CN114759413A

CN114759413A - Connector assembly with solid cooling medium and vehicle

Info

Publication number: CN114759413A
Application number: CN202210248434.8A
Authority: CN
Inventors: 王超; 苗云
Original assignee: Jilin Zhong Ying High Technology Co Ltd
Current assignee: Jilin Zhong Ying High Technology Co Ltd
Priority date: 2022-03-14
Filing date: 2022-03-14
Publication date: 2022-07-15
Also published as: WO2023174293A1

Abstract

The invention discloses a connector assembly with solid cooling media and a vehicle, wherein the connector assembly comprises at least one electric connection framework and a connector, the connector comprises a connecting terminal, two ends of the electric connection framework are respectively and electrically connected with the connecting terminal, the electric connection framework is provided with a hollow inner cavity, the periphery of the electric connection framework is sleeved with a protective shell with shielding effectiveness, a cavity is formed between the periphery of the electric connection framework and the inner wall of the protective shell with shielding effectiveness, and at least part of the hollow inner cavity and the cavity is filled with solid or semi-solid cooling media. The invention can reduce the failure of the electric connection framework and the connecting terminal caused by high temperature generated by electrifying, improve the safety of the whole vehicle and play a role in shielding electromagnetic interference.

Description

Connector assembly with solid cooling medium and vehicle

Technical Field

The invention relates to the technical field of automotive electrical appliances, in particular to a connector assembly with a solid cooling medium and a vehicle.

Background

With the increasing popularization of new energy automobiles, equipment and facilities for transmitting electric energy for the new energy automobiles are developed, the connector assemblies on the new energy automobiles have large transmission current due to the fact that the requirements of high-power motors are met, the diameters of high-voltage cables on the connector assemblies are increased, the connectors can be assembled on automobile bodies only by hand, and labor cost and time cost are wasted.

In addition, in the normal use process, the high-voltage cable can flow through very large current, so that the high-voltage cable and the connecting joint can generate a large amount of heat, high temperature can be caused due to excessive heat, the connecting position of the high-voltage cable and peripheral connecting pieces and fixing pieces can be out of work due to high temperature, the normal use of the connector assembly is influenced, short circuit and open circuit are generated, even electric shock hazard is generated, and the life is threatened.

High-voltage cable can produce very strong electromagnetic interference because the electric current is great, and in order to reduce electromagnetic interference's influence, high-voltage cable adopts the shielding net to carry out electromagnetic interference's shielding usually, and the shielding net of current commonly used adopts the wire to compile and forms, need increase the shielding braider in cable production facility, and equipment price is high, and area is big, and the shielding cable price that leads to the connector is high at all. At present, the shielding technology of the connector is not particularly perfect, and the electric appliances in the automobile are interfered and cannot be used.

At present, no practical solution is provided for the above problems, and therefore, a connector assembly which has a small wire diameter, a low cable heat productivity and can realize automatic production and assembly is urgently needed in the technical field of automobile electrical appliances.

Disclosure of Invention

The object of the present invention is to provide a new solution for a connector assembly with a solid cooling medium and a vehicle. The connector assembly with the solid cooling medium can reduce the failure of the electric connection framework and the connecting terminal caused by high temperature generated by electrifying, reduce the diameter of the electric connection framework, prolong the service life of the connector, improve the safety of the whole vehicle and play a role in shielding electromagnetic interference.

According to a first aspect of the invention, there is provided a connector assembly with a solid cooling medium, comprising: skeleton and connector are connected to an at least electricity, include connecting terminal in the connector, it is connected with connecting terminal electricity respectively to connect the skeleton both ends to connect the skeleton, it has the cavity inner chamber to connect the skeleton electricity, it cup joints the protective housing that has shielding efficiency to connect the skeleton periphery electricity, connect the skeleton periphery electricity with form the cavity between the protective housing inner wall that has shielding efficiency, the cavity inner chamber with at least part fills solid-state or semi-solid state coolant medium in the cavity.

Optionally, the material of the electrical connection framework comprises a rigid hollow conductor material.

Optionally, the annular cross-sectional area of the electrical connection skeleton is 0.33mm ²-240mm²。

Optionally, the electrical connection framework is electrically connected with the connection terminal by welding or crimping.

Optionally, the protective shell material includes a rigid conductive material.

Optionally, the protective shell is made of metal or conductive plastic.

Optionally, the connector further comprises a shielding inner shell inside, and the material of the shielding inner shell contains a conductive material.

Optionally, the material of the shielding inner shell includes metal or conductive plastic.

Optionally, the conductive plastic is a polymer material containing conductive particles, and the conductive particle material contains one or more of metal, conductive ceramic, a carbon-containing conductor, a solid electrolyte and a mixed conductor; the material of the high polymer material comprises tetraphenyl ethylene, polyvinyl chloride, polyethylene, polyamide, polytetrafluoroethylene, tetrafluoroethylene/hexafluoropropylene copolymer, ethylene/tetrafluoroethylene copolymer, polypropylene, polyvinylidene fluoride, polyurethane, poly terephthalic acid, polyurethane elastomer, styrene block copolymer, perfluoroalkoxy alkane, chlorinated polyethylene, polyphenylene sulfide, polystyrene, crosslinked polyolefin, ethylene-propylene rubber, ethylene/vinyl acetate copolymer, chloroprene rubber, natural rubber, styrene-butadiene rubber, nitrile rubber, silicone rubber, butadiene rubber, isoprene rubber, ethylene-propylene rubber, chloroprene rubber, butyl rubber, fluorine rubber, polyurethane rubber, polyacrylate rubber, chlorosulfonated polyethylene rubber, epichlorohydrin rubber, chlorinated polyethylene rubber, chlorosulfonated sulfur rubber, styrene butadiene rubber, ethylene-propylene rubber, polyphenylene sulfide, polystyrene-butadiene rubber, styrene-butadiene rubber, styrene-butadiene rubber, styrene-butadiene rubber, styrene, Hydrogenated nitrile rubber, polysulfide rubber, crosslinked polyethylene, polycarbonate, polysulfone, polyphenyl ether, polyester, phenolic resin, urea formaldehyde, styrene-acrylonitrile copolymer, polymethacrylate and polyformaldehyde resin.

Optionally, the material of the metal contains one or more of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium and beryllium.

Optionally, the carbon-containing conductor contains one or more of graphite powder, carbon nanotube material, graphene material, graphite silver, or graphene silver.

Optionally, the protective shell is electrically connected with the shielding inner shell by means of crimping or welding.

Optionally, the impedance between the protective shell and the shielding inner shell is less than 80m Ω.

Optionally, the transfer impedance of the protective shell is less than 100m Ω.

Optionally, the transfer impedance of the shielding inner housing is less than 100m Ω.

Optionally, the thickness of the protective shell accounts for 1% -15% of the outer diameter of the protective shell.

Optionally, the outer diameter of the cavity is 1.02 times to 1.3 times of the outer diameter of the electrical connection skeleton.

Optionally, the cooling rate of the cooling medium to the electrical connection skeleton is 0.04K/s-9.8K/s.

Optionally, the cooling medium is a heat conduction adhesive tape, a heat conduction insulating elastic rubber, a flexible heat conduction pad, a heat conduction filler and a heat conduction insulating potting adhesive.

Optionally, the cooling medium is disposed on the periphery of the electrical connection framework by injection molding, extrusion molding, dipping, foaming, winding, weaving, pouring, filling or wrapping.

Optionally, the cooling medium contains one or more of quartz glass, silicon carbide, mica, sand, diamond, silicon, graphene, and derivatives or silicone grease.

Optionally, the volume of the cooling medium in the hollow inner cavity is greater than 1.1% of the volume of the hollow inner cavity.

Optionally, the volume of the cooling medium in the cavity is greater than 1.1% of the volume of the cavity.

Optionally, the cooling medium is distributed in an uneven state in the hollow inner cavity or the cavity.

Optionally, one of the connectors is a cradle.

Optionally, a partial region of the electrical connection skeleton is flexible.

Optionally, the electrical connection skeleton includes at least one bending part.

Optionally, the cross section of the electrical connection framework is in one or more of a circle, an ellipse, a rectangle, a polygon, an A shape, a B shape, a D shape, an M shape, a P shape, an N shape, an O shape, an S shape, an E shape, an F shape, an H shape, a K shape, an L shape, a T shape, a U shape, a V shape, a W shape, an X shape, a Y shape, a Z shape, a P shape, a semi-arc shape, an arc shape and a wave shape.

According to a second aspect of the present invention, there is provided a vehicle comprising a connector assembly with a solid cooling medium as described in any of the above embodiments.

The beneficial effects of the invention are:

1. the connector assembly with the solid cooling medium can reduce the failure of the electric connection framework and the connecting terminal caused by high temperature generated by electrifying, reduce the diameter of the electric connection framework, prolong the service life of the connector and improve the safety of the whole vehicle.

2. The form of adopting the outer cover of electricity connection skeleton to connect the protective housing, the protective housing both had played the effect of constructing the cavity, can play the effect of shielding layer again, and the electromagnetic interference that the skeleton circular telegram produced is connected in effectual shielding electricity.

3. The problem that the wire diameter of the existing high-voltage wire harness is thick is solved, the technology of adding the solid cooling medium is used, the heat productivity of the electric connection framework is reduced, and the electric connection framework can conduct large current with small wire diameter.

4. The problem of present high-pressure pencil use flexible cable, can't realize automated production and assembly is solved, use the electric connection skeleton of at least part stereoplasm, can realize the automatic assembly and the equipment of high-pressure pencil.

5. The invention solves the problem of low cooling efficiency of the existing liquid cooling wire harness, and the existing liquid cooling wire harness is cooled by the liquid cooling pipe.

6. The problem of flexible cable and hull contact friction, lead to the damaged short circuit of insulating layer is solved, the electric connection skeleton can follow the automobile body shape and arrange, but also can have the certain distance with the automobile body, can guarantee not rub with the hull to guarantee the life of electric connection skeleton.

7. The connector is internally provided with the shielding inner shell, so that electromagnetic interference generated by a terminal of the connector can be effectively prevented, the shielding inner shell made of conductive plastic can be integrally formed with the connector in an injection molding mode, the processing time is saved, the production efficiency is improved, and the production cost is reduced.

8. The electric connection framework is further provided with a flexible part and a bending part, so that the structure of the connector assembly can be reasonably designed according to the installation environment of the automobile body, the connector assembly is easier to install on the automobile body, and the assembly time is saved.

Other features of the present invention and advantages thereof will become apparent from the following detailed description of exemplary embodiments thereof, which proceeds with reference to the accompanying drawings.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention.

FIG. 1 is a schematic view of a connector assembly with a solid cooling medium according to a preferred embodiment of the present invention.

Fig. 2 is a schematic structural diagram of the connection between the electrical connection skeleton of the connector assembly with solid cooling medium and the second connector according to the first embodiment of the present invention.

Fig. 3 is a schematic structural diagram of the connection between the electrical connection skeleton of the connector assembly with solid cooling medium and the second connector according to the second embodiment of the present invention.

Fig. 4 is a cross-sectional view of an electrical connection backbone of a connector assembly having a solid cooling medium in accordance with a preferred embodiment of the present invention.

The figures are labeled as follows:

11-a first connector, 12-a second connector, 2-an electric connection framework, 3-a hollow inner cavity, 4-a shielding inner shell, 5-a protective shell, 6-a cavity, 7-a connecting terminal and 8-a sealing ring.

Detailed Description

Various exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that: the relative arrangement of the components and steps, the numerical expressions and numerical values set forth in these embodiments do not limit the scope of the present invention unless specifically stated otherwise.

The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses.

Techniques, methods, and apparatus known to one of ordinary skill in the relevant art may not be discussed in detail but are intended to be part of the specification where appropriate.

In all examples shown and discussed herein, any particular value should be construed as exemplary only and not as limiting. Thus, other examples of the exemplary embodiments may have different values.

As shown in fig. 1 to 4, a connector assembly with a solid cooling medium includes at least one electrical connection frame 2 and a connector (as shown in fig. 1, the connector may include a first connector 11 and a second connector 12), the connector includes a connection terminal 7, two ends of the electrical connection frame 2 are respectively electrically connected to the connection terminal 7, the electrical connection frame 2 has a hollow inner cavity 3, the outer periphery of the electrical connection frame 2 is sleeved with a protective shell 5 with shielding effectiveness, a cavity 6 is formed between an outer wall of the electrical connection frame 2 and an inner wall of the protective shell 5, and at least part of the hollow inner cavity 3 and the cavity 6 is filled with a solid or semi-solid cooling medium.

Preferably, the cooling medium is disposed on the periphery of the electrical connection framework 2 by injection molding, extrusion molding, dipping, foaming, winding, weaving, pouring, filling or wrapping.

The injection molding process is a process for manufacturing a semi-finished product with a certain shape by pressurizing, injecting, cooling, separating and the like molten raw materials.

Extrusion molding is a high-efficiency, continuous and low-cost molding processing method, is an early technology in the processing of high polymer materials, and is a molding processing method with the most production varieties, the most changes, high productivity, strong adaptability, wide application and the largest proportion of output in the processing field of polymers.

The plastic dipping process is a process of electrically heating a workpiece to reach a certain temperature, then dipping the workpiece into plastic dipping liquid, and curing the plastic dipping liquid on the workpiece.

The foaming process is that in the foaming forming process or the foaming polymer material, a honeycomb or cellular structure is formed through the addition and reaction of a physical foaming agent or a chemical foaming agent. The basic steps of foam molding are the formation of bubble nuclei, the growth or enlargement of the bubble nuclei, and the stabilization of the bubble nuclei. At a given temperature and pressure, the solubility of the gas decreases so that saturation is reached, allowing excess gas to escape and form bubbles, thus achieving nucleation.

The winding is to directly wind the heat conduction adhesive tape on the periphery of the electric connection framework 2.

The weaving is to weave a plurality of strip-shaped cooling mediums alternately or in a hooking manner to be filled between the electric connection framework 2 and the protective shell 5.

The pouring is to pour the unformed cooling medium between the electrical connection framework 2 and the protective shell 5 and wait for solidification and forming.

The wrapping is that the heat conduction adhesive tape is integrally wrapped on the periphery of the electric connection framework 2.

The filling is to arrange a filling cavity at the periphery of the electric connection framework 2 and then fill the cooling medium into the filling cavity.

Preferably, the cooling medium comprises one or more of quartz glass, silicon carbide, mica, sand, diamond, silicon, graphene, and derivatives or silicone grease. The type of cooling medium can be selected according to actual needs.

Quartz glass is made by melting various pure natural quartz (such as crystal, quartz sand, etc.).

The silicon carbide is an inorganic substance, has a chemical formula of SiC, and is prepared by smelting quartz sand, petroleum coke (or coal coke), wood chips (salt is required when green silicon carbide is produced) and other raw materials in a resistance furnace at high temperature.

Mica is a rock-making mineral, presents a hexagonal flaky crystal form, and is one of the main rock-making minerals.

Sand, which refers to a loose mixture of sand and gravel.

Diamond is a mineral composed of carbon elements and is the hardest naturally occurring substance in nature. Graphite can be formed into synthetic diamonds at high temperature and high pressure.

Silicon exists mainly in the form of oxides and silicates with very high melting points. And is also a material for semiconductors.

Graphene is one represented by sp²The hybridized and connected carbon atoms are tightly packed into a new material with a single-layer two-dimensional honeycomb lattice structure.

The silicone grease is refined by taking silicone oil as a thickening inorganic thickening agent of base oil, and has good waterproof sealing property, waterproof property, solvent resistance and creepage resistance.

At present, cables on most connector assemblies are multi-core copper cables, so that the cables are heavy in weight and high in price, and become obstacles for limiting the popularization of new energy automobiles. In addition, although the multi-core cable is soft, the multi-core cable can be conveniently processed and wired, due to the fact that the diameter of the cable is too thick and the weight of the multi-core cable is large, the cable can frequently rub a car shell in the driving process of a car, an insulating layer of the cable is damaged, high-voltage discharge is caused, the car is damaged slightly, and serious traffic accidents are caused seriously. Therefore, the cable form of the electric connection framework can be used for replacing a multi-core cable structure, so that the cable can be fixed on a car shell, the friction between the cable and the car shell along with the vibration of a car can be avoided, the service life of the connector assembly is prolonged, and the accident rate is reduced. When the automobile charges, the current of the electric connection skeleton of flowing through is very big, and the temperature of the electric connection skeleton rises fast, and the cavity 6 and the hollow inner cavity 3 between the protective housing and the electric connection skeleton that have shielding effectiveness are filled with solid or semi-solid cooling medium and are used for cooling the electric connection skeleton 2, thereby cooling the electric connection skeleton 2 that generates heat and enabling the connector assembly to work at safe temperature.

In some embodiments, the material of the electrical connection frame 2 comprises a rigid hollow conductor material. Thereby, the hollow cavity 3 described above is formed. Furthermore, in order to reduce the heat generation of the electrical connection framework 2, the hollow interior 3 is also at least partially filled with a solid or semi-solid cooling medium.

In some embodiments, the volume of cooling medium in the hollow interior 3 is greater than 1.1% of the volume of the hollow interior 3. In order to verify the influence of the volume of the cooling medium on the temperature rise of the electrically-connected frameworks 2, the inventor selects 10 electrically-connected frameworks 2 with the same cross section area, the same material and the same length, applies the same current, adopts cooling media with different volumes to cool the electrically-connected frameworks 2, reads the temperature rise value of each electrically-connected framework 2, and records the temperature rise value in table 1.

The experimental method is that in a closed environment, the same current is conducted to the electric connection framework 2 adopting cooling media with different volumes, the temperature before electrifying and the temperature after electrifying are stable are recorded, and the absolute value is obtained by taking the difference. In this embodiment, a temperature rise of less than 50K is a pass value.

Table 1: influence of different volumes of cooling medium on temperature rise of electrical connection framework 2

As can be seen from table 1 above, when the volume fraction is less than 1.1%, the temperature rise value of the electrically connecting bobbin 2 is not good. Accordingly, the inventors set up to: the volume of the cooling medium in the hollow cavity 3 is more than 1.1% of the volume of the hollow cavity 3.

In some embodiments, the volume of cooling medium in the cavity 6 is greater than 1.1% of the volume of the cavity 6. In order to verify the influence of the volume of the cooling medium on the temperature rise of the electrically-connected framework 2, the inventor adopts the verification process that the volume of the cooling medium in the hollow inner cavity accounts for the volume percentage of the hollow inner cavity, and for the sake of brevity, the detailed description is omitted.

In some embodiments, the cooling medium is distributed in a non-uniform state in the hollow interior 3. In the vehicle body space, the heating values of different positions are inconsistent, the part needing better heat dissipation effect can be filled with more cooling media between the outer wall of the electric connection framework 2 and the inner wall of the protective shell, when the electric connection framework 2 is in a bending state, the heating value of the bending part is larger, more cooling media need to be filled, when the straight line part of the electric connection framework is in a small heating value, less cooling media can be filled, even the cooling media are not filled, the weight of the connector assembly is reduced, the consumption of the cooling media is reduced, and the cost is saved.

In some embodiments, a partial region of the electrical connection backbone 2 is flexible. The flexible body can ensure that the electric connection framework 2 can be bent to a larger angle so as to be conveniently arranged in a vehicle body with a larger corner. Meanwhile, the flexible body can absorb the vibration of the electric connection framework 2, so that the vibration of the electric connection framework 2 does not influence the connector and other electric devices on the corresponding vehicle body.

In some embodiments, the electrical connection skeleton 2 comprises at least one bent portion to meet the requirement of mounting the electrical connection skeleton 2 on the vehicle body.

In some embodiments, the cross-sectional shape of the electrical connection backbone 2 is one or more of circular, oval, rectangular, polygonal, A-shaped, B-shaped, D-shaped, M-shaped, P-shaped, N-shaped, O-shaped, S-shaped, E-shaped, F-shaped, H-shaped, K-shaped, L-shaped, T-shaped, U-shaped, V-shaped, W-shaped, X-shaped, Y-shaped, Z-shaped, P-shaped, semi-arc-shaped, and wave-shaped. The electric connection framework 2 with different cross sections can be selected according to actual requirements.

In some embodiments, the annular cross-sectional area of the electrical connection backbone 2 is 0.33mm²-240mm². The cross-sectional area of the electrically connecting frame 2 determines the current that the electrically connecting frame 2 can conduct, and generally, the electrically connecting frame 2 for realizing signal conduction has smaller current and smaller cross-sectional area of the electrically connecting frame 2, for example, the minimum cross-sectional area of the electrically connecting frame 2 for transmitting signals can reach 0.33mm²The electric connection framework 2 for realizing the power supply conduction has larger current, and the sectional area of the electric connection framework 2 is also larger, for example, the maximum sectional area of a conductor of a wire harness of an automobile storage battery reaches 240mm²。

In some embodiments, the connector further comprises a shielding inner housing 4, and the material of the shielding inner housing 4 comprises a conductive material. Further, in some embodiments, the material of the shielding inner case 4 includes metal or conductive plastic. The conductive plastic is conductive plastic or conductive rubber containing metal particles. The conductive plastic has the advantages that the conductive plastic is convenient to be injection molded, and a user can select the shielding inner shell 4 made of a proper material according to needs. In order to reduce the influence of electromagnetic interference, the conductive cable generally adopts a shielding net to shield the electromagnetic interference, the shielding net commonly used at present is woven by metal wires, a shielding braiding machine needs to be added in cable production equipment, the equipment price is high, the occupied area is large, and the price of the shielding cable of the connector is high. The shielding inner shell 4 made of conductive material is electrically connected with the protective shell 5 with shielding effect to form a complete shielding device. The shielding layer can play a role in effectively shielding electromagnetic interference generated by electrifying the electric connection framework 2, the use of a shielding net is saved, and the cost of the connector assembly is reduced. Preferably, a sealing ring 8 may be provided between the inner shielding shell 4 and the protective shell 5 to ensure that the cooling medium does not overflow the connector and the electrical connection backbone 2.

In some embodiments, the protective shell 5 comprises a rigid conductive material. Therefore, the cable can be fixed on the automobile shell, the friction between the cable and the automobile shell along with the vibration of the automobile is avoided, the service life of the connector assembly is prolonged, and the accident rate is reduced.

In some embodiments, the material of the protective shell 5 includes conductive metal or conductive plastic. The conductive plastic is conductive plastic or conductive rubber containing metal particles. The benefit of adopting electrically conductive plastic is that can make things convenient for injection moulding, and the user can select the protective housing 5 of suitable material as required.

Because the electric connection framework 2 conducts large current, and the protective shell 5 with shielding effect needs to be connected with electricity in order to achieve the shielding effect, the electric connection framework 2 and the protective shell 5 with shielding effect cannot be electrically connected, otherwise, short circuit can be caused. The solid or semi-solid cooling medium filled in the cavity 6 between the electrical connection backbone 2 and the protective shell 5 with shielding effectiveness must be insulated.

In some embodiments, the conductive plastic is a polymer material containing conductive particles, and the conductive particles include one or more of metal, conductive ceramic, carbon-containing conductor, solid electrolyte, and mixed conductor. The material of the high polymer material comprises tetraphenyl ethylene, polyvinyl chloride, polyethylene, polyamide, polytetrafluoroethylene, tetrafluoroethylene/hexafluoropropylene copolymer, ethylene/tetrafluoroethylene copolymer, polypropylene, polyvinylidene fluoride, polyurethane, poly terephthalic acid, polyurethane elastomer, styrene block copolymer, perfluoroalkoxy alkane, chlorinated polyethylene, polyphenylene sulfide, polystyrene, cross-linked polyolefin, ethylene-propylene rubber, ethylene/vinyl acetate copolymer, chloroprene rubber, natural rubber, styrene-butadiene rubber, nitrile rubber, silicone rubber, butadiene rubber, isoprene rubber, ethylene-propylene rubber, butyl rubber, fluorine rubber, polyurethane rubber, polyacrylate rubber, chlorosulfonated polyethylene rubber, epichlorohydrin rubber, chlorinated polyethylene rubber, chlorosulfonated sulfur rubber, styrene butadiene rubber, hydrogenated nitrile rubber, One or more of polysulfide rubber, crosslinked polyethylene, polycarbonate, polysulfone, polyphenyl ether, polyester, phenolic resin, urea formaldehyde, styrene-acrylonitrile copolymer, polymethacrylate and polyformaldehyde resin. The conductive plastics containing different particles can be selected according to requirements.

Furthermore, the material of the metal contains one or more of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium and beryllium. In order to demonstrate the influence of different metal materials on the conductivity of the shielding inner shell 4, the inventor performed an experiment to manufacture a sample of the shielding inner shell 4 using metal particles with the same specification and size and different materials, and respectively test the conductivity of the shielding inner shell 4, where the experimental result is shown in table 2 below, and in this embodiment, the conductivity of the shielding inner shell 4 is greater than 99% as an ideal value.

Table 2: influence of metallic particles of different materials on the conductivity of the shielded inner shell 4

As can be seen from table 2 above, the conductivity of the conductive plastic made of different metal particles is within the ideal value range, and in addition, phosphorus is a non-metal material and cannot be directly used as a material of the conductive plating layer, but can be added into other metals to form an alloy, so that the conductivity and mechanical properties of the metal itself are improved. Therefore, the inventors set the material of the metal particles to contain one or more of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium and beryllium.

Further, the carbon-containing conductor contains one or more of graphite powder, carbon nanotube material, graphene material, graphite silver or graphene silver. The graphite powder is mineral powder, and the main components are carbon simple substance, soft and black gray; graphite powder is a good non-metallic conductive substance. The carbon nano tube has good electric conductivity, and has good electric property because the structure of the carbon nano tube is the same as the lamellar structure of the graphite. The graphene, the graphite silver and the graphene silver have extremely high electrical properties, and the carbon-containing conductor containing the three materials has high conductivity and good shielding property, so that the electromagnetic shielding of the electric connection framework 2 can be well realized.

In some embodiments, the material of the connection terminal 7 includes copper or copper alloy, the material of the electrical connection frame 2 includes aluminum or aluminum alloy, and the electrical connection frame 2 is electrically connected to the connection terminal 7 by soldering or pressing.

Copper or copper alloy conductivity are high to antifriction, and most of power consumption device connect the electric part material all be copper at present moreover, consequently need use the material to carry out plug connection for connecting terminal 7 of copper or copper alloy, and connecting terminal 7 can wide application in various electric transmission scenes.

The electric connection framework 2 made of aluminum or aluminum alloy has the advantages of good rigidity, light weight and high transmission efficiency, and is particularly suitable for large current transmission.

The connecting terminal 7 and the electric connection framework 2 are connected through welding, and the adopted welding modes comprise one or more of resistance welding, friction welding, ultrasonic welding, arc welding, laser welding, electron beam welding, pressure diffusion welding and magnetic induction welding, so that the contact positions of the connecting terminal 7 and the electric connection framework 2 are in fusion connection by adopting concentrated heat energy or pressure, and the welding modes are stable in connection.

In addition, the metal inertia of copper is greater than that of aluminum, the electrode potential difference between copper and aluminum is 1.9997V, the two metals can generate electrochemical reaction after being connected and electrified, the aluminum wire is gradually oxidized, the mechanical strength and the conductivity of the aluminum wire are reduced, the connection of dissimilar materials can be realized by adopting a welding mode, and the conductive effect is better because the contact positions are mutually fused.

The resistance welding method is a method of welding by using a strong current to pass through a contact point between an electrode and a workpiece and generating heat by a contact resistance.

The friction welding method is a method of welding by plastically deforming a workpiece under pressure using heat generated by friction of a contact surface of the workpiece as a heat source.

The ultrasonic welding method is a method in which a high-frequency vibration wave is transmitted to the surfaces of two objects to be welded, and the surfaces of the two objects are rubbed against each other under pressure to form fusion between molecular layers.

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

The laser welding method is an efficient and precise welding method using a laser beam with high energy density as a heat source.

The electron beam welding mode is that accelerated and focused electron beams are used to bombard the welding surface in vacuum or non-vacuum to melt the workpiece to be welded for welding.

The pressure welding method is a method of applying pressure to a workpiece to bring the joining surfaces into close contact with each other to generate a certain plastic deformation, thereby completing welding.

The magnetic induction welding mode is that two workpieces to be welded produce instantaneous high-speed collision under the action of strong pulse magnetic field, and the surface layer of the material makes the atoms of the two materials meet in the interatomic distance under the action of very high pressure wave, so that a stable metallurgical bonding is formed on the interface. Is one type of solid state cold welding that can weld together conductive metals that may or may not have similar properties.

And the compression joint mode is a production process of assembling the electric connection framework 2 and the connecting terminal 7 and then punching the electric connection framework and the connecting terminal into a whole by using a compression joint machine. The advantage of crimping is mass productivity, and the adoption of automatic crimping machines can rapidly manufacture a large number of products of stable quality.

In some embodiments, the protective shell 5 is electrically connected to the shield inner shell 4 by crimping or welding. The aluminum or aluminum alloy material has good conductivity, light weight and low price. The shielding inner shell 4 is made of aluminum or aluminum alloy, so that a good shielding effect can be achieved, and the connection terminal 7 and the electromagnetic radiation of the electric connection framework 2 are prevented from affecting other equipment.

The crimping is a production process of assembling the shielding inner shell 4 and the shielding inner shell 5 and then punching the shielding inner shell and the shielding inner shell into a whole by using a crimping machine. The advantage of crimping is mass productivity, and the adoption of automatic crimping machines can rapidly manufacture a large number of products of stable quality.

The welding or crimping method is substantially the same as the welding method of the connection terminal 7 and the electrical connection frame 2, and is not described again.

In some embodiments, the transfer impedance of the protective shell 5 is less than 100m Ω. The shielding material generally represents the shielding effect of the protective shell 5 by transfer impedance, and the smaller the transfer impedance is, the better the shielding effect is. The transfer impedance of the protective shell 5 Is defined as the ratio of the differential mode voltage U induced by the shield per unit length to the current Is passing through the surface of the shield, namely:

Z_T＝U/I_Sit can therefore be understood that the transfer impedance of the protective case 5 converts the protective case 5 current into differential mode interference. The smaller the transfer impedance, the better, namely, the differential mode interference conversion is reduced, and the better shielding performance can be obtained.

In order to verify the influence of the protective cases 5 with different transfer impedance values on the shielding effect, the inventor selects the electrical connection framework 2, the connector and the connection terminal 7 with the same specification, adopts the protective cases 5 with different transfer impedance values, manufactures a series of samples, respectively tests the shielding effect, and the experimental result is shown in the following table 3, wherein in the embodiment, the shielding performance value is greater than 40dB, which is an ideal value.

The method for testing the shielding performance value comprises the following steps: the testing instrument outputs a signal value (the value is a testing value 2) to the electric connection framework 2, and a detecting device is arranged on the outer side of the electric connection framework 2 and detects a signal value (the value is a testing value 1). Shielding performance value is test value 2-test value 1.

Table 3: influence of transfer impedance of protective case 5 on shielding performance

As can be seen from table 3 above, when the transfer resistance value of the protective case 5 is greater than 100m Ω, the shielding performance value of the protective case 5 is less than 40dB, which is not satisfactory for the ideal value, and when the transfer resistance value of the protective case 5 is less than 100m Ω, the shielding performance value of the protective case 5 is all satisfactory for the ideal value, and the trend is better and better, so the inventors set the transfer resistance of the protective case 5 to be less than 100m Ω.

In some embodiments, the transfer impedance of the shield inner housing 4 is less than 100m Ω. In order to verify the influence of the shielding inner shells 4 with different transfer impedance values on the shielding effect, the inventor selects the electrical connection framework 2, the connector and the connection terminal 7 with the same specification, adopts the shielding inner shells 4 with different transfer impedance values, manufactures a series of samples, respectively tests the shielding effect, and the experimental result is shown in the following table 4, wherein in the embodiment, the shielding performance value is greater than 40dB, which is an ideal value.

The method for testing the shielding performance value comprises the following steps: the testing instrument outputs a signal value (the value is a testing value 2) to the electric connection framework 2, and a detecting device is arranged on the outer side of the shielding inner shell 4 and detects a signal value (the value is a testing value 1). Shielding performance value is test value 2-test value 1.

Table 4: influence of transfer impedance of the shield inner case 4 on the shield performance

As can be seen from table 4 above, when the transfer impedance value of the shield inner case 4 is greater than 100m Ω, the shielding performance value of the shield inner case 4 is less than 40dB, which does not meet the requirement of the ideal value, and when the transfer impedance value of the shield inner case 4 is less than 100m Ω, the shielding performance values of the shield inner case 4 all meet the requirement of the ideal value, and the trend is better, and therefore, the inventors set the transfer impedance of the shield inner case 4 to be less than 100m Ω.

In some embodiments, the protective shell 5 has a thickness of 1% -15% of the outer diameter of the electrical connection backbone 2. If the thickness of the protective case 5 is too small, the electric conductivity is insufficient, and the shielding effect cannot be satisfied. If the thickness of the protective case 5 is too large, material is wasted increasing the weight of the vehicle body. In order to demonstrate the influence of the ratio of the different protective cases 5 occupying the outer diameter of the electrical connection framework 2 on the conductivity of the protective cases 5, the inventors manufactured samples of the protective cases 5 with different thicknesses and the same material, and tested the conductivity respectively, the experimental results are shown in table 5, and in this embodiment, the conductivity of the protective cases 5 is equal to or greater than 99% which is an ideal value.

Table 5: the thickness of the protective shell 5 is different from that of the protective shell 5, and the external diameter of the electrical connection framework 2 is influenced by the conductivity of the protective shell 5

As can be seen from table 5, when the percentage of the protective shell 5 to the outer diameter of the electrical connection frame 2 is less than 1%, the electrical conductivity of the protective shell 5 is less than 99%, which is not qualified, and when the percentage of the protective shell 5 to the outer diameter of the electrical connection frame 2 is more than 15%, the electrical conductivity has not been significantly increased, the shielding effect is not further enhanced, and the thicker protective shell 5 increases the cost and the weight of the vehicle body, so the inventor prefers that the thickness of the protective shell 5 is 1% -15% of the outer diameter of the electrical connection frame 2.

In some embodiments, the outer diameter of the cavity 6 is 1.02 times to 1.3 times the outer diameter of the electrical connection backbone 2. The outer diameter of the cavity 6 is too small, the cooling efficiency is insufficient due to insufficient space for placing the cooling medium, in order to find the relation between the outer diameter of the cavity 6 and the outer diameter of the electric connection framework 2, the inventor conducts relevant tests, the test method is to select the same electric connection framework 2 and the cavities 6 with different outer diameters, fill the same cooling medium, measure the temperature rise after electrifying the electric connection framework 2, and the temperature rise is lower than 50K and is a qualified value. The results are shown in Table 6.

Table 6: the external diameter of the cavity 6 is compared with the external diameter of the electric connection framework 2 to influence the temperature rise of the electric connection framework

As can be seen from table 6 above, when the ratio of the outer diameter of the cavity 6 to the outer diameter of the electrically connecting frame 2 is less than 1.02, the temperature rise of the electrically connecting frame 2 is greater than 50K, which is not acceptable, and when the ratio of the outer diameter of the cavity 6 to the outer diameter of the electrically connecting frame 2 is greater than 1.3, the temperature rise of the electrically connecting frame 2 is not significantly changed, and the thicker cavity 6 increases the cost and the weight of the vehicle body, so the inventors prefer that the outer diameter of the cooling cavity 6 is 1.02 times to 1.3 times the outer diameter of the electrically connecting frame 2.

In some embodiments, the cooling medium cools the electrical connection backbone 2 at a rate of 0.04K/s to 9.8K/s. In order to verify the influence of the cooling rate of the cooling medium on the temperature rise of the electrically-connected frameworks 2, the inventors selected 10 electrically-connected frameworks 2 with the same cross-sectional area, the same material and the same length, passed the same current, cooled the electrically-connected frameworks 2 with the cooling medium of different cooling rates, read the temperature rise values of the electrically-connected frameworks 2, and recorded them in table 7.

The experimental method is that in a closed environment, the same current is conducted to the electric connection framework 2 adopting cooling media with different cooling rates, the temperature before electrifying and the temperature after electrifying are stable are recorded, and the absolute value is obtained by taking the difference. In this embodiment, a temperature rise of less than 50K is a qualified value.

Table 7: influence of cooling media with different cooling rates on temperature rise of electric connection framework 2

As can be seen from table 7 above, when the cooling rate of the cooling medium is less than 0.04K/s, the temperature rise value of the electrically-connected bobbin 2 is not qualified, and the larger the cooling rate of the cooling medium is, the smaller the temperature rise value of the electrically-connected bobbin 2 is. However, when the cooling rate of the cooling medium is more than 9.8K/s, the temperature rise of the electric connection skeleton 2 is not significantly reduced, and a higher cooling rate means a higher price and a more complicated process, and therefore, the inventors set the cooling rate of the cooling medium to 0.04K/s to 9.8K/s.

In some embodiments, the cooling medium is a thermally conductive adhesive tape, a thermally conductive insulating elastic rubber, a flexible thermally conductive pad, a thermally conductive filler, and a thermally conductive insulating potting adhesive. The connector assembly with the solid cooling medium can reduce the failure of the electric connection framework 2 and the connecting terminal 7 caused by high temperature generated by electrifying, reduce the diameter of the electric connection framework 2, prolong the service life of the connector 1 and improve the safety of the whole vehicle.

The heat conduction adhesive tape takes high heat conduction rubber as a heat conduction base material, and one side or two sides of the heat conduction adhesive tape are back-provided with pressure-sensitive heat conduction adhesive, so that the bonding is reliable and the strength is high. The heat-conducting adhesive tape is thin in thickness, good in flexibility and very easy to attach to the surfaces of devices and radiators. The heat conduction adhesive tape can also adapt to the changes of cold and hot temperatures, and the consistency and the stability of the performance are ensured.

The heat-conducting insulating elastic rubber adopts a silicon rubber substrate, and ceramic particles such as boron nitride, aluminum oxide and the like are used as fillers, so that the heat-conducting effect is very good. Under the same condition, the thermal impedance is smaller than that of other heat conduction materials. The glass fiber reinforced pressure-sensitive adhesive has the characteristics of softness, cleanness, no pollution, radioactivity and high insulating property, provides good mechanical property for glass fiber reinforcement, can prevent puncture, shear and tear, and can be provided with a heat-conducting pressure-sensitive adhesive.

The flexible heat conducting pad is a heat conducting material with thickness, the base materials used at present are basically silicone rubber and foamed rubber, the silicone rubber is characterized by good elasticity, and the foamed rubber is characterized by large deformation range, good heat conducting effect and higher pressure-resistant grade.

The heat-conducting filler is a filler added in a base material to increase the heat conductivity of the material, and commonly used heat-conducting fillers include aluminum oxide, magnesium oxide, zinc oxide, aluminum nitride, boron nitride, silicon carbide and the like.

The heat-conducting pouring sealant is an electronic adhesive prepared from main raw materials of silicon rubber, has excellent high and low temperature resistance, can keep elasticity within a temperature range of-60-200 ℃, can effectively increase the waterproof and anti-seismic functions of electronic equipment after being poured and sealed, and ensures the application reliability of the electronic equipment.

In some embodiments, the impedance between the protective shell 5 and the shield inner shell 4 is less than 80m Ω.

The impedance between the protective shell 5 and the inner shielding shell 4 is as small as possible, so that the current generated by the inner shielding shell 4 flows back to the energy source or the ground without hindrance, and if the impedance between the protective shell 5 and the inner shielding shell 4 is large, a large current is generated between the protective shell 5 and the inner shielding shell 4, so that a large radiation is generated at the cable connection.

In order to verify the influence of the impedance value between the protective shell 5 and the shielding inner shell 4 on the shielding effect, the inventor selects the electrical connection framework 2, the connector and the connection terminal 7 with the same specification, selects different impedances between the protective shell 5 and the shielding inner shell 4, manufactures a series of samples, and respectively tests the shielding effect, and the experimental result is shown in the following table 8, wherein in the embodiment, the shielding performance value is greater than 40dB, which is an ideal value.

Table 8: influence of impedance between the protective case 5 and the shield inner case 4 on the shield performance

As can be seen from table 8, when the impedance value between the protective case 5 and the shield inner case 4 is greater than 80m Ω, the shielding performance value is less than 40dB, which is not satisfactory for the ideal value, and when the impedance value between the protective case 5 and the shield inner case 4 is less than 80m Ω, the shielding performance values are all satisfactory for the ideal value, and the trend is better and better, so the inventors set the impedance between the protective case 5 and the shield inner case 4 to be less than 80m Ω.

In some embodiments, one of the connectors 1 is a cradle. One connector is connected to each of the two ends of the electrical connection frame 2, and in some cases, one of the connectors (e.g., the first connector 11) may be a charging socket, and the charging socket charges the electrical connection frame 2 by using the connector (e.g., the second connector 12) at the other end.

The present invention also provides a vehicle comprising a connector assembly as described above with a solid cooling medium.

Although some specific embodiments of the present invention have been described in detail by way of examples, it should be understood by those skilled in the art that the above examples are for illustrative purposes only and are not intended to limit the scope of the present invention. It will be appreciated by those skilled in the art that modifications may be made to the above embodiments without departing from the scope and spirit of the invention. The scope of the invention is defined by the appended claims.

Claims

1. The utility model provides a connector assembly with solid-state cooling medium, includes that skeleton and connector are connected to an at least electricity, its characterized in that, include connecting terminal in the connector, it is connected with connecting terminal electricity respectively to connect the skeleton both ends, it has the cavity inner chamber to connect the skeleton periphery to connect, connect the skeleton periphery to connect and cup joint the protective housing that has shielding efficiency, connect the skeleton periphery with form the cavity between the protective housing inner wall that has shielding efficiency, the cavity inner chamber with at least part fills solid state or semi-solid state cooling medium in the cavity.

2. The connector assembly with solid state cooling medium of claim 1, wherein the electrical connection backbone comprises a rigid hollow conductor material.

3. The connector assembly with solid cooling medium of claim 1, wherein the electrical connection backbone has an annular cross-sectional area of 0.33mm²-240mm²。

4. The connector assembly with solid state cooling medium of claim 1, wherein the electrical connection backbone is electrically connected to the connection terminals by soldering or crimping.

5. The connector assembly with solid state cooling medium of claim 1, wherein the protective shell material comprises a rigid conductive material.

6. The connector assembly with solid state cooling medium of claim 5, wherein the protective shell comprises a metal or a conductive plastic.

7. The connector assembly with solid cooling medium of claim 1, wherein the connector interior further comprises an inner shielding shell, and the material of the inner shielding shell comprises a conductive material.

8. The connector assembly with solid cooling medium of claim 7, wherein the material of the shielding inner housing comprises metal or conductive plastic.

9. The connector assembly with solid cooling medium of claim 6 or 8, wherein the conductive plastic is a polymer material containing conductive particles, and the conductive particles comprise one or more of metal, conductive ceramic, carbon-containing conductor, solid electrolyte and mixed conductor; the material of the high polymer material comprises tetraphenyl ethylene, polyvinyl chloride, polyethylene, polyamide, polytetrafluoroethylene, tetrafluoroethylene/hexafluoropropylene copolymer, ethylene/tetrafluoroethylene copolymer, polypropylene, polyvinylidene fluoride, polyurethane, poly terephthalic acid, polyurethane elastomer, styrene block copolymer, perfluoroalkoxy alkane, chlorinated polyethylene, polyphenylene sulfide, polystyrene, crosslinked polyolefin, ethylene-propylene rubber, ethylene/vinyl acetate copolymer, chloroprene rubber, natural rubber, styrene-butadiene rubber, nitrile rubber, silicone rubber, butadiene rubber, isoprene rubber, ethylene-propylene rubber, chloroprene rubber, butyl rubber, fluorine rubber, polyurethane rubber, polyacrylate rubber, chlorosulfonated polyethylene rubber, epichlorohydrin rubber, chlorinated polyethylene rubber, chlorosulfonated sulfur rubber, styrene butadiene rubber, ethylene-propylene rubber, polyphenylene sulfide, polystyrene-butadiene rubber, styrene-butadiene rubber, styrene-butadiene rubber, styrene-butadiene rubber, styrene, Hydrogenated nitrile rubber, polysulfide rubber, crosslinked polyethylene, polycarbonate, polysulfone, polyphenyl ether, polyester, phenolic resin, urea formaldehyde, styrene-acrylonitrile copolymer, polymethacrylate and polyformaldehyde resin.

10. The connector assembly with solid cooling medium of claim 9, wherein the metal comprises one or more of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, gold, phosphorus, tellurium, and beryllium.

11. The connector assembly with solid cooling medium of claim 9, wherein the carbon-containing conductor comprises one or more of graphite powder, carbon nanotube material, graphene material, graphite silver, or graphene silver.

12. The connector assembly with solid state cooling medium of claim 7, wherein the protective shell is electrically connected to the shielded inner shell by crimping or welding.

13. The connector assembly with solid state cooling medium of claim 12, wherein the impedance between the protective shell and the shielded inner shell is less than 80m Ω.

14. The connector assembly with solid cooling medium of claim 1, wherein the protective shell has a transfer impedance of less than 100m Ω.

15. The connector assembly with solid cooling medium of claim 7, wherein the transfer impedance of the shielded inner housing is less than 100m Ω.

16. The connector assembly with solid state cooling medium of claim 1, wherein the protective shell has a thickness of 1% -15% of an outer diameter of the protective shell.

17. The connector assembly with solid state cooling medium of claim 1, wherein the cavity has an outer diameter that is 1.02 times to 1.3 times an outer diameter of the electrical connection backbone.

18. The connector assembly with solid cooling medium of claim 1, wherein the cooling medium cools the electrical connection backbone at a rate of 0.04K/s to 9.8K/s.

19. The connector assembly with solid state cooling medium of claim 1, wherein the cooling medium is a thermally conductive tape, a thermally conductive insulating elastomeric rubber, a flexible thermally conductive pad, a thermally conductive filler, and a thermally conductive insulating potting adhesive.

20. The connector assembly with solid state cooling medium of claim 19, wherein the cooling medium is injection molded, extruded, dip molded, foamed, wound, woven, poured, filled or wrapped around the periphery of the electrical connection backbone.

21. The connector assembly with solid state cooling medium of claim 1, wherein the cooling medium comprises one or more of quartz glass, silicon carbide, mica, sand, diamond, silicon, graphene and derivatives or silicone grease.

22. The connector assembly with solid cooling medium of claim 1, wherein a volume of the cooling medium in the hollow interior cavity is greater than 1.1% of a volume of the hollow interior cavity.

23. The connector assembly with solid cooling medium of claim 1, wherein a volume of the cooling medium in the cavity is greater than 1.1% of a volume of the cavity.

24. The connector assembly with solid cooling medium of claim 1, wherein the cooling medium is distributed unevenly in the hollow interior cavity or the cavity.

25. The connector assembly with solid state cooling medium of claim 1 wherein one of said connectors is a charging dock.

26. The connector assembly with solid state cooling medium of claim 1, wherein a portion of the electrical connection backbone is flexible.

27. The connector assembly with solid state cooling medium of claim 1, wherein the electrical connection backbone comprises at least one bend.

28. The connector assembly with solid cooling medium of claim 1, wherein the cross-sectional shape of the electrical connection backbone is one or more of circular, oval, rectangular, polygonal, A-shaped, B-shaped, D-shaped, M-shaped, P-shaped, N-shaped, O-shaped, S-shaped, E-shaped, F-shaped, H-shaped, K-shaped, L-shaped, T-shaped, U-shaped, V-shaped, W-shaped, X-shaped, Y-shaped, Z-shaped, P-shaped, semi-arc-shaped, and wave-shaped.

29. A vehicle comprising a connector assembly with a solid cooling medium as claimed in any one of claims 1 to 28.