Electrical connector assembly and method of assembling the same

Abstract

To provide an electric connector assembly capable of quickly performing waterproof sealing, and a method for assembling the electric connector assembly.SOLUTION: The electrical connector assembly comprises an insulating connector housing, a conductive terminal mounted in the connector housing, a busbar module comprising a busbar and an insulating busbar housing containing the busbar, wherein the busbar is electrically connected to the conductive terminal, and a fastener mechanically and electrically connecting the busbar to the conductive terminal. A first seal ring 140 formed by supplying a sealant is provided on one of the connector housing and the busbar housing, and the first seal ring circumferentially surrounds a position where the busbar 211 is connected to the conductive terminal, so as to realize a waterproof seal between the connector housing and the busbar housing.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority from Chinese Patent Application No. 202410884037.9, filed with the State Intellectual Property Office of China on July 3, 2024, the entire disclosure of which is incorporated herein by reference.

[0002] FIELD OF THE DISCLOSURE Embodiments of the present disclosure relate to the field of electrical connectors, and more particularly to an electrical connector assembly that provides quick waterproof sealing, and a method for assembling the electrical connector assembly. [Background technology]

[0003] Electrical connectors are typically used to establish electrical connections between various electronic elements or devices, and their application fields cover industries such as consumer electronics, home appliances, vehicles, industrial equipment, etc. Electrical connectors typically include connection terminals provided within a housing to achieve such electrical connections, such as conductive terminals for charging or power transmission in electric vehicles.

[0004] In conventional designs, electrical connectors are connected by wires, and when the charging current increases, the temperature rise can be reduced by using thick, rectangular wires. However, in electric vehicle charging applications, when the overall vehicle charging current requirement increases to a maximum of 1000 A, conventional wires currently cannot meet the temperature rise requirements caused by the current flowing through the entire vehicle. To meet the need for high-current transmission, bus bars with higher current transmission capacity and better stability can be used to connect the charging connector. During assembly, multiple separately prepared seal rings are usually installed between the bus bar and the connector housing to seal the positions where the bus bar connects to the conductive terminals. However, multiple seal rings must be assembled in place, which complicates the process and occupies additional installation space. Summary of the Invention [Problem to be solved by the invention]

[0005] The present disclosure is proposed to solve at least one of the above and other problems and drawbacks present in the prior art. [Means for solving the problem]

[0006] According to an embodiment of one aspect of the present disclosure, there is provided an electrical connector assembly including: an insulating connector housing; conductive terminals mounted within the connector housing; a busbar module including an insulating busbar housing encapsulating the busbar, wherein the busbar is electrically connected to the conductive terminals; and fasteners that mechanically and electrically connect the busbar to the conductive terminals. A first seal ring formed by dispensing a sealant is provided on one of the connector housing and the busbar housing, the first seal ring circumferentially surrounding the location where the busbar is connected to the conductive terminals to achieve a waterproof seal between the connector housing and the busbar housing.

[0007] In some embodiments, the connector housing has a mounting surface, the busbar module is attached to the mounting surface by fasteners, a first annular groove is formed in the mounting surface, and a first seal ring is formed in the first annular groove by applying a sealant before the busbar module is placed on the mounting surface.

[0008] In some embodiments, the connector housing comprises a housing body and a cover connected to each other, wherein terminal insertion passages are defined in the housing body for at least partially receiving and holding inserted conductive terminals, the cover covers at least connection ends of the conductive terminals connected to the bus bar, the cover has a mounting surface formed therein and an opening formed in the mounting surface, a portion of the connection end disposed within the cover is exposed from the opening for electrical connection with the bus bar, and a first annular groove surrounds the opening.

[0009] In some embodiments, the busbar housing has two faces opposite each other in the thickness direction of the busbar housing, and a first of the two faces is pressed against the mounting face of the cover via the fastening part, whereby the first seal ring is pressed between the first face of the busbar housing and the mounting face of the cover.

[0010] In some embodiments, a first through hole is formed in a first surface of the busbar housing such that a portion of a busbar contained in the busbar housing is exposed through the first through hole for electrical connection with a connection end, the busbar module is partially positioned on the mounting surface such that the first through hole is aligned with the opening in a thickness direction, a portion of a fastener is inserted through the first through hole and the opening, and a first annular groove surrounds the first through hole.

[0011] In some embodiments, terminal connection holes are formed at the connection ends of the conductive terminals, and busbar connection holes are formed at the ends of the busbars for connection with the conductive terminals, the busbar module is partially positioned on the mounting surface such that the first through holes, the openings, the terminal connection holes, and the busbar connection holes are aligned with one another in the thickness direction, and portions of the fastening components are inserted through the aligned busbar connection holes, the first through holes, the openings, and the terminal connection holes to secure the busbar module to the connector housing and electrically connect the busbar to the conductive terminals.

[0012] In some embodiments, the busbar module comprises at least two busbars, and the busbar housing includes the at least two busbars such that the at least two busbars are spaced apart from one another and fixedly positioned within the busbar housing.

[0013] In some embodiments, the fastening component comprises a bolt and a nut, the bolt having a rod with a threaded end, the rod being inserted through the aligned busbar connection hole, the first through hole, the opening, and the terminal connection hole from the opposite side of the mounting surface in the thickness direction of the busbar, so that the threaded end is threadedly connected to a nut located on the side of the connection end facing away from the busbar and disposed within the cover.

[0014] In some embodiments, the fastener further comprises an insulating cap, the head of the bolt being disposed within the cap, the cap comprising a flange, and a second seal ring formed by dispensing a sealant being provided on one of the flange and the busbar housing and circumferentially surrounding the bolt to provide a watertight seal between the cap and the busbar housing.

[0015] In some embodiments, a second annular groove is formed on a surface of the flange facing the busbar housing, and a second seal ring is formed in the second annular groove by supplying a sealant before the rod is inserted through the aligned busbar connection hole, the first through hole, the opening, and the terminal connection hole.

[0016] In some embodiments, the face of the flange is pressed against a second of the two faces of the busbar housing, whereby the second seal ring is pressed between the face of the flange and the second face of the busbar housing.

[0017] In some embodiments, a second through hole is formed in the second surface of the busbar housing, thereby exposing a portion of the busbar contained in the busbar housing through the second through hole, the busbar module is partially positioned on the mounting surface so that the second through hole is aligned with the busbar connection hole in the thickness direction, a bolt rod is inserted through the second through hole and the busbar connection hole which are aligned with each other, and a second seal ring formed in a second annular groove surrounds the second through hole.

[0018] According to an embodiment of another aspect of the present disclosure, there is provided a method of assembling the electrical connector assembly described according to any one of the embodiments of the present disclosure, the method including: providing an insulating connector housing; installing conductive terminals in the connector housing; providing a busbar module including a busbar and an insulating busbar housing containing the busbar; providing a first seal ring on one of the connector housing and the busbar housing by supplying a sealant; placing the busbar module in the connector housing and mechanically and electrically connecting the busbar to the conductive terminals by using fasteners, whereby the first seal ring circumferentially surrounds the locations where the busbar is connected to the conductive terminals, thereby achieving a watertight seal between the connector housing and the busbar housing.

[0019] In some embodiments, providing the first seal ring includes providing a sealant in the first annular groove to form the first seal ring, such that after the busbar module is attached to the connector housing by the fasteners, the first seal ring is pressed between the busbar housing and the connector housing.

[0020] In some embodiments, the method further includes providing a second seal ring on one of the flange and the busbar housing by supplying a sealant before the rod is inserted through the aligned busbar connection hole, the first through hole, the opening, and the terminal connection hole, and then inserting the rod through the aligned busbar connection hole, the first through hole, the opening, and the terminal connection hole, whereby the second seal ring circumferentially surrounds the bolt, thereby achieving a watertight seal between the cap and the busbar housing.

[0021] The above and other aspects, features, and advantages of embodiments of the present disclosure will become more apparent from the following detailed description taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0022] [Figure 1] 1 is a perspective view schematically illustrating the structure of an electrical connector assembly according to an exemplary embodiment of the present disclosure; [Figure 2] 1 is another perspective view schematically illustrating the structure of an electrical connector assembly according to an exemplary embodiment of the present disclosure. [Figure 3] FIG. 1 is a rear perspective view schematically illustrating the structure of an electrical connector assembly according to an exemplary embodiment of the present disclosure, with the cover removed to show the connections between the bus bars and the conductive terminals. [Figure 4] 1 is a perspective view schematically illustrating the structure of a cover of an electrical connector assembly according to an exemplary embodiment of the present disclosure, with one conductive terminal partially disposed within the cover; [Figure 5] 2 is a schematic partial cross-sectional view of an electrical connector assembly taken along line AA' of FIG. 1, according to an exemplary embodiment of the present disclosure. [Figure 6] FIG. 1 is a side perspective view schematically illustrating an electrical connector assembly with the cover removed to show connections between bus bars and conductive terminals according to an exemplary embodiment of the present disclosure. [Figure 7]1 is a perspective view schematically illustrating the structure of a fastener of an electrical connector assembly according to an exemplary embodiment of the present disclosure; FIG. [Figure 8] 1 is a schematic exploded view illustrating a fastening component of an electrical connector assembly according to an exemplary embodiment of the present disclosure; [Figure 9] FIG. 1 is a perspective view schematically illustrating the structure of a bus bar module of an electrical connector assembly according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0023]

[0023] Embodiments of the present disclosure will now be described in detail in conjunction with the accompanying drawings. In the description, the same or similar parts are designated by the same or similar reference numerals. The following description of each of the embodiments of the present disclosure, which refers to the accompanying drawings, is intended to illustrate the general inventive concept of the present disclosure and should not be construed as a limitation on the present disclosure.

[0024] Also, in the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. It will be apparent, however, that one or more embodiments may be practiced without these specific details. In other instances, well-known structures and devices are diagrammatically shown to simplify the drawings.

[0025] In the following detailed description, terms indicating directions such as "front," "rear," "up," "down," "top," "bottom," "left," "right," "upper," "lower," "inner," and "outer" may be defined by the drawings, but the shapes and positions of components are not limited by these terms and may be adjusted according to actual applications.

[0026] Furthermore, the terms used herein are for the purpose of describing example embodiments only and are not intended to limit and / or restrict the present disclosure. The singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly indicates otherwise. In this disclosure, terms such as "comprise," "have," and the like are used to specify features, numbers, operations, elements, components, or combinations thereof, but do not exclude the presence or addition of one or more of the features, elements, operations, elements, components, or combinations thereof.

[0027] In this specification, terms such as "first," "second," etc. may be used to describe various elements, but the elements are not limited by these terms. These terms are merely used to distinguish one element from another. For example, a first element may be referred to as a second element, and a second element may be referred to as a first element, without departing from the scope of the present disclosure. The term "and / or" includes multiple combinations of associated items or any one item of multiple associated items.

[0028] Exemplary embodiments of the present disclosure provide electrical connector assemblies that can be used to establish electrical connections between various types of electronic elements or devices. As an example, the electrical connector assemblies provided by embodiments of the present disclosure can be used as charging connectors for electric vehicles, such as charging sockets that can be used for high current transmission. In other embodiments, the provided bus bar assemblies and corresponding electrical connector assemblies can also be used to make safe and reliable power and signal connections between, for example, electronic devices, communication devices, medical devices, industrial electrical devices, etc. Exemplary embodiments of the present disclosure also provide methods of assembling the electrical connector assemblies, which allow for quick assembly and provide a waterproof seal.

[0029] An electrical connector assembly according to an exemplary embodiment of the present disclosure includes an electrical connector and a busbar module connected to each other, and the busbar module may include a busbar and a busbar housing including the busbar. As a result, when fastening the busbar module to the electrical connector using fasteners, as described below, a sealant can be supplied to quickly achieve a seal between the busbar and the connector housing and / or the fasteners. Therefore, assembly of the electrical connector and the busbar can be completed with a simple operation, improving assembly efficiency. In an electric vehicle charging application, the conductive terminal for connecting to the busbar may include, for example, a direct current conductive terminal, such as a DC+ terminal and / or a DC− terminal, capable of transmitting a current of up to 1000 A.

[0030] In an exemplary embodiment of the present disclosure, an electrical connector assembly includes an electrical connector and a bus bar adapted to be assembled (e.g., removably) to one another. The electrical connector may be a socket connector having a connector housing 110 and conductive terminals 120. The connector housing 110 may be formed of an insulating material such as plastic and defines sockets 101 (see FIG. 2 ) for receiving terminals of a mating connector (not shown). The conductive terminals 120 are adapted to be inserted into and mounted in the connector housing 110 and to be connected to a bus bar module 210 or its bus bar 211. 3 to 6 , the conductive terminals 120 have a connection end 121 and an insertion end 122, the connection end 121 being configured to be mechanically and electrically connected to the bus bar 211 of the bus bar module 210 via a fastening component 220, and the insertion end 122 being configured to be inserted into the connector housing 110 to make electrical contact with a terminal of a mating connector (not shown). The electrical connector including the connector housing 110 and the conductive terminals can be fixed to the bus bar module 210 using the fastening component 220.

[0031] As an example, the connector housing 110 may include a housing body 111 and a cover 112 that define the socket 101, with terminal insertion passages 1111 defined in the housing body 111 for at least partially receiving and holding inserted conductive terminals 120. The terminal insertion passages 1111 extend along an insertion direction (which may be the same as the length direction of the conductive terminals) and can accommodate at least the insertion ends 122 of the conductive terminals 120. The terminal insertion passages 1111 may communicate with the socket 101, such that a portion of the insertion end 122 of the conductive terminals 120 inserted into the terminal insertion passages 1111 is exposed or adapted to make electrical contact with a terminal of a mating connector.

[0032] In the illustrated embodiment, the cover 112 may have a flat cylindrical extension 1121 that covers or accommodates at least the connection portions of the conductive terminals 120 connected to the bus bars 211 and the portions of the conductive terminals that are located outside the housing body. For example, at least the connection ends 121 of the conductive terminals 120 are disposed within the extension 1121 of the cover 112. The cover 112 may be connected to the housing body 111 in various ways. In the illustrated embodiment, the cover 112 may be snap-connected to the housing body 111; for example, a snap joint or protrusion 1112 may be formed on the housing body 111 and an opening or groove 1122 for engaging or locking the snap joint or protrusion 1112 may be formed on the cover 112, or vice versa. The cover may also be connected or engaged to the housing body in other removably manners, or the connector housing may be an integrally formed part, as the present disclosure is not specifically limited thereto.

[0033] According to an exemplary embodiment of the present disclosure, a busbar module 210 including at least one busbar 211 is provided. In some embodiments, two or more busbars 211 may be contained together by an insulating busbar housing 212, thereby allowing the busbar module 210 to be assembled together into an electrical connector. In the illustrated embodiment, the busbar module 210 includes two busbars 211, such as a DC+ busbar and a DC- busbar, contained in the busbar housing 212. The two busbars 211 are electrically insulated and spaced apart from each other and fixedly disposed in the busbar housing 212 to form a 2-in-1 busbar module. Use of this module can reduce the work steps required to assemble multiple separate busbars, thereby improving assembly efficiency. The busbar may be formed of a suitable conductive material, such as a copper busbar, an aluminum busbar, etc. In the illustrated embodiment, the length or extension direction of the busbar may be substantially perpendicular to the length direction of the conductive terminals, but the present disclosure is not limited thereto, and in other embodiments, the orientation of the conductive terminals or the connector housing relative to the busbar may be adjusted according to actual installation requirements.

[0034] A first seal ring 140 may be provided on the connector housing 110 or the bus bar housing 212, and the first seal ring 140 circumferentially surrounds at least the position where the bus bar 211 is connected to the conductive terminal 120, thereby realizing a waterproof seal between the connector housing and the bus bar housing. Unlike a conventional separately prepared seal ring, the first seal ring 140 according to the exemplary embodiment of the present disclosure is formed by supplying a sealant when the connector housing 110 and the bus bar housing 212 are assembled. For example, using a dispenser (not shown), a circle of sealant is applied to the connector housing 110 or the bus bar housing 212 around the location where the connector housing 110 or the bus bar housing 212 will connect, and then the connector housing 110 and the bus bar housing 212 are pressed together, and the first seal ring 140 formed by the sealant application provides a watertight seal between the connector housing 110 and the bus bar housing 212, thereby eliminating the need to position and assemble a separate seal ring.

[0035] The connector housing 110 may have a mounting surface; for example, the cover 112 or a generally cylindrical extension 1121 of the cover may form a mounting surface 1122, such as a flat surface, and the bus bar module 210 is attached to the mounting surface 1122 by fasteners 220, whereby the bus bars 211 of the bus bar module 210 are electrically connected to the connection ends 121 of the connection ends 120 disposed within the cover 112. In some examples, a first annular groove 1124 is formed in the mounting surface 1122. Before the bus bar module 210 is placed on the mounting surface 1122, a sealant is applied to the first annular groove 1124 by supplying the sealant to form a first seal ring 140, which may be higher than or protrude out of the first annular groove 1124. During assembly, the seal ring is formed by dispensing the sealant, thereby eliminating the need to place and assemble a separate seal ring, reducing the additional installation space occupied by the separate seal ring, and enabling a more compact product.

[0036] As shown in Figures 4 and 5, a through hole or opening 1123 may be formed in the mounting surface 1122 of the cover 112, with a portion of the connection end 121 disposed within the cover 112 exposed through the opening 1123 for electrical connection with the busbar 211, and a first annular groove 1124 surrounding the opening 1123, such that when the busbar housing 212 is pressed against the mounting surface 1122, the first seal ring 140 formed in the first annular groove 1124 circumferentially surrounds the opening 1123 and further circumferentially surrounds the portion or location on the outside where the connection end 121 is connected to the busbar 211, thereby achieving a waterproof seal.

[0037] In the illustrated embodiment, the busbar module 210 may have a generally flat profile corresponding to the outer shape of the included busbar 211, such that the busbar housing 212 has two opposite faces in its thickness direction, namely, a first face 2122 and a second face 2123. After the first seal ring 140 is formed by applying a sealant, the first face 2122 of the busbar housing 212 is pressed against the mounting face 1122 of the cover 112 via the fastener 220, such that the first seal ring 140 is pressed between the first face 2122 of the busbar housing 212 and the mounting face 1122 of the cover 112.

[0038] As shown in Figures 5 and 9, a first through hole 2122 is formed in a first surface 2121 of the busbar housing 212, a portion of the busbar 211 contained in the busbar housing 212 is exposed from the first through hole 2122 for electrical connection with the connection end 121 of the conductive terminal 120, and the busbar module 210 is at least partially positioned on the mounting surface 1122 of the connector housing 110 so that the first through hole 2122 of the busbar housing 212 is aligned with the opening 1123 of the cover 112 in the thickness direction of the busbar module 210. A portion of the fastening part 220 is inserted into the first through hole 2122 and the opening 1123, which are aligned with each other, and the first annular groove 1124 and the first sealing ring 140 formed in the first annular groove 1124 surround the first through hole 2122 and the opening 1123 from the outside, thereby preventing water or foreign objects from entering the busbar housing 212 or the cover 112 through the first through hole 2122 or the opening 1123.

[0039] 3 to 6 and 9 , in the illustrated embodiment, terminal connection holes 123 are formed in connection ends 121 of conductive terminals 120, and busbar connection holes 2111 are formed in ends of busbars 211 that connect to conductive terminals 120. Second through holes 2124 may be formed in second surfaces 2123 of busbar housings 212, and may be concentric with busbar connection holes 2111. A portion of busbar 211 included in busbar housing 212 may be exposed through second through holes 2124. The diameters of first through holes 2122 and second through holes 2124 of busbar housings and / or the diameter of openings 1123 of cover 112 may be greater than or equal to the diameter of busbar connection holes 2111. After the busbar module 210 is placed on the mounting surface of the connector housing 110, the second through hole 2124, the busbar connection hole 2111, the first through hole 2121, the opening 1123, and the terminal connection hole 123 are aligned with each other in the thickness direction, and a portion of the fastening part 220 is inserted into the aligned second through hole 2124, the busbar connection hole 2111, the first through hole 2121, the opening 1123, and the terminal connection hole 123, thereby fixing the busbar module 210 to the connector housing 110 and electrically connecting the busbar 211 to the connection end 121 of the conductive terminal 120.

[0040] In the illustrated embodiment, the fastener 220 can removably connect the connection end 121 of the conductive terminal 120 to the bus bar 211. For example, as shown in FIGS. 3 and 5-8, the fastener 220 includes a bolt 221 and a nut 223, and the bolt 221 has a rod with a threaded end 2211. During assembly, the rod of the bolt 221 can be inserted from the side of the busbar 211 opposite the mounting surface 1122, i.e., from the second surface 2123 of the busbar housing 212, through the second through-hole 2124, the busbar connection hole 2111, the first through-hole 2121, the opening 1123, and the terminal connection hole 123, which are aligned with one another in the thickness direction, so that the threaded end 2211 is threadedly connected to the nut 223 located on the other opposite side of the busbar 211 (i.e., the side of the connection end 121 facing away from the busbar), thereby electrically connecting the busbar 211 to the connection end 121 of the conductive terminal 120. The nut 223 may be disposed within the cover 112, for example.

[0041] In some examples, to ensure a stable electrical connection between the conductive terminal and the bus bar, a portion of the fastening component 220, such as the bolt 221 and the nut 223, may preferably be formed of a conductive material. Additionally or alternatively, as shown in Figures 3 to 6, the fastening component 220 may further include a conductive sleeve 224, which is wrapped around the rod of the bolt 221 and disposed between the bus bar 211 and the connection end 121 of the conductive terminal 120, thereby making contact with the bus bar 211 and the connection end 121 and establishing an electrical connection between the bus bar 211 and the connection end 121.

[0042] In some embodiments, as shown in FIGS. 1 to 3 and 5 to 8 , fastener 220 may further include cap 222 within which the head of bolt 221 can be disposed. Cap 222 may be formed of an insulating material and adapted to abut against second surface 2123 of bus bar housing 212. According to some exemplary embodiments of the present disclosure, second seal ring 150 may be provided between cap 222 and bus bar housing 212. After assembly, second seal ring 150 circumferentially surrounds second through hole 2124 of bus bar housing 212, thereby achieving a waterproof seal between cap 222 and bus bar housing 212 and preventing water or foreign matter from entering bus bar housing 212 through second through hole 2124.

[0043] Unlike a conventional separately prepared seal ring, the second seal ring 150 according to the exemplary embodiment of the present disclosure is formed by supplying sealant when the connector housing 110 and the bus bar housing 212 are connected by the fastener 220. For example, a dispenser (not shown) is used to apply a circular shaped sealant around the bolt 221 in the cap 222 or around the second through-hole 2124 in the bus bar housing 212. Then, the rod of the bolt 221 is inserted through the aligned second through-hole 2124, bus bar connection hole 2111, first through-hole 2121, opening 1123, and terminal connection hole 123, so that the cap 222 abuts against the second surface 2123 of the bus bar housing 212. This allows the second seal ring 150 to achieve a waterproof seal between the cap 222 and the bus bar housing 212, eliminating the need to arrange and assemble a separate seal ring.

[0044] In some examples, the cap 222 may include an integrated flange 2221 and cap cover 2222. After the head of the bolt 221 is placed in the cap cover 2222 and before the rod of the bolt 221 is inserted through the second through-hole 2124, the busbar connection hole 2111, the first through-hole 2121, the opening 1123, and the terminal connection hole 123, a sealant may be applied to the surface 2223 of the flange 2221 facing the busbar housing 212 to form a second seal ring 150, and then the rod of the bolt 221 is inserted into and connected to the nut 223. At this time, the second seal ring 150 surrounds the rod of the bolt 221 from the outside, and thus surrounds the second through-hole 2124, to achieve a waterproof seal between the surface 2223 of the flange 2221 and the second surface 2123 of the busbar housing 212.

[0045] 5 to 8 , a second annular groove 2225 circumferentially surrounding the rod of the bolt 221 is formed in the inner surface of the flange 2221 of the cap 222, i.e., the surface 2223 facing the busbar housing 212. Before the rod of the bolt 221 is inserted through the aligned second through-hole 2124, the busbar connection hole 2111, the first through-hole 2121, the opening 1123, and the terminal connection hole 123, a sealant is supplied to apply the sealant to the second annular groove 2225 to form the second seal ring 150. The second seal ring 150 may be higher than or protrude beyond the second annular groove 2225. Therefore, when the fastener 220 is assembled to secure the bus bar module 210 to the mounting surface of the connector housing 110, the surface 2223 of the flange 2221 is pressed against the second surface 2123 of the bus bar housing 212, and the second seal ring 150 is thereby pressed between the surface 2223 of the flange 2221 and the second surface 2123 of the bus bar housing 212, surrounding from the outside the rod of the bolt 221 and the second through hole 2124 formed in the second surface 2123 of the bus bar housing 212. In the described embodiment, the seal ring is formed in the corresponding groove by supplying a sealant, but it will be understood that the present disclosure is not limited thereto, and that in other embodiments, separately formed seal rings can be attached to the corresponding grooves, which can similarly achieve a watertight seal, and that the presence of the grooves can similarly reduce the additional space occupied by the seal ring.

[0046] According to exemplary embodiments of the present disclosure, a corresponding assembly method is also provided, which is used to assemble an electrical connector with a bus bar or bus bar module to form the electrical connector assembly described in the above embodiments of the present disclosure. The method mainly includes the following operations or steps: Providing an electrical connector, such as an insulating connector housing 110, and mounting conductive terminals 120 within the connector housing; providing a bus bar module 210, which may include at least one bus bar 211 and an insulating bus bar housing 212 containing the bus bar; applying a sealant to one of the connector housing 110 and the bus bar housing 212 by dispensing a sealant to form a first seal ring 140; Thereafter, the bus bar module 210 is placed in the connector housing 110, and the bus bar 211 is mechanically and electrically connected to the conductive terminal 120 by using the fastening component 220, so that the first seal ring 140 circumferentially surrounds the position where the bus bar 211 is connected to the conductive terminal 120 from the outside, thereby realizing a waterproof seal between the connector housing 110 and the bus bar housing 212. Includes:

[0047] Illustratively, an annular groove may be formed in a surface of at least one of the connector housing 110 and the bus bar housing 212, such as the mounting surface of the connector housing 110. Prior to assembly, a sealant may be applied to the annular groove with a dispenser, or a separately formed seal ring may be placed in the annular groove to form or function as the first seal ring 140, so that after the bus bar module 210 is attached to the connector housing 110 with the fasteners 220, the first seal ring 140 is pressed between the bus bar housing 212 and the connector housing 110 to provide a reliable watertight seal between the bus bar housing 212 and the connector housing 110.

[0048] In further embodiments, another annular groove may be formed in a surface of at least one of the cap 222 of the fastener 220 and the busbar housing 212, for example, in the inner surface 2223 of the flange 2221 of the cap 222. Before assembly, for example, before the rod of the bolt 221 is inserted through the second through hole 2124, the busbar connection hole 2111, the first through hole 2121, the opening 1123 and the terminal connection hole 123, a sealant may be applied to the annular groove by a dispenser, or a separately formed seal ring may be placed in the annular groove to form or function as the second seal ring 150, and then the rod of the bolt 221 is inserted through the second through hole 2124, the busbar connection hole 2111, the first through hole 2121, the opening 1123 and the terminal connection hole 123, so that the second seal ring 150 circumferentially surrounds the bolt 221 and the second through hole 2124 of the busbar housing 212 from the outside and is pressed between the cap 222 and the busbar housing 212, thereby achieving a reliable waterproof seal between the cap 222 and the busbar housing 212.

[0049] While exemplary embodiments of the present disclosure have been shown and described, those skilled in the art will appreciate that various modifications may be made to these embodiments without departing from the principles and spirit of the present disclosure, the scope of which is defined by the appended claims and their equivalents. It should also be noted that the terms "comprise," "include," and "have" as used herein do not exclude other elements or steps. Furthermore, any reference signs in the claims should not be construed as limiting the scope of the present disclosure.

Claims

1. 1. An electrical connector assembly comprising: an insulating connector housing (110); a conductive terminal (120) mounted within the connector housing; a busbar module (210) comprising a busbar (211) and an insulating busbar housing (212) containing the busbar, the busbar being electrically connected to the conductive terminal; a fastener (220) that mechanically and electrically connects the bus bar to the conductive terminal; Equipped with a first seal ring (140) formed by applying a sealant is provided on one of the connector housing and the bus bar housing, the first seal ring circumferentially surrounding a position where the bus bar is connected to the conductive terminal to achieve a watertight seal between the connector housing and the bus bar housing; Electrical connector assembly.

2. the connector housing has a mounting surface (1122), and the bus bar module is attached to the mounting surface by the fasteners; 2. The electrical connector assembly of claim 1, wherein a first annular groove (1124) is formed in the mounting surface, and the first seal ring is formed in the first annular groove by applying a sealant before the bus bar module is placed on the mounting surface.

3. The connector housing comprises a housing body (111) and a cover (112) connected to each other, a terminal insertion passage (1111) for at least partially receiving and holding the inserted conductive terminal is defined in the housing body, and the cover covers at least a connection end (121) of the conductive terminal connected to the bus bar; 3. The electrical connector assembly of claim 2, wherein the cover has the mounting surface (1122), an opening (1123) formed in the mounting surface, a portion of the connection end disposed within the cover exposed from the opening for electrical connection with the bus bar, and the first annular groove (1124) surrounding the opening.

4. 4. The electrical connector assembly of claim 3, wherein the bus bar housing has two surfaces opposite each other in the thickness direction of the bus bar housing, and a first surface (2122) of the two surfaces is pressed against the mounting surface (1122) of the cover via the fastening part, thereby pressing the first seal ring between the first surface of the bus bar housing and the mounting surface (1122) of the cover.

5. a first through-hole (2122) is formed in the first surface (2121) of the bus bar housing, whereby a portion of the bus bar (211) contained in the bus bar housing is exposed through the first through-hole for electrical connection with the connection end (121); 5. The electrical connector assembly of claim 4, wherein the busbar module is partially positioned on the mounting surface so that the first through hole is aligned with the opening in the thickness direction, a portion of the fastening component is inserted through the first through hole and the opening, and the first annular groove (1124) surrounds the first through hole.

6. A terminal connection hole (123) is formed in the connection end (121) of the conductive terminal (120), A busbar connection hole (2111) is formed at the end of the busbar (211) for connection with the conductive terminal (120), 6. The electrical connector assembly of claim 5, wherein the busbar module is partially positioned on the mounting surface so that the first through hole, the opening, the terminal connection hole (123), and the busbar connection hole (2111) are aligned with one another in the thickness direction, and a portion of the fastening component is inserted through the aligned busbar connection hole, the first through hole, the opening, and the terminal connection hole, thereby fixing the busbar module to the connector housing and electrically connecting the busbar to the conductive terminal.

7. 7. The electrical connector assembly of claim 6, wherein the bus bar module comprises at least two bus bars (211), and the bus bar housing (212) includes the at least two bus bars (211) such that the at least two bus bars (211) are spaced apart from one another and fixedly positioned within the bus bar housing (212).

8. 7. The electrical connector assembly of claim 6, wherein the fastening part (220) comprises a bolt (221) and a nut (223), the bolt having a rod with a threaded end (2211), the rod being inserted through the busbar connection hole, the first through hole, the opening, and the terminal connection hole, which are aligned with each other, from the opposite side of the mounting surface in the thickness direction of the busbar, thereby threadingly connecting the threaded end (2211) to the nut (223) located on the side of the connection end (121) facing away from the busbar (211) and disposed within the cover.

9. The fastening component (220) further comprises an insulating cap (222), and the head of the bolt (221) is disposed within the cap; 9. The electrical connector assembly of claim 8, wherein the cap includes a flange (2221), and a second seal ring (150) formed by dispensing a sealant is provided on one of the flange and the bus bar housing and circumferentially surrounds the bolt to provide a watertight seal between the cap and the bus bar housing.

10. 10. The electrical connector assembly of claim 9, wherein a second annular groove (2225) is formed in a surface (2223) of the flange facing the bus bar housing, and the second seal ring is formed in the second annular groove by supplying a sealant before the rod is inserted through the bus bar connection hole, the first through hole, the opening, and the terminal connection hole, which are aligned with each other.

11. 11. The electrical connector assembly of claim 10, wherein the surface (2223) of the flange is pressed against a second surface (2123) of the two surfaces of the bus bar housing, whereby the second seal ring is pressed between the surface (2223) of the flange and the second surface (2123) of the bus bar housing.

12. a second through-hole (2124) is formed in the second surface (2123) of the bus bar housing, thereby exposing a portion of the bus bar (211) included in the bus bar housing through the second through-hole; The electrical connector assembly of claim 11, wherein the busbar module is partially positioned on the mounting surface so that the second through hole is aligned with the busbar connection hole in the thickness direction, the rod of the bolt is inserted through the second through hole and the busbar connection hole which are aligned with each other, and the second seal ring formed in the second annular groove (1124) surrounds the second through hole.

13. 13. A method of assembling the electrical connector assembly of any one of claims 1 to 12, comprising: providing the insulating connector housing (110); Mounting the conductive terminal (120) within the connector housing; providing the busbar module (210) comprising the busbar (211) and the insulating busbar housing (212) containing the busbar; providing a first seal ring (140) on one of the connector housing and the busbar housing by applying a sealant; placing the bus bar module in the connector housing, and mechanically and electrically connecting the bus bar to the conductive terminal by using the fastening components (220), so that the first seal ring circumferentially surrounds the location where the bus bar is connected to the conductive terminal, thereby realizing the waterproof seal between the connector housing and the bus bar housing; A method comprising:

14. The electrical connector assembly is the electrical connector assembly of claim 2, Providing the first seal ring includes:

14. The method of claim 13, further comprising: dispensing a sealant into the first annular groove to form the first seal ring, whereby the first seal ring is pressed between the bus bar housing and the connector housing after the bus bar module is attached to the connector housing by the fasteners.

15. The electrical connector assembly is the electrical connector assembly of claim 9, The method comprises: providing a second seal ring (150) on one of the flange and the bus bar housing by supplying a sealant before the rod is inserted through the bus bar connection hole, the first through hole, the opening, and the terminal connection hole, which are aligned with each other; Thereafter, the rod is inserted through the bus bar connection hole, the first through hole, the opening, and the terminal connection hole, which are aligned with each other, so that the second seal ring circumferentially surrounds the bolt, thereby realizing the waterproof seal between the cap and the bus bar housing.

15. The method of claim 14, further comprising:

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