystem radiating outwards along the high-voltage cable. In addition, existing metal structures such as triangular springs, shielding circlips, and stamped springs, used as connecting conductors between the high-voltage cable shielding layer and the metal cable joint, suffer from poor spatial continuity due to their structural limitations, resulting in inadequate electromagnetic shielding and high-frequency electromagnetic leakage. Utility Model Content

[0005] To address the problems in the existing technology, this utility model provides an electromagnetic shielding connector for high-voltage cables of new energy vehicles, which can simultaneously achieve mechanical fixing, waterproof sealing and double electromagnetic shielding through a single crimping and thread tightening.

[0006] The technical solution adopted by this utility model to solve its technical problem is an electromagnetic shielding connector for high-voltage cables of new energy vehicles, including a connector body, a clamping nut and a shielding ring structure. The shielding ring structure is coaxially built into the connector body in a detachable manner, and simultaneously forms a conductive connection with the metal shielding layer of the high-voltage cable, the connector body and the clamping nut; the clamping nut and the connector body are axially locked through a threaded pair.

[0007] The shielding ring structure includes a flip-cap crimping ring, a boss washer, and an annular metal mesh shielding gasket. The flip-cap crimping ring is fitted onto the outer surface of the metal shielding layer of the high-voltage cable and crimped in place. The boss washer is coaxially fitted to the axial end face of the flip-cap crimping ring. The metal mesh shielding gasket is fitted onto the annular step on the outer periphery of the boss washer and is elastically compressed between the boss washer and the flip-cap crimping ring under the axial pressure of the tightening nut, forming a 360° radial shielding interface.

[0008] As a preferred technical solution, the inner wall of the connector body is provided with a radially inward protruding limiting plate, which is used to position one end of the flip cap crimping ring in the axial direction and prevent it from moving away from the boss washer.

[0009] As a preferred technical solution, the flip-cap crimping ring is composed of a cylindrical body and a radially extending flange cap integrally formed at its end, wherein the axial hole of the cylindrical body matches the outer diameter of the high-voltage cable connector.

[0010] As a preferred technical solution, the inner wall of the tightness nut is provided with an annular groove, and a waterproof sealing ring is embedded in the groove; the end of the waterproof sealing ring facing the boss washer axially abuts against the end face of the boss washer, and its outer peripheral wall is provided with an annular recess; the axially extended end of the connector body with external threads is embedded in the recess.

[0011] As a preferred technical solution, the axial hole of the boss washer is of the same diameter as the axial hole of the flip-cap crimping ring and is coaxially connected, allowing the high-voltage cable conductor to pass through, and forming a continuous shielding cavity on the outer periphery of the penetration area.

[0012] Compared with the prior art, the present invention has the following beneficial effects:

[0013] The high-voltage cable electromagnetic shielding connector proposed in this utility model integrates mechanical fixing, environmental sealing, and high-efficiency electromagnetic shielding functions. Assembly can be completed through a simple operation of one crimping and one thread tightening. It fundamentally solves the technical problems existing in the prior art, such as discontinuous shielding connection, easy loosening, serious high-frequency leakage, and insufficient sealing reliability. It also solves the electromagnetic compatibility problem caused by the shielding failure or low shielding effectiveness of existing high-voltage cable connectors, improves the shielding effectiveness of the electric drive subsystem, protects its surrounding sensitive controllers and sensors from electromagnetic interference, and ensures good electromagnetic compatibility performance of the whole vehicle. Attached Figure Description

[0014] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0015] Figure 1 This is a front view of the electromagnetic shielding connector of this utility model;

[0016] Figure 2 This is a schematic diagram of the boss washer of this utility model;

[0017] Figure 3 This is a schematic diagram of the metal wire mesh shielding pad of this utility model;

[0018] Figure 4 This is a schematic diagram of the flip-cap crimping ring of this utility model.

[0019] In the diagram: 1. Shielded cable; 2. Connector body; 3. Flip-cap crimping ring; 4. Boss washer; 5. Metal wire mesh shielding gasket; 6. Waterproof sealing ring; 7. Fastening nut. Detailed Implementation

[0020] To make the technical means, creative features, objectives and effects of this utility model easier to understand, the present utility model will be further described below in conjunction with specific embodiments.

[0021] Please see Figures 1 to 4 This utility model provides an electromagnetic shielding connector for high-voltage cables in new energy vehicles. Its structure mainly includes a connector body 2, a waterproof sealing ring 6, a clamping nut 7, and a shielding ring structure. The shielding ring structure is detachably coaxially integrated within the connector body 2, simultaneously forming conductive connections with the metal shielding layer of the high-voltage cable, the connector body 2, and the clamping nut 7. The clamping nut 7 is axially locked to the connector body 2 via a threaded joint. During the locking process, continuous axial pressure is applied to the shielding ring structure, causing it to elastically deform and simultaneously establishing a continuous low-impedance circumferential electrical connection with the cable's metal shielding layer, a continuous low-impedance circumferential electrical connection with the inner wall of the connector body 2, and an axial waterproof sealing connection with the clamping nut 7. This creates a continuous, closed, and low-impedance electromagnetic shielding and sealing path between the cable shielding layer, the connector body 2, and the clamping nut 7.

[0022] In a specific embodiment, the outer surface of the metal shielding layer of the high-voltage cable connector is fitted with the flip-cap crimping ring 3, and the entire assembly is housed inside the connector body 2; a continuous, low-impedance electromagnetic shield is established through the threaded engagement between the connector body 2 and the tightening nut 7. The connector body 2, the tightening nut 7, the flip-cap crimping ring 3, and the boss washer 4 are all made of metal to collectively form a complete electromagnetic shielding cage.

[0023] The connector body 2 connects the shielded connector to the metal junction box by setting external threads. The junction box is connected to the motor or controller, and then connected to the vehicle reference plane through a grounding cable to achieve the shortest grounding for electromagnetic shielding.

[0024] In some preferred embodiments, the shielding ring structure further includes a flip-cap crimping ring 3, an annular metal wire mesh shielding pad 5, and a boss washer 4.

[0025] The inner wall of the connector body 2 is provided with a radially inward protruding limiting plate, which is used to constrain the axial displacement of the flip-cap crimping ring 3, effectively preventing it from shifting during operation, thereby improving the stability and reliability of the connection. The flip-cap crimping ring 3 is composed of a cylindrical body and an integrally formed flange cap extending radially outward at one end. The interior of the flip-cap crimping ring 3 is provided with a central hole that matches the outer diameter of the high-voltage cable connector, ensuring uniform and continuous mechanical and electrical contact after crimping.

[0026] A boss washer 4 is coaxially disposed inside the connector body 2, and the boss washer 4 fits tightly against the flip-cap crimping ring 3. Preferably, the axial hole of the boss washer 4 and the axial hole of the flip-cap crimping ring 3 are of the same diameter and coaxially connected, allowing the high-voltage cable conductor to pass through, and forming a continuous shielding cavity around the periphery of the passage area to suppress high-frequency electromagnetic leakage. The outer wall of the boss washer 4 has an annular step along the circumference, and an annular metal wire mesh shielding gasket 5 is fitted at the step. The gasket is tightly pressed between the boss washer 4 and the flip-cap crimping ring 3 to form a stable and continuous electromagnetic shielding interface, effectively suppressing high-frequency electromagnetic leakage and improving the overall shielding performance.

[0027] The inner wall of the tightening nut 7 has an annular groove extending radially inward, into which a waterproof sealing ring 6 is embedded. The end of the waterproof sealing ring 6 facing the boss washer 4 axially abuts against the end face of the boss washer 4. The outer circumferential side of the waterproof sealing ring 6 has an annular recess. The end of the connector body 2 with external threads extends axially and is embedded in this recess. The internal thread of the tightening nut 7 engages with the external thread of the connector body 2. Through this threaded fastening, the waterproof sealing ring 6 undergoes radial elastic deformation under axial compression, thereby achieving reliable radial sealing and axial positioning, ensuring excellent waterproof and dustproof performance and mechanical stability of the connector in harsh environments.

[0028] The connection method of the high-voltage cable electromagnetic shielding joint of this utility model is as follows:

[0029] First, a flip-cap crimping ring 3 is fitted onto the metal shielding layer on the outer surface of the high-voltage cable connector, and the two are tightly connected by crimping. Then, the crimped high-voltage cable connector is inserted into the connector body 2. The connector body 2 is equipped with a limiting plate to fix the axial position of the flip-cap crimping ring 3 and prevent it from moving.

[0030] Next, the boss washer 4 with the metal mesh shielding gasket 5 is inserted into the connector body 2, ensuring that one end fits tightly against the end face of the flip-cap crimping ring 3. Finally, the tightening nut 7 with the waterproof sealing ring 6 is threaded onto the connector body 2. When the tightening nut 7 is tightened, the waterproof sealing ring 6 is compressed and expands radially, pushing the metal platform towards the flip-cap crimping ring 3. Simultaneously, the metal mesh shielding gasket 5 undergoes elastic deformation, forming a 360-degree all-around tight contact with the inner wall of the connector body 2.

[0031] This invention forms a continuous and complete shielding path through the inner wall of the connector body 2, the metal wire mesh shielding gasket 5, the boss washer 4, the flip-cap crimping ring 3, and the cable shielding layer. This structure not only effectively suppresses the outward radiation of high-frequency electromagnetic energy from inside the drive subsystem, providing excellent electromagnetic shielding, but also ensures stable connection performance under vibration or temperature change environments. Simultaneously, the waterproof sealing ring 6, under the action of the tightening nut 7, achieves a reliable waterproof seal, making the connector suitable for various harsh environmental conditions.

[0032] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The descriptions of the above embodiments and specifications are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of protection claimed by this utility model. The scope of protection of this utility model is defined by the appended claims and their equivalents.

Claims

1. An electromagnetic shielding connector for high-voltage cables in new energy vehicles, comprising a connector body, a tightening nut, and a shielding ring structure, characterized in that: The shielding ring structure is detachably and coaxially built into the connector body, and simultaneously forms a conductive connection with the metal shielding layer of the high-voltage cable, the connector body, and the clamping nut; the clamping nut and the connector body are axially locked through a threaded pair. The shielding ring structure includes a flip-cap crimping ring, a boss washer, and an annular metal mesh shielding gasket. The flip-cap crimping ring is fitted onto the outer surface of the metal shielding layer of the high-voltage cable and crimped in place. The boss washer is coaxially fitted to the axial end face of the flip-cap crimping ring. The metal mesh shielding gasket is fitted onto the annular step on the outer periphery of the boss washer and is elastically compressed between the boss washer and the flip-cap crimping ring under the axial pressure of the tightening nut, forming a 360° radial shielding interface.

2. The electromagnetic shielding connector according to claim 1, characterized in that: The inner wall of the connector body is provided with a radially inward protruding limiting plate, which is used to position one end of the flip cap crimping ring in the axial direction and prevent it from moving away from the boss washer.

3. The electromagnetic shielding connector according to claim 1, characterized in that: The flip-cap crimping ring consists of a cylindrical body and a radially extending flange cap integrally formed at its end. The axial hole of the cylindrical body matches the outer diameter of the high-voltage cable connector.

4. The electromagnetic shielding connector according to claim 1, characterized in that: The inner wall of the tight nut has an annular groove, in which a waterproof sealing ring is embedded; the end of the waterproof sealing ring facing the boss washer axially abuts against the end face of the boss washer, and its outer peripheral wall has an annular recess; the axially extended end of the connector body with external threads is embedded in the recess.

5. The electromagnetic shielding connector according to claim 1, characterized in that: The axial hole of the boss washer is of the same diameter as the axial hole of the flip-cap crimping ring and is coaxially connected, allowing the high-voltage cable conductor to pass through, and forming a continuous shielding cavity on the outer periphery of the penetration area.

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