Connector assembly and vehicle using new shielding material

Abstract

The present application discloses a connector assembly and a vehicle using a new shielding material, comprising an electrical connection skeleton and a connector connected to both ends of the electrical connection skeleton, the connector including a connection terminal and an inner shell having a shielding function, both ends of the electrical connection skeleton being electrically connected to the connection terminals, the outer periphery of the electrical connection skeleton being covered with an insulating layer, the insulating layer containing conductive particles in the radial direction, and the conductive particles being distributed with non-uniform density at at least one location within the insulating layer. In the connector assembly using the new shielding material in the present application, the insulating layer contains conductive particles, so that when it is used instead of a braided shielding net, the use of shield braiding equipment is reduced, the site area is reduced, the processing cost of the cable is reduced, and the production cost of the connector assembly is reduced.

Description

Related Applications

[0001] This application claims priority to a Chinese patent application filed on March 14, 2022, bearing application number 202210250047.8 and entitled "New Shielding Material Connector Assembly and Vehicle," the entire contents of which are incorporated herein by reference. [Technical field]

[0002] The present application relates to the technical field of automotive electrical equipment, and more particularly to a new type of shielded connector assembly and vehicle. [Background technology]

[0003] As new energy vehicles are becoming more and more popular, the development of equipment and facilities for charging new energy vehicles is also progressing. The connector assemblies in new energy vehicles must meet the requirements for driving high-power motors, so the current transmitted is also large. Accordingly, the diameter of the high-voltage cable in the connector assembly is also large. Currently, the high-voltage cables in most connector assemblies are generally multi-core copper cables, but their weight and high price are obstacles that limit the popularization of new energy vehicles. In addition, multi-core cables are soft and can be easily processed and wired, but their wire diameter is too thick and heavy, so that during the running process of the vehicle, the cable frequently rubs against the body shell of the vehicle, causing the insulation layer in the cable to be damaged, resulting in high-voltage discharge, which in a minor case will damage the vehicle, and in a severe case will cause a terrible traffic accident.

[0004] To reduce the effects of electromagnetic interference, conductive cables are usually shielded from electromagnetic interference by a shielding net. Currently, the most commonly used shielding nets are made of braided metal wires. Therefore, a shielding braiding machine needs to be added to the cable production equipment. This increases the cost of the equipment and the land area required, resulting in the price of the shielded cable remaining high.

[0005] Therefore, there is a need in the automotive electrical technology field for low cost, long life shielded cables and connector assemblies with novel shielding materials. Summary of the Invention

[0006] The present application aims to provide a technical solution for a connector assembly using a new type of shielding material.

[0007] In a first aspect of the present application, there is provided a connector assembly of a new shielding material, comprising an electrical connection skeleton and connectors connected to both ends of the electrical connection skeleton, the connectors including connection terminals and an inner shell having a shielding function, both ends of the electrical connection skeleton being electrically connected to the connection terminals, the outer periphery of the electrical connection skeleton being covered by an insulating layer, conductive particles being radially contained in the insulating layer, and the conductive particles being distributed with non-uniform density in at least one location within the insulating layer.

[0008] In a second aspect of the present application, there is provided a vehicle including a connector assembly of the new shielding material described above.

[0009] The beneficial effects of the present invention are as follows:

[0010] 1. The use of a rigid electrical connection framework allows for a smaller cable diameter, lighter cable weight, easier cable installation, and reduced friction with the vehicle body shell, thereby extending the service life of the connector assembly.

[0011] 2. The insulating layer contains conductive particles in the radial direction, which can provide shielding function. By using it instead of braided shielding net, the use of shield braiding equipment is reduced, the site area is reduced, the processing cost of the cable is reduced, the weight of the cable is reduced, the production process is simplified, the production cycle is shortened, and the production cost of the connector assembly is reduced.

[0012] 3. Conductive particles are sandwiched between the inner and outer surfaces of the insulating layer. In this case, the inner and outer surfaces of the insulating layer perform an insulating function, and the conductive layer formed by the conductive particles performs a shielding function. Therefore, there is no need to install a separate shielding net on the outside of the insulating layer, simplifying the production process and eliminating the need for additional production equipment, thereby improving production efficiency.

[0013] 4. A shield connection device is provided between the inner shell and the conductive layer formed by the conductive particles. The conductive layer and the shield connection device are first fixed and electrically connected, and then the shield connection device can be assembled in contact with the inner shell so as to be electrically connected. This improves the stability of the shield connection and reduces the difficulty of processing. It also ensures that the connection between the conductive layer in the insulating layer and the inner shell is stronger and the shielding effect is better.

[0014] 5. By ensuring that the conductive particles are distributed non-uniformly in at least one location within the insulating layer, a directional insulating layer can be arranged according to the EMC (electromagnetic compatibility) requirements of the entire vehicle. When shielding requirements are met, insulating layers with a low conductive particle density can be used in some locations, which can result in significant cost savings.

[0015] Other features and advantages of the present application will become apparent from the following detailed description of exemplary embodiments of the present application, taken in conjunction with the accompanying drawings, in which: [Brief description of the drawings]

[0016] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the present application and, together with the description, serve to explain the principles of the present application. [Figure 1] 1 is a schematic structural diagram of a connector assembly of the new shielding material of the present application. [Diagram 2] A cross-sectional view showing the connection between the inner shell and conductive particles in a connector assembly of the new shielding material of the present application. [Diagram 3] A cross-sectional view showing the connection between an inner shell and conductive particles in a connector assembly of another new type of shielding material according to the present application. [Figure 4] 1 is a schematic structural diagram of a shield connection device in a connector assembly of the new shielding material of the present application. [Diagram 5] 1 is a structural schematic diagram of another shield connection device of a connector assembly of the new shielding material of the present application. FIG. [Figure 6] FIG. 2 is an axial cross-sectional view showing that the insulating layer according to the present application covers the electrical connection framework. [Figure 7] FIG. 2 is a radial cross-sectional view showing that the insulating layer according to the present application covers the electrical connection framework. [Figure 8] FIG. 2 is a radial cross-sectional view showing that the shield connection device of the present application covers an electrical connection framework with an insulating layer. [Explanation of symbols]

[0017] 1 electrical connection skeleton; 2 connector; 3 insulating layer; 4 inner shell; 5 connection terminal; 6 shield connection device; 31 conductive particle; 32 notch; 21 protrusion; 61 insertion portion; 62 contact portion. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] The following clearly and completely describes the technical solutions in the embodiments of the present application with reference to the accompanying drawings of the embodiments of the present application, but it is obvious that the described embodiments are only some of the embodiments of the present application, and not all of the embodiments. Based on the embodiments of the present application, all other embodiments that a person skilled in the art can obtain without any creative efforts are within the scope of protection of the present application.

[0019] As shown in Figures 1 to 8, the connector assembly of the new shielding material of the present application includes an electrical connection skeleton 1 and a connector 2 connected to both ends of the electrical connection skeleton 1, the connector 2 including a connection terminal 5 and an inner shell 4 having a shielding function, both ends of the electrical connection skeleton 1 being electrically connected to the connection terminals 5, the outer periphery of the electrical connection skeleton 1 being covered with an insulating layer 3, the insulating layer 3 containing conductive particles 31 in the radial direction, and the conductive particles 31 being distributed with a non-uniform density in at least one location within the insulating layer.

[0020] In practical implementation, in order to reduce the effects of electromagnetic interference, conductive cables are usually shielded against electromagnetic interference by a shielding net. At present, the shielding nets commonly used are made of braided metal wires. Therefore, a shielding braiding machine needs to be added to the cable production equipment. This increases the cost of the equipment, the site area, and the number of production steps, resulting in the price of the shielded cable remaining high.

[0021] The electrical connection framework 1 is generally used for transmitting large currents inside a vehicle, and generates a large electromagnetic field when current flows. The electromagnetic field generated by the large current must be electromagnetically shielded to prevent electromagnetic interference with electrical equipment inside the vehicle from affecting the normal operation of other electrical equipment. A data communication cable is like the opposite, transmitting electromagnetic signals inside. The electromagnetic signals are distorted by interference from external electromagnetic fields, making it impossible to transmit signals effectively. Therefore, an electromagnetic shield is required to shield against interference from external electromagnetic fields.

[0022] In electromagnetic shielding, the shielding body is mainly used to prevent the influence of high-frequency electromagnetic fields, thereby effectively controlling the radiation and propagation of electromagnetic waves from one area to another. The basic principle is as follows. The shielding body is made of a conductive material with a low resistance value, and exhibits a shielding function by reflecting electromagnetic waves on the surface of the shielding body, absorbing electromagnetic waves inside the shielding body, and dissipating electromagnetic waves during the transmission process. In addition to the electrical connection skeleton 1, the connection positions of the electrical connection skeleton 1 with the connector 2 and the connection positions with the connection terminal 5 are also positions where electromagnetic shielding is specially performed. Both ends of the electrical connection skeleton 1 in this application are connected to one connector 2 and one connection terminal 5, respectively, and the connection positions are provided in the inner shell 4, and the inner shell 4 is electrically connected to the conductive layer formed by the conductive particles 31 in the insulating layer 3 outside the electrical connection skeleton 1. This provides a complete shielding effect.

[0023] In order to simplify the production process, reduce the wire diameter of the cable, and reduce the production cost, the present application provides an insulating layer containing conductive particles in the radial direction, and the conductive particles form a conductive layer. In this case, the conductive layer has a shielding function. By using it instead of a braided shielding net, the use of shielding braiding equipment is reduced, the site area is reduced, the processing cost of the cable is reduced, the weight of the cable is reduced, the production process is simplified, the production cycle is shortened, and the production cost of the connector assembly is reduced. Conductive particles 31 are sandwiched between the inner and outer surfaces of the insulating layer 3. In this case, the inner and outer surfaces of the insulating layer 3 perform an insulating function, and the conductive layer formed by the conductive particles 31 has a shielding function. Therefore, there is no need to provide a separate shielding net on the outside of the insulating layer 3, and the production process is simplified, and there is no need to add many facilities, and the production efficiency is improved.

[0024] In one embodiment of the connector assembly of the new shielding material of the present application, the material of the connection terminals 5 includes copper or copper alloy, the material of the electrical connection framework 1 includes aluminum or aluminum alloy, and the electrical connection framework 1 is electrically connected to the connection terminals by welding or crimping.

[0025] In a specific implementation, copper or copper alloy has high electrical conductivity and excellent abrasion resistance. Moreover, currently, the material of the power connection part in most power consumption devices is copper, so it is necessary to use the connection terminal 5 made of copper or copper alloy for insertion and removal connection. The connection terminal 5 can be widely applied to various power transmission situations. The electrical connection framework 1 made of aluminum or aluminum alloy has the advantages of good rigidity, light weight, and high transmission efficiency, and is therefore particularly suitable for transmitting large currents.

[0026] Instead of the copper conductor commonly used in the prior art, pure aluminum or an aluminum alloy with an aluminum content of 90% or more is used. Since the density of aluminum is only one-third of that of copper, and the resistivity of solid conductors varies depending on electrical performance, on the premise that the same conductive performance is satisfied, the wire diameter ratio between aluminum and copper is only 1.28 times different, and when the current capacity is the same, the weight of the aluminum material is only half that of copper. The weight of the wire material can be greatly reduced without expanding the cable mounting space inside the vehicle, which is advantageous for realizing a lighter vehicle body. Moreover, by using an aluminum conductor (aluminum core or its alloy material) with a low density and low material price instead of a copper conductor with a high density and high material price, the material cost and transportation cost can be reduced, and the production cost of the automobile can be saved. Preferably, the aluminum alloy is an aluminum copper alloy, an aluminum magnesium alloy, an aluminum lithium alloy, an aluminum manganese alloy, an aluminum zinc alloy, or an aluminum silicon alloy with an aluminum content of 90% or more.

[0027] The electrical connection framework 1 is connected to the connection terminal 5 by welding, and the welding method includes one or more of resistance welding, friction welding, ultrasonic welding, arc welding, laser welding, electron beam welding, pressure diffusion welding, and magnetic induction welding. That is, by concentrating thermal energy or pressure, a fusion connection is generated at the contact position between the connection terminal 5 and the electrical connection framework 1. The welding method can realize a strong connection and can also realize a connection between different materials. In addition, since the connection position is fused, the conductive effect is even better.

[0028] Resistance welding is a method in which a strong electric current flows through the contact point between an electrode and a workpiece, causing the contact resistance to generate heat and thus achieve welding.

[0029] Friction welding is a welding method that uses heat generated by friction on the contact surfaces of the workpieces as a heat source to plastically deform the workpieces through the application of pressure.

[0030] Ultrasonic welding is a method of welding two objects by transmitting high frequency vibration waves to the surfaces of the objects to be welded, which when pressurized causes the surfaces of the two objects to rub against each other, forming a fusion between the molecular layers.

[0031] Arc welding is a method of connecting metals by using an arc as a heat source and converting electrical energy into the thermal and mechanical energy required for welding through the physical phenomenon of air discharge. The main methods include shielded metal arc welding, submerged arc welding, and gas shielded welding.

[0032] Laser welding is a highly efficient precision welding method that uses a laser beam with high energy density as a heat source.

[0033] Friction welding is a welding method that uses heat generated by friction on the contact surfaces of the workpieces as a heat source to plastically deform the workpieces through the application of pressure.

[0034] Electron beam welding is a method of achieving welding by using an accelerated and focused electron beam to impact a welding surface placed in a vacuum or non-vacuum, thereby melting the workpieces to be welded.

[0035] The pressure welding method is a method in which pressure is applied to the solder members to bring the joining surfaces into intimate contact with each other, causing a certain degree of plastic deformation to occur, thereby completing the welding.

[0036] Magnetic induction welding is a method in which two workpieces to be welded are instantaneously collided at high speed under the action of a strong pulsed magnetic field, and the atoms of the two materials meet within the interatomic distance under the action of a very high pressure wave on the surface of the materials, forming a stable metallurgical bond at the interface. This magnetic induction welding is a type of solid-state cold welding, and can be used to weld conductive metals with similar or dissimilar properties together.

[0037] In the crimp connection method, the crimping is a production process in which the electrical connection framework 1 and the connection terminal 5 are assembled and then integrated and pressed together using a crimping machine. Crimp connection has the advantage of being suitable for mass production, and by using an automatic crimping machine, products with stable quality can be manufactured quickly and in large quantities.

[0038] In one embodiment of the connector assembly of the new shielding material of the present application, the electrical connection skeleton is rigid, and the tensile strength of the electrical connection skeleton is greater than 75 MPa.

[0039] Currently, most connector assemblies generally use multi-core copper cables for charging cables, but their weight and high price are obstacles that limit the popularization of new energy vehicles. In addition, multi-core cables are soft and can be easily processed and wired, but their wire diameter is too thick and their weight is too heavy, so that the cable frequently rubs against the body shell of the vehicle during the vehicle's running process, causing the insulation layer in the cable to be damaged and high-voltage discharge to occur, resulting in damage to the vehicle in a minor case and a terrible traffic accident in a major case. Therefore, in this application, instead of the structure of a multi-core cable, a cable aspect of the rigid electrical connection framework 1 is used, so that the cable can be fixed to the body shell and will not rub against the body shell due to the vibration of the vehicle, thereby extending the service life of the connector and reducing the occurrence of accidents. The electrical connection framework 1 may be a single-core copper bar, an aluminum bar, or an aluminum tape.

[0040] A rigid body is an object whose shape and size remain unchanged during the process of movement or after it is subjected to a force, and whose relative positions of each point inside it do not change. An absolutely rigid body does not actually exist, but is merely an ideal model. This is because any object will deform more or less after it is subjected to a force. If the degree of deformation is extremely small compared to the geometric dimensions of the object itself, it can be ignored when considering the movement of the object. Therefore, the electrical connection skeleton 1 made of a rigid material is so extremely small that the amount of deformation that occurs during use can be ignored. The greater the tensile strength of the rigid body, the smaller the amount of deformation.

[0041] In order to verify the influence of the tensile strength of the electrical connection skeleton 1 on the tensile force value when the electrical connection skeleton 1 is tensile broken, the torque when it is bent, and whether or not abnormal noise occurs during the vibration process, the inventors selected samples of the electrical connection skeleton 1 having the same dimensional specifications but different tensile strengths, and performed tests on the tensile force value when the electrical connection skeleton 1 is tensile broken, the torque when it is bent, and whether or not abnormal noise occurs during the vibration process.

[0042] The test method for the tensile strength of the electrical connection framework 1 is as follows: Using a universal tensile tester, both ends of the electrical connection framework 1 are fixed to the tensile jig of the universal tensile tester, and the electrical connection framework 1 is pulled at a speed of 50 mm / min, and the tensile strength value at the time of final tensile break is recorded. In this embodiment, the acceptable value for the tensile strength value is set to be more than 1600 N.

[0043] The method for testing the torque of the electrical connection skeleton 1 is as follows. Using a torque tester, the electrical connection skeleton 1 is bent 90° at the same radius and speed, and a test is performed on the torque value required to deform the electrical connection skeleton 1 during the bending process. In this embodiment, the preferred torque value is set to less than 60 N·m.

[0044] The test method for whether the electrical connection framework 1 generates abnormal noise is as follows: Select samples of the electrical connection framework 1 with the same dimensions but different tensile strengths, assemble them with connectors 2 of the same specifications, and then fix them on a vibration test stand. During the vibration test, observe whether the electrical connection framework 1 generates abnormal noise.

[0045] [Table 1]

[0046] As can be seen from Table 1 above, when the tensile strength of the electrical connection skeleton 1 is less than 75 MPa, the tensile force value at which the electrical connection skeleton 1 is tensile-broken is less than 1600 N. In this case, the strength of the electrical connection skeleton 1 itself is not high and it is prone to tensile breakage when subjected to a small external force, so that the electrical connection skeleton 1 cannot perform its function and the purpose of transmitting electrical energy cannot be achieved.

[0047] On the other hand, the greater the tensile strength of the electrical connection skeleton 1, the less likely the electrical connection skeleton 1 is to be deformed, and therefore, in the course of the vibration test, it is also less likely that the electrical connection skeleton 1 will generate abnormal sounds due to vibrations caused by the connectors 2 connected to both ends. In other words, the smaller the tensile strength of the electrical connection skeleton 1, the more likely the electrical connection skeleton 1 is to be deformed, and therefore, in the course of the vibration test, it is also more likely that the electrical connection skeleton 1 will generate abnormal sounds due to vibrations caused by the connectors 2 connected to both ends. From Table 1 above, it is clear that, when the tensile strength of the electrical connection skeleton 1 is 75 MPa or less, the electrical connection skeleton 1 will generate abnormal sounds in the course of the vibration test. For this reason, the inventor considers it preferable that the tensile strength of the electrical connection skeleton 1 exceeds 75 MPa.

[0048] At the same time, as can be seen from Table 1, when the tensile strength of the electrical connection skeleton 1 exceeds 480 MPa, the torque value when the electrical connection skeleton 1 is bent 90 degrees exceeds 60 N·m, and at that time, the electrical connection skeleton 1 is difficult to bend. Therefore, the inventor further states that it is preferable that the tensile strength of the electrical connection skeleton 1 exceeds 75 MPa and is 480 MPa or less.

[0049] In one embodiment of the connector assembly of the new shielding material of the present application, at least a portion of the electrical connection framework 1 includes a flexible body, which is a multi-core cable, a braided cable, or a flexible flat cable made of laminated multi-layer thin plates.

[0050] In a specific embodiment, the flexible body portion of the electrical connection framework 1 may be configured as a multi-core cable, a braided cable, or a flexible flat cable formed by laminating multi-layer thin plates. This facilitates wiring processing when mounting the electrical connection framework 1 on the body of an automobile. In this case, the electrical connection framework 1 has excellent bendability, making it convenient to mount and store.

[0051] In one embodiment of the connector assembly using the new shielding material of the present application, the material of the insulating layer 3 is selected from the group consisting of tetraphenylethylene, polyvinyl chloride, polyethylene, polyamide, polytetrafluoroethylene, tetrafluoroethylene-hexafluoropropene copolymer, ethylene-tetrafluoroethylene copolymer, polypropylene, polyvinylidene fluoride, polyurethane, polyethylene terephthalate, polyurethane elastomer, styrene block copolymer, perfluoroalkoxyalkane, chlorinated polyethylene, polyphenylene sulfide, polystyrene, crosslinked polyolefin, ethylene propylene rubber, ethylene-vinyl acetate copolymer, chloroprene rubber, and tetrafluoroethylene. The rubber may be one or more of natural rubber, styrene butadiene rubber, nitrile rubber, silicone rubber, butadiene rubber, isoprene rubber, ethylene propylene rubber, butyl rubber, fluororubber, polyurethane rubber, polyacrylate rubber, chlorosulfonated polyethylene rubber, epichlorohydrin rubber, chlorinated polyethylene rubber, sulfur chloride rubber, styrene butadiene rubber, butadiene rubber, hydrogenated nitrile rubber, polysulfide rubber, cross-linked polyethylene, polycarbonate, polysulfone, polyphenylene ether, polyester, phenolic resin, urea formaldehyde, styrene-acrylonitrile copolymer, polymethacrylate, and polyoxymethylene resin.

[0052] The following describes the properties of the materials with examples.

[0053] Polyoxymethylene is a smooth, glossy, hard and dense material with a light yellow or white color, and can be used for a long period of time within the temperature range of -40°C to 100°C. Compared with most engineering plastics, polyoxymethylene has excellent wear resistance and self-lubrication, as well as good oil resistance and peroxide resistance.

[0054] Polycarbonate is colorless and transparent, has heat and impact resistance, is flame-retardant BI grade, and exhibits good mechanical properties at normal use temperatures. Compared to polymethyl methacrylate, which has similar properties, polycarbonate has superior impact resistance, a high refractive index, good processing properties, and can exhibit high flame retardancy without the need for additives.

[0055] Polyamides are non-toxic, lightweight, have good mechanical strength, and have excellent wear and corrosion resistance, and may be used to manufacture bearings, gears, pump blades and other parts in the machinery, chemical, instrument, automotive and other industries, replacing metals such as copper.

[0056] In one embodiment of the connector assembly of the novel shielding material of the present application, the material of the conductive particles 31 includes one or more of metal, conductive ceramic, carbon-containing conductor, solid electrolyte, and mixed conductor.

[0057] In a specific implementation, conductive particles 31 are incorporated into the polymer material to form a conductive plastic. An insulating layer 3 is integrally molded on both sides of the conductive plastic. Since the conductive plastic has conductive properties, the insulating layer can perform a shielding function, that is, it has the greatest advantages of having a shielding function, being low-cost, simple and practical, and having a wide range of applications. The insulating layer contains conductive particles to perform a shielding function. By using it instead of the braided shielding net, the use of shielding braiding equipment is reduced, the site area is reduced, the processing cost of the cable is reduced, the weight of the cable is reduced, the production process is simplified, the production cycle is shortened, and the production cost of the connector assembly is reduced.

[0058] Further, the metallic material may include one or more of gold, silver, copper, nickel, titanium, tin, aluminum, cadmium, zirconium, chromium, cobalt, manganese, zinc, phosphorus, tellurium, beryllium, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, or silver-gold-zirconium alloy.

[0059] In order to verify the effect of different metal materials on the conductivity of the conductive particles 31 in the insulating layer 3, the inventors conducted tests using the insulating layer 3 with the conductive particles 31 attached. Specifically, the inventors produced samples of the insulating layer 3 using conductive particles 31 with the same specifications and dimensions but different materials, and tested the conductivity of each. The test results are shown in Table 2 below. In this example, the ideal value of the conductivity of the conductive plastic is set to be over 99%.

[0060] [Table 2]

[0061] As can be seen from Table 2 above, the electrical conductivity of the insulating layer 3 made of the selected different conductive particles is within the ideal range. In addition, phosphorus is a non-metallic material and cannot be directly used as the material of the conductive layer, but it can be added to other metals to form an alloy, which can improve the conductive performance and mechanical performance of the metal itself. Therefore, the inventors set the metal material of the conductive particles to include one or more of gold, silver, copper, nickel, titanium, tin, aluminum, cadmium, zirconium, chromium, cobalt, manganese, zinc, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, or silver-gold-zirconium alloy.

[0062] Additionally, the carbon-containing conductor includes one or more of graphite powder, carbon nanotube material, graphene material, graphite silver, or graphene silver.

[0063] Graphite powder is a mineral powder whose main component is soft, dark gray carbon. Graphite powder is a good nonmetallic conductive material. Carbon nanotubes have good conductive properties. The structure of carbon nanotubes is the same as the sheet structure of graphite, so they have good electrical properties. Graphene has even higher electrical properties. The carbon-containing conductors containing these five materials have high electrical conductivity and good shielding properties, so they can better realize electromagnetic shielding for the electrical connection framework 1.

[0064] In one embodiment of the connector assembly using the new shielding material of the present application, the space factor of the conductive particles 31 in the insulating layer 3 is 3.5% to 95%.

[0065] If the ratio of the volume of the conductive particles 31 to the volume of the insulating layer 3 is too small, the conductivity is insufficient and an ideal shielding effect cannot be obtained. Therefore, the inventors conducted tests on insulating layers with different conductive particle volume fractions. A conductive particle conductivity of less than 99% was deemed to be unsuccessful. The test results are shown in Table 3.

[0066] [Table 3]

[0067] As can be seen from Table 3, when the space factor of the conductive particles in the insulating layer is less than 3.5%, the conductivity of the conductive particles 31 in the insulating layer 3 is less than 99%, and the requirements cannot be met. When the space factor of the conductive particles 31 in the insulating layer 3 exceeds 95%, the conductivity does not increase and the required process becomes increasingly complicated. For this reason, the inventors consider that the suitable space factor of the conductive particles in the insulating layer 3 is 3.5% to 95%.

[0068] In one embodiment of the connector assembly of the new shielding material of the present application, the maximum diameter of the conductive particles 31 occupies 0.1% to 97% of the thickness of the insulating layer 3 .

[0069] If the proportion of the maximum diameter of a single conductive particle 31 is too large, the conductive particle 31 is likely to puncture the insulating layer, so that the inner and outer surfaces of the insulating layer will not have an insulating effect. Therefore, the inventors conducted tests on insulating layers 3 made of conductive particles 31 with different diameters.

[0070] The test method for the insulation performance of the insulating layer 3 is as follows: Using an insulation withstand voltage tester, different AC or DC high voltages are applied between the conductive particles 31 and the inner surface of the insulating layer 3, and between the conductive particles 31 and the outer surface of the insulating layer 3, to test the withstand voltage capability of the insulating layer 3 on the outside of the electrical connection framework 1. If the breakdown voltage of the insulating layer 3 is less than 2.1 KV, it is considered to be unsuccessful. The test results are shown in Table 4.

[0071] [Table 4]

[0072] As can be seen from Table 4, when the ratio of the diameter of the conductive particles 31 to the thickness of the insulating layer 3 is less than 97%, the breakdown voltage of the insulating layer 3 exceeds 2.1 KV, which satisfies the requirement, and when the ratio of the diameter of the conductive particles 31 to the thickness of the insulating layer 3 exceeds 97%, the breakdown voltage of the insulating layer 3 is less than 2.1 KV, which does not satisfy the requirement. Therefore, the maximum diameter of the conductive particles 31 occupies 97% of the thickness of the insulating layer 3. In addition, when the ratio of the diameter of the conductive particles to the thickness of the insulating layer 3 is less than 0.1%, it is difficult to manufacture and it is difficult to further increase the breakdown voltage. Therefore, the inventor selects the maximum diameter of the conductive particles 31 to occupy 0.1% to 97% of the thickness of the insulating layer 3.

[0073] In one embodiment of the connector assembly of the novel shielding material of the present application, the conductive particles 31 in the insulating layer 3 conduct electricity in the axial direction of the electrical connection framework 1 .

[0074] In a specific implementation, the conductive particles 31 in the insulating layer 3 are configured to conduct electricity in the axial direction of the electrical connection skeleton 1, thereby ensuring that the magnetic field generated by the current during use of the electrical connection skeleton 1 is shielded, and the shielding function of the conductive particles is also ensured, thereby avoiding any impact on the use of other electrical equipment.

[0075] In one embodiment of the connector assembly of the new shielding material of the present application, the conductive particles 31 in the insulating layer 3 conduct electricity in the circumferential direction of the electrical connection framework 1 .

[0076] In a specific implementation, the conductive particles 31 in the insulating layer 3 are made to conduct electricity in the circumferential direction of the electrical connection skeleton 1, thereby ensuring that the conductive particles surround the electrical connection skeleton 1 to form a closed loop, and also ensuring that the magnetic field generated by the current can be shielded during use of the electrical connection skeleton 1.

[0077] In a specific implementation, the conductive particles 31 are constantly sandwiched between the inner and outer surfaces of the insulating layer 3, and the conductive particles 31 are arranged in a cylindrical shape between the inner and outer surfaces of the insulating layer 3, so that the magnetic field generated during use of the electrical connection framework 1 fitted thereto by the insulating layer 3 can be completely shielded.

[0078] In one embodiment of the connector assembly of the novel shielding material of the present application, the transfer impedance of the conductive particles 31 in the insulating layer 3 in the axial direction of the electrical connection framework 1 is less than 100 mΩ.

[0079] In general, the shielding effect of an insulating layer 3 is expressed by the transfer impedance of the conductive particles 31 in the insulating layer 3. The smaller the transfer impedance, the better the shielding effect. The transfer impedance of an insulating layer 3 is defined as the ratio of the differential mode voltage U induced in the shield per unit length to the current Is flowing through the shield surface, i.e., Zt=U / Is.

[0080] Therefore, the transfer impedance of the insulating layer 3 may be understood as the conversion of the current carried by the conductive particles 31 into differential mode interference. The smaller the transfer impedance, the better, i.e., the better the shielding performance, by reducing the conversion of differential mode interference.

[0081] In order to verify the influence of conductive particles 31 having different transfer impedances on the shielding effect, the inventor selected an electrical connection framework 1, a connector 2, and a connection terminal 5 having the same specifications, manufactured a series of samples using conductive particles 31 having different transfer impedances, and performed tests on the shielding effect of each. The test results are shown in Table 5 below. In this embodiment, the ideal value of the shielding performance value is exceeded by 40 dB.

[0082] The shielding performance value is tested as follows: The test device outputs one signal value to the electrical connection structure 1 (this value is called test value 2). A detector is installed on the outside of the insulating layer 3, and the detector detects one signal value (this value is called test value 1).

[0083] Shielding performance value = test value 2 - test value 1.

[0084] [Table 5]

[0085] As can be seen from Table 5 above, when the transfer impedance of the conductive particles 31 in the insulating layer 3 exceeds 100 mΩ, the shielding performance value of the insulating layer 3 is less than 40 dB, which is not preferable as an ideal value. On the other hand, when the transfer impedance of the conductive particles 31 in the insulating layer 3 is less than 100 mΩ, the shielding performance value of the insulating layer 3 satisfies all the requirements for the ideal value and tends to get better. Therefore, the inventor sets the transfer impedance of the conductive particles 31 in the insulating layer 3 to be less than 100 mΩ.

[0086] In one embodiment of the connector assembly of the novel shielding material of the present application, the dielectric strength value for the conductive particles on the inner and outer surfaces of the insulating layer 3 is greater than 2.1 KV.

[0087] In a specific implementation, the operating voltage of the electrical connection framework 1 is in the range of 500V to 600V, and the detection voltage for the insulating layer 3 is generally three times the operating voltage, so the inventors select the dielectric strength values ​​on the inner and outer surfaces of the insulating layer 3 to be greater than 2.1KV, thereby ensuring that the insulating layer will not break down due to high voltage during use.

[0088] In one embodiment of the connector assembly of the novel shielding material of the present application, the material of the inner shell 4 includes a conductive metal or a polymeric material containing conductive particles.

[0089] Further, the material of the conductive particles includes one or more of metals, conductive ceramics, carbon-containing conductors, solid electrolytes, and mixed conductors, and the material of the polymer material includes tetraphenylethylene, polyvinyl chloride, polyethylene, polyamide, polytetrafluoroethylene, tetrafluoroethylene-hexafluoropropene copolymer, ethylene-tetrafluoroethylene copolymer, polypropylene, polyvinylidene fluoride, polyurethane, polyethylene terephthalate, polyurethane elastomer, styrene block copolymer, perfluoroalkoxyalkane, chlorinated polyethylene, polyphenylene sulfide, polystyrene, crosslinked polyolefin, ethylene propylene rubber, ethylene-vinyl acetate, and the like. copolymer, chloroprene rubber, natural rubber, styrene butadiene rubber, nitrile rubber, silicone rubber, butadiene rubber, isoprene rubber, ethylene propylene rubber, butyl rubber, fluororubber, polyurethane rubber, polyacrylate rubber, chlorosulfonated polyethylene rubber, epichlorohydrin rubber, chlorinated polyethylene rubber, sulfur chloride rubber, styrene butadiene rubber, butadiene rubber, hydrogenated nitrile rubber, polysulfide rubber, crosslinked polyethylene, polycarbonate, polysulfone, polyphenylene ether, polyester, phenolic resin, urea formaldehyde, styrene-acrylonitrile copolymer, polymethacrylate, polyoxymethylene resin.

[0090] In a specific implementation, polymeric materials containing different conductive particles may be selected as needed.

[0091] Furthermore, the metallic material of the conductive particles may include one or more of gold, silver, copper, nickel, titanium, tin, aluminum, cadmium, zirconium, chromium, cobalt, manganese, zinc, phosphorus, tellurium, beryllium, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, or silver-gold-zirconium alloy.

[0092] In order to verify the influence of different conductive particles on the conductivity of the inner shell 4, the inventors conducted tests using the inner shell 4. Specifically, the inventors manufactured samples of the inner shell 4 using conductive particles of different materials, but with the same specifications and dimensions, and conducted tests on the conductivity of each. The test results are shown in Table 6 below. In this embodiment, the conductivity of the inner shell 4 is said to exceed the ideal value by 99%.

[0093] [Table 6]

[0094] As can be seen from Table 5 above, the conductivity of the inner shell 4 made of the selected different conductive particles is within the ideal range. In addition, phosphorus is a non-metallic material and cannot be directly used as the material of the inner shell, but it can be added to other metals to form an alloy, which can improve the conductive performance and mechanical performance of the metal itself. Therefore, the inventors set the material of the conductive particles to include one or more of gold, silver, copper, nickel, titanium, tin, aluminum, cadmium, zirconium, chromium, cobalt, manganese, zinc, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, or silver-gold-zirconium alloy.

[0095] Further, the carbon-containing conductor of the conductive particles includes one or more of graphite, carbon nanotube material, graphene material, graphite silver, or graphene silver.

[0096] Graphite powder is a mineral powder whose main component is soft, dark gray carbon. Graphite powder is a good nonmetallic conductive material. Carbon nanotubes have good conductive properties. The structure of carbon nanotubes is the same as the sheet structure of graphite, so they have good electrical properties. Graphene has even higher electrical properties. The carbon-containing conductor containing these five materials has high electrical conductivity and good shielding properties, so it can better realize electromagnetic shielding for the connection terminal 5.

[0097] In one embodiment of the connector assembly of the new shielding material of the present application, as shown in Figs. 2 to 5, the inner shell 4 is electrically connected to the conductive particles.

[0098] In concrete implementation, the inner shell 4 is electrically connected to the conductive layer formed by adding conductive particles in the insulating layer 3, thereby shielding the electromagnetic interference generated during the use of the electrical connection skeleton 1, and preventing it from affecting the normal use of electronic devices such as other control systems. This prevents the control system from failing to function due to electromagnetic interference, resulting in traffic accidents, property damage, and even injury and death to personnel.

[0099] In one embodiment of a connector assembly using the new shielding material of the present application, as shown in Figures 2 and 3, a notch 32 is provided in at least a portion of the insulating layer 3 located within the connector 2, the conductive particles 31 are exposed within the notch 32, and a protrusion 21 is provided at a corresponding position on the inner shell 4, the protrusion 21 is connected to match the notch 32 and is electrically connected to the conductive particles.

[0100] In a specific implementation, the inner shell 4 is generally attached and integrated inside the housing of the connector 2. In one embodiment, the inner shell 4 may be made of conductive plastic material and injection molded together with the case of the connector 2. When assembling the electrical connection skeleton 1 and the connector 2, the inner shell 4 is connected to the conductive layer formed by adding conductive particles in the insulating layer 3, and a notch 32 is provided in the insulating layer 3, and a protrusion 21 is provided at a corresponding position on the inner shell, so that the protrusion 21 and the notch 32 can realize an electrical connection between the inner shell 4 and the conductive layer formed by the conductive particles 31. This makes it possible to shield electromagnetic interference generated during the use of the electrical connection skeleton 1.

[0101] In a specific implementation, the conductive layer formed by the conductive particles 31 in the notches 32 may be protruded to form protrusions on the outer surface of the insulating layer 3, and a groove may be provided corresponding to the inner shell 4, and the electrical connection between the groove and the protrusion may be used to realize the electrical connection between the conductive layer and the inner shell 4. This can also provide a function of shielding electromagnetic interference generated during the use of the electrical connection framework 1.

[0102] In order to make the contact between the inner shell 4 and the conductive layer more complete, thereby making the shielding function of the connector 2 more complete and improving the shielding effect, the notch or protrusion in the insulating layer 3 for exposing the conductive particles may be an annular groove or annular protrusion, making the electrical connection between the two more stable and sufficient.

[0103] In one embodiment of the connector assembly of the new shielding material of the present application, the impedance between the conductive particles 31 and the inner shell 4 is less than 80mΩ.

[0104] In order to verify the influence of the impedance between the conductive layer formed of the conductive particles 31 and the inner shell 4 on the shielding effect, the inventor selected an electrical connection skeleton 1, a connector 2, an inner shell 4, and a connection terminal 5 having the same specifications, manufactured a series of samples using different impedances between the conductive particles 31 and the inner shell 4, and performed tests on the shielding effect of each. The test results are shown in Table 7 below. In this embodiment, the ideal value of the shielding performance value is set to be 40 dB more than the ideal value.

[0105] The shielding performance value is tested as follows: The test device outputs one signal value to the electrical connection framework 1 (this value is called test value 2). A detector is installed on the outside of the inner shell 4, and the detector detects one signal value (this value is called test value 1).

[0106] Shielding performance value = test value 2 - test value 1.

[0107] [Table 7]

[0108] As can be seen from Table 7, when the impedance between the conductive particles 31 and the inner shell 4 exceeds 80 mΩ, the shielding performance value is less than 40 dB, which is not preferable as an ideal value. On the other hand, when the impedance between the conductive particles 31 and the inner shell 4 is less than 80 mΩ, the shielding performance value satisfies all the requirements for the ideal value and tends to get better. Therefore, the inventor sets the impedance between the conductive particles 31 and the inner shell 4 to be less than 80 mΩ.

[0109] In one embodiment of the connector assembly of the new shielding material of the present application, the transfer impedance of the inner shell 4 is less than 100 mΩ.

[0110] In order to verify the influence of the inner shell 4 having different transfer impedance on the shielding effect, the inventor selected the electrical connection framework 1, the connector 2, and the connection terminal 5 having the same specifications, manufactured a series of samples using the inner shell 4 having different transfer impedance, and performed tests on the shielding effect of each. The test results are shown in Table 8 below. In this embodiment, the ideal value of the shielding performance value is exceeded by 40 dB.

[0111] The shielding performance value is tested as follows: The test device outputs one signal value to the electrical connection framework 1 (this value is called test value 2). A detector is installed on the outside of the inner shell 4, and the detector detects one signal value (this value is called test value 1).

[0112] Shielding performance value = test value 2 - test value 1.

[0113] [Table 8]

[0114] As can be seen from Table 7 above, when the transfer impedance of the inner shell 4 exceeds 100 mΩ, the shielding performance value within the inner shell 4 is less than 40 dB, which is not preferable as an ideal value. On the other hand, when the transfer impedance of the inner shell 4 is less than 100 mΩ, the shielding performance value of the inner shell 4 satisfies all the requirements for the ideal value and tends to get better. Therefore, the inventor sets the transfer impedance of the inner shell 4 to be less than 100 mΩ.

[0115] In one embodiment of a connector assembly of the new shielding material of the present application, as shown in Figures 4 and 5, the connector 2 further includes a shield connection device 6, which has at least one insertion portion 61 and a contact portion 62, the insertion portion 61 being inserted along the outer peripheral surface of the insulating layer 3 and electrically connected to the conductive particles 31, and the contact portion 62 being electrically connected to the inner shell 4.

[0116] In a specific implementation, the shield connection device 6 is installed between the inner shell 4 and the conductive layer formed of the conductive particles 31 in the insulating layer 3, and is used to electrically connect the conductive layer and the inner shell 4, thereby shielding electromagnetic interference generated during the current-carrying process between the electrical connection framework 1 and the connection terminal 5. The shield connection device 6 can electrically connect the conductive layer and the inner shell 4 more firmly, and the shielding effect between them can be made more stable. This makes the shielding function of the connector 2 more complete, improving the shielding effect, and the installation of the shield connection device 6 can also reduce the difficulty of assembly between the inner shell 4 and the electrical connection framework 1.

[0117] Furthermore, the vertical length of the insertion portion 61 in the radial direction of the electrical connection framework 1 is smaller than the thickness of the insulating layer 3 .

[0118] In a specific implementation, the insert 61 is inserted into the insulating layer 3 and electrically connected to the conductive particles 31, but does not puncture the insulating layer 3.

[0119] Furthermore, as shown in Figures 4 and 8, the contact portion 62 is cylindrical, at least one insertion portion 61 is provided inside the cylinder, and the outer wall of the cylindrical contact portion 62 is electrically connected to the inner surface of the inner shell 4.

[0120] In a specific implementation, the contact portion 62 is a cylindrical conductive elastic piece, which is electrically connected to the inner shell 4 and exerts an elastic force on the inner shell 4, thereby making the connection between the inner shell 4 and the contact portion 62 tighter and preventing the occurrence of the detachment phenomenon, and making the shielding function of the connector 2 more complete, thereby improving the shielding effect.

[0121] Furthermore, as shown in FIG. 5, the contact portion 62 has a columnar shape, and the contact portion 62 is inserted into the inner shell 4 and electrically connected to the inner shell 4 .

[0122] In a specific implementation, a notch is provided at a corresponding position inside the inner shell 4, and the notch of the inner shell 4 is connected to the column-shaped contact portion 62, thereby ensuring a tighter connection between the shield connection device 6 and the inner shell 4, making the shielding function between the two more complete, and improving the shielding effect.

[0123] Furthermore, the contact portion 62 is an elastic piece, and at least a part of the outer surface of the elastic piece is electrically connected to the inner surface of the inner shell 4 .

[0124] In a specific implementation, the contact portion 62 is a conductive elastic piece, at least a part of which has elasticity, and the conductive elastic piece is electrically connected to the inner shell 4 to form a complete shield structure. The insert portion 61 is fixed and electrically connected to one end of the conductive elastic piece. The insert portion 61 is connected to a conductive layer formed of conductive particles 31. The other end of the conductive elastic piece is in contact with and electrically connected to the inner shell 4. The contact portion 62 has the insert portion 61 embedded in the conductive layer at both ends, and the conductive elastic piece protrudes in the middle, and the inner shell 4 is electrically connected to the protrusion position in the middle, and the outer diameter of the conductive elastic piece at the protruding position may be larger than the inner diameter at the position connected to the inner shell 4. Then, after the connector 2 is assembled, the conductive elastic piece is tightly connected to the inner shell 4 by elasticity.

[0125] Furthermore, the impedance between the shield connection device 6 and the conductive particles 31 is less than 80 mΩ, and the impedance between the shield connection device 6 and the inner shell 4 is less than 80 mΩ.

[0126] In order to verify the influence of the impedance between the shield connection device 6 and the conductive particles 31 on the shielding effect, the inventor selected the electrical connection framework 1, the connector 2, the inner shell 4, and the connection terminal 5 having the same specifications, and manufactured a series of samples using different impedances between the shield connection device 6 and the conductive particles 31, and performed tests on the shielding effect of each. The test results are shown in Table 9 below. In this embodiment, the ideal value of the shielding performance value is exceeded by 40 dB.

[0127] The shielding performance value is tested as follows: The test device outputs one signal value to the electrical connection framework 1 (this value is called test value 2). A detector is installed outside the shield connection device 6, and the detector detects one signal value (this value is called test value 1).

[0128] Shielding performance value = test value 2 - test value 1.

[0129] [Table 9]

[0130] As can be seen from the table, when the impedance between the shield connection device 6 and the conductive particles 31 exceeds 80 mΩ, the shielding performance value is less than 40 dB, which is not preferable as an ideal value. On the other hand, when the impedance between the shield connection device 6 and the conductive particles 31 is less than 80 mΩ, the shielding performance values ​​all meet the requirements for the ideal value and tend to become better. Therefore, the inventor sets the impedance between the shield connection device 6 and the conductive particles 31 to be less than 80 mΩ.

[0131] In a similar manner, the inventors set the impedance between the shield connection device 6 and the inner shell 4 to be less than 80 mΩ.

[0132] In one embodiment of the connector assembly of the new shielding material of the present application, the thickness of the insulating layer 3 is 0.1 mm to 3.8 mm.

[0133] FIG. 6 shows an axial cross-sectional view showing that the insulating layer 3 covers the electrical connection skeleton 1, and FIG. 7 shows a radial cross-sectional view showing that the insulating layer 3 covers the electrical connection skeleton 1. The thinner the insulating layer 3, the smaller the breakdown voltage that the insulating layer 3 can withstand. Conversely, the thicker the insulating layer 3, the larger the breakdown voltage that the insulating layer 3 can withstand, and if the insulating layer 3 breaks down, it will not be able to perform its insulating function. Therefore, the inventors have performed tests on insulating layers 3 with different thicknesses.

[0134] The test method for the insulation performance of the insulating layer 3 is as follows: Using an insulation withstand voltage tester, different AC or DC high voltages are applied between the electrical connection framework 1 and the insulating layer 3 to test the withstand voltage capability of the insulating layer 3 on the outside of the electrical connection framework 1. If the breakdown voltage of the insulating layer 3 is less than 2.1KV, it is considered a failure. The test results are shown in Table 10.

[0135] [Table 10]

[0136] As can be seen from Table 10, when the thickness ratio of the insulating layer 3 is less than 0.1 mm, the breakdown voltage of the insulating layer 3 is less than 2.1 KV, which cannot satisfy the requirement. And when the thickness ratio of the insulating layer 3 exceeds 3.8 mm, the increase in the breakdown voltage of the insulating layer tends to be gentle, and at the same time, the thickness of the insulating layer 3 increases, which increases the cost of raw materials. Moreover, the increase in the thickness of the insulating layer 3 necessarily increases the wire diameter, which makes it difficult to bend the cable. In that case, the increase in the thickness of the insulating layer 3 loses its practical meaning and cannot satisfy the requirement. Therefore, the inventor sets the thickness of the insulating layer to be 0.1 mm to 3.8 mm.

[0137] In one embodiment of the connector assembly of the new shielding material of the present application, the cross-sectional shape of the electrical connection skeleton 1 is one or more of a circle, an ellipse, a rectangle, a polygon, an A-shape, a B-shape, a D-shape, an M-shape, an N-shape, an O-shape, an S-shape, an E-shape, an F-shape, an H-shape, a K-shape, an L-shape, a T-shape, a U-shape, a V-shape, a W-shape, an X-shape, a Y-shape, a Z-shape, a P-shape, a semi-arc shape, an arc shape, and a wavy shape.

[0138] In specific implementation, the cross-sectional shape of the electrical connection framework 1 may be specifically designed according to the wiring space in the vehicle, which can facilitate the wiring process in the vehicle and the assembly of the vehicle by the operator.

[0139] In one embodiment of the connector assembly of the new shielding material of the present application, the cross-sectional shape of the electrical connection framework 1 is polygonal, and all corners of the polygon are chamfered or rounded.

[0140] In a specific implementation, all corners of the electrical connection framework 1, which has a polygonal cross-sectional shape, are chamfered or rounded, so that the electrical connection framework 1 and the connection terminal can be easily connected, and when the two are connected by welding or crimping, the connection between the electrical connection framework 1 and the connection terminal can be made stronger, and the contact area can be made wider to better conduct current. In addition, when the electrical connection framework 1 and the connection terminal are connected, the contact area is too small, which causes the resistance to be too large, and the occurrence of heat dissipation and even combustion accidents can be prevented. In addition, the margin formed by two adjacent sides of the polygon during use can also be prevented from puncturing the insulating layer, which can cause accidents in which personnel are injured or killed, and damage to property.

[0141] In one embodiment of the connector assembly of the novel shielding material of the present application, the cross-sectional area of ​​the electrical connection framework is 3.5 mm 2 ~240mm 2 It is.

[0142] The cross-sectional area of ​​the electrical connection skeleton 1 determines the current that can be conducted by the electrical connection skeleton 1. In general, an electrical connection skeleton 1 that can realize signal conduction has a small current and a small cross-sectional area of ​​the electrical connection skeleton 1. For example, the minimum cross-sectional area of ​​the electrical connection skeleton 1 for transmitting a signal is set to 3.5 mm 2 The electrical connection framework 1 capable of realizing power supply conduction has a large current and a large cross-sectional area. For example, a battery harness in an automobile can be used, and the maximum cross-sectional area of ​​the electrical connection framework 1 can be set to 240 mm 2 It can be made to be.

[0143] In one embodiment of the connector assembly of the novel shielding material of the present application, the electrical connection framework includes at least one bent portion.

[0144] In a specific implementation, the following requirements for wiring processing in a vehicle can be met by providing bent portions in the electrical connection framework 1 as necessary: ​​In the process of wiring processing in a vehicle, bent portions are provided at locations where it is necessary to change the direction of the electrical connection framework 1, making it easier for an operator to process the wiring, reducing the processing time for the vehicle, lowering the production costs of the vehicle, and improving market competitiveness.

[0145] The vehicle of the present application includes a connector assembly of the novel shielding material described above.

[0146] Although some specific embodiments of the present application have been described in detail with reference to examples, those skilled in the art should understand that the above examples are for illustrative purposes only and are not intended to limit the scope of the present application, and those skilled in the art can understand that modifications can be made to the above embodiments without departing from the scope and spirit of the present application.

Claims

1. A connector assembly of a new shielding material, comprising an electrical connection framework and connectors connected to both ends of the electrical connection framework, The connector includes a connection terminal and an inner shell having a shielding function, Both ends of the electrical connection framework are electrically connected to the connection terminals, the electrical connection framework is covered with an insulating layer; The insulating layer includes conductive particles arranged radially therein, A connector assembly using a new shielding material, characterized in that, in at least one location within the insulating layer, the conductive particles are distributed with non-uniform density.

2. The material of the connection terminal includes copper or a copper alloy; the material of the electrical connection framework includes aluminum or an aluminum alloy; 2. The connector assembly of the new shielding material as claimed in claim 1, wherein the electrical connection framework is electrically connected to the connection terminal by welding or crimping.

3. The electrical connection framework is a rigid body, The connector assembly of the new shielding material as claimed in claim 1, characterized in that the tensile strength of said electrical connection framework is greater than 75 MPa.

4. At least a portion of the electrical connection framework includes a flexible body; 2. The connector assembly of the new shielding material according to claim 1, wherein the flexible body is a multi-core cable, a braided cable, or a flexible flat cable made of laminated multi-layer thin plates.

5. Materials for the insulating layer include tetraphenylethylene, polyvinyl chloride, polyethylene, polyamide, polytetrafluoroethylene, tetrafluoroethylene-hexafluoropropene copolymer, ethylene-tetrafluoroethylene copolymer, polypropylene, polyvinylidene fluoride, polyurethane, polyethylene terephthalate, polyurethane elastomer, styrene block copolymer, perfluoroalkoxyalkane, chlorinated polyethylene, polyphenylene sulfide, polystyrene, crosslinked polyolefin, ethylene propylene rubber, ethylene-vinyl acetate copolymer, chloroprene rubber, natural rubber, styrene-butadiene rubber, nitrile rubber, silicone rubber, and butadiene rubber.

2. The connector assembly of the new shielding material according to claim 1, characterized in that the new shielding material includes one or more of diene rubber, isoprene rubber, ethylene propylene rubber, butyl rubber, fluororubber, polyurethane rubber, polyacrylate rubber, chlorosulfonated polyethylene rubber, epichlorohydrin rubber, chlorinated polyethylene rubber, sulfur chloride rubber, styrene butadiene rubber, butadiene rubber, hydrogenated nitrile rubber, polysulfide rubber, cross-linked polyethylene, polycarbonate, polysulfone, polyphenylene ether, polyester, phenolic resin, urea formaldehyde, styrene-acrylonitrile copolymer, polymethacrylate, and polyoxymethylene resin.

6. The connector assembly of the new shielding material according to claim 1, characterized in that the material of the conductive particles includes one or more of metals, conductive ceramics, carbon-containing conductors, solid electrolytes, and mixed conductors.

7. 7. The connector assembly of the new shielding material according to claim 6, characterized in that the metal material includes one or more of gold, silver, copper, nickel, titanium, tin, aluminum, cadmium, zirconium, chromium, cobalt, manganese, zinc, phosphorus, tellurium, beryllium, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, or silver-gold-zirconium alloy.

8. The connector assembly of claim 6, wherein the carbon-containing conductor comprises one or more of graphite powder, carbon nanotube material, graphene material, graphite silver, or graphene silver.

9. 2. The connector assembly of the new shielding material according to claim 1, wherein the space factor of the conductive particles in the insulating layer is 3.5% to 95%.

10. The connector assembly of the new shielding material according to claim 1, characterized in that the maximum diameter of the conductive particles is 0.1% to 97% of the thickness of the insulating layer.

11. 2. The connector assembly of the new shielding material according to claim 1, wherein the conductive particles in the insulating layer conduct electricity in the axial direction of the electrical connection framework.

12. 2. The connector assembly of the new shielding material according to claim 1, wherein the conductive particles in the insulating layer conduct electricity in a circumferential direction of the electrical connection framework.

13. The connector assembly of the new shielding material according to claim 1, characterized in that the transfer impedance of the conductive particles in the insulating layer in the axial direction of the electrically connecting skeleton is less than 100 mΩ.

14. 2. The connector assembly of the new shielding material according to claim 1, wherein the dielectric strength value of the conductive particles on the inner and outer surfaces of the insulating layer is greater than 2.1 KV.

15. 2. The connector assembly of the new shielding material according to claim 1, wherein the material of the inner shell includes a conductive metal or a polymer material containing conductive particles.

16. the material of the conductive particles includes one or more of a metal, a conductive ceramic, a carbon-containing conductor, a solid electrolyte, and a mixed conductor; The polymeric material may include tetraphenylethylene, polyvinyl chloride, polyethylene, polyamide, polytetrafluoroethylene, tetrafluoroethylene-hexafluoropropene copolymer, ethylene-tetrafluoroethylene copolymer, polypropylene, polyvinylidene fluoride, polyurethane, polyethylene terephthalate, polyurethane elastomer, styrene block copolymer, perfluoroalkoxyalkane, chlorinated polyethylene, polyphenylene sulfide, polystyrene, crosslinked polyolefin, ethylene propylene rubber, ethylene-vinyl acetate copolymer, chloroprene rubber, natural rubber, styrene-butadiene rubber, nitrile rubber, silicone rubber, and styrene-butadiene rubber. The connector assembly of the new shielding material according to claim 15, characterized in that the new shielding material includes one or more of the following: butyl rubber, fluororubber, polyurethane rubber, polyacrylate rubber, chlorosulfonated polyethylene rubber, epichlorohydrin rubber, chlorinated polyethylene rubber, sulfur chloride rubber, styrene butadiene rubber, butadiene rubber, hydrogenated nitrile rubber, polysulfide rubber, cross-linked polyethylene, polycarbonate, polysulfone, polyphenylene ether, polyester, phenolic resin, urea formaldehyde, styrene-acrylonitrile copolymer, polymethacrylate, and polyoxymethylene resin.

17. The connector assembly of the new shielding material according to claim 16, characterized in that the metallic material of the conductive particles includes one or more of gold, silver, copper, nickel, titanium, tin, aluminum, cadmium, zirconium, chromium, cobalt, manganese, zinc, phosphorus, tellurium, beryllium, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, or silver-gold-zirconium alloy.

18. 17. The connector assembly of claim 16, wherein the carbon-containing conductor of the conductive particles comprises one or more of graphite powder, carbon nanotube material, graphene material, graphite silver, or graphene silver.

19. 2. The connector assembly of claim 1, wherein the inner shell is electrically connected to the conductive particles.

20. A notch is provided in at least a portion of the insulating layer located within the connector; The conductive particles are exposed in the notches, A protrusion is provided at a corresponding position on the inner shell; 2. The connector assembly of the new shielding material according to claim 1, wherein the protrusions are fitted to the notches and electrically connected to the conductive particles.

21. 2. The connector assembly of the new shielding material as claimed in claim 1, wherein the impedance between the conductive particles and the inner shell is less than 80 mΩ.

22. 2. The connector assembly of the new shielding material as claimed in claim 1, wherein the transfer impedance of the inner shell is less than 100 mΩ.

23. The connector further includes a shield connection device; The shield connection device has at least one insertion portion and a contact portion, the insertion portion is inserted along an outer peripheral surface of the insulating layer and is electrically connected to the conductive particles; 2. The connector assembly of claim 1, wherein the contact portion is electrically connected to the inner shell.

24. The connector assembly of the new shielding material according to claim 23, characterized in that the vertical length of the insert part in the radial direction of the electrical connection framework is smaller than the thickness of the insulating layer.

25. The contact portion is cylindrical, At least one of the inserts is provided inside the cylindrical portion, 24. The connector assembly of claim 23, wherein said cylindrical outer wall is electrically connected to an inner surface of said inner shell.

26. The contact portion is columnar, 24. The connector assembly of the new shielding material according to claim 23, wherein the contact portion is inserted into the inner shell and electrically connected to the inner shell.

27. The contact portion is an elastic piece, The connector assembly of the new shielding material according to claim 23, characterized in that at least a part of the outer surface of the elastic piece is electrically connected to the inner surface of the inner shell.

28. the impedance between the shield connection device and the conductive particles is less than 80 mΩ; 24. The connector assembly of claim 23, wherein the impedance between the shield connection device and the inner shell is less than 80 m[Omega].

29. The connector assembly of the new shielding material according to claim 1, characterized in that the thickness of the insulating layer is 0.1 mm to 3.8 mm.

30. The connector assembly of the new shielding material according to claim 1, characterized in that the cross-sectional shape of the electrical connection framework is one or more of the following: circular, elliptical, rectangular, polygonal, A-shaped, B-shaped, D-shaped, M-shaped, N-shaped, O-shaped, S-shaped, E-shaped, F-shaped, H-shaped, K-shaped, L-shaped, T-shaped, U-shaped, V-shaped, W-shaped, X-shaped, Y-shaped, Z-shaped, P-shaped, semi-arc-shaped, arc-shaped, and wavy.

31. The cross-sectional shape of the electrical connection framework is polygonal, 2. The connector assembly of the new shielding material according to claim 1, wherein all corners of said polygonal shape are chamfered or rounded.

32. The cross-sectional area of ​​the electrical connection framework is 3.5 mm ２ ~240mm ２ 2. The connector assembly of claim 1, wherein the shielding material is

33. 2. The connector assembly of the new shielding material according to claim 1, wherein the electrical connection framework includes at least one bent portion.

34. A vehicle comprising a connector assembly of the new shielding material according to any one of claims 1 to 33.

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