Shielded connection mechanism, power transmission device and automobile

Abstract

The present invention provides a shielded connection mechanism, a power transmission device, and a vehicle, in which the connection mechanism includes a functional cable (10), a plug-in terminal (11), a protective conductor (20), a ground terminal (21), an inner housing (30) integrally molded with the functional cable (10) and the plug-in terminal (11), and a protective shield case (40) provided on at least a portion of the outer periphery of the inner housing (30), the functional cable (10) is provided with a shield layer (12), and one end of the protective shield case (40) is at least partially electrically connected to the shield layer (12), and the other end is at least partially electrically connected to the protective conductor (20) or the ground terminal (21). The shielded connection mechanism includes the inner housing (30) integrally injection molded with the functional cable (10) and the plug-in terminal (11), which allows for easy processing and is much less expensive than a metal housing for shielding. The insertion connection between the shielded connection mechanism and the mating connection mechanism, and the electrical connection with the shield layer (12) and protective conductor (20) of the functional cable, effectively shields electromagnetic interference within the connection mechanism, thereby reducing the occurrence of electromagnetic interference with other devices.

Description

[Technical Field]

[0001] This application claims priority to a Chinese patent application filed on October 1, 2021, bearing application number 202111167054.3 and entitled "Shielded Connection Mechanism, Power Transmission Device and Automobile," the entire contents of which are incorporated herein by reference.

[0002] This application also claims priority to a Chinese utility model entitled "Shielded Connection Mechanism, Power Transmission Device and Automobile" filed on October 1, 2021, with application number 202122400684.2, the entire contents of which are incorporated herein by reference.

[0003] This application relates to the field of electrical connections, and more particularly to shielded connection mechanisms, power transmission devices and automobiles. [Background technology]

[0004] New energy batteries for new energy vehicles are supplemented with energy by a charging system. The charging system includes a charging stand and a high-voltage connection mechanism that connects to the battery system. The charging harness is the most important unit in an electric vehicle high-voltage system. Conventional charging harnesses use copper wires as charging cables, with plug-in terminals at the ends of the copper wires that electrically connect to the battery system. Existing high-voltage connection mechanisms are assembly-type connection mechanisms, which have issues such as a complex structure, difficult assembly, and high connection mechanism costs. Furthermore, the cables and terminals use a large amount of copper material, which complicates the connection process. This is one of the reasons why high-voltage connection mechanisms are always expensive.

[0005] In addition, in charging systems, the charging base is equipped with a temperature measuring device, but the charging harness connection mechanism generally does not. However, because the current flow is the same, the charging harness connection mechanism also needs to be monitored to ensure the safety of the charging harness and battery system, and charging operations must be stopped immediately if the temperature becomes too high.

[0006] Furthermore, to suppress the effects of electromagnetic interference, high-voltage connection mechanisms usually require shielding of the PE line. Currently, connection mechanisms generally lack shielding devices. Therefore, electromagnetic interference from the PE line is significant in connection mechanisms. However, shielding effects can be achieved by installing a metal cover inside or outside the connection mechanism. However, metal covers are difficult to process and expensive. Furthermore, assembling the metal cover and connection mechanism is time-consuming and requires a large number of assembly steps. Furthermore, when a metal cover is installed inside the connection part, a short circuit with the guide core is likely to occur, damaging the shielding layer and ultimately causing the cable to burn, resulting in a serious accident.

[0007] Therefore, with the expansion of the electric vehicle market, there is a demand for charging systems that have a simple structure, cost advantages, and high-voltage connection mechanisms and power transmission devices that provide a shielding effect for PE lines. Summary of the Invention [Problem to be solved by the invention]

[0008] The present invention aims to provide a shielded connection mechanism that has an inner housing that is injection-molded integrally with the functional cable and insertion terminals, which is easy to process and much less expensive than a metal housing for shielding. The insertion connection between the shielded connection mechanism and the mating connection mechanism, and the electrical connection with the functional cable shield network and protective conductor, effectively shields electromagnetic interference within the connection mechanism, reducing the occurrence of electromagnetic interference in other devices. [Means for solving the problem]

[0009] The above object of the present invention may be achieved by the following technical solutions.

[0010] The present invention provides a shielded connection mechanism comprising a functional cable, an insertion terminal, an inner housing integrally molded with the functional cable and the insertion terminal, and a protective shielding case provided on at least a portion of the outer periphery of the inner housing, wherein a shielding layer is provided on the functional cable, and the protective shielding case and the shielding layer are at least partially electrically connected.

[0011] In a preferred embodiment, the connection mechanism further includes a protective conductor and a ground terminal, and one end of the protective shielding case is electrically connected at least in part to the shielding layer, and the other end is electrically connected at least in part to the protective conductor or the ground terminal.

[0012] In a preferred embodiment, the protective shielding case includes a shielding device, and the shielding device and the shielding layer are at least partially electrically connected.

[0013] In a preferred embodiment, a conductive elastic piece is further provided on the inner surface of the protective shielding case, the conductive elastic piece being in contact with and connected to the shielding layer, and the conductive elastic piece applying pressure to the shielding layer.

[0014] In a preferred embodiment, the pressure applied by the conductive elastic pieces ranges from 0.3N to 95N.

[0015] In a preferred embodiment, the impedance between the protective shielding case and the shielding layer is less than 80 mΩ.

[0016] In a preferred embodiment, the protective shielding case has a transimpedance of less than 100 mΩ.

[0017] In a preferred embodiment, the protective shielding case is injection molded integrally with at least a portion of the shielding layer.

[0018] In a preferred embodiment, the insertion terminal includes a first fixing portion and an insertion portion, which are arranged in sequence.

[0019] In a preferred embodiment, the functional cable includes a wire core located at the innermost position, a shielding layer fitted around the outer periphery of the wire core, and an insulating layer fitted around the outer periphery of the shielding layer, and the first fixing portion and the conductive portion of the wire core are electrically connected.

[0020] In a preferred embodiment, the insertion portion is columnar and at least a portion of the insertion portion protrudes from the inner housing, or the inner housing has a groove and at least a portion of the insertion portion protrudes from the bottom surface of the groove but does not extend beyond the inner housing.

[0021] In a preferred embodiment, the insertion portion is cylindrical and at least a portion of the insertion portion protrudes from the outer wall of the inner housing, or the inner housing is provided with an opening boss and at least a portion of the insertion portion is provided within the opening boss.

[0022] In a preferred embodiment, the protective shielding case encloses at least the first fixing portion and at least a portion of the functional cable, but is insulated from the insertion terminal and the conductive portion of the functional cable.

[0023] In a preferred embodiment, the inner housing is injection molded integrally with at least the first fixing portion, the insertion terminal, and the conductive portion of the functional cable, and exhibits an insulating function.

[0024] In a preferred embodiment, the protective shielding case surrounds at least a portion of the outer periphery of the inner housing, and the protective shielding case is injection molded integrally with at least a portion of the outer periphery of the inner housing.

[0025] In a preferred embodiment, the outer periphery of the inner housing and / or the protective shielding case is further integrally injection molded into an outer insulating case, and the outer insulating case encloses at least a portion of the inner housing and / or the protective shielding case, at least a portion of the functional cable, and the protective conductor.

[0026] In a preferred embodiment, the connection mechanism includes an interlock connection mechanism, and the interlock connection mechanism is at least partially integrally injection molded within the inner housing.

[0027] In a preferred embodiment, the ground terminal includes a second fixing portion and a mating insertion portion, and the second fixing portion is electrically connected to the protective conductor.

[0028] In a preferred embodiment, the mating insertion portion is columnar, and at least a portion of the mating insertion portion protrudes from the inner housing, or the inner housing has a groove, and at least a portion of the mating insertion portion protrudes from the bottom surface of the groove but does not extend beyond the inner housing.

[0029] In a preferred embodiment, the mating insertion portion is cylindrical, and at least a portion of the mating insertion portion protrudes from the outer wall of the inner housing, or the inner housing is provided with an opening boss, and at least a portion of the mating insertion portion is provided within the opening boss.

[0030] In a preferred embodiment, the inner housing is injection molded to be integrated with at least the outer periphery of the second fixing portion and the conductive portion of the protective conductor, and exhibits an insulating function.

[0031] In a preferred embodiment, the protective shielding case surrounds at least the outer periphery of the second fixed portion and / or the conductive portion of the protective conductor, and the protective shielding case is electrically connected to the second fixed portion and / or the conductive portion of the protective conductor.

[0032] In a preferred embodiment, the connection mechanism has a sealed structure.

[0033] In a preferred embodiment, the outer periphery of the inner housing and / or the protective shielding case includes an outer insulating case, and the sealing structure is secondary injection molded into the inner housing and / or the protective shielding case, and / or the sealing structure is secondary injection molded into the outer insulating case.

[0034] In a preferred embodiment, the device comprises at least one temperature measuring component for measuring the temperature of the insertion terminal and / or the ground terminal.

[0035] In a preferred embodiment, the sensor further comprises at least one temperature measuring component that is in close contact with the insertion terminal and / or the ground terminal and that measures the temperature of the insertion terminal and / or the ground terminal.

[0036] In a preferred embodiment, the connection mechanism weighs 272 g or less.

[0037] In a preferred embodiment, the connection mechanism has a height of 274 mm or less in the insertion / removal direction.

[0038] In a preferred embodiment, a conductive anticorrosion layer is provided on at least a portion of the surface of the insertion terminal and / or the ground terminal.

[0039] In a preferred embodiment, the conductive portion of the protective conductor is integrally formed with the ground terminal.

[0040] In a preferred embodiment, the conductive portion of the functional cable is integrally formed with the insertion terminal.

[0041] The present invention provides a power transmitting device including any one of the above-described shielded connection mechanisms.

[0042] The present invention provides an automobile equipped with any one of the above-described shielded connection mechanisms. [Effects of the Invention]

[0043] The present invention has the following features and advantages:

[0044] 1. The shielded connection mechanism of the present invention is provided with an inner housing that is injection-molded integrally with the functional cable and plug-in terminals, which simplifies processing and is much less expensive than a metal shielding housing. The plug-in connection between the shielded connection mechanism and the mating connection mechanism, and the electrical connection with the functional cable shield network and protective conductor, effectively shields electromagnetic interference within the connection mechanism, reducing the occurrence of electromagnetic interference in other devices.

[0045] 2. In the present invention, the connection between the protective shielding case and the functional cable shielding network is carried out using multiple methods, so that the protective shielding case and the shielding network can be connected stably and effectively, and good shielding effect can be obtained.

[0046] 3. The protective shield case of the present invention is electrically connected not only to the functional cable shield network but also to the protective conductor or ground terminal, ensuring double grounding. Even if grounding via the functional cable shield network fails, grounding via the protective conductor is still possible, allowing the outflow of shielded current to be smoothly guided and reducing electromagnetic shield interference.

[0047] 4. The fitted high-voltage interlock structure is used in place of the conventional assembled high-voltage interlock structure, and is integrated into the connection mechanism and fixed by injection molding, eliminating the need for assembly, reducing costs, and ensuring the full effect of the high-voltage interlock.

[0048] 5. The sealing structure of the connection mechanism does not require a separate seal ring, but instead uses a secondary injection-molded sealing structure instead of the traditional seal ring, which can be directly molded into the connection mechanism, improving the joining properties of the injection molding and reducing costs.

[0049] 6. By using a temperature measurement mechanism, the temperature of the terminals inside the connection mechanism can be monitored individually, avoiding the inability to monitor the temperature of the connection mechanism due to damage to temperature sensors in other locations. [Brief explanation of the drawings]

[0050] In order to more clearly explain the technical solutions of the present invention, the following will briefly describe the accompanying drawings necessary for describing the embodiments. It should be apparent that the accompanying drawings in the following description are only some embodiments of the present invention, and those skilled in the art can further obtain other accompanying drawings based on these accompanying drawings without any creative efforts. [Figure 1] 1 is a structural schematic diagram of a shielded connection mechanism according to the present invention; [Figure 2] 2 is a structural schematic diagram of an inner housing according to the present invention. FIG. [Figure 3] 1 is a structural schematic diagram of a protective shield case according to the present invention. [Figure 4] FIG. 2 is a structural schematic diagram of an insulating outer case according to the present invention. [Figure 5] 3A and 3B are schematic diagrams illustrating the columnar structures of the insertion terminal and the ground terminal according to the present invention. [Figure 6] 3A and 3B are schematic diagrams illustrating the cylindrical structures of the insertion terminal and the ground terminal according to the present invention. [Figure 7] 1 is a cross-sectional view of a shielded connection mechanism according to the present invention. [Figure 8] 10 is another cross-sectional view of a shielded connection mechanism according to the present invention. FIG. [Figure 9] 10 is another cross-sectional view of a shielded connection mechanism according to the present invention. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0051] The following clearly and completely describes the technical solutions in the embodiments of the present invention with reference to the accompanying drawings of the embodiments of the present invention, but it is obvious that the described embodiments are only some of the embodiments of the present invention, and do not cover all of the embodiments. Based on the embodiments of the present invention, those skilled in the art can obtain all other embodiments without any creative efforts, and all of these embodiments fall within the scope of protection of the present invention.

[0052] As shown in Figures 1 to 4, the shielded connection mechanism includes a functional cable 10, an insertion terminal 11, an inner housing 30 integrally molded with the functional cable 10 and the insertion terminal 11, and a protective shield case 40 provided on at least a portion of the outer periphery of the inner housing 30, and the functional cable 10 is provided with a shield layer 12, and the protective shield case 40 and the shield layer 12 are at least partially electrically connected.

[0053] In a shielded connection mechanism, the functional cable 10 must transmit a large current, and when a current flows, a large electromagnetic field is generated around the functional cable 10. To prevent the electromagnetic field caused by the large current from causing electromagnetic interference to electrical devices in the surrounding environment and affecting the normal operation of other electrical devices, a shield layer 12 is installed outside the conductive core of the functional cable 10 to electromagnetically shield the electromagnetic field generated after the functional cable 10 is energized.

[0054] As shown in FIGS. 7 to 9, the functional cable 10 is provided with a shielding layer 12, and one end of the protective shielding case 40 is electrically connected to at least a part of the shielding layer 12.

[0055] The shielded connection mechanism of the present invention is provided with an inner housing 30 that is injection-molded to integrate the functional cable 10 and the insertion terminal 11, making it easy to process and far less expensive than a metal housing for shielding. Furthermore, the insertion connection between the shielded connection mechanism and the mating connection mechanism, and the electrical connection between the shielded connection mechanism and the functional cable 10 and shield layer 12, effectively shields electromagnetic interference within the connection mechanism, reducing the occurrence of electromagnetic interference with other devices.

[0056] In one embodiment, the connection mechanism further includes a protective conductor 20 and a ground terminal 21, and the protective shielding case 40 has one end electrically connected to at least a portion of the shielding layer 12 and the other end electrically connected to at least a portion of the protective conductor 20 or the ground terminal 21.

[0057] The protective shield case 40 of the present invention is electrically connected to the functional cable 10 and the shielding layer, and also to the protective conductor 20 or the grounding terminal 21. This ensures double grounding, and even if grounding via the shielding network of the functional cable 10 fails, grounding via the protective conductor 20 is possible. This allows the outflow of shielded current to be smoothly guided, thereby reducing electromagnetic shield interference.

[0058] In some embodiments, the insert terminals 11 and the ground terminals 21 are made of conductive metal materials, including one or more of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium, beryllium, and lead, which have stable properties and good electrical conductivity. Suitable materials include copper or copper alloys, or aluminum or aluminum alloys.

[0059] In some embodiments, the conductive portions of the functional cable 10 and the protective conductor 20 are made of one or more of aluminum, phosphorus, tin, copper, iron, manganese, chromium, titanium, and lithium. Using aluminum or an aluminum alloy as the conductive portion of the functional cable 10 and the protective conductor 20 has recently become a major means of saving energy and reducing costs. In the electrical connection field, copper conductors, which have high conductivity and good ductility, are commonly used to conduct current. However, as the price of copper continues to rise, the use of copper as a conductor material inevitably increases costs. Therefore, alternatives to metallic copper are being explored to reduce costs. The content of metallic aluminum in the earth's crust is approximately 7.73%. With the optimization of refining technology, the price of metallic aluminum has become relatively low. Moreover, aluminum is lighter than copper and has second-highest conductivity, making it suitable for use as a partial copper substitute in the electrical connection field. Therefore, there is a growing trend to use aluminum instead of copper in the field of automotive electrical connections.

[0060] In one embodiment, as shown in FIG. 8, the protective shielding case 40 includes a shielding device 41, and the shielding device 41 and the shielding layer 21 are at least partially electrically connected.

[0061] The protective shielding case 40 includes a shielding device 41, which is in contact with and electrically connected to the shielding layer 21 to form a sealed electromagnetic shielding structure. This makes it possible to optimize the electromagnetic shielding effect. Furthermore, as shown in Figures 8 and 9, the formation of a sealed electromagnetic shielding structure makes it possible to effectively control the radiation of electromagnetic waves, thereby achieving a good shielding effect.

[0062] The shielding layer 12 may be a shielding mesh or a conductive foil. While the shielding layer 12 has a flexible structure, the shielding device 41, which is the male end, generally has a rigid structure. When the two come into contact, the shielding layer 12 deforms, transiently interrupting the connection between the shielding device 41 and the shielding layer 12 and changing the impedance at the contact point. This destabilizes the shielding effect of the connection structure of the functional cable 10, affecting signal transmission. Therefore, a stable connection between the shielding device 41 and the shielding layer 12 is required. To achieve a good electrical connection between the functional cable 10 and the protective shielding case 40, the shielding device 41 generally needs to have a rigid structure, enabling stable shielding.

[0063] In one embodiment, as shown in FIG. 9 , a conductive elastic piece 42 is further provided on the inner surface of the protective shielding case 40, and the conductive elastic piece 42 is in contact with and connected to the shielding layer 12, and the conductive elastic piece 42 applies pressure to the shielding layer 12.

[0064] The protective shielding case 40 is electrically connected to the shielding layer 12 by the conductive elastic pieces 42. At least a portion of the conductive elastic pieces 42 is elastic and tends to contract inward to crimp the functional cable 10. This ensures, on the one hand, the stability of the electrical connection between the protective shielding case 40 and the shielding layer 12, and, on the other hand, as shown in Figures 7 to 9, when the functional cable 12 is inserted into the protective shielding case 40, it comes into contact with and connects to the conductive elastic pieces 42, thereby reducing the number of steps in assembly and processing.

[0065] Furthermore, the range of pressure applied by the conductive elastic piece 42 is 0.3N to 95N.

[0066] The inventors conducted tests with a narrowed focus to verify the effect of the pressure applied to the shield layer 12 by the conductive elastic piece 42 on the contact resistance between the conductive elastic piece 42 and the shield layer 12. Taking the pressure applied to the shield layer 12 by the conductive elastic piece 42 as an example, the inventors selected conductive elastic pieces 42 and shield layers 12 that had the same shape and the same dimensions, and set the pressure between the conductive elastic piece 42 and the shield layer 12 to different pressures, and observed the contact resistance between the conductive elastic piece 42 and the shield layer 12.

[0067] The contact resistance is detected as follows: A precision resistance meter is used to measure the resistance at the contact point between the conductive elastic piece 42 and the shield layer 12, and the value displayed on the precision resistance meter is read. In this embodiment, it is ideal for the contact resistance to be less than 50 μΩ.

[0068] Table 1. Effect of different pressures on contact resistance between the conductive elastic piece and the shield layer [Table 1] As can be seen from Table 1, when the pressure between the conductive elastic piece 42 and the shield layer 12 is less than 0.3 N, the bonding force is too weak, resulting in a higher than ideal contact resistance between the two and failing to meet the requirements. When the pressure between the conductive elastic piece 42 and the shield layer 12 exceeds 95 N, the contact resistance does not decrease significantly, but the material selection and processing become more difficult. Moreover, if the pressure is too high, the shield layer 12 may be damaged. Therefore, the inventors limit the pressure applied by the conductive elastic piece 42 to a range of 0.3 N to 95 N.

[0069] The inventors have also found that when the pressure between the conductive elastic piece 42 and the shield layer 12 exceeds 0.5 N, the contact resistance between the conductive elastic piece 42 and the shield layer 12 is good and tends to decrease quickly, but when the pressure between the conductive elastic piece 42 and the shield layer 12 is less than 50 N, the conductive elastic piece is easy to manufacture, attach, and use, and the cost is low. Therefore, the inventors have determined that the preferred range of pressure applied by the conductive elastic piece 42 is 0.5 N to 50 N.

[0070] In one embodiment, the conductive elastic piece 42 and the protective shielding case 40 are connected by welding, adhesive, integral injection molding, fitting, or fastening.

[0071] The welding method includes laser welding, ultrasonic welding, resistance welding, pressure diffusion welding, brazing, etc., and is a method of using concentrated heat energy or pressure to melt and connect the conductive elastic piece 42 and the inner surface of the protective shielding case 42 at the contact points. The welding method produces a strong connection, can realize connections between different types of materials, and has a better conductivity due to the melting of the contact points.

[0072] The adhesive method uses a conductive paste to bond the conductive elastic piece 42 to the inner surface of the protective shielding case 40. This method eliminates the need for equipment, and the conductive paste ensures a sufficient electrical connection between the conductive elastic piece 42 and the inner surface of the protective shielding case 40, resulting in good conductivity. However, because the connection strength is low, it is suitable for use in environments where the requirements for connection strength are not high and where the melting point or strength of the conductive elastic piece 42 and the inner surface of the protective shielding case 40 is low.

[0073] The integrated injection molding method is a method in which the conductive elastic piece 42 is placed in an injection mold and, during processing of the connection mechanism, is directly injection molded integrally with the inner surface of the protective shielding case 40. This simplifies and speeds up the processing, and since there are no additional assembly steps, it saves time during assembly.

[0074] The fitting method is a method in which a groove is provided on the inner surface of the protective shielding case 40, and the conductive elastic piece 42 is fitted into the groove, thereby fixing the conductive elastic piece 42 to the inner surface of the protective shielding case 40.

[0075] The fastening method is a method in which a locking claw or locking groove is provided on the inner surface of the protective shielding case 40, a corresponding locking groove or locking claw is provided on the conductive elastic piece 42, and the locking claw and the locking groove are connected and assembled to fix the conductive elastic piece 42 to the inner surface of the protective shielding case 40.

[0076] The protective shielding case of the present invention connects the functional cable 10 and the shielding layer 12 using multiple methods, so that the protective shielding case and the shielding mesh can be connected stably and effectively, resulting in good shielding effect.

[0077] In one embodiment, the impedance between protective shielding case 40 and shielding layer 12 is less than 80 mΩ.

[0078] The impedance between the protective shielding case 40 and the shielding layer 12 must be kept as small as possible so that the current generated in the shielding layer 12 can smoothly return to the energy source or ground. If the impedance between the protective shielding case 40 and the shielding layer 12 is large, a large current will be generated between the protective shielding case 40 and the shielding layer 12, resulting in large radiation at the connection point between the functional cable 10 and the insertion terminal 11.

[0079] Taking the impact of the impedance between the protective shielding case 40 and the shielding layer 12 on the shielding effectiveness of a shielded connection mechanism as an example, the inventors selected functional cables 10 and terminals 11 with the same specifications, but selected different impedances between the protective shielding case 40 and the shielding layer 12. They then manufactured samples of the shielded connection mechanism and sealed the opening of the protective shielding case 40 with a metal shielding device to ensure complete shielding throughout the entire protective shielding case 40. The shielding effectiveness of each shielded connection mechanism was then tested. The experimental results are shown in Table 2 below. In this example, a shielding performance value of over 40 dB is ideal.

[0080] The shielding performance value is tested as follows: The test equipment outputs one signal value (here, this value is called Test Value 2) to the protective shielding case 40 and the shielding layer 12. A detector is placed outside the shielded connection mechanism, and the detector detects one signal value (here, this value is called Test Value 1). Shielding performance value = Test Value 2 - Test Value 1.

[0081] Table 2. Effect of impedance between protective shielding case 40 and shielding layer 12 on shielding performance [Table 2] As can be seen from Table 2, when the impedance between the protective shielding case 40 and the shielding layer 12 exceeds 80 mΩ, the shielding performance of the shielded connection mechanism falls below 40 dB, which is undesirable as an ideal value. On the other hand, when the impedance between the protective shielding case 40 and the shielding layer 12 is less than 80 mΩ, the shielding performance of the shielded connection mechanism generally meets the ideal value requirements and tends to improve. Therefore, the inventors set the impedance between the protective shielding case 40 and the shielding layer 12 to be less than 80 mΩ.

[0082] In one embodiment, the transimpedance of the protective shielding case 40 is less than 100 mΩ.

[0083] For shielding materials, the shielding effectiveness of the protective shielding case 40 is usually expressed as transimpedance. The smaller the transimpedance, the better the shielding effectiveness. The transimpedance of the protective shielding case 40 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. That is, ZT = U / IS.

[0084] Therefore, it may be understood that the transimpedance of the protective shielding case 40 converts the current in the protective shielding case 40 into differential mode interference. The smaller the transimpedance, the better, i.e., the reduced conversion into differential mode interference results in better shielding performance.

[0085] To verify the impact of different transimpedances on the shielding effectiveness of the shielded connection mechanism, the inventors selected the same protective shielding case 40, functional cable 10, and insertion terminal 11 specifications and manufactured a series of shielded connection mechanism connection structure samples using the protective shielding case 40 with different transimpedances. The openings of the protective shielding case 40 were sealed with a metal shielding device to ensure complete shielding throughout the entire protective shielding case 40. The shielding effectiveness of each shielded connection mechanism was then tested. The experimental results are shown in Table 3 below. In this example, the shielding performance value of the shielded connection mechanism connection structure is ideally 40 dB or more.

[0086] The shielding performance value is tested as follows: The test equipment outputs one signal value to the shielded connection mechanism (here, this value is called Test Value 2). A detector is placed outside the shielded connection mechanism, and the detector detects one signal value (here, this value is called Test Value 1). Shielding performance value = Test Value 2 - Test Value 1.

[0087] Table 3. Effect of transimpedance on shielding performance of protective shield case 40 [Table 3] As can be seen from Table 3 above, when the transimpedance of the protective shielding case 40 exceeds 100 mΩ, the shielding performance of the shielded connection mechanism falls below 40 dB, which is undesirable as an ideal value. On the other hand, when the transimpedance of the protective shielding case 40 is less than 100 mΩ, the shielding performance of the shielded connection mechanism generally meets the ideal value requirements and tends to improve. Therefore, the inventors set the transimpedance of the protective shielding case 40 to be less than 100 mΩ.

[0088] In one embodiment, the material of the protective shielding case 40 includes one or more of conductive ceramics, carbon-containing conductors, solid electrolytes, mixed conductors, and conductive polymer materials.

[0089] To verify the effect of different materials on the conductivity of the protective shielding case 40, the inventors manufactured samples of the protective shielding case 40 using different materials with the same specifications and dimensions. The conductivity of each protective shielding case 40 was tested. The experimental results are shown in Table 4 below. In this example, it is ideal for the conductivity of the protective shielding case 40 to be greater than 99%.

[0090] Table 4. Effect of different materials on the conductivity of the protective shielding case 40 [Table 4] As can be seen from Table 4 above, the electrical conductivities of the protective shielding case 40 made from the selected materials are all within the ideal range. Therefore, the inventors select the material of the protective shielding case 40 to be one or more of conductive ceramics, carbon-containing conductors, solid electrolytes, mixed conductors, and conductive polymer materials.

[0091] Additionally, the carbon-containing conductor includes one or more of graphite powder, carbon nanotube material, and graphene material.

[0092] Furthermore, the conductive polymer material is a polymer material containing metal particles. The material of the metal particles includes one or more of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium, and beryllium. The material of the polymer material includes polyvinyl chloride, polyethylene, polyamide, polytetrafluoroethylene, tetrafluoroethylene / hexafluoropropylene copolymer, ethylene / tetrafluoroethylene copolymer, polypropylene, polyvinylidene fluoride, polyurethane, polyethylene terephthalic acid, polyurethane elastomer, styrene block copolymer, perfluoroalkoxyalkane, chlorinated polyethylene, polyphenylene sulfide, polystyrene, silicone rubber, cross-linked polyolefin, ethylene propylene rubber, ethylene / vinyl acetate copolymer, chloroprene rubber, natural rubber, styrene butadiene rubber, nitrile, and the like. The rubber may be one or more of styrene rubber, butadiene rubber, isoprene rubber, ethylene propylene rubber, chloroprene rubber, butyl rubber, fluororubber, polyurethane rubber, polyacrylate rubber, chlorosulfonated polyethylene rubber, chloroether rubber, chlorinated polyethylene rubber, chlorosulfur 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, polyoxymethylene resin.

[0093] The following describes the properties of the materials with examples.

[0094] Polyoxymethylene is a smooth, glossy, hard, and dense material with a light yellow or white color that can be used for long periods of time within a temperature range of -40°C to 100°C. Compared to most engineering plastics, polyoxymethylene has excellent wear resistance and self-lubricating properties, as well as good oil resistance and peroxide resistance.

[0095] Polycarbonate is a colorless, transparent material with heat and impact resistance, flame retardant grade BI, and exhibits good mechanical properties at normal operating temperatures. Compared to polymethyl methacrylate, which has similar properties, polycarbonate has superior impact resistance, a high refractive index, good processability, and can exhibit high flame retardancy without the need for additives.

[0096] Polyamide is non-toxic, lightweight, and has good mechanical strength as well as excellent wear resistance and corrosion resistance, and may be used in place of metals such as copper to manufacture bearings, gears, pump blades, and other parts in industries such as machinery, chemical industry, measuring instruments, and automobiles. Polycarbonate or polyamide is suitable as a conductive polymer material.

[0097] In one embodiment, the protective shielding case 40 is fabricated by one or more of the following methods: extrusion, injection molding, dip molding, blow molding, foaming, spraying, printing, and 3D printing.

[0098] Injection molding is a method of manufacturing a semi-finished product having a predetermined shape by applying pressure to a molten material, injecting it, cooling it, and removing it.

[0099] The dip-molding method is a method in which a workpiece is electrically heated to a certain temperature, and then immersed in a dip-molding liquid, which is then hardened on the workpiece.

[0100] The blow molding method involves extruding a tubular parison from an extruder, then inserting it into a mold while it is still hot, blowing it up with compressed air to create a cavity, and then cooling and molding it to obtain the final product. This method is applicable to multiple types of plastics, can produce large products, and has the advantages of high production efficiency, more uniform parison temperature, and low equipment costs.

[0101] The foaming method is a method of forming a honeycomb or porous structure in a foam molding process or foamed polymer material by adding and reacting a physical or chemical foaming agent. The basic steps of foam molding include forming a bubble nucleus, growing or expanding the bubble nucleus, and stabilizing the bubble nucleus. Under certain temperature and pressure conditions, the solubility of the gas is reduced to a saturated state, thereby eliminating excess gas and forming bubbles, thereby realizing the formation of the nucleus.

[0102] Spraying is a coating method in which spray material is dispersed into uniform, fine droplets by pressure or centrifugal force using a spray gun or disk atomizer and applied to the surface of the object to be coated. Spraying methods are divided into air spraying, airless spraying, electrostatic spraying, and various derivative methods based on the above basic spraying methods.

[0103] A printing method is a method of transferring ink or other viscous fluid material to the surface of a substrate using a printing plate, and includes screen printing, letterpress printing, flexographic printing, intaglio printing, or lithographic printing.

[0104] 3D printing, also known as additive manufacturing, is a rapid forming technology that builds objects from a digital model file by printing them layer by layer using bondable materials such as powdered metal or plastic.

[0105] In one embodiment, the protective shielding case 40 is injection molded integrally with at least a portion of the shielding layer 12. In the injection molding method, the protective shielding case 40 may be injection molded integrally with the shielding layer 12 of the functional cable 10. In this case, the shielded connection mechanism can achieve electrical connection between the protective shielding case 40 and the shielding layer 12 without using a shielding device 41, and a good shielding effect can be obtained.

[0106] In one embodiment, the insertion terminal 11 includes a first fixing portion 111 and an insertion portion 112, which are arranged in sequence, and the insertion portion 112 may be cylindrical or columnar. The first fixing portion 111 is electrically connected to a conductive portion of the functional cable 10, thereby achieving circuit continuity. The insertion portion 112 may be cylindrical or columnar. The power device, which is the counterpart to the connection mechanism, also has a terminal, and the tip of the terminal may be columnar or cylindrical. As shown in FIGS. 5 and 6, the columnar terminal and the cylindrical terminal are mated and inserted into each other, allowing the circuit connection to be removable.

[0107] The functional cable 10 further includes an innermost core 101, a shielding layer 12 fitted around the core 101, and an insulating layer 102 fitted around the shielding layer 12. The first fixing portion 111 is electrically connected to the conductive portion of the core 101. The functional cable 10 may be a multi-core cable, with each core representing a different circuit. The number of insertable terminals 11 is the same as the number of cores. The first fixing portions 111 of the multiple insertable terminals 11 are electrically connected to the conductive portions of the multiple cores. The shielding layer 12 fitted around the core 101 is electrically connected to the protective shield case 40, thereby achieving the purpose of shielding against signal interference. The insulating layer 102 fitted around the shielding layer 12 provides insulation protection and prevents the insertable terminals 11, core 101, and shielding layer 12 from contacting an external conductor and causing a short circuit, as shown in Figures 7 to 9.

[0108] Furthermore, the connection between the first fixing portion 111 and the conductive portion of the wire core 101 is made by one or more connection methods including resistance welding, friction welding, ultrasonic welding, arc welding, laser welding, electron beam welding, pressure diffusion welding, magnetic induction welding, screwing, fastening, joining, and crimping.

[0109] Resistance welding is a method in which a strong current flows through the contact point between the electrode and the workpiece, causing contact resistance to generate heat, thereby achieving welding. The first fixed portion 111 and the conductive portion of the wire core 101 are welded by resistance welding.

[0110] Friction welding is a welding method in which the heat generated by friction on the contact surfaces of the workpieces is used as a heat source to plastically deform the workpieces by applying pressure. The first fixing portion 111 and the conductive portion of the wire core 101 are welded by friction welding.

[0111] The ultrasonic welding method uses high-frequency vibration waves transmitted to the surfaces of two objects to be welded, and when pressure is applied, the surfaces of the two objects are rubbed against each other to form inter-molecular fusion. The first fixing part 111 and the conductive part of the wire core 101 are welded by the ultrasonic welding method.

[0112] Arc welding uses an arc as a heat source and uses the physical phenomenon of air discharge to convert electrical energy into the thermal and mechanical energy required for welding, thereby achieving the goal of joining metals.The main methods include shielded arc welding, submerged arc welding, and gas-shielded welding.

[0113] Laser welding is a highly efficient precision welding method that uses a laser beam with high energy density as a heat source.

[0114] Electron beam welding is a method of achieving welding by using an accelerated and focused electron beam to impact the welding surface placed in a vacuum or non-vacuum, thereby melting the workpiece to be welded.

[0115] Pressure welding is a method of completing welding by applying pressure to the welding parts to bring the joining surfaces into close contact and causing a certain degree of plastic deformation.

[0116] Diffusion welding is a solid-state welding method in which the workpieces are pressed together at high temperatures without visible deformation or relative movement.

[0117] The magnetic induction welding method is a method in which two workpieces to be welded are instantaneously collided at high speed by the action of a strong pulsed magnetic field, and the action of a very high pressure wave on the surface of the materials causes the atoms of the two materials to meet within the interatomic distance, forming a stable metallurgical bond at the interface. This magnetic induction welding method is a type of solid-state cold welding and can weld the first fixed part 111 and the first cable, which have similar or dissimilar properties.

[0118] The screw connection method refers to a screw connection, which is a method of using a threaded part (or the threaded portion of the connected parts) to integrate and detachably connect the connected parts. General-purpose threaded connections include bolts, studs, screws, and fastening screws, and standard parts are often used.

[0119] The locking method refers to the provision of corresponding locking claws or locking grooves on the connection ends or connection surfaces, and the assembly and connection are carried out by the locking grooves or locking claws. The locking method has the advantage of being quick to connect and detachable.

[0120] The joint method refers to the installation of corresponding grooves or protrusions on the connecting ends or connecting surfaces, and the assembly and connection are carried out by means of mortise and tenon joints or joints through the grooves or protrusions. The joint method has the advantages of being stable and detachable.

[0121] The crimp connection method is a production process in which the connection end and the connection surface are assembled and then 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 produced quickly and in large quantities.

[0122] According to the above-mentioned connection method, an appropriate connection method or combination of connection methods can be selected depending on the actual usage environment and the actual usage state of the first fixing portion 111 and the conductive portion of the wire core 101, thereby enabling effective electrical connection.

[0123] In one embodiment, the insertion portion 112 is columnar, and at least a portion of the insertion portion 112 protrudes from the inner housing 30. Alternatively, the inner housing 30 has a groove, and at least a portion of the insertion portion 112 protrudes from the bottom of the groove but does not extend beyond the inner housing 30. The insertion portion 112 protrudes from the inner housing 30 and can be inserted into a corresponding recessed ground terminal 21 of the power device to be inserted into, thereby achieving electrical connection. Alternatively, as shown in FIG. 5 , the inner housing 30 has a groove, and the insertion portion 112 protrudes from the bottom of the groove. The power device to be inserted into has a protruding ground terminal 21, and the ground terminal 21 can be inserted into the insertion portion 112 in the groove to achieve electrical connection.

[0124] In one embodiment, the insertion portion 112 is cylindrical, and at least a portion of the insertion portion 112 protrudes from the outer wall of the inner housing 30. Alternatively, the inner housing 30 may have an opening boss, and at least a portion of the insertion portion 112 may be disposed within the opening boss. The insertion portion 112 protrudes from the outer wall of the inner housing 30 and may be inserted into a recessed mating insertion portion 212 of the power device to be inserted therein for electrical connection. Alternatively, as shown in FIG. 6 , the inner housing 30 may have an opening boss, the insertion portion 112 may be positioned within the opening boss, and the power device to be inserted therein may have a protruding ground terminal 21, and the ground terminal 21 may be inserted into the insertion portion 112 within the opening boss for electrical connection.

[0125] In one embodiment, the protective shield case 40 encases at least the first fixing portion 111 and at least a portion of the functional cable 10, but is insulated from the insertion terminal 11 and the conductive portion of the functional cable 10. Because the insertion terminal 11 and the wire core 101 are sources of interference signals, the protective shield case 40 encases at least the insertion terminal 11 and the wire core 101 to shield the interference signals. Furthermore, because the insertion portion 112 and the mating insertion portion 212 are inserted and electrically connected, the protective shield case 40 must also form a shielding mechanism together with the power device. However, the protective shield case 40 must encase at least the first fixing portion 111. Furthermore, because signals in most functional cables 10 are shielded by the shielding layer 12, it is sufficient to simply remove the portion of the shielding layer 12 that has entered the protective shield case 40 and electrically connect it to the protective shield case 40. Therefore, as shown in FIGS. 7 to 9, the protective shield case 40 encases at least the first fixing portion 111 and at least a part of the functional cable 10.

[0126] In one embodiment, the inner housing 30 is injection molded integrally with at least the outer periphery of the first fixing portion 111 and the conductive portions of the insertable terminals 11 and functional cable 10, thereby providing an insulating function. The integral injection molding method allows the inner housing 30 to be molded directly around at least the outer periphery of the first fixing portion 111 and the conductive portions of the insertable terminals 11 and functional cable 10, ensuring that the conductive portions of the insertable terminals 11 and functional cable 10 will not be connected to other conductors in the outside world and short-circuited.

[0127] Furthermore, the protective shielding case 40 surrounds at least a portion of the outer periphery of the inner housing 30, and is injection molded to be integrated with at least a portion of the outer periphery of the inner housing 30. The integrated injection molding method allows the protective shielding case 40 to be molded directly onto a portion of the outer periphery of the inner housing 30 and to be directly electrically connected to the shielding layer 12, ensuring good signal shielding performance.

[0128] In one embodiment, an outer insulating case 50 is integrally injection molded around the outer periphery of the inner housing 30 and / or the protective shielding case 40, and the outer insulating case 50 encloses at least a portion of the inner housing 30 and / or the protective shielding case 40, as well as at least a portion of the functional cable 10 and the protective conductor 20. The integral injection molding method allows the outer insulating housing 50 to be molded directly around the outer periphery of the inner housing 30 and / or the protective shielding case 40, ensuring that the protective shielding case will not be connected to other conductors in the outside world and cause a short circuit.

[0129] In one embodiment, the shielded connection mechanism includes an interlock connection mechanism 13, at least a portion of which is integrally injection molded within the inner housing 30. A high-voltage interlock is a security design method for monitoring the integrity of a high-voltage circuit using a low-voltage signal. Specific implementations of the high-voltage interlock vary depending on the application. The high-voltage interlock monitors for unexpected interruptions in the high-voltage circuit and prevents damage to the vehicle in the event of a sudden loss of power. As shown in FIG. 7 , the interlock connection mechanism 13 in this embodiment has two mating pins that are electrically connected, forming a U-shaped or V-shaped low-voltage circuit. This low-voltage circuit does not require installation; it is molded directly into the inner housing 30 using an integral injection molding method and can be matched and connected to the high-voltage interlock structure of the mating mechanism to form a low-voltage monitoring circuit. If the shielded connection mechanism in this embodiment is accidentally disconnected, the connection between the interlock connection mechanism 13 and the high-voltage interlock structure will also be disconnected at the same time, and a warning will be sent from the low-voltage monitoring circuit to the central control system, making it possible to control the vehicle so that it does not suffer damage due to a sudden loss of power.

[0130] In one embodiment, the ground terminal 21 includes a second fixing portion 211 and a mating insertion portion 222. The second fixing portion 211 is electrically connected to the protective conductor 20, and the mating insertion portion 212 is cylindrical or columnar. The second fixing portion 211 is electrically connected to a conductive portion of the protective conductor 20, thereby achieving circuit continuity. The mating insertion portion 212 may be cylindrical or columnar. A power device that is mated with the connection mechanism is also provided with a terminal, and the tip of the terminal may be columnar or cylindrical. As shown in FIGS. 5 and 6 , the columnar terminal and the cylindrical terminal are mated with each other to enable a releasable connection in the circuit.

[0131] Furthermore, the connection between the second fixing part 111 and the conductive part of the protective conductor 20 may be made by one or more of resistance welding, friction welding, ultrasonic welding, arc welding, laser welding, electron beam welding, pressure diffusion welding, magnetic induction welding, screwing, fastening, bonding, and crimping, similar to the connection between the first fixing part 111 and the functional cable 10.

[0132] In one embodiment, the mating insertion portion 212 is columnar, and at least a portion of the mating insertion portion 212 protrudes from the inner housing 30; or the inner housing 30 has a groove, and at least a portion of the mating insertion portion 212 protrudes from the bottom of the groove but does not extend beyond the inner housing 30. As shown in FIG. 5 , the mating insertion portion 212 protrudes from the inner housing 30 and can be inserted into a recessed ground terminal 21 of the power device to be inserted into for electrical connection. Alternatively, the inner housing 30 has a groove, and the mating insertion portion 212 protrudes from the bottom of the groove, and the power device to be inserted into has a protruding ground terminal 21, and the ground terminal 21 can be inserted into the mating insertion portion 212 in the groove for electrical connection.

[0133] In one embodiment, the mating insertion portion 212 is cylindrical, and at least a portion of the mating insertion portion 212 protrudes from the outer wall of the inner housing 30, or the inner housing 30 is provided with an open boss, and at least a portion of the mating insertion portion 212 is provided within the open boss. As shown in Fig. 6, the mating insertion portion 222 protrudes from the outer wall of the inner housing 30 and can be inserted into a recessed ground terminal 21 of the power device to be inserted into for electrical connection. Alternatively, the inner housing 30 has an open boss, the mating insertion portion 212 is located within the open boss, and the power device to be inserted into can be provided with a protruding ground terminal 21 and can be inserted into the mating insertion portion 212 within the open boss for electrical connection.

[0134] In one embodiment, the inner housing 30 is injection molded integrally with at least the outer periphery of the second fixing portion 211 and the conductive portion of the protective conductor 20, thereby providing an insulating function. The integral injection molding method allows the inner housing 30 to be molded directly around at least the outer periphery of the second fixing portion 211 and the conductive portion of the protective conductor 21, ensuring that the ground terminal 21 and the conductive portion of the protective conductor 20 are not connected to other conductors in the outside world and short-circuited.

[0135] In one embodiment, the protective shielding case 40 surrounds at least the outer periphery of the second fixed portion 211 and / or the conductive portion of the protective conductor 20, and the protective shielding case 40 is electrically connected to the second fixed portion 211 and / or the conductive portion of the protective conductor 20.

[0136] The protective shield case 40 of the present invention is electrically connected to the functional cable shield network, and also to the protective conductor 20 or the ground terminal, ensuring double grounding. Even if grounding via the functional cable shield network fails, grounding via the protective conductor 20 is possible, allowing the outflow of shielded current to be smoothly guided, and reducing electromagnetic shield interference.

[0137] In one embodiment, the connection mechanism has a sealing structure that is secondary injection molded into the inner housing 30 and / or the protective shield case 40. The sealing structure allows for a tighter connection between the connection mechanism and the power device to which it is inserted. The sealing structure of the connection mechanism does not use a separately attached sealing ring, but instead uses a secondary injection molded structure that can be molded directly into the connection mechanism, improving the bonding strength of injection molding and reducing costs.

[0138] In one embodiment, the connection mechanism has a sealed structure, which is formed by secondary injection molding on the outer insulating case 50. The sealed structure allows for a tighter connection between the connection mechanism and the mating power device.

[0139] Furthermore, the sealing structure is made of rubber, soft rubber, or silicone rubber. Using these materials allows the material to be heated and melted using an injection molding machine and then injected into a corresponding mold, simplifying processing and enabling strong bonding, thereby maximizing the service life of the sealing structure 30. Furthermore, these materials have good elasticity, allowing them to be pressed and deformed during assembly of the connection mechanism, filling gaps and providing good sealing performance. Furthermore, the materials are water- and oil-resistant, ensuring a long service life and stable sealing performance of the sealing structure.

[0140] The maximum gap between the sealed structure and the inner housing 30 and / or the protective shield case 40 is less than 520 nm.

[0141] To verify the effect of the size of the gap between each sealing structure and adjacent equipment on the sealing level, the inventors tested the sealing devices using a dry air method. The internal and external pressures of the sample being measured were controlled differently by vacuum suction or air pressure application. If there was a leak, the difference between the internal and external pressures would be small. The seal integrity could be detected by detecting changes in air pressure. The detection medium was dry air, which is non-toxic and harmless and will not damage the item being measured. The testing environment was clean. Taking the case of testing a sealing structure installed in the inner housing 30 as an example, the inventors completely sealed the remaining connections between the inner housing 30 and the protective shield case 40. They selected sealing structures with different sealing levels, sucked in some of the dry air from the sealing structure to ensure that the air pressure inside the sealing structure was lower than the external air pressure, and continuously monitored the internal air pressure of the sealing structure. A higher air pressure was deemed a failure. The test results are shown in Table 5.

[0142] Table 5. Effect of maximum gap between the sealing structure and the inner housing 30 and / or the protective shield case 40 on changes in air pressure [Table 5] As can be seen from Table 5, if the maximum gap between the sealing structure and the inner housing 30 and / or the protective shielding case 40 exceeds 520 nm, the air pressure will change, indicating that gas has entered the sealing structure, resulting in a test failure. Therefore, the inventors select the maximum gap between the sealing structure and the inner housing 30 and / or the protective shielding case 40 to be 520 nm or more.

[0143] In one embodiment, the connection mechanism has at least one temperature measuring component for measuring the temperature of the insertion terminals 11 and / or the ground terminals 21. The temperature measuring component may be located at a certain distance from the insertion terminals 11 and / or the ground terminals 21, and may transmit thermal radiation from the insertion terminals 11 and / or the ground terminals 21 to the temperature measuring component, which then measures the temperature of the insertion terminals 11 and / or the ground terminals 21. Alternatively, the temperature measuring component may include a conductive element that is in close contact with the insertion terminals 11 and / or the ground terminals 21, and may measure the temperature of the insertion terminals 11 and / or the ground terminals 21 from the temperature transmitted by the conductive element, transmit the measured temperature to a control system, and adjust the temperature of the connection mechanism 10 by adjusting the current flowing through the insertion terminals 11 and / or the ground terminals 21.

[0144] Furthermore, the temperature measuring component is in close contact with the insertion terminal 11 and / or the ground terminal 21, and the temperature measuring component is a temperature sensor that is directly in close contact with the insertion terminal 11 and / or the ground terminal 21, thereby directly obtaining the actual temperature of the insertion terminal 11 and / or the ground terminal 21. There is no need to obtain the actual temperature of the insertion terminal 11 and / or the ground terminal 21 by calculation, which simplifies the structure and enables more accurate temperature measurement.

[0145] The temperature sensor is an NTC temperature sensor or a PTC temperature sensor. The use of these two types of temperature sensors offers the following advantages: Their small volume allows them to measure gaps that other thermometers cannot measure. They are easy to use, and their resistance value can be selected from the range of 0.1 to 100 kΩ. They can be easily processed into complex shapes, allowing for mass production. They are stable and have a strong overload capacity, making them suitable for products that require small volume and stable performance, such as conversion adapters.

[0146] By using a temperature measurement component, the temperature of the terminals inside the connection mechanism can be monitored individually, avoiding the inability to monitor the temperature of the connection mechanism due to damage to temperature sensors in other locations.

[0147] In one embodiment, the material of the insertion terminal 11 and / or the ground terminal 21 includes one or more of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium, and beryllium.

[0148] To verify the influence of different materials on the conductivity of the insertion terminal 11 or the ground terminal 21, the inventors took the ground terminal 21 as an example and tested the conductivity of two samples of the ground terminal 11 that had the same specifications and dimensions but were made of different materials. The experimental results are shown in Table 6. In this example, it is ideal for the conductivity of the ground terminal 21 to be over 99%.

[0149] Table 6. Effect of different materials on the conductivity of the ground terminal 21 [Table 6] As can be seen from Table 6, the electrical conductivity of the ground terminal 21 made from the selected metal materials is within the ideal range. Furthermore, phosphorus is a non-metallic material and cannot be used directly as a material for the metal insert. However, when added to other metals to form an alloy, it can improve the electrical conductivity and mechanical properties of the metal itself. Therefore, the inventors selected the material of the ground terminal 21 to include one or more of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium, and beryllium.

[0150] In one embodiment, the material of the conductive portion of the functional cable 10 or the protective conductor 20 includes one or more of aluminum, phosphorus, tin, copper, iron, manganese, chromium, titanium, and lithium.

[0151] To verify the influence of different materials on the conductivity of the functional cable 10 or protective conductor 20, the inventors took the functional cable 10 as an example and tested the conductivity of functional cable 10 using samples of functional cable 10 that had the same specifications and dimensions but were made of different materials. The experimental results are shown in Table 7. In this example, it is ideal for the conductivity of the functional cable 10 to be over 99%.

[0152] Table 7. Influence of different materials on the conductivity of functional cable 10 [Table 7] As can be seen from Table 7, the electrical conductivity of the functional cable 10 made from the metal materials selected by the inventors is within the ideal range, while some other materials do not meet the requirements. Furthermore, phosphorus is a non-metallic material and cannot be used directly as a material for the functional cable 10. However, when added to other metals to form an alloy, it can improve the conductive and mechanical properties of the metal itself. Therefore, the inventors have set the material of the conductive portion of the functional cable 10 or the protective conductor 20 to include one or more of aluminum, phosphorus, tin, copper, iron, manganese, chromium, titanium, and lithium.

[0153] Furthermore, the material of the functional cable 10 or the protective conductor 20 includes (or is) aluminum. When the material of the functional cable 10 or the protective conductor 20 is aluminum, the functional cable 10 or the protective conductor 20 becomes a charged aluminum wire. Aluminum wire has excellent electrical properties and its density is one-third that of copper, making it lighter than a copper harness and less expensive than copper.

[0154] In one embodiment, the weight of the connection mechanism is 272 g or less. If the weight of the connection mechanism is too large, the gravity force applied to the connection mechanism will be large, and if a vibration occurs in the power device, the entire connection mechanism will vibrate along with it. In this case, the connection mechanism will vibrate significantly due to inertia, and may emit abnormal noise. However, the generation of abnormal noise is unacceptable during use of the power device.

[0155] To verify the influence of the weight of the connection mechanism on the generation of abnormal noise, the inventors used connection mechanism samples with different weights, combined them with the power equipment to be inserted, and then mounted them on a vibration test stand to conduct a vibration test. During the vibration test, it was observed whether the connection mechanism generated abnormal noise. The test results are shown in Table 8.

[0156] Table 8. Effect of weight of connecting mechanism on generation of abnormal noise of connecting mechanism [Table 8] As can be seen from Table 8, if the weight of the connecting mechanism exceeds 272g, the connecting mechanism will generate abnormal noise during the vibration test, resulting in a failure of the test. Therefore, the inventors select the weight of the connecting mechanism to be 272g or less.

[0157] In one embodiment, the height of the connection mechanism in the insertion / removal direction is 274 mm or less. The connection mechanism needs to be attached to the power device, but generally, the reserved space in the power device is relatively small. If the height of the connection mechanism is high, on the one hand, it cannot be attached to the power device, and on the other hand, raw materials may be wasted. Therefore, the connection mechanism needs to be designed to be lower than a certain height.

[0158] To verify the effect of the height of the connecting mechanism in the insertion / removal direction on the installation of the connecting mechanism, the inventors assembled and installed samples of connecting mechanisms with different heights in the insertion / removal direction to a power device. During the installation process, they observed whether the connecting mechanism interfered with other components in the power device. The test results are shown in Table 9.

[0159] Table 9. Effect of altitude on the installation of the connection mechanism in the insertion / removal direction of the connection mechanism [Table 9] As can be seen from Table 9, if the height of the connection mechanism in the insertion / removal direction exceeds 274 mm, it cannot be attached to the specified position on the power device, and the test result will be a failure. Therefore, the inventors set the height of the connection mechanism in the insertion / removal direction to be 274 mm or less.

[0160] In one embodiment, at least a portion of the surface of the insertion terminal 11 and / or the ground terminal 21 is provided with a conductive anticorrosion layer.

[0161] If the materials of the insertion terminals 11 and the ground terminals 21 do not match the materials of the mating terminals, the conduction between them will cause a potential difference, resulting in galvanic corrosion and shortening the service life of the insertion terminals 11 and the ground terminals 21. To reduce the occurrence of such galvanic corrosion, a conductive anticorrosion layer may be provided on at least a portion of the surface of the insertion terminals 11 and the ground terminals 21. The material of the conductive anticorrosion layer may be a metallic material whose potential is between the potential of the material of the insertion terminals 11 and the ground terminals 21 and the potential of the material of the mating terminals. This will insulate the insertion terminals 11 and the ground terminals 21 from the mating terminals, reducing the occurrence of galvanic corrosion and extending the service life of the insertion terminals 11 and the ground terminals 21.

[0162] Furthermore, the conductive anticorrosion layer is attached to at least a portion of the surface of the insertion terminal 11 and / or the ground terminal 21 by one or more of the following methods: electrolytic plating, electroless plating, magnetron sputtering, vacuum plating, pressure welding, diffusion welding, friction welding, resistance welding, ultrasonic welding, and laser welding.

[0163] Electroplating is a process that uses electrolysis to plate a thin layer of another metal or alloy onto the surface of some metals.

[0164] Electroless plating is a process in which metals are deposited through a controllable oxidation-reduction reaction under the catalytic action of the metal.

[0165] The magnetron sputtering method uses the interaction of a magnetic field and an electric field to cause electrons to move in a spiral pattern near the target surface, increasing the probability that the electrons will collide with argon gas and generate ions.The generated ions then collide with the target surface due to the action of the electric field and are sputtered from the target.

[0166] Vacuum plating is the process of depositing various metal and non-metal thin films on the surface of plastic materials by evaporation or sputtering under vacuum conditions.

[0167] Pressure welding is a method of completing welding by applying pressure to the welding parts to bring the joining surfaces into close contact and generate a certain amount of plastic deformation.

[0168] Friction welding is a welding method that uses the heat generated by friction on the contact surfaces of the workpieces as a heat source to plastically deform the workpieces using pressure.

[0169] Resistance welding is a method in which a strong current flows through the contact point between an electrode and a workpiece, causing the contact resistance to generate heat and thereby achieving welding.

[0170] Ultrasonic welding is a method of transmitting high-frequency vibration waves to the surfaces of two objects to be welded, and when pressure is applied, the surfaces of the two objects are rubbed against each other to form a fusion between the molecular layers.

[0171] Laser welding is a highly efficient precision welding method that uses a laser beam with high energy density as a heat source.

[0172] Diffusion welding is a solid-state welding method in which workpieces are pressed at high temperatures without visible deformation or relative movement. By using any one of the above methods or a combination thereof, the conductive anticorrosion layer can be stably installed on at least a portion of the surface of the insertion terminal 11 and / or the ground terminal 21.

[0173] In one embodiment, the thickness of the conductive anticorrosion layer is 0.3 μm to 3000 μm.

[0174] In one embodiment, the thickness of the conductive and anticorrosive layer is 2.5 μm to 1000 μm.

[0175] To test the effect of different thicknesses of the conductive anticorrosion layer on the voltage drop, the inventors used insertion terminals 11 and ground terminals 21 that have the same material and structure, and placed conductive anticorrosion layers of different thicknesses on at least a portion of the surface of the insertion terminals 11 and ground terminals 21. After that, they tested the voltage drop after inserting the insertion terminals 11 and ground terminals 21 into their mating terminals. The results are shown in Table 10.

[0176] In this embodiment, if the voltage drop after the insertion terminal 11 and the ground terminal 21 are inserted into the mating terminal exceeds 4 mV, the connector is deemed to be unacceptable.

[0177] Table 10. Effect of different thicknesses of conductive anticorrosion layer on voltage drop (mV) [Table 10] As can be seen from the data in Table 10 above, when the thickness of the conductive corrosion protection layer exceeds 3000 μm or is less than 0.3 μm, the voltage drop in the insertion structure after the insertion terminals 11 and ground terminals 21 are inserted into the mating terminals exceeds 4 mV, which does not satisfy the required value. Therefore, the inventors selected the thickness of the conductive corrosion protection layer to be 0.3 μm to 3000 μm. Here, when the thickness of the conductive corrosion protection layer is within the range of 2.5 μm to 1000 μm, the voltage drop in the insertion structure in which the insertion terminals 11 and ground terminals 21 are inserted into the mating terminals is optimal. Therefore, the inventors preferably selected the thickness of the conductive corrosion protection layer to be 2.5 μm to 1000 μm.

[0178] In one embodiment, the material of the conductive anticorrosion layer includes one or more of nickel, cadmium, manganese, zirconium, cobalt, tin, titanium, chromium, gold, silver, zinc, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, hard silver, and silver-gold-zirconium alloy.

[0179] Preferably, the potential of the material of the conductive anticorrosion layer is between the potential of the material of the insertion terminal 11 and the ground terminal 21 and the potential of the material of the mating terminal, which can reduce the occurrence of galvanic corrosion after the insertion terminal 11 and the ground terminal 21 are inserted into the mating terminal.

[0180] Similarly, the following will take the insertion terminal 11 and the ground terminal 21 as an example. The insertion terminal 11 and the ground terminal 21 are provided with a conductive anticorrosion layer. To verify the effect of different materials for the conductive anticorrosion layer on the performance of the insertion terminal 11 and the ground terminal 21, the inventors conducted a series of corrosion resistance time tests using insertion terminals 11 and ground terminals 21 with the same specifications and materials but different materials for the conductive anticorrosion layer. The experimental results are shown in Table 11.

[0181] The corrosion resistance time test in Table 11 is performed as follows: A sample of the terminal 11 and the ground terminal 21 is placed in a salt spray test box, and salt spray is applied to each position on the terminal 11 and the ground terminal 21. Every 20 hours, the terminal 11 and the ground terminal 21 are removed and the surface corrosion is observed. This series of operations constitutes one cycle. When the corrosion area on the surface of the terminal 11 and the ground terminal 21 sample exceeds 10% of the total area, the test is terminated and the number of cycles at that time is recorded. In this example, a test is deemed to have failed if the number of cycles is less than 80.

[0182] Table 11. Influence of differences in the material of the conductive anticorrosion layer on the corrosion resistance of the specimens of the insertion terminal 11 and the ground terminal 21 [Table 11] As can be seen from Table 11, when the conductive protection layer material contains the common metals tin, nickel, and zinc, the experimental results are far inferior to those of the other selected metals. The experimental results for the other selected metals far exceeded the standard values, revealing relatively stable performance. Therefore, the inventors selected the conductive protection layer material to include (or be) one or more of nickel, cadmium, manganese, zirconium, cobalt, tin, titanium, chromium, gold, silver, zinc, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, hard silver, and silver-gold-zirconium alloy. More preferably, the conductive protection layer material is selected to include (or be) one or more of cadmium, manganese, zirconium, cobalt, titanium, chromium, gold, silver, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, hard silver, and silver-gold-zirconium alloy.

[0183] In one embodiment, the conductive portion of the protective conductor 20 is integrally molded with the ground terminal 21. The conductive portion of the protective conductor 20 and the ground terminal 21 may be manufactured using the same material. That is, the conductive portion of the protective conductor 20 may be extended and molded as the ground terminal 21. This eliminates the need for the ground terminal 21, reduces material costs, reduces the number of processing steps, and allows the tip of the conductive portion of the protective conductor 20 to be molded into multiple shapes as required, eliminating the need to consider assembly issues.

[0184] In one embodiment, the conductive portion of the cable 10 is integrally molded with the insertion terminal 11. The conductive portion of the cable 10 and the insertion terminal 11 may be manufactured from the same material. That is, the conductive portion of the cable 10 may be extended and molded into the insertion terminal 11. This eliminates the need for the insertion terminal 11, reduces material costs, reduces processing man-hours, and allows the tip of the conductive portion of the cable 10 to be molded into multiple shapes as required, eliminating the need to consider assembly issues.

[0185] The present invention further discloses a power transmission device including the above-described shielded connection mechanism.

[0186] The present invention further discloses a vehicle comprising a shielded connection mechanism as described above and a power transmission device as described above.

[0187] The shielded connection mechanism of the present invention is provided with an inner housing that is injection-molded integrally with the functional cable and the insertion terminals, making it easy to process and far less expensive than a metal housing for the shield. The insertion engagement between the shielded connection mechanism and the mating connection mechanism, and the electrical connection between the shielded connection mechanism and the functional cable shield network and protective conductor, effectively shields electromagnetic interference within the connection mechanism, reducing the occurrence of electromagnetic interference in other devices.

[0188] The connection between the protective shield case and the functional cable shield mesh in the present invention can be made using multiple methods, so that the protective shield case and the shield mesh can be connected stably and effectively, resulting in good shielding effect.

[0189] The protective shield case of the present invention is electrically connected to the functional cable shield network, and also to the protective conductor or ground terminal, ensuring double grounding. Even if grounding via the functional cable shield network fails, grounding via the protective conductor is possible, allowing the outflow of shielded current to be smoothly guided, and reducing electromagnetic shield interference.

[0190] The fitted-in type high-voltage interlock structure is used in place of the conventional assembled type high-voltage interlock structure, and is injection-molded and fixed integrally with the connection mechanism, eliminating the need for assembly, reducing costs, and providing the full benefits of the high-voltage interlock.

[0191] The sealing structure of the connection mechanism is not a separately attached sealing ring, but a secondary injection molded structure is used instead of the traditional sealing ring, which can be molded directly onto the connection mechanism, improving the bonding properties of the injection molding and reducing costs.

[0192] By using a temperature measurement component, the temperature of the terminals inside the connection mechanism can be monitored individually, avoiding the inability to monitor the temperature of the connection mechanism due to damage to temperature sensors in other locations.

[0193] The above description is merely a few examples of the present invention, and those skilled in the art can make various modifications and variations to the embodiments of the present invention based on the contents disclosed in the application documents without departing from the spirit and scope of the present invention. [Explanation of symbols]

[0194] 10 Function Cable 11 Insertion terminal 12 Shielding layer 111 1st fixed part 112 Insertion part 101 wire core 102 Insulating layer 13 Interlock connection mechanism 20 Protective conductor 21 Ground terminal 211 Second fixed part 212 Mating insertion part 30 Inner housing 40 Protective Shield Case 41 Shielding Device 42 Conductive elastic piece 50 Outer insulating case.

Claims

1. A function cable, A plug terminal and an inner housing integrally formed with the functional cable and the insertion terminal; a protective shield case provided on at least a portion of the outer periphery of the inner housing, The functional cable is provided with a shielding layer, a gap is formed between the inner surface of the protective shielding case and the outer surface of the shielding layer; At least one pair of conductive elastic pieces is provided on the inner surface of the protective shielding case to electrically connect the protective shielding case and the shielding layer, The pair of conductive elastic pieces sandwich the shield layer so as to be electrically connected to the shield layer. Shielded connection mechanism.

2. a protective conductor and a ground terminal; the protective shield case is at least partially electrically connected to the protective conductor or the ground terminal; 2. The shielded connection mechanism of claim 1.

3. 2. The shielded connection mechanism according to claim 1, wherein the pressure applied by the conductive elastic piece ranges from 0.3N to 95N.

4. The impedance between the protective shielding case and the shielding layer is less than 80 mΩ.

2. The shielded connection mechanism of claim 1.

5. 2. The shielded connection mechanism of claim 1, wherein the protective shielding case has a transimpedance of less than 100 mΩ.

6. The insertion terminal includes a first fixing portion and an insertion portion, which are sequentially arranged.

2. The shielded connection mechanism of claim 1.

7. The functional cable includes: The innermost wire core; a shield layer fitted around the outer periphery of the wire core; an insulating layer fitted around the outer periphery of the shielding layer, The first fixed portion and the conductive portion of the wire core are electrically connected to each other.

7. The shielded connection mechanism of claim 6.

8. The insertion portion is columnar, At least a portion of the insertion portion protrudes from the inner housing, or The inner housing has a recessed groove, and at least a portion of the insertion portion protrudes from a bottom surface of the recessed groove but does not extend beyond the inner housing.

7. The shielded connection mechanism of claim 6.

9. The insertion portion is cylindrical, At least a portion of the insertion portion protrudes from the outer wall of the inner housing, or The inner housing is provided with an opening boss, and at least a portion of the insertion portion is provided within the opening boss.

7. The shielded connection mechanism of claim 6.

10. the protective shielding case encloses at least the first fixing portion and at least a portion of the functional cable, but is insulated from the insertion terminal and a conductive portion of the functional cable; 7. The shielded connection mechanism of claim 6.

11. The inner housing is injection-molded to be integrated with at least the first fixing portion, the insertion terminal, and the conductive portion of the functional cable, thereby providing an insulating function.

7. The shielded connection mechanism of claim 6.

12. the protective shield case encloses at least a portion of the outer periphery of the inner housing, The protective shield case is injection molded integrally with at least a portion of the outer periphery of the inner housing.

2. The shielded connection mechanism of claim 1.

13. an outer insulating case is integrally formed by injection molding on the outer periphery of the inner housing and / or the protective shield case; the outer insulating case encases at least a portion of the inner housing and / or the protective shield case and at least a portion of the functional cable; 2. The shielded connection mechanism of claim 1.

14. the connection mechanism includes an interlock connection mechanism; At least a portion of the interlock connection mechanism is integrally injection molded within the inner housing.

2. The shielded connection mechanism of claim 1.

15. the ground terminal includes a second fixing portion and a mating insertion portion, The shielded connection mechanism according to claim 2 , wherein the second fixing portion is electrically connected to the protective conductor.

16. The mating insertion portion is columnar, At least a portion of the mating insertion portion protrudes from the inner housing, or The inner housing has a recessed groove, and the mating insertion portion at least partially protrudes from the bottom surface of the recessed groove but does not extend beyond the inner housing.

16. The shielded connection mechanism of claim 15.

17. The mating insertion portion is cylindrical, At least a portion of the mating insertion portion protrudes from the outer wall of the inner housing, or The inner housing is provided with an opening boss, and at least a portion of the mating insertion portion is provided within the opening boss.

16. The shielded connection mechanism of claim 15.

18. The inner housing is injection-molded to be integrated with at least the outer periphery of the second fixing portion and the conductive portion of the protective conductor, and exhibits an insulating function.

16. The shielded connection mechanism of claim 15.

19. the protective shielding case surrounds at least an outer periphery of the second fixing portion and / or a conductive portion of the protective conductor, the protective shielding case is electrically connected to the second fixed portion and / or the conductive portion of the protective conductor.

16. The shielded connection mechanism of claim 15.

20. 2. The shielded connection mechanism according to claim 1, wherein the shielded connection mechanism has a sealed structure.

21. The outer periphery of the inner housing and / or the protective shield case includes an outer insulating case, the sealing structure is secondary injection molded into the inner housing and / or the protective shield case; and / or The sealing structure is formed by secondary injection molding on the outer insulating case.

21. The shielded connection mechanism of claim 20.

22. at least one temperature measuring component for measuring the temperature of the insertion terminal and / or the ground terminal; 3. The shielded connection mechanism of claim 2.

23. and at least one temperature measuring component that is in close contact with the insertion terminal and / or the ground terminal and that measures the temperature of the insertion terminal and / or the ground terminal.

3. The shielded connection mechanism of claim 2.

24. 2. The shielded connection mechanism of claim 1, wherein the shielded connection mechanism weighs 272 g or less.

25. 2. The shielded connection mechanism according to claim 1, wherein the length in the insertion / removal direction is 274 mm or less.

26. 3. The shielded connection mechanism according to claim 2, wherein a conductive anticorrosion layer is provided on at least a portion of the surface of the insertion terminal and / or the ground terminal.

27. 3. The shielded connection mechanism according to claim 2, wherein the conductive portion of the protective conductor is integrally molded with the ground terminal.

28. 2. The shielded connection mechanism according to claim 1, wherein the conductive portion of the functional cable is integrally formed with the insertion terminal.

29. A power transmission device comprising the shielded connection mechanism according to any one of claims 1 to 28.

30. A motor vehicle comprising the shielded connection mechanism according to any one of claims 1 to 28.

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