A cable waterproof joint assembly
Patent Information
- Application Number
- CN202522508875.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-26
- Publication Date
- 2026-10-27
- Estimated Expiration
- 2035-11-26
AI Technical Summary
作为电动汽车的主要部件，电机控制器的质量和性能直接关系到电动车的质量，现有技术采用防水接头组件将电机控制器与电机电连接，防水接头组件通常包括有采用PVC材料制成壳体、定位于壳体内的导电片和一根与导电片固定连接且能导通的线缆，线缆一端位于壳体外，PVC材料制成的壳体具有一定的弹性形变能力，在线缆被侧拉或牵扯时，壳体局部产生相应形变，能减缓线缆的损坏速度，壳体上设置有用于导电柱插入的套接口，通过将线缆位于壳体外的一端和套接口分别与电机和电机控制器相连使得电机与电机控制器电连接，壳体在套接口与导电柱插接到位后而与相应的电机控制器外壳紧贴而起到密封作用，但现有技术存在缺陷，因长时间工作状态下，导电片与导电柱均因电流较大而产生较高的温度，PVC材料制成的壳体发生软化，导致壳体发生形变而无法与相应的外壳紧密贴合，防水效果变差，存在外界雨水渗进套接部内的情况，影响导电效率且有安全隐患
[0012]本实用新型的有益效果：通过将阻隔件位于壳体外的一端与相应的电机或电机控制器插接使得导电柱与导电片接触且壳体相应的电机或电机控制器的外壳紧密贴合，如此设计相比现有技术增加了采用PBT材料制成的耐高温阻隔件，阻隔件取代壳体而与导电片以及导电柱直接接触，因阻隔件具有良好的热稳定性，导电片与导电柱所产生的高温对阻隔件影响小，同时壳体的结构稳定而不会发生形变，间接确保了壳体与电机外壳之间的密封性和防水性。
Smart Images
Figure CN224908615U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of electric vehicle technology, and more specifically to a waterproof cable connector assembly. Background Technology
[0002] New energy vehicles refer to automobiles that use unconventional vehicle fuels as their power source and integrate advanced technologies in vehicle power control and drive, resulting in vehicles with advanced technical principles, new technologies, and new structures. Globally, the power sources for new energy vehicles mainly include lithium-ion batteries, nickel-metal hydride batteries, fuel cells, lead-acid batteries, and supercapacitors, with supercapacitors mostly appearing as auxiliary power sources. As a key component of electric vehicles, the quality and performance of the motor controller directly affect the overall quality of the vehicle. Current technology uses waterproof connector assemblies to electrically connect the motor controller and the motor. These assemblies typically include a PVC shell, a conductive sheet positioned inside the shell, and a conductive cable fixedly connected to the conductive sheet. One end of the cable is located outside the shell. The PVC shell has a certain degree of elastic deformation; when the cable is pulled or stretched, the shell deforms locally, slowing down cable damage. The shell has a socket for inserting conductive posts. By connecting the cable's outer end and the socket to the motor and motor controller respectively, the motor and motor controller are electrically connected. After the socket and conductive post are inserted, the shell fits tightly against the corresponding motor controller housing, providing a seal. However, this technology has drawbacks. During prolonged operation, the conductive sheet and conductive post generate high temperatures due to the large current, causing the PVC shell to soften and deform, preventing a tight seal with the corresponding housing. This reduces the waterproof effect, allowing rainwater to seep into the connector, affecting conductivity and posing safety hazards. Utility Model Content
[0003] In view of the shortcomings of the existing technology, the purpose of this utility model is to provide a connector assembly that is structurally stable and effectively waterproof.
[0004] To achieve the above objectives, this utility model provides the following technical solution: a waterproof cable connector assembly, comprising a housing made of PVC material, a conductive sheet positioned inside the housing, and a cable with its two ends located inside and outside the housing, respectively. The end of the cable inside the housing is fixedly connected to the conductive sheet. The housing is provided with a sleeve interface for the conductive post to pass through. A high-temperature resistant barrier component coaxial with the sleeve interface is provided inside the housing. The barrier component has a hollow inner cavity. One end of the barrier component extends out of the housing through the sleeve interface. A side mounting hole for the conductive sheet to pass through is provided on the peripheral wall of the barrier component. By inserting the end of the barrier component outside the housing into a corresponding motor or motor controller, the conductive post contacts the conductive sheet, and the housing tightly fits the outer shell of the corresponding motor or motor controller.
[0005] As a further improvement of this utility model, the housing is provided with an inspection hole coaxial with the sleeve interface, and the inspection hole is detachably connected with a waterproof plug.
[0006] As a further improvement of this utility model, the waterproof plug is provided with a corrugated portion that can extend into the barrier and contact the top of the conductive sheet.
[0007] As a further improvement of this utility model, the barrier includes a plug-in portion with a through sleeve interface, an intermediate portion with a side mounting hole and coaxially connected to the plug-in portion, and a pressing portion coaxially connected to the intermediate portion and through which the corrugated portion passes. The inner diameter of the intermediate portion is larger than the inner diameter of the plug-in portion, and the end of the plug-in portion and the corrugated portion together generate a clamping force on the conductive sheet.
[0008] As a further improvement of this utility model, the outer diameter of the insertion part and the outer diameter of the pressing part are both smaller than the outer diameter of the middle part.
[0009] As a further improvement of this utility model, the portion of the conductive sheet located in the middle part is adapted to the inner cavity of the middle part.
[0010] As a further improvement of this utility model, a waterproof ring is provided at the port of the socket, which is fitted over the barrier.
[0011] As a further improvement of this utility model, a positioning block is provided on the outer wall of the housing on the same side as the sleeve interface.
[0012] The beneficial effects of this utility model are as follows: By connecting the end of the barrier component located outside the housing to the corresponding motor or motor controller, the conductive post and the conductive sheet are in contact, and the housing is tightly fitted to the corresponding motor or motor controller housing. Compared with the prior art, this design adds a high-temperature resistant barrier component made of PBT material. The barrier component replaces the housing and directly contacts the conductive sheet and conductive post. Because the barrier component has good thermal stability, the high temperature generated by the conductive sheet and conductive post has little impact on the barrier component. At the same time, the structure of the housing is stable and will not deform, which indirectly ensures the sealing and waterproof performance between the housing and the motor housing. Attached Figure Description
[0013] Figure 1 This is a perspective view of the present utility model; Figure 2 This is an exploded view of the present invention; Figure 3 This is a diagram showing the state of the present invention when it is inserted into the partial motor housing and the corrugated part is not elastic. Figure 4 This is a perspective view of the corrugated portion of this invention when it is elastic and in contact with the conductive sheet.
[0014] Reference numerals: 1. Housing; 2. Conductive sheet; 3. Cable; 4. Socket; 5. Barrier; 51. Insertion part; 52. Middle part; 53. Pressing part; 6. Side mounting hole; 7. Waterproof ring; 8. Inspection hole; 9. Waterproof plug; 91. Corrugated part; 10. Positioning block. Detailed Implementation
[0015] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Identical components are indicated by the same reference numerals.
[0016] Reference Figures 1 to 4 As shown, a waterproof cable connector assembly of this embodiment includes a housing 1 made of PVC material, a conductive sheet 2 positioned inside the housing 1, and a cable 3 with its two ends located inside and outside the housing 1, respectively. One end of the cable 3 located inside the housing 1 is fixedly connected to the conductive sheet 2. The housing 1 is provided with a sleeve interface 4 for the conductive post to pass through. The conductive sheet 2 is a terminal block and has good conductivity. Based on the aforementioned prior art, the barrier 5 is made of PBT material, which has excellent chemical stability, mechanical strength, electrical insulation properties, and thermal stability. During processing, the conductive sheet 2 is placed in a corresponding mold, then PBT material is injected into the mold and coated to cover the conductive sheet 2. After injection molding and cooling, the barrier 5 is formed. The barrier 5 is cylindrical with a hollow inner cavity. The conductive sheet 2 is partially located inside the barrier 5, and a side mounting hole 6 is formed at the position where the conductive sheet 2 passes through. Then, the barrier 5 and the conductive sheet 2 are removed from the mold, and the portion of the conductive sheet 2 outside the barrier 5 is fixedly connected to one end of the cable 3. The entire assembly is then moved to another mold for a second injection molding process. PVC material is injected into the mold and wrapped around the barrier 5. The housing 1 is then molded with soft rubber. After processing, the conductive sheet 2 is positioned inside the housing 1, and part of the cable is located inside the housing 1. The barrier 5 is positioned inside the housing 1 with only one end protruding from the socket 4. To further illustrate, the assembly method of the barrier 5 and the conductive sheet 2 can also be to first injection mold the barrier 5, then process the side mounting hole 6 on the peripheral wall, then insert one end of the conductive sheet 2 into the barrier 5 through the side mounting hole 6, and finally wrap the barrier 5 and the conductive sheet 2 with PVC to fix the barrier 5 and the conductive sheet 2 together. During use, one end of cable 3 can be fixedly connected to the motor controller and electrically connected to the internal circuit of the motor controller. Then, one end of the barrier 5 is inserted through the socket 4 and plugged into the socket on the motor. The conductive post in the center of the motor socket will extend into the barrier 5. When the outer wall of the housing 1 is tightly attached to the outer wall of the motor, the conductive post and the conductive sheet 2 touch and conduct electricity. Finally, the motor can be controlled by the motor controller. During this period, both the conductive sheet 2 and the conductive post will generate heat, causing the temperature inside the barrier 5 to rise. Compared to existing technologies, this design adds a high-temperature resistant barrier component 5 made of PBT material. The barrier component 5 replaces the housing 1 and directly contacts the conductive sheet 2 and the conductive post. Because the barrier component 5 has good thermal stability, the high temperature generated by the conductive sheet 2 and the conductive post has little impact on the barrier component 5. At the same time, the structure of the housing 1 remains stable and will not deform, indirectly ensuring the sealing and waterproof performance between the housing 1 and the motor housing. Furthermore, compared to directly replacing the PVC material of the housing 1 with PBT material, this design can ensure that the housing 1 still has the ability to deform when the cable 3 is pulled, thus slowing down the rate at which the cable 3 is damaged and extending the service life of the cable 3.
[0017] As an improved specific implementation, the existing housing 1 has only one socket 4 while the rest is in a closed state. If the motor controller and motor cannot be powered after the conductive post and the barrier 5 are inserted, it is necessary to inspect the contact between the conductive post and the conductive sheet 2, but there is no way to start. To solve the aforementioned problem, refer to Figure 3 and Figure 4As shown, an inspection hole 8 coaxial with the sleeve interface 4 can be cut into the molded housing 1. Alternatively, during processing, a sealing rod that will not adhere to PVC can be inserted into the barrier 5. The length of the sealing rod is greater than the length of the inner cavity of the barrier 5. Then, the barrier 5 with the sealing rod is placed in the mold, with the end of the sealing rod outside the barrier 5 outside the mold. PVC is then injected into the mold and formed. Finally, the housing 1 is removed from the mold, and the sealing rod is pulled out, thus forming an inspection hole 8 on the housing 1. Then, the waterproof plug 9 is pressed into the inspection hole 8 by interference fit. Compared with the existing technology, this design can not only avoid the problems caused by the process... The phenomenon of PVC easily flowing into the inner cavity of the barrier component 5 has been addressed by optimizing the processing flow. Furthermore, when the conductive sheet 2 is in contact with the conductive post, removing the waterproof plug 9 allows maintenance personnel to use a test pen to check the conductive sheet 2 in the contact state, making it easier to determine if the conductive sheet 2 and the conductive post are making good contact, reducing maintenance difficulty. The interference fit between the waterproof plug 9 and the inspection hole 8 improves the stability and tightness of the connection between them, effectively preventing water ingress. Further explanation: of the two processing methods for the inspection hole 8, the latter is preferred, as the inspection hole 8 has higher dimensional accuracy and a smoother inner wall, which facilitates the fit of the waterproof plug 9. As an improved specific implementation, when the conductive post and the barrier 5 are inserted, the conductive post is prone to impacting the conductive sheet 2, causing the conductive sheet 2 to bend and deform, resulting in poor contact between the conductive sheet 2 and the conductive post. To solve the aforementioned problem, refer to... Figure 2 and Figure 4 As shown, the waterproof plug 9 is integrally formed with a corrugated part 91 that can extend into the barrier 5. The structure of the corrugated part 91 is the same as that of the bellows and has a certain elasticity. After the waterproof plug 9 and the inspection hole 8 are installed in place, one end of the corrugated part 91 contacts the conductive sheet 2 and the corrugated part 91 is compressed and contracts. The force generated by the contraction of the corrugated part 91 is much smaller than the static friction between the waterproof plug 9 and the inspection hole 8. Subsequently, when the conductive post impacts the conductive sheet 2, the corrugated part 91 can reduce the impact force. At the same time, the thrust generated by the corrugated part 91 on the conductive sheet 2 promotes full contact between the conductive sheet 2 and the conductive post. This design can ensure good conductivity between the conductive post and the conductive sheet 2. At the same time, after the conductive post and the conductive sheet 2 are separated, the corrugated part 91 can help the conductive sheet 2 return to its initial state, indirectly improving the structural stability of the conductive sheet 2. For further explanation, refer to Figure 3 As shown, the outer wall of the corrugated part 91 can be designed to be corrugated and the inner cavity to be cylindrical. In this case, the corrugated part 91 may not be elastic and may not necessarily be in contact with the conductive sheet 2. The maximum outer diameter of the corrugated part 91 is the same as the inner diameter of the barrier 5, meaning that a portion of the outer wall of the corrugated part 91 fits against the inner wall of the barrier 5. This design ensures that even if the waterproof plug 9 and the inspection hole 8 become loose, water can still be prevented from seeping into the barrier 5 through the outer wall of the corrugated part 91. This design creates multiple seals, thus providing effective waterproofing.
[0018] As an improved specific implementation, because the corrugated part 91 exerts a pushing force on the conductive sheet 2, causing the conductive sheet 2 to bend towards the sleeve interface 4, over time the shape of the conductive sheet 2 becomes fixed and difficult to restore, affecting the depth of the conductive post insertion into the blocking member 5, resulting in the housing 1 not being able to fit tightly with the corresponding motor housing. To solve the aforementioned problem, refer to Figures 2 to 4 As shown, the barrier 5 includes an integrally formed and coaxial plug-in portion 51, a middle portion 52, and a pressing portion 53. The plug-in portion 51 passes through the sleeve interface 4, the pressing portion 53 is adjacent to the inspection hole 8, and the side mounting hole 6 is located on the middle portion 52. The inner diameter of the middle portion 52 is larger than the inner diameter of the plug-in portion 51, that is, a step is formed at the connection between the middle portion 52 and the plug-in portion 51. The side mounting hole 6 is flush with the hole wall of the plug-in portion 51. After the conductive sheet 2 is connected to the barrier 5, the surface of the conductive sheet 2 facing the plug-in portion 51 contacts the step surface. When the corrugated portion 91 pushes the conductive sheet 2, the conductive sheet 2 fits against the step surface. That is, the corrugated portion 91 and the step surface together hold the conductive sheet 2. This design can ensure that the conductive sheet 2 is always in a vertical state, the structure is stable, and at the same time, it can ensure that the end of the conductive post is in effective contact with the surface of the conductive sheet 2, resulting in good conductivity.
[0019] As one specific implementation method of the improvement, refer to Figure 2 As shown, the outer diameter of the insertion part 51 and the outer diameter of the pressing part 53 are both smaller than the outer diameter of the middle part 52. This design, compared with the design of the outer wall of the barrier 5 being a complete circumferential surface, can increase the degree of unevenness of the outer wall of the barrier 5. After the housing 1 is injection molded, the connection stability between the housing 1 and the outer wall of the barrier 5 is stronger, effectively avoiding the result of the barrier 5 moving relative to the housing 1 along the axis of the sleeve interface 4 due to long-term use.
[0020] As one specific implementation method of the improvement, refer to Figure 3 and Figure 4 As shown, if the barrier 5 is connected to the conductive sheet 2 by injection molding, the part of the conductive sheet 2 located in the middle part 52 matches the inner cavity contour of the middle part 52. If the barrier 5 is molded first and then inserted into the conductive sheet 2, the size of the conductive sheet 2 needs to be selected so that the part of the conductive sheet 2 inserted into the middle part 52 matches the inner cavity contour of the middle part 52. This design aims to make the size of the local conductive sheet 2 located in the middle part 52 as large as possible to increase the contact area between the conductive post and the corrugated part 91 and the conductive sheet 2. The increased conduction area of the conductive sheet 2 can improve the conduction efficiency, and at the same time, the conductive sheet 2 is subjected to uniform force.
[0021] As one specific implementation of the improvement, due to processing errors or wear caused by prolonged use, a local gap exists after the housing 1 and the motor housing are fitted together. Rainwater can flow into the barrier 5 through this local gap, affecting normal use. To solve the aforementioned problem, refer to... Figures 2 to 4As shown, a groove adjacent to the socket 4 is machined on the outer wall of the insertion part 51. Then, a waterproof ring 7 is fitted onto the outside of the insertion part 51 and moves towards the socket 4. When the waterproof ring 7 moves to the groove, it retracts and engages with the groove. The waterproof ring 7 fits against the surface of the socket 4. After the barrier 5 and the conductive post are inserted into place, the waterproof ring 7 can fit tightly against the surface of the motor housing to form an effective seal. This design improves the sealing stability and waterproof effect compared to the design where the housing 1 is tightly fitted to the motor housing. Furthermore, the gap between the housing 1 and the motor housing facilitates the removal efficiency between the barrier 5 and the conductive post, making it more convenient to use.
[0022] As one specific implementation of the improvement, during use, the cable 3 is easily pulled, causing the barrier 5 to rotate relative to the conductive post and bend the conductive post, resulting in difficulty in subsequent insertion and removal between the barrier 5 and the conductive post. To solve the aforementioned problem, refer to Figures 1 to 4 As shown, a positioning block 10 is provided on the outer wall of the housing 1 on the same side as the socket 4. A positioning groove is machined on the corresponding motor housing. After the barrier 5 and the conductive post are inserted into place, the positioning block 10 will be inserted into the positioning groove. This design can prevent the cable 3 from driving the housing 1 to rotate relative to the motor housing, thereby improving the connection stability of the housing 1 relative to the motor housing, indirectly improving the structural stability of the conductive post, and ensuring the smooth insertion and removal between the barrier 5 and the conductive post.
[0023] The above description is merely a preferred embodiment of this utility model. The protection scope of this utility model is not limited to the above embodiments. All technical solutions falling within the scope of this utility model's concept are protected. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of this utility model should also be considered within the protection scope of this utility model.
Claims
1. A waterproof cable connector assembly, comprising a housing (1) made of PVC material, a conductive sheet (2) positioned inside the housing (1), and a cable (3) with its two ends located inside and outside the housing (1) respectively, wherein one end of the cable (3) inside the housing (1) is fixedly connected to the conductive sheet (2), and the housing (1) is provided with a sleeve (4) for the conductive post to pass through, characterized in that: The housing (1) is provided with a high temperature resistant barrier (5) that is coaxial with the sleeve interface (4). The inner cavity of the barrier (5) is hollow. One end of the barrier (5) passes through the sleeve interface (4) and extends out of the housing (1). A side mounting hole (6) for the conductive sheet (2) to pass through is provided on the peripheral wall of the barrier (5). By plugging the end of the barrier (5) outside the housing (1) into the corresponding motor or motor controller, the conductive post contacts the conductive sheet (2) and the housing (1) is tightly fitted to the corresponding motor or motor controller shell.
2. The waterproof cable connector assembly according to claim 1, characterized in that: The housing (1) is provided with an inspection hole (8) coaxial with the sleeve interface (4), and the inspection hole (8) is detachably connected with a waterproof plug (9).
3. The waterproof cable connector assembly according to claim 2, characterized in that: The waterproof plug (9) is provided with a corrugated part (91) that can extend into the barrier (5) and contact the conductive sheet (2).
4. A waterproof cable connector assembly according to claim 3, characterized in that: The barrier (5) includes a plug-in portion (51) with a through sleeve interface (4), an intermediate portion (52) with a side mounting hole (6) and coaxially connected to the plug-in portion (51), and a pressing portion (53) coaxially connected to the intermediate portion (52) and through which the corrugated portion (91) passes. The inner diameter of the intermediate portion (52) is larger than the inner diameter of the plug-in portion (51), and the end of the plug-in portion (51) and the corrugated portion (91) together generate a clamping force on the conductive sheet (2).
5. A waterproof cable connector assembly according to claim 4, characterized in that: The outer diameter of the insertion part (51) and the outer diameter of the pressing part (53) are both smaller than the outer diameter of the middle part (52).
6. A waterproof cable connector assembly according to claim 4, characterized in that: The portion of the conductive sheet (2) located within the middle portion (52) is adapted to the inner cavity of the middle portion (52).
7. A waterproof cable connector assembly according to claim 1, 2, 3, 4, 5, or 6, characterized in that: A waterproof ring (7) is provided at the port of the socket (4) and is fitted outside the barrier (5).
8. A waterproof cable connector assembly according to claim 1, 2, 3, 4, 5, or 6, characterized in that: The outer wall of the housing (1) is provided with a positioning block (10) on the same side as the sleeve interface (4).