A high-voltage cable shielding type conversion box for vehicle and vehicle

Abstract

This application discloses a high-voltage cable shielding conversion box and vehicle for vehicles, including a box body and a cover detachably connected to the box body. The cover closes to the box body to form a receiving area. The receiving area is provided with a limiting component, which has multiple limiting grooves for the core wires of the cable to pass through. Connectors are respectively provided at both ends of the box body, one of which is used to match a single-core cable and the other is used to match a multi-core cable. The single-core cable is crimped to the corresponding connector. Through integrated design, reliable electrical connection and shielding effectiveness conversion between single-core and multi-core cables are achieved within the conversion box, effectively solving the electromagnetic compatibility problem caused by inconsistent connector standards, and improving the mechanical reliability and environmental protection capabilities of high-voltage wiring harness connections.

Description

Technical Field

[0001] This application belongs to the field of vehicle technology, specifically relating to a vehicle high-voltage cable shielding type conversion box and the vehicle. Background Technology

[0002] With the rapid development of the new energy commercial vehicle industry, the market demand for light trucks is increasing. In the overall vehicle design and development process, high-voltage wiring harnesses, as key components for power transmission and distribution, are crucial for their electromagnetic compatibility and shielding effectiveness. In practical engineering applications, due to the high degree of globalization of projects, differences in connector standards and design philosophies among different countries and brands result in varying shielding structures for the matched high-voltage cables, primarily manifested as single-core and multi-core cables.

[0003] Currently, the interface connectors for some high-voltage electrical equipment in vehicles (such as air conditioning compressors, air pumps, and PTC heaters) often only support a single type of shielded cable within the same product series. For example, some connectors only offer versions compatible with single-core cables, while others are only compatible with multi-core cables. This design incompatibility means that in order to meet the physical connection and basic conductivity requirements of different device interfaces during the overall vehicle wiring harness design, the shielding effectiveness of the cable section often has to be sacrificed. This manifests as the use of unshielded connections or the adoption of inadequate shielding adapters, resulting in electromagnetic interference risks in the high-voltage circuit and affecting the stability and reliability of the entire vehicle's electrical system.

[0004] Therefore, a solution is needed that can effectively solve the problem of reliable switching between two different types of shielded cables, while ensuring the physical connection and maintaining the shielding integrity of the entire current path. Utility Model Content

[0005] This application provides a vehicle-mounted high-voltage cable shielding type conversion box and vehicle, which solves the problem that single-core cables and multi-core cables in vehicle high-voltage wiring harnesses cannot be efficiently and reliably converted due to different interface standards.

[0006] The technical solution adopted in this application is as follows: A shielded conversion box for automotive high-voltage cables includes a box body and a cover detachably connected to the box body. The cover closes onto the box body to form a receiving area. The receiving area is provided with a limiting component, which has multiple limiting grooves for the core wires of the cable to pass through. Connectors are provided at both ends of the box body, one of which is used to match a single-core cable and the other is used to match a multi-core cable. The single-core cable is crimped to the corresponding connector.

[0007] Preferably, the multi-core cable includes multiple core wires, each core wire is located in a different limiting groove, and the core wire passes through the limiting groove and is welded to the multiple single-core cables one by one.

[0008] Preferably, the conversion box has a mounting surface for the connector that matches the single-core cable to pass through, the connector has a mounting hole corresponding to the mounting surface, and a fastener is provided at the mounting hole.

[0009] Preferably, the limiting component includes a limiting block, the top of which is recessed to form the limiting groove, and the limiting groove extends axially along the limiting block.

[0010] Preferably, the bottom of the limiting block is provided with an clearance opening, and the top of the limiting block is provided with a positioning hole corresponding to the clearance opening. The positioning hole extends through the clearance opening, and a fastener is inserted into the positioning hole to fix the limiting block to the box body.

[0011] Preferably, the limiting component includes a limiting cover plate, which is disposed on the top of the limiting block and at least partially covers the limiting groove.

[0012] Preferably, the limiting cover plate is provided with an avoidance groove corresponding to the limiting groove, and the limiting cover plate covers the top of the limiting block so that the avoidance groove corresponds one-to-one with the limiting groove.

[0013] Preferably, the conversion box further includes a sealing gasket disposed between the box body and the cover body, the box body having a sealing groove adapted to the sealing gasket, and the sealing gasket engaging with the sealing groove to seal the receiving area.

[0014] Preferably, the box body has a recessed portion, the recessed portion has the sealing groove, and the recessed portion has a first connecting hole located outside the edge of the sealing groove. The cover body has a second connecting hole adapted to the first connecting hole, and the cover body and the box body are fastened together through the first connecting hole and the second connecting hole.

[0015] This application also includes, in another aspect, a vehicle equipped with a conversion box as described in any of the preceding claims.

[0016] Due to the adoption of the above technical solution, the beneficial effects achieved by this application are as follows: This application solution, through an integrated structural design, successfully solves the problem of inefficient and unreliable connection between single-core and multi-core cables in vehicle high-voltage wiring harnesses due to inconsistent interface standards. It achieves complete electromagnetic shielding effectiveness, significantly improving the system's electromagnetic compatibility (EMC). The metal enclosure area formed by the housing and cover creates a highly efficient Faraday cage shielding cavity, completely sealing the welding points of single-core and multi-core cables. This effectively suppresses the outward radiation of internal high-frequency interference and blocks the intrusion of complex external electromagnetic environments, ensuring continuous and complete shielding protection for the entire signal and power transmission path from the multi-core cable end to the single-core cable end, meeting stringent automotive-grade EMC standards.

[0017] Meanwhile, this solution provides highly reliable mechanical connections and comprehensive physical protection. The limiting components located within the housing area, through multiple limiting slots, provide independent and orderly fixation and guidance for each core of the multi-core cable. This design effectively avoids risks such as insulation wear and weld fatigue fracture caused by relative displacement of the wiring harness under long-term vehicle vibration conditions. Placing vulnerable electrical connection points inside a robust enclosure allows them to withstand mechanical shock, vibration, and environmental corrosion, greatly improving the long-term operational reliability of the high-voltage connection system.

[0018] Furthermore, applying this solution helps optimize assembly processes and achieve standardized and modular production. The complex shielding and conversion process is integrated into a single conversion box, making it a functional module that can be prefabricated offline and quickly installed online. Wiring harness suppliers can complete the precision welding, shielding treatment, and sealing assembly of all single-core and multi-core cables within the box under controlled conditions, and perform pre-inspection; ultrasonic welding is sufficient for welding. During final vehicle assembly, operators only need to connect the connectors at both ends of the conversion box to the corresponding interfaces on the vehicle, simplifying the assembly process, improving production efficiency, and ensuring product quality consistency and traceability. Attached Figure Description

[0019] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings: Figure 1 This is an exploded view of the conversion box in one embodiment of the present invention; Figure 2 This is a schematic diagram of the conversion box assembly structure in one embodiment of the present invention.

[0020] Explanation of reference numerals in the attached figures: 1-Box body, 11-Mounting surface, 12-Mounting hole, 13-Recessed part, 131-Sealing groove, 132-First connecting hole, 2-Cover body, 21-Second connecting hole, 3-Accommodation area, 4-Limiting component, 41-Limiting block, 411-Limiting groove, 42-Limiting cover plate, 421-Allowing groove, 43-Positioning hole, 5-Sealing gasket, 6-IPT through-hole connector, 7-Glander head, 8-Single core cable, 9-Multi-core cable. Detailed Implementation

[0021] To more clearly illustrate the overall concept of this application, a detailed explanation is provided below with reference to the accompanying drawings.

[0022] Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application may also be implemented in other ways different from those described herein. Therefore, the scope of protection of this application is not limited to the specific embodiments disclosed below. It should be noted that, unless otherwise specified, the embodiments of this application and the features thereof can be combined with each other.

[0023] Furthermore, it should be understood in the description of this application that the terms "top", "bottom", "inner", "outer", "axial", "radial", "circumferential", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and 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, and therefore should not be construed as a limitation of this application.

[0024] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0025] In this application, unless otherwise expressly specified and limited, the "above" or "below" of the second feature can mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediate medium. In the description of this specification, references to terms such as "an embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described can be combined in any suitable manner in one or more embodiments or examples.

[0026] This application provides a shielded conversion box for automotive high-voltage cables, including a box body and a cover detachably connected to the box body. The cover closes to the box body to form an accommodating area. The accommodating area is provided with a limiting component, which has multiple limiting grooves for the core wires of the cable to pass through. Connectors are provided at both ends of the box body, one of which is used to match a single-core cable and the other is used to match a multi-core cable. The single-core cable is crimped to the corresponding connector.

[0027] This application solution, through an integrated structural design, successfully solves the problem of inefficient and unreliable connection between single-core and multi-core cables in vehicle high-voltage wiring harnesses due to inconsistent interface standards. It achieves complete electromagnetic shielding effectiveness, significantly improving the system's electromagnetic compatibility (EMC). The metal enclosure area formed by the housing and cover creates a highly efficient Faraday cage shielding cavity. This structure completely seals the welding points of single-core and multi-core cables, effectively suppressing the outward radiation of internal high-frequency interference and blocking the intrusion of complex external electromagnetic environments. This ensures continuous and complete shielding protection for the entire signal and power transmission path from the multi-core cable end to the single-core cable end, meeting stringent automotive-grade EMC standards.

[0028] Meanwhile, this solution provides highly reliable mechanical connections and comprehensive physical protection. The limiting components located within the housing area, through multiple limiting slots, provide independent and orderly fixation and guidance for each core of the multi-core cable. This design effectively avoids risks such as insulation wear and weld fatigue fracture caused by relative displacement of the wiring harness under long-term vehicle vibration conditions. Placing vulnerable electrical connection points inside a robust enclosure allows them to withstand mechanical shock, vibration, and environmental corrosion, greatly improving the long-term operational reliability of the high-voltage connection system.

[0029] Furthermore, applying this solution helps optimize assembly processes and achieve standardized and modular production. The complex shielding and conversion process is integrated into a single conversion box, making it a functional module that can be prefabricated offline and quickly installed online. Wiring harness suppliers can complete the precision welding, shielding treatment, and sealing assembly of all single-core and multi-core cables within the box under controlled conditions, and perform pre-inspection; ultrasonic welding is sufficient for welding. During final vehicle assembly, operators only need to connect the connectors at both ends of the conversion box to the corresponding interfaces on the vehicle, simplifying the assembly process, improving production efficiency, and ensuring product quality consistency and traceability.

[0030] In one embodiment, the multi-core cable includes multiple core wires, each core wire being located in a different limiting groove, and the core wires passing through the limiting grooves are welded to the multiple single-core cables one-to-one.

[0031] By having each core wire pass through different limiting slots and welded to the corresponding single-core cable, physical isolation and precise positioning of multiple conductors are achieved. This ensures the orderliness and accuracy of the welding operation, fundamentally eliminating the risk of phase sequence errors or short circuits caused by wire harness crossings and interference. At the same time, it provides a clear and orderly form for the internal wire harness layout, which is beneficial for heat dissipation and later maintenance.

[0032] Preferably, the adapter box has a mounting surface for inserting the connector that matches the single-core cable, the connector having a mounting hole corresponding to the mounting surface, and a fastener being provided at the mounting hole.

[0033] By setting up dedicated mounting surfaces and mounting holes, and using fasteners, a standardized, high-strength mechanical interface is provided for this section of the single-core cable connector, ensuring that the connector maintains a stable connection with the adapter box in the vibration environment of vehicle operation, and maintaining the mechanical integrity of the interface and the continuity of electrical contact.

[0034] In one embodiment, an IPT through-hole connector is used to fix a single-core cable, and a gland connector is used to connect a multi-core cable. Both the single-core and multi-core cables are pre-treated (a certain length of outer insulation and shielding is stripped to expose the conductors).

[0035] Strip the end of the single-core cable as required, then insert it into the crimping sleeve of the through-hole connector, and use a crimping tool to crimp and secure it.

[0036] Insert the multi-core cable into the junction box beforehand through one of the through holes on the bottom or side, leaving sufficient length for welding. Perform ultrasonic welding (inside the junction box): Align one core wire of the multi-core cable (e.g., phase A, usually a specific color wire) with the conductor of the single-core cable and weld them together using an ultrasonic welder to form a strong metal connection. Repeat this process for all the wire pairs that need to be connected (phase B, phase C, etc.). Each weld joint needs to be covered with insulating heat shrink tubing and heated to tighten it, achieving insulation and protection. After welding, the other end of the single-core cable will naturally be located outside the junction box.

[0037] After welding, the cable is inserted into the conversion box from the mounting surface. Inside the conversion box, the shielding layer of the multi-core cable is grounded (for example, by pressing the shielding layer to the grounding post of the box with a grounding clamp). The multi-core cable is then passed out from the gland end.

[0038] Use nuts as fasteners to secure the IPT through-hole connector to the mounting surface of the adapter box through the mounting holes.

[0039] After completing the above connections, use a multimeter to test the continuity between the power line section and the shielding mesh section of the cable; use specialized equipment to test the waterproofness of the junction box; if both tests pass, it can be determined that the high-voltage cable shielding type conversion box is well assembled and can meet the usage requirements.

[0040] In one embodiment, the limiting component includes a limiting block, the top of which is recessed to form a limiting groove, the limiting groove extending axially along the limiting block.

[0041] The limiting block and the axially extending limiting groove formed by its concave top make it a wire harness centralized management device with an integrated structure and simple processing. It not only provides effective support and guidance for the core wire, but its simple structure is also easy to form in one mold, reducing manufacturing costs.

[0042] Furthermore, the bottom of the limiting block is provided with an clearance opening, and the top of the limiting block is provided with a positioning hole corresponding to the clearance opening. The positioning hole extends through the clearance opening, and a fastener is inserted into the positioning hole to fix the limiting block to the box body.

[0043] By using the clearance opening at the bottom of the limit block, the positioning hole at the top, and the fasteners, the limit block can be quickly positioned and securely locked inside the box. This effectively prevents the limit block from shifting under vibration and impact, ensuring the long-term stability of the internal wire harness fixing structure.

[0044] Furthermore, the limiting component includes a limiting cover plate, which is disposed on the top of the limiting block and at least partially covers the limiting groove.

[0045] By setting a limiting cover plate to cover the limiting groove on the top of the limiting block, a double-locking anti-detachment mechanism is provided, which can effectively prevent the core wire that has been placed in the limiting groove from coming out during subsequent assembly or vibration environment, and further enhance the reliability of wire harness fixation.

[0046] Preferably, the limiting cover plate is provided with a relief groove corresponding to the limiting groove, and the limiting cover plate covers the top of the limiting block so that the relief groove corresponds one-to-one with the limiting groove.

[0047] The clearance groove on the limiting cover plate, which corresponds to the limiting groove, allows the two to form a complete and shape-matched cable channel after they are closed together. This effectively constrains the core wire while preventing the pressure of the closing mechanism from damaging the insulation layer of the core wire, thus achieving a balance between protection and fixation.

[0048] In one embodiment, the conversion box further includes a sealing gasket disposed between the box body and the cover body, the box body having a sealing groove adapted to the sealing gasket, the sealing gasket engaging with the sealing groove to seal the receiving area.

[0049] By setting a sealing gasket between the box body and the cover body, and a sealing groove that matches the sealing gasket, a sealing barrier is formed together to effectively prevent moisture, dust and other contaminants from entering the storage area, protect the internal high-voltage connection points from environmental corrosion, and ensure the insulation safety and service life of the product under complex working conditions.

[0050] Furthermore, the box body has a recessed portion with a sealing groove, and the recessed portion has a first connecting hole located on the outer edge of the sealing groove. The cover body has a second connecting hole that matches the first connecting hole, and the cover body and the box body are fastened together through the first connecting hole and the second connecting hole.

[0051] The recessed design of the box body, along with the fit between the first connecting hole located on the outer edge of the sealing groove and the second connecting hole on the cover, optimizes the synergistic effect of sealing and fastening of the conversion box. This layout allows the fasteners to apply a more uniform clamping force to the sealing gasket when locking, thereby forming a more reliable and durable sealing interface, which is beneficial to improving the overall protective performance.

[0052] This application also includes, in another aspect, a vehicle equipped with a conversion box as described in any of the above embodiments.

[0053] For any parts not mentioned in this application, existing technologies may be used or referenced.

[0054] The various embodiments in this specification are described in a progressive manner. The same or similar parts between the various embodiments can be referred to each other. Each embodiment focuses on describing the differences from other embodiments.

[0055] The above description is merely an embodiment of this application and is not intended to limit the scope of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of the claims of this application.

Claims

1. A vehicle-mounted high-voltage cable shielding type conversion box, characterized in that, The device includes a housing and a cover detachably connected to the housing. The cover closes to the housing to form a receiving area. The receiving area is provided with a limiting component, which has multiple limiting grooves for the core wires of the cable to pass through. Connectors are provided at both ends of the housing, one of which is used to match a single-core cable and the other is used to match a multi-core cable. The single-core cable is crimped to the corresponding connector.

2. The converter box according to claim 1, characterized in that, The multi-core cable includes multiple core wires, each of which is located in a different limiting groove, and the core wire passes through the limiting groove and is welded to the multiple single-core cables one by one.

3. The conversion box of claim 2, wherein, The conversion box has a mounting surface for inserting the connector that matches the single-core cable, and the connector has a mounting hole corresponding to the mounting surface, with a fastener provided at the mounting hole.

4. The converter box according to claim 1, characterized in that, The limiting component includes a limiting block, the top of which is recessed to form the limiting groove, and the limiting groove extends axially along the limiting block.

5. The converter box according to claim 4, characterized in that, The bottom of the limiting block is provided with an clearance opening, and the top of the limiting block is provided with a positioning hole corresponding to the clearance opening. The positioning hole extends through the clearance opening, and a fastener is inserted into the positioning hole to fix the limiting block to the box body.

6. The converter box according to claim 4, characterized in that, The limiting component includes a limiting cover plate, which is disposed on the top of the limiting block and at least partially covers the limiting groove.

7. The converter box according to claim 6, characterized in that, The limiting cover plate is provided with an avoidance groove corresponding to the limiting groove, and the limiting cover plate covers the top of the limiting block so that the avoidance groove corresponds one-to-one with the limiting groove.

8. The conversion box of claim 1, wherein, The conversion box also includes a sealing gasket disposed between the box body and the cover body. The box body is provided with a sealing groove that is adapted to the sealing gasket. The sealing gasket engages with the sealing groove to seal the receiving area.

9. The conversion box of claim 8, wherein, The box body has a recessed portion, the recessed portion has the sealing groove, and the recessed portion has a first connecting hole located on the outer edge of the sealing groove. The cover body has a second connecting hole adapted to the first connecting hole, and the cover body and the box body are fastened together through the first connecting hole and the second connecting hole.

10. A vehicle characterized by comprising: The device is equipped with a conversion box as described in any one of claims 1-9.

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