Shield conductor for a vehicle and for connecting a battery pack to a high-voltage distribution box in a circuit

Abstract

Umbrella ladder for a vehicle, comprising: a cylindrical protective device (11) into which shielded and unshielded wires (10a, 10b) are inserted, wherein the cylindrical protective device (11) is configured to connect a battery pack and a high-voltage distribution box; and a protective device clip closure (13) comprising a wire opening (12) through which the shielded and unshielded wires (10a, 10b) are inserted, and which is formed from an injection-molded plastic, wherein the protective device clip closure (13) is configured to seal an end region of the cylindrical protective device, wherein the wire opening (12) has wire receiving grooves (16a, 16b, 16c) which form the entire inner diameter, wherein each of the wire receiving grooves (16a, 16b, 16c) has an arc shape with the same curvature as the respective shielded and unshielded wires (10a, 10b), wherein the protective device clip closure (13) is inserted over the outer circumference of the end region of the cylindrical protective device (11) in such a way that a hook (14) formed at the rear end region is attached to a clip opening (15) formed in the cylindrical protective device (11), the hook (14) projecting from the inside of the receiving end region of the protective device clip closure (13).

Description

BACKGROUND(a) Technical field

[0001] The present invention relates to a shield conductor used in a power circuit of a vehicle, such as an electric vehicle, a hybrid vehicle, etc. It relates in particular to a shield conductor for connecting a battery pack and a high-voltage distribution box, which together form a power circuit of an electric vehicle. (b) State of the art

[0002] Environmentally friendly vehicles, such as hybrid and electric vehicles, produce fewer emissions than vehicles with internal combustion engines and are typically (at least partially) powered by a motor driven by a battery, rather than solely by a combustion engine. Due to current consumer environmental awareness and rising oil prices, the importance of vehicles with low carbon dioxide emissions and high efficiency has gradually developed into a growing market.

[0003] Electric vehicles are powered either by an AC or DC motor, which is operated by electric current from a battery, and include a mechanism for supplying both the current required to drive the vehicle and the current required for electrical and electronic devices fitted in the vehicle, using the current generated by an armature (i.e. winding) of a shaft connected to the motor, which is set up to generate a driving force.

[0004] The motor is connected to an inverter, battery pack, etc., via an electrical connection cable. The battery pack is electrically connected to a high-voltage distribution box to supply power to various electrical loads, and a safe connection cable is necessary for the electrical connection between the battery pack and the high-voltage distribution box. Typically, the connection cable consists of three insulated electrical conductors, such as shielded and unshielded conductors, which are also enclosed by an electrical shield.

[0005] For example, a screen conductor used in an electric vehicle's power circuit serves to shield conductors, prevent thermal damage, and protect the wires. It has a structure in which multiple wires are inserted into a cylindrical metal shield. The wires extend beyond both ends of the shield and are connected to various devices. The cylindrical metal shield connects the battery pack and the high-voltage distribution box and is curved to prevent interference with peripheral equipment and to conform to the surface of the vehicle's floor panel.

[0006] In hybrid vehicles, at least those delivered in Korea, a shielding material is typically encased in a resin sheath to protect the shielding material and the wires. However, when using a resin sheath, or when using a metal sheath to encase the shielded and unshielded wires in foreign vehicles, the number of parts increases significantly.

[0007] The publication of Japanese patent applications JP 2007-157435A and JP 2007-080692A demonstrates the use of such shielded conductors. However, these techniques present the following problems. First, when wires are inserted into a protective device, they are scratched by sharp edges at both ends of the device. Furthermore, when the protective device is mounted on the vehicle floor panel and bent to prevent interference with peripheral equipment, the wires become twisted within the device. Additionally, the shielded conductors are susceptible to the ingress of foreign matter or water, making it quite difficult to maintain a perfect airtight seal.

[0008] Furthermore, DE 10 2010 042 963 A1 discloses a wiring harness installed at a predetermined position in a hybrid vehicle. The wiring harness comprises a multitude of high-voltage and low-voltage electrical wires, as well as a protective element into which a portion of the multitude of electrical wires to be protected is inserted in the form of a bundle. The protective element protects the multitude of high-voltage and low-voltage electrical wires. The protective element is formed by a flexible, long standard tube.

[0009] US Patent 7,429,193 B2 also discloses a connector, for example, for harsh environments, which may include first and second connector sections that are movable between unconnected and connected positions. The first connector section may include a first base, a male contact supported by the first base and extending outward from it, and a first sheath supported by the first base and surrounding the male contact. The second connector section may include a second base and a socket contact supported by the second base and extending outward from it. The second connector section may further include a single-stage bladder supported by the second base, defining only a single-stage bladder chamber surrounding the socket contact, and a second sheath supported by the second base and surrounding the single-stage bladder.A two-stage bladder design can include an end cap that forms a seal to the end sections of the inner bladder against the second base, and an outer bladder that surrounds the inner bladder. The outer bladder can define a first seal with the inner bladder next to the base and a second seal with the end cap.

[0010] JP 2007-026 821 A describes a sealing plug whose inner circumferential surface can be brought into close contact with the pipe in a watertight condition. It is provided with a wire insertion opening into which a wire can be inserted in a watertight condition. The plug is installed in the front and rear end sections of a protective tube, leaving no gap through which water can penetrate. A lip is formed on the outer circumferential surface of the sealing plug, and a braided element is embedded in the outer circumferential surface of the protective tube in an area corresponding to the sealing plug. This further improves the watertightness of the front and rear end sections of the protective tube.

[0011] JP 2003-174 716 A also shows a coupling part of a cylinder that is coupled to one end of a casing to attach the cylinder to the casing. A gap formed between the outer surface of the casing and the opposite part of the cylinder is filled with sealing material injected through the cylinder opening. Spaces are formed between a multitude of wires, etc., and between a bundle of the multitude of wires and the casing, as well as within a region in the casing at a prescribed distance from the casing opening to the other end of the casing; these spaces are also filled with the sealing material. The interior of the cylinder extension 5c is filled with the sealing material.

[0012] The information disclosed above in this background section is intended only to improve the understanding of the background of the invention and may therefore contain information that does not constitute the prior art already known to a person skilled in the art in this country. OVERVIEW OF THE REVELATION

[0013] The object of the present invention is to provide a shield conductor for an electric vehicle or a hybrid vehicle, which comprises a protective device made of aluminium with excellent corrosion resistance, wherein the protective device connects a battery pack and a high-voltage distribution box and protects shielded and unshielded wires.

[0014] The problem is solved by a shield conductor having the features of claim 1 and a circuit having the features of claim 5. Advantageous further developments are found in the dependent claims.

[0015] Furthermore, the protective device also includes a protective device clip closure, formed from an injection-molded plastic and attached to the outside of the protective device, and a rubber grommet which has excellent water-sealing properties and is designed to encase the circumferences of the wires exposed to the outside of the protective device. As a result, the present invention prevents scratches when the wires are inserted into the protective device, prevents the wires from twisting when the protective device is bent, and prevents foreign matter or water from penetrating the protective device from the outside.

[0016] In one embodiment, the present invention provides a shielded conductor for a vehicle, wherein the shielded conductor particularly comprises a cylindrical protective device into which shielded and unshielded wires are inserted. The cylindrical protective device serves in particular as a means for connecting a battery pack and a high-voltage distribution box.A protective device clip closure, comprising a wire opening through which the shielded and unshielded wires are inserted, and formed from injection-molded plastic, serves as a means for closing an end region of the protective device, wherein the wire opening has wire receiving grooves forming the entire inner diameter, each of the wire receiving grooves having an arc shape with the same curvature as the respective shielded and unshielded wires, wherein the protective device clip closure is placed on the outer circumference of the end region of the protective device in such a way that a hook formed on the rear end region is attached to a clip opening formed in the protective device, the hook projecting from the inside of the receiving end region of the protective device clip closure.

[0017] In one embodiment, the wire opening of the protective device clip closure can have three wire receiving grooves, which closely accommodate a part of the circumference of the shielded wire with a larger diameter and a part of the two unshielded wires with a smaller diameter.

[0018] In some exemplary embodiments, the shield conductor may further include a cable gland mounted to enclose the protective device clip closure attached to the end of the protective device, and the shielded and unshielded wires extend from the end of the protective device to the outside, thus preventing foreign matter or water from entering the protective device from the outside. Furthermore, the shielded and unshielded wires extending from the end of the protective device to the outside may be sheathed by a braided element. The protective device may also be made of aluminum with excellent corrosion resistance.

[0019] Further embodiments and preferred embodiments of the invention are explained below. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The above and further features of the present invention will now be described in detail with reference to certain exemplary embodiments shown in the accompanying drawings, which below serve only for illustration and are therefore not limiting to the present invention, and wherein: Fig. Figure 1 shows a perspective exploded view representing a shield conductor according to an exemplary embodiment of the present invention; Fig. Figure 2 shows a perspective sectional view representing a shield conductor according to an exemplary embodiment of the present invention; and Fig. Figure 3 shows a sectional view illustrating a method for manufacturing a shield conductor according to an exemplary embodiment of the present invention.

[0021] The reference symbols shown in the drawings include a reference to the following structural elements, as explained below: 10a & 10b shielded and unshielded wires 11 Protective device 12 wire opening 13 Protective device clip closure 14 hooks 15 Clip opening 16a, 16b & 16c wire receiving grooves 17 cable grommet 18 mesh elements 19 Harzband

[0022] It should be noted that the accompanying drawings are not necessarily to scale and represent a somewhat simplified depiction of various illustrative features of the principles of the invention. The specific design features of the present invention, as disclosed herein, including, for example, specific dimensions, orientations, installation locations, and shapes, are partly determined by the application specifically provided for this purpose and the working environment.

[0023] In the figures, the reference numerals refer to the same or equivalent parts of the present invention throughout the individual figures of the drawings. DETAILED DESCRIPTION

[0024] The various embodiments of the present invention will now be discussed in detail, with examples of these illustrated in the accompanying drawings and described below.

[0025] It should be noted that the term "vehicle" or "vehicle-" or other equivalent terms as used herein include motor vehicles in general, such as passenger cars including sports utility vehicles (SUVs), buses, trucks, various utility vehicles, watercraft including a variety of boats and ships, aircraft and the like, and include hybrid vehicles, electric vehicles, plug-in hybrid electric vehicles, hydrogen-powered vehicles and other vehicles powered by alternative fuels (for example, fuel derived from sources other than petroleum). As referenced herein, a hybrid vehicle is a vehicle that has two or more sources of propulsion, such as both gasoline-powered and electric-powered vehicles.

[0026] Fig. Figure 1 shows a perspective exploded view representing a shield conductor according to an exemplary embodiment of the present invention, and Fig. Figure 2 shows a perspective sectional view representing a shield conductor according to an exemplary embodiment of the present invention.

[0027] As in Fig. 1 and Fig. As shown in Figure 2, the shielded conductor protects the wires by a single, all-encompassing shield, rather than by individual shielding of each wire. It has a structure in which an injection-molded product is attached to the outside of a cylindrical aluminum protective device, and a cable gland made of plastic, such as ethylene propylene diene monomer, is used to prevent the ingress of foreign matter or water. For this purpose, a cylindrical protective device 11 is provided as a means of connecting a battery pack and a high-voltage distribution box in a power circuit of a vehicle equipped with a high-voltage battery, such as an electric vehicle, a hybrid vehicle, etc. Shielded and unshielded wires 10a and 10b are inserted into the protective device 11 and are thus protected without the need for individual shielding of each wire.Preferably, the protective device 11 can be formed in a non-restrictive manner from aluminium, which has excellent corrosion resistance.

[0028] In particular, a protective device clip fastener 13, which is an injection-molded product made of plastic, is mounted at each end region of the protective device 11. The protective device clip fastener 13 is inserted around the outer circumference of at least one end region of the protective device 11 in such a way that at least one hook 14 is engaged with openings 15 formed in the protective device 11. In some embodiments, for example, three hooks 14 can be arranged at 90° intervals and project from the inside of the receiving end region of the clip fastener 13, which receives the protective device 11, in order to secure the hooks 14 in the openings 15 of the protective device 11.

[0029] The protective device clip closure 13 has a cylindrical cap-like shape, similar to the protective device 11, and is arranged concentrically on each end region of the protective device 11 to close the end region of the protective device 11 by means of the fastening arrangement via the hooks 14 and the clip openings 15.

[0030] Furthermore, a wire opening 12 is formed at the front end of the protective device clip closure 13 for the insertion of the shielded wire 10a and the unshielded wire 10b. Preferably, the wire has a shape that can hold a total of three wires stably and securely, although in some embodiments the design is not limited to this. Preferably, the wire opening 12 comprises three wire receiving grooves 16a, 16b, and 16c, which can closely accommodate a portion of the circumference of a shielded wire 10a with a larger diameter and a portion of two unshielded wires 10b with a smaller diameter, i.e., on which a portion of the circumference of each wire can be accommodated. The wire receiving grooves 16a, 16b, and 16c form the entire inner diameter and constitute a connection.Furthermore, each of the wire receiving grooves 16a, 16b and 16c can have an arc shape with the same curvature as each wire.

[0031] Accordingly, the outer circumferences of the shielded wire 10a and the unshielded wire 10b, which are bound together with a resin tape 19 and inserted into the wire opening 12, are in close contact with the wire receiving grooves 16a, 16b, and 16c. As a result, the protective clip closure 13 of the wire opening 12 holds the wires 10a and 10b in place, thus preventing them from twisting within the protective device 11 when the device is mounted and bent on a vehicle floor panel, thereby preventing interference with peripheral devices. Furthermore, since the protective clip closures 13 are injection-molded plastic products attached to both ends of the protective device 11, scratches are prevented when the wires 10a and 10b are inserted into the protective device 11.

[0032] In the present invention, a rubber grommet 17 is provided, in particular, as a means of preventing foreign bodies or water from penetrating the protective device 11 from the outside. The grommet 17 is designed to enclose the protective device clip closure 13 mounted on the end region of the protective device 11 and a predetermined length of the shielded and unshielded wires 10a and 10b extending from the end region of the protective device 11 to the outside. Preferably, the grommet 17 can be designed as a pre-formed grommet that is press-fitted or can be formed by injection molding.Therefore, by using the protective device clip closure 13, which acts to prevent foreign bodies from entering the protective device 11, and by using the grommet 17, which acts to prevent water from entering the protective device 11, the ingress of foreign bodies and water can be prevented so that they do not come into contact with the wires.

[0033] Furthermore, a braided element 18 is wrapped around the shielded and unshielded wires 10a and 10b, which extend from the end region of the protective device 11 to the outside, instead of the ground connection. Preferably, the braided element 18 is inserted between the outer circumferences of the wires 10a and 10b and the inner circumference of the grommet 17 and secured by a clamp (not shown).

[0034] Fig. Figure 3 shows a sectional view illustrating a method for manufacturing a shield conductor according to an exemplary embodiment of the present invention. As shown in Fig. As shown in Figure 3, three individual wires of shielded and unshielded wires 10a and 10b, which are to be inserted into the protective device 11, are first bound and bundled together at regular intervals with the resin tape 19. Before the bound wires 10a and 10b are inserted into the protective device 11, the protective device clip closure 13, an injection-molded product, is attached to the end region of the protective device 11. That is, the hook 14 of the protective device clip closure 13 is attached to the clip opening 15 formed in the protective device 11 to close the end region of the protective device 11.

[0035] After the protective device clip closure 13 is attached to the protective device 11, a bundle of wires 10a and 10b is inserted into the protective device 11 through the wire opening 12 of the protective device clip closure 13. The shielded wires 10a and 10b are in contact with the protective device clip closure 13 and are inserted into the protective device 11, while a sharp end area of ​​the protective device 11 is avoided, thus preventing scratching of the wires 10a and 10b.

[0036] After the shielded wires 10a and 10b are inserted into the protective device 11, the remaining wires 10a and 10b exposed to the outside of the protective device 11 are again bundled with the resin tape 19 in front of the protective device clip closure 13 to increase the fastening force. Subsequently, the braided element 18, instead of the ground connection, encases the circumferences of the wires 10a and 10b extending from the end area of ​​the protective device 11 to the outside and is then fastened by the clip.

[0037] After the work is completed, the rubber grommet 17 is fitted to enclose a predetermined length of the protective device 11, the total length of the protective device clip closure 13, and a predetermined length of the shielded and unshielded wires 10a and 10b extending from the end region of the protective device 11 to the outside, thus preventing foreign matter or water from entering the protective device 11 from the outside and preventing corrosion.

[0038] As described above, the present invention provides the following advantages.

[0039] Firstly, because the conventional guard has a sharp, cut edge, wires in the conventional design are often scratched when inserted into the guard. By using the injection-molded product applied to both ends of the guard, it is possible to prevent the wires from being scratched by the sharp, cut edge when inserted.

[0040] Secondly, the injection-molded plastic product has an opening with the same diameter as the wires through which the wires are inserted, thus preventing the inserted wires from twisting when the guard is bent, as they are secured within the injection-molded product.

[0041] Thirdly, the injection-molded part serves to hold the wires, thus allowing for adjustment of the guard's twisting, thereby reducing the cost of developing a mold. This means that if the injection-molded part is not used, a surface smoothing process for the aluminum guard is unnecessary. However, using the injection-molded part eliminates this smoothing process, further reducing production costs.

[0042] Fourthly, the injection-molded product mounted on the end area of ​​the protective device prevents foreign bodies from entering the protective device, and the nozzle prevents water from entering the protective device, thus making it possible to prevent the ingress of foreign bodies and water.

Claims

[1] Shield conductor for a vehicle, comprising: a cylindrical protective device (11) into which shielded and unshielded wires (10a, 10b) are inserted, wherein the cylindrical protective device (11) is configured to connect a battery pack and a high-voltage distribution box; and a protective device clip closure (13) comprising a wire opening (12) through which the shielded and unshielded wires (10a, 10b) are inserted, and which is formed from an injection-molded plastic, wherein the protective device clip closure (13) is configured to seal an end region of the cylindrical protective device, wherein the wire opening (12) has wire receiving grooves (16a, 16b, 16c) which form the entire inner diameter, wherein each of the wire receiving grooves (16a, 16b, 16c) has an arc shape with the same curvature as the respective shielded and unshielded wires (10a, 10b), wherein the protective device clip closure (13) is inserted over the outer circumference of the end region of the cylindrical protective device (11) in such a way that a hook (14) formed at the rear end region is attached to a clip opening (15) formed in the cylindrical protective device (11), the hook (14) protruding from the inside of the receiving end region of the protective device clip closure (13). [2] Shield conductor according to claim 1, wherein the wire opening (12) of the protective device clip closure (13) has three wire receiving grooves (16a, 16b, 16c) which closely receive a part of the circumference of the shielded wire (10a) with a larger diameter and a part of the unshielded wires (10b) with a smaller diameter. [3] Shield conductor according to claim 1, further comprising a grommet (17) which is configured to enclose the protective device clip closure (13) mounted on the end region of the cylindrical protective device (11) and the shielded and unshielded wires (10a, 10b) extending from the end region of the cylindrical protective device (11) to the outside, in order to prevent foreign bodies or water from entering the cylindrical protective device (11) from the outside. [4] Shield conductor according to claim 1, wherein the shielded and unshielded wires (10a, 10b) extending from the end region of the cylindrical protective device (11) to the outside are sheathed by a braid element (18). [5] Circuit comprising: a battery pack; a high-voltage distribution box connected to the battery pack via a shield conductor, the shield conductor having: a cylindrical protective device (11) into which shielded and unshielded wires (10a, 10b) are inserted, wherein the cylindrical protective device (11) is configured to connect a battery pack and a high-voltage distribution box; and a protective device clip closure (13) comprising a wire opening (12) through which the shielded and unshielded wires (10a, 10b) are inserted, and is formed from an injection-molded plastic, wherein the protective device clip closure (13) is configured to seal an end region of the cylindrical protective device (11), wherein the wire opening (12) has wire receiving grooves (16a, 16b, 16c) which form the entire inner diameter, wherein each of the wire receiving grooves (16a, 16b, 16c) has an arc shape with the same curvature as the respective shielded and unshielded wires (10a, 10b), wherein the protective device clip closure (13) is inserted over the outer circumference of the end region of the cylindrical protective device (11) in such a way that a hook (14) formed at the rear end region is attached to a clip opening (15) formed in the cylindrical protective device (11), the hook (14) protruding from the inside of the receiving end region of the protective device clip closure (13). [6] Circuit according to claim 5, wherein the wire opening (12) of the protective device clip closure (13) has three wire receiving grooves (16a, 16b, 16c) which closely receive a part of the circumference of the shielded wire (10a) with a larger diameter and a part of the two unshielded wires (10b) with a smaller diameter. [7] Circuit according to claim 5, further comprising a grommet (17) which is configured to enclose the protective device clip closure (13) mounted on the end region of the cylindrical protective device (11) and the shielded and unshielded wires (10a, 10b) extending from the end region of the cylindrical protective device (11) to the outside, in order to prevent foreign bodies or water from entering the cylindrical protective device (11) from the outside. [8] Circuit according to claim 5, wherein the shielded and unshielded wires (10a, 10b) extending from the end region of the cylindrical protective device (11) to the outside are sheathed by a braided element (18).

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