Connector assembly for a dc-dc converter

Abstract

The utility model relates to a connector assembly for DC-DC converter, wherein, the connector assembly (100) includes: the insulating plastic shell (1) is equipped with the annular rubber groove (10) for sealing, at least one electric component (2), each electric component includes an electric element (3) and the metal stud (4) fixedly connected to the electric element, and at least one pair of communication pins (5), wherein at least one electric component (2) and at least one pair of communication pins (5) are integrally made with plastic shell (1) by injection molding process. This connector assembly realizes the integrated molding of electric component, communication pin and plastic shell through integrated injection molding process, effectively reduces assembly complexity and process cost, and improves structural consistency and sealing performance.

Description

Technical Field

[0001] This utility model relates to the field of electronic assembly technology, and more specifically to a connector assembly for a DC-DC converter. Background Technology

[0002] With the development of technologies such as new energy vehicles, energy storage systems, and high-voltage direct current transmission, DC-DC converters (DC-Voltage Converters) are widely used in power electronic systems. To achieve reliable connections between high-power devices, connectors, as key components in electrical systems, have a significant impact on the overall system's safety and stability.

[0003] Currently, most high-current connectors on the market adopt a stud-type structure. This type of structure has advantages such as convenient installation and strong current carrying capacity, making it suitable for various high-voltage and high-current electrical connection scenarios. However, these stud-type connectors are usually difficult to seal effectively, making it difficult to protect against the intrusion of harmful substances such as moisture, dust, or corrosive gases from the external environment. This can easily lead to corrosion, arcing, or even insulation failure at the connection points, seriously affecting the reliability of the system.

[0004] On the other hand, with the increasing integration of systems, connectors not only need to transmit large currents, but also need to integrate communication and signal transmission functions. For example, Controller Area Network (CAN) communication, as a commonly used industrial communication protocol, has been widely applied in various power electronic systems. However, existing connector structures are relatively simple, lack scalability, and are difficult to arrange multiple functional pins simultaneously in a limited space, thus limiting the integration of functions and the flexibility of applications.

[0005] Furthermore, due to the exposed structure of traditional connectors, they are prone to arcing or short-circuit faults under high voltage and high current conditions, which can lead to component damage or system failure. Therefore, effective insulation and encapsulation measures need to be incorporated into the connector's structural design to prevent flashover, short circuits, and other phenomena. Utility Model Content

[0006] The purpose of this invention is to solve at least one of the above-mentioned problems and / or other defects in the prior art, and to provide a connector assembly for a DC-DC converter that not only achieves a sealing function, but also integrates other signal pins and reduces flashover and short circuits.

[0007] Therefore, this utility model provides a connector assembly for a DC-DC converter, the connector assembly comprising: an insulating plastic housing having an annular groove for sealing; at least one conductive component, each of the conductive components including a conductive element and a metal stud fixedly connected to the conductive element; and at least one pair of communication pins; wherein at least one conductive component and at least one pair of communication pins are integrally formed with the plastic housing by an injection molding process.

[0008] In the above solution, the conductive components and studs are injection molded as embedded metal parts into the plastic housing in a single process. This overmolding helps reduce flashover and short circuits, preventing performance degradation and damage to sensitive components. Furthermore, it avoids secondary assembly, reduces labor and assembly costs, improves the overall structural strength and stability, and prevents parts from loosening or making poor contact.

[0009] According to a preferred embodiment of this utility model, the at least one conductive component includes three spaced-apart conductive components, and the conductive element of each conductive component can be a conductive bus, wherein the metal studs are fixedly connected to the conductive bus by welding; and at least one pair of communication pins are, for example, two pairs of CAN communication pins. Using three spaced-apart conductive components enables three-phase DC output / input or positive-negative-ground multi-channel current transmission, effectively dispersing heat and current load, reducing heat concentration and electrical interference. Furthermore, the spaced arrangement helps improve insulation safety distance, meets electrical clearance requirements, and enhances withstand voltage and insulation performance; this configuration also facilitates modular wiring layout at the back end.

[0010] In one embodiment of this invention, the plastic housing can be constructed as a generally rectangular plate, having a first end, a second end opposite to the first end, and a main body segment extending between the first end and the second end; three conductive components are arranged at equal intervals in the main body segment; and two pairs of CAN communication pins are spaced apart near the first end and located between the first end and the conductive components adjacent to the first end. Here, the communication pins are arranged near the edge of the housing, which helps to reduce signal interference. The equal intervals between the three conductive components help to distribute current evenly, reduce local heat generation, and improve the mechanical stability and shape compatibility of the entire connector.

[0011] According to a preferred embodiment of the present invention, the plastic housing further comprises a first mounting lug at a first end and a second mounting lug at a second end, both the first and second mounting lugs being provided with screw holes for fixed mounting. Furthermore, the plastic housing has a first surface and an opposite second surface, and a first partition wall extending vertically from the first surface, the first partition wall engaging with the first surface to form three partitioned chambers partially surrounding the respective conductive component. An annular groove is arranged to extend circumferentially within the first surface of the plastic housing. This arrangement of the annular groove enhances the connector's sealing and environmental adaptability.

[0012] In a preferred embodiment, each conductive bus includes a rectangular substrate, preferably square, and four independent bends extending perpendicularly to the rectangular substrate, each bend having multiple bus pins at its free end. The rectangular substrate is configured with through-holes suitable for receiving metal studs, which pass through the through-holes and are fixedly connected to the rectangular substrate by soldering. The conductive components are configured such that the rectangular substrate and the metal studs are located within respective partitioned chambers, and the multiple bus pins extend beyond the second surface. This compact structural layout of the conductive bus facilitates standardized manufacturing and multidirectional connections, provides multi-point electrical connections, and enhances current carrying capacity and redundancy. Furthermore, the conductive components are separated by partition walls, enabling electrical isolation and preventing short circuits or signal crosstalk.

[0013] In a preferred embodiment, the four bends include a pair of opposing first bends and a pair of opposing second bends, wherein each first bend has three bus pins and each second bend has four bus pins. This structure improves the mechanical strength and electrical connection redundancy of the conductive bus through a four-sided three-dimensional bending design. The opposing pair of first bends and the pair of second bends form a highly symmetrical and spatially distributed structure, improving overall assembly stability and electrical balance. Furthermore, this asymmetrical pin configuration allows for differentiated electrical function configurations to meet the needs of different current, voltage, or signal channels.

[0014] In a preferred embodiment, the conductive busbar can be made of brass through a stamping process, and the metal studs can be made of stainless steel for connecting external wiring harnesses. Brass has excellent conductivity and machinability, making it suitable for efficient current conduction. The stamping process is low-cost, efficient, and facilitates mass production, while also enabling high-precision forming of complex structures and improving consistency. The stamped edges are neat and can be directly integrated into injection molding, which is beneficial for subsequent processes.

[0015] According to a preferred embodiment of this invention, the CAN communication pin can be made of CuSn6 with a nickel-based tin plating on its surface for implementing CAN communication connection. The portion of the CAN communication pin extending beyond the first surface is surrounded by a second partition wall extending vertically from the first surface, and the CAN communication pin also partially extends beyond the second surface. The second partition wall provides structural isolation and electromagnetic shielding, reducing interference from adjacent components to the CAN signal; it also prevents pin deformation or breakage due to external impact, improving the pin's physical protection capability.

[0016] Compared with existing technologies, the connector assembly for DC-DC voltage converters provided by this utility model has the following advantages: Reliable sealing: By setting a sealing groove on the plastic housing and using it in conjunction with sealing materials, the connector can form an effective seal with the DC-DC equipment housing, significantly improving the product's environmental adaptability and long-term reliability under complex working conditions such as humidity, dust, and high pollution; Integration of other functional pins: Based on the high-current connection function, a CAN signal pin for communication is further integrated, enabling the connector to simultaneously possess power transmission and data communication capabilities, improving system integration and meeting the needs of modern intelligent power electronic systems for multifunctional, high-density connectors; Injection molding / overmolding structure design: By encasing the conductive bus and communication pins in the plastic housing, good electrical insulation is achieved, effectively reducing the risk of arc flashover and short circuits, avoiding damage to sensitive components in the system, thereby improving the overall electrical safety and operational stability of the system. Attached Figure Description

[0017] The features and advantages of this utility model will become clear from the following detailed description provided with reference to the accompanying drawings. It should be understood that the following drawings are merely schematic and not necessarily drawn to scale, and therefore should not be considered as limitations on this utility model, wherein:

[0018] Figure 1 This is a perspective view of a connector assembly according to an exemplary embodiment of the present invention;

[0019] Figure 2 for Figure 1 A top view of the connector assembly shown;

[0020] Figure 3 for Figure 2 A cross-sectional view of the connector assembly shown along line AA; and

[0021] Figure 4 This is a perspective view of an embodiment of the conductive component according to the present invention, which includes a conductive busbar and metal bolts fixedly connected to the conductive busbar. Detailed Implementation

[0022] Embodiments of the present invention are described below with reference to the accompanying drawings. In the following description, numerous specific details are set forth to enable those skilled in the art to more fully understand and implement the present invention. However, it will be apparent to those skilled in the art that implementations of the present invention may not include some of these specific details. Furthermore, it should be understood that the present invention is not limited to the specific embodiments described. Rather, the present invention can be conceived to be implemented with any combination of the features and elements described below, regardless of whether they relate to different embodiments. Therefore, the following aspects, features, embodiments, and advantages are for illustrative purposes only and should not be construed as elements or limitations of the claims unless expressly set forth in the claims.

[0023] The terms "first" and "second" are used below to describe the elements of this application. These terms are used only to distinguish the individual elements and not to limit the nature, order, or number of these elements. The terms "comprising" and "having" are used to indicate an open-ended inclusion and mean that there may be additional elements / components besides those listed.

[0024] See Figure 1 , Figure 2 and Figure 3 The figure illustrates a connector assembly 100 for a DC-DC (voltage) converter according to an embodiment of the present invention. As can be seen from the figure, the connector assembly includes an insulating plastic housing 1, three conductive components 2, and two pairs of communication pins 5, such as CAN communication pins. Advantageously, the conductive components 2 and communication pins 5 are integrally formed with the plastic housing 1 as metal inserts during the injection molding process, i.e., the conductive components 2 and communication pins are encased within the plastic housing. This manufacturing method of the connector assembly 100 helps reduce flashover and short circuits, thereby reducing performance and damaging sensitive components. It should be understood that the number of conductive components and communication pins here is merely exemplary, and other suitable numbers can be selected according to specific needs, which are also covered within the scope of this application. Furthermore, providing two pairs of CAN communication pins supports dual-channel CAN communication, enabling redundant designs or independent communication between multiple nodes, facilitating communication with multi-module systems or master-slave architectures, and improving system interconnectivity.

[0025] The plastic housing 1 can be made of an insulating material such as PBT-GF30 and is constructed in a generally rectangular plate shape, having a first end 11, an opposing second end 12, and a main body segment 13 located between the two. The plastic housing 1 also has a first surface 14. Figure 3 The upper surface shown) and the opposite second surface 15 ( Figure 3(See the lower surface shown). The plastic housing 1 also includes a first mounting lug 110 and a second mounting lug 120 located at both ends. Each mounting lug has a screw hole 130 for securing the connector assembly to the DC-DC converter, so as to facilitate the fastening of the connector assembly to the mounting base (not shown) of the DC-DC converter. The first surface 14 of the plastic housing 1 has an annular groove 10 extending circumferentially (especially along the inner side of the outer periphery) of the plastic housing, which provides a sealing function when the connector assembly is installed to the DC-DC converter, thereby preventing moisture or impurities from entering the interior of the housing.

[0026] In a preferred embodiment, three conductive components 2 are arranged at equal intervals along the main body segment 13 of the plastic housing 1. For example, each conductive component 2 may include a conductive element 3, such as a conductive bus, and a metal stud 4, for example, fixedly connected to the conductive bus by welding. Two pairs of CAN communication pins are spaced apart near the first end 11 and located between the first end 11 and the conductive component 2 adjacent to the first end, i.e., spaced apart from the conductive component 2 at the leftmost end in the figure. The welded connection between the metal stud 4 and the conductive bus 4 forms a low-resistance, mechanically stable contact, improving overall conductivity reliability, avoiding the loosening problems of traditional riveting and crimping methods, and enhancing shock resistance; furthermore, the welded point is integrated with the bus, which is beneficial for heat conduction and reduces hot spots.

[0027] See Figure 4 Preferably, the conductive bus 3 is made of, for example, brass material through a stamping process, and is a one-piece molded structure, including a rectangular substrate (preferably a square substrate) 30 and four bent portions extending vertically downward from its four edges. Each bent portion has multiple bus pins 33 at its free end. In one embodiment of the conductive component (also called a conductive bus assembly), the four bent portions of the conductive bus include a pair of opposing first bent portions 31 and a pair of opposing second bent portions 32, wherein each first bent portion 31 has three bus pins and each second bent portion has four bus pins to meet different load requirements. In this embodiment, the conductive element 3 is constructed as a conductive bus with good electrical conductivity and mechanical strength, suitable for carrying large currents. The rectangular substrate 30 has a through hole 301 in the middle for receiving a metal stud 4, for example, made of stainless steel. The metal stud 4 passes through the through hole 301 and is fixedly connected to the rectangular substrate 30 by welding, thereby forming a strong electrical connection and used to connect external wiring harnesses to realize power transmission.

[0028] To enhance structural stability and electrical isolation, a first partition wall 16 is provided on the first surface 14 of the plastic housing 1. The first partition wall extends vertically from the first surface and together with the first surface, encloses three partition chambers 60. The rectangular substrate 30 of each conductive bus and its connected metal stud 4 are housed in the corresponding partition chamber, and the bus pins 33 extend from the second surface 15 of the plastic housing to facilitate docking with the DC-DC converter body.

[0029] The two pairs of CAN communication pins 5 located at the first end 11 of the plastic housing are used to enable data communication with an external control system. For example, the CAN communication pins 5 can be made of CuSn6 copper-tin alloy material with a nickel-based tin plating to provide excellent conductivity and corrosion resistance.

[0030] In addition, to enhance the mechanical protection and electromagnetic isolation of the communication pin, the first surface 14 is also provided with a second partition wall 17, which extends vertically from the surface and forms a partition area around the portion extending from the CAN communication pin. Meanwhile, the other end of the CAN communication pin also extends from the second surface 15 for insertion into the main control board.

[0031] The connector assembly of this utility model achieves integrated molding of conductive components, communication pins and plastic housing through integrated injection molding process, which effectively reduces assembly complexity and process cost, while improving structural consistency and sealing performance. It is particularly suitable for automotive DC-DC converter applications with high reliability requirements.

[0032] Various modifications and variations can be made to the embodiments disclosed above without departing from the scope or spirit of this invention. Other embodiments of this invention will be apparent to those skilled in the art based on the practice of this invention disclosed in this specification. This specification and the examples disclosed herein should be considered illustrative only, and the true scope of this invention is defined by the appended claims and their equivalents.

Claims

1. A connector assembly for a DC-DC converter, characterized in that, The connector assembly (100) includes: An insulating plastic housing (1) is provided with an annular groove (10) for sealing; At least one conductive component (2), each of the conductive components comprising a conductive element (3) and a metal stud (4) fixedly connected to the conductive element; and At least one pair of communication pins (5); The at least one conductive component (2) and the at least one pair of communication pins (5) are integrally formed with the plastic housing (1) by injection molding.

2. The connector assembly according to claim 1, characterized in that, The at least one conductive component (2) includes three conductive components arranged at intervals; The conductive element (3) of each of the conductive components is a conductive bus, wherein the metal stud is fixedly connected to the conductive bus by welding; and The at least one pair of communication pins includes two pairs of CAN communication pins.

3. The connector assembly according to claim 2, characterized in that, The plastic shell (1) has a first end (11), an opposing second end (12), and a main body section (13) extending between the first end and the second end; The three conductive components (2) are arranged at equal intervals in the main body section (13); and The two pairs of CAN communication pins are spaced apart near the first end (11) and located between the first end (11) and a conductive component adjacent to the first end.

4. The connector assembly according to claim 3, characterized in that, The plastic housing (1) also has a first mounting lug (110) at the first end and a second mounting lug (120) at the second end, both the first mounting lug and the second mounting lug being provided with screw holes (130) for fixed installation; The plastic housing has a first surface (14) and an opposite second surface (15), and has a first partition wall (16) extending vertically from the first surface, the first partition wall engaging with the first surface to form three partitioned chambers (60) partially surrounding the respective conductive components; and The annular groove extends circumferentially along the first surface (14) of the plastic housing.

5. The connector assembly according to claim 4, characterized in that, Each of the conductive busbars includes a rectangular substrate (30) and four independent bends extending perpendicularly to the rectangular substrate, each bend having a plurality of bus pins (33) at its free end; The rectangular substrate has a through hole (301) suitable for receiving the metal stud, and the metal stud is fixedly connected to the rectangular substrate by welding; and The conductive components are configured such that the rectangular substrate and the metal stud are located in respective partition chambers, and the plurality of bus pins extend beyond the second surface (15).

6. The connector assembly according to claim 5, characterized in that, The four bends include a pair of oppositely arranged first bends (31) and a pair of oppositely arranged second bends (32), wherein each first bend (31) is provided with three bus pins and each second bend is provided with four bus pins.

7. The connector assembly according to any one of claims 2 to 6, characterized in that, The conductive bus is made of brass by a stamping process; the metal stud is made of stainless steel and is used to connect external wiring harnesses.

8. The connector assembly according to claim 4, characterized in that, The CAN communication pin is made of CuSn6 and has a nickel-based tin plating layer on its surface, used to achieve CAN communication connection; and The portion of the CAN communication pin extending beyond the first surface is surrounded by a second partition wall (17) extending vertically from the first surface, and the CAN communication pin also extends partially beyond the second surface.

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