WO2023174246A1 - 新型屏蔽材料的连接器总成及车辆 - Google Patents

新型屏蔽材料的连接器总成及车辆 Download PDF

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Publication number
WO2023174246A1
WO2023174246A1 PCT/CN2023/081259 CN2023081259W WO2023174246A1 WO 2023174246 A1 WO2023174246 A1 WO 2023174246A1 CN 2023081259 W CN2023081259 W CN 2023081259W WO 2023174246 A1 WO2023174246 A1 WO 2023174246A1
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WIPO (PCT)
Prior art keywords
connector assembly
rubber
shielding material
material according
conductive particles
Prior art date
Application number
PCT/CN2023/081259
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English (en)
French (fr)
Inventor
王超
Original Assignee
吉林省中赢高科技有限公司
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Publication of WO2023174246A1 publication Critical patent/WO2023174246A1/zh

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R31/00—Coupling parts supported only by co-operation with counterpart
    • H01R31/06—Intermediate parts for linking two coupling parts, e.g. adapter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/10—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
    • B60L53/14—Conductive energy transfer
    • B60L53/16—Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/10—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
    • B60L53/14—Conductive energy transfer
    • B60L53/18—Cables specially adapted for charging electric vehicles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
    • H01B5/16—Non-insulated conductors or conductive bodies characterised by their form comprising conductive material in insulating or poorly conductive material, e.g. conductive rubber
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/40—Insulated conductors or cables characterised by their form with arrangements for facilitating mounting or securing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B9/00—Power cables
    • H01B9/02—Power cables with screens or conductive layers, e.g. for avoiding large potential gradients
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/648—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding  
    • H01R13/658—High frequency shielding arrangements, e.g. against EMI [Electro-Magnetic Interference] or EMP [Electro-Magnetic Pulse]
    • H01R13/6581—Shield structure
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/648—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding  
    • H01R13/658—High frequency shielding arrangements, e.g. against EMI [Electro-Magnetic Interference] or EMP [Electro-Magnetic Pulse]
    • H01R13/6591—Specific features or arrangements of connection of shield to conductive members
    • H01R13/6592—Specific features or arrangements of connection of shield to conductive members the conductive member being a shielded cable

Definitions

  • the present application relates to the technical field of automotive electrical appliances, and more specifically, to connector assemblies and vehicles using new shielding materials.
  • shielding nets In order to reduce the impact of electromagnetic interference, conductive cables usually use shielding nets to shield electromagnetic interference.
  • the commonly used shielding nets are made of metal wires. It is necessary to add a shielding braiding machine to the cable production equipment. The equipment is expensive and accounts for The large ground area causes the price of shielded cables to remain high.
  • the automotive electrical technology field is in urgent need of a low-price, long-life shielded cable and a connector assembly of new shielding materials.
  • One purpose of this application is to provide a new technical solution for a connector assembly of new shielding materials.
  • a connector assembly of a new type of shielding material which includes an electrical connection skeleton and connectors connected to both ends of the electrical connection skeleton.
  • the connector includes connection terminals and a shielding
  • An efficient inner shell the two ends of the electrical connection frame are electrically connected to the connection terminals respectively, and the outer periphery of the electrical connection frame is covered with insulation.
  • the insulating layer contains conductive particles in the radial direction, and the conductive particles are distributed in at least one density unevenly within the insulating layer.
  • a vehicle including a connector assembly of the novel shielding material as described above.
  • Using a rigid body electrical connection skeleton can reduce the diameter of the cable, reduce the weight of the cable, make the cable installation easier, reduce friction with the car shell, and extend the service life of the connector assembly.
  • the insulation layer contains conductive particles in the radial direction and has a shielding effect. It can replace the braided shielding net and reduce the use of shielding net braiding equipment. It occupies a small area, reduces the processing cost of the cable, reduces the weight of the cable, and simplifies the The production process shortens the production cycle and reduces the production cost of the connector assembly.
  • the conductive layer formed by the conductive particles has a shielding effect and does not need to be outside the insulating layer. Setting up a separate shielding net simplifies the production process, does not require additional production equipment, and improves production efficiency.
  • a shielding connection device is provided between the inner shell and the conductive layer formed by the conductive particles.
  • the conductive layer and the shielding connection device can be fixed and electrically connected first, and then the shielding connection device can be assembled and contacted with the inner shell and electrically connected to improve the shielding connection. Stability, reducing processing difficulty, while ensuring a stronger connection between the conductive layer in the insulation layer and the inner shell, and better shielding effect.
  • the density of conductive particles is unevenly distributed in the insulating layer in at least one place, so that targeted insulating layer settings can be made according to the EMC (electromagnetic compatibility) requirements of the entire vehicle. When shielding requirements are met, conductive particles are used in some places. Low-density insulation layers can significantly save costs.
  • Figure 1 is a schematic structural diagram of a connector assembly of a new type of shielding material in this application;
  • Figure 2 is a cross-sectional view of the connection between the inner shell and the conductive particles of a connector assembly made of a new type of shielding material according to the present application;
  • Figure 3 is a cross-sectional view of the connection between the inner shell and the conductive particles of the connector assembly of another new shielding material of the present application;
  • Figure 4 is a schematic structural diagram of a shielding connection device of a connector assembly made of a new type of shielding material according to the present application;
  • Figure 5 is a schematic structural diagram of another shielding connection device of a new shielding material connector assembly of the present application.
  • Figure 6 is an axial cross-sectional view of the electrical connection skeleton covered with an insulation layer in this application;
  • Figure 7 is a radial cross-sectional view of the electrical connection skeleton covered with an insulation layer in this application;
  • Figure 8 is a radial cross-sectional view of the electrical connection skeleton covered with an insulating layer by the shielding connection device in this application.
  • a new shielding material connector assembly of the present application includes an electrical connection frame 1 and a connector 2 connected to both ends of the electrical connection frame 1.
  • the connector 2 It includes connecting terminals 5 and an inner shell 4 with shielding effect. Both ends of the electrical connecting frame 1 are electrically connected to the connecting terminals 5 respectively.
  • the outer periphery of the electrical connecting frame 1 is covered with an insulating layer 3, and the insulating layer 3 has a diameter of Conductive particles 31 are contained therein, and the conductive particles 31 are distributed in at least one density unevenly within the insulating layer.
  • shielding nets to shield electromagnetic interference.
  • the commonly used shielding nets are made of metal wires. It is necessary to add a shielding braiding machine and equipment to the cable production equipment. The price is high, the floor space is large, and the production process is increased, resulting in the high price of shielded cables.
  • the electrical connection skeleton 1 is mostly used to transmit large currents in the car. When the current passes through, a large electromagnetic field will be generated. In order to prevent the electromagnetic field generated by the large current from causing electromagnetic interference to the electrical appliances in the car and affecting the normal operation of other electrical appliances, it is necessary to The electromagnetic field generated by large current is electromagnetic shielded. Data communication cables, on the contrary, transmit electromagnetic signals internally. This electromagnetic signal will be interfered by external electromagnetic fields, resulting in electromagnetic signal distortion and inability to effectively transmit signals. Therefore, electromagnetic shielding is required to shield external electromagnetic field interference.
  • Electromagnetic shielding mainly uses shielding bodies to prevent the influence of high-frequency electromagnetic fields, thereby effectively controlling the radiation propagation of electromagnetic waves from one area to another.
  • the basic principle is to use conductor materials with low resistance values to make shields
  • the shielding effect is generated by the reflection of electromagnetic waves on the surface of the shielding body, absorption inside the shielding body, and loss during transmission.
  • its connection with the connector 2 and the connection terminal 5 also requires special electromagnetic shielding.
  • the two ends of the electrical connection frame 1 of the present application are connected to a connector 2 and a connector respectively.
  • the terminals 5 are connected, and these connections are arranged in the inner shell 4.
  • the inner shell 4 is electrically connected to the conductive layer formed by the conductive particles 31 in the insulating layer 3 outside the electrical connection skeleton 1, thereby achieving a complete shielding effect.
  • the insulating layer contains conductive particles in the radial direction, and the conductive particles form a conductive layer.
  • the insulating layer has a shielding effect, instead of weaving a shielding net. , reduces the use of shielding network preparation equipment, occupies a small area, reduces cable processing costs, reduces cable weight, simplifies the production process, shortens the production cycle, and reduces the production cost of the connector assembly.
  • the conductive particles 31 are sandwiched between the inner surface and the outer surface of the insulating layer 3.
  • the inner surface and the outer surface of the insulating layer 3 have an insulating effect, and the conductive layer formed by the conductive particles 31 has a shielding effect, and there is no need to insulate.
  • a separate shielding net is installed outside layer 3, which simplifies the production process, does not require the addition of more equipment, and improves production efficiency.
  • connection terminal 5 is made of copper or copper alloy
  • electrical connection frame 1 is made of aluminum or aluminum alloy
  • electrical connection frame 1 is made of aluminum or aluminum alloy.
  • the connection terminal is electrically connected by welding or crimping.
  • connection terminals 5 containing copper or copper alloy for plug-in connection.
  • the connection terminal 5 can be widely used in various electrical transmission scenarios.
  • the electrical connection skeleton 1 made of aluminum or aluminum alloy has the advantages of good rigidity, light weight and high transmission efficiency, and is particularly suitable for the transmission of large currents.
  • the use of aluminum conductors with small specific gravity and cheap materials to replace copper conductors with large specific gravity and high material prices can reduce material costs and transportation costs, and save the production cost of motor vehicles.
  • the aluminum alloy is an aluminum-copper alloy, an aluminum-magnesium alloy, an aluminum-lithium alloy, an aluminum-manganese alloy, an aluminum-zinc alloy, or an aluminum-silicon alloy with an aluminum content of more than 90%.
  • the electrical connection skeleton 1 is connected to the connection terminal 5 through welding, and the welding method used includes one or more of resistance welding, friction welding, ultrasonic welding, arc welding, laser welding, electron beam welding, pressure diffusion welding, and magnetic induction welding. , uses concentrated heat energy or pressure to create a molten connection at the contact position between the connection terminal 5 and the electrical connection frame 1.
  • the welding method is a stable connection and can realize the connection of dissimilar materials. Since the contact positions are fused, the conductive effect is better.
  • Resistance welding refers to a method that uses strong current to pass through the contact point between the electrode and the workpiece, and generates heat due to the contact resistance to achieve welding.
  • Friction welding refers to a method that uses the heat generated by friction on the contact surface of the workpiece as a heat source to cause plastic deformation of the workpiece under pressure for welding.
  • Ultrasonic welding uses high-frequency vibration waves to transmit to the surfaces of two objects to be welded. Under pressure, the surfaces of the two objects rub against each other to form fusion between the molecular layers.
  • the arc welding method refers to using the arc as a heat source and utilizing the physical phenomenon of air discharge to convert electrical energy into the thermal energy and mechanical energy required for welding, thereby achieving the purpose of joining metals.
  • the main methods include electrode arc welding, submerged arc welding, and gas shielding. Welding etc.
  • Laser welding is an efficient and precise welding method that uses high-energy-density laser beams as heat sources.
  • Friction welding refers to a method that uses the heat generated by friction on the contact surface of the workpiece as a heat source to cause plastic deformation of the workpiece under pressure for welding.
  • Electron beam welding refers to the use of accelerated and focused electron beams to bombard the welding surface placed in a vacuum or non-vacuum, so that the workpiece to be welded melts to achieve welding.
  • Pressure welding is a method of applying pressure to the weldment to bring the joint surfaces into close contact to produce a certain degree of plastic deformation to complete the welding.
  • Crimping is a production process in which after assembling the electrical connection frame 1 and the connecting terminal 5, a crimping machine is used to stamp the two into one body.
  • the advantage of crimping is mass production. By using an automatic crimping machine, products of stable quality can be manufactured quickly and in large quantities.
  • the electrical connection skeleton is a rigid body, and the tensile strength of the electrical connection skeleton is greater than 75 MPa.
  • the electrical connection skeleton 1 can be a single-core copper rod, aluminum rod or aluminum flat strip.
  • a rigid body is an object whose shape and size remain unchanged during motion and after being subjected to force, and the relative positions of internal points remain unchanged.
  • absolutely rigid bodies do not actually exist. They are just an ideal model, because any object will deform more or less after being subjected to force. If the degree of deformation is extremely small relative to the geometric size of the object itself, it is difficult to study The deformation of the object during motion is negligible. Therefore, during use, the amount of deformation produced by the electrical connection skeleton 1 made of rigid body material is negligible. The greater the tensile strength of the rigid body, the smaller the deformation amount.
  • the inventor selected the same size specifications and used different resistance
  • the tensile strength of the electrical connection skeleton 1 sample was tested on the tensile force value when the electrical connection skeleton 1 was broken, the torque during bending and the abnormal sound during vibration.
  • Test method for the tensile force value of the electrical connection frame 1 Use a universal tensile testing machine, fix both ends of the electrical connecting frame 1 on the tensile fixture of the universal tensile testing machine, and stretch at a speed of 50mm/min. Record the tensile force value at the final break. In this embodiment, a tensile force value greater than 1600N is considered a qualified value.
  • Torque test method of electrical connection skeleton 1 Use a torque tester to bend the electrical connection skeleton 1 at 90° with the same radius and the same speed, and test the torque value of the deformation of the electrical connection skeleton 1 during the bending process.
  • a torque value less than 60 N ⁇ m is a preferred value.
  • the test method is to select electrical connection skeleton 1 samples of the same size and specifications and different tensile strengths, assemble the connectors 2 of the same specifications together, and fix them on the vibration test bench. During the vibration test, observe whether there is any abnormal sound in the electrical connection frame 1.
  • Table 1 Effects of different tensile strengths on the tensile force value, torque value and abnormal sound of the electrical connection skeleton 1
  • the tensile strength of the electrical connection skeleton 1 is less than 75MPa
  • the tensile force value when the electrical connection skeleton 1 is broken is less than 1600N.
  • the strength of the electrical connection skeleton 1 itself is not high, and it is subject to a smaller It is easily broken by external force, causing the function of the electrical connection skeleton 1 to fail, thereby failing to achieve the purpose of transmitting electric energy.
  • the inventor prefers that the tensile strength of the electrical connection skeleton 1 is greater than 75MPa.
  • the electrical connection skeleton 1 at least partially contains a flexible body, and the flexible body is a multi-core cable or a braided cable or a flexible cable stacked by multiple layers of thin plates. .
  • the flexible body part in the electrical connection skeleton 1 can also be set as a multi-core cable or a braided cable or a flexible cable stacked with multiple layers of thin plates, which can facilitate wiring when installed on the car body.
  • the electrical connection skeleton 1 has excellent flexibility and is convenient for installation and storage.
  • the material of the insulating layer 3 contains tetrastyrene, polyvinyl chloride, polyethylene, polyamide, polytetrafluoroethylene, tetrafluoroethylene/hexafluoroethylene Propylene copolymer, ethylene/tetrafluoroethylene copolymer, polypropylene, polyvinylidene fluoride, polyurethane, polyterephthalic acid, polyurethane elastomer, styrene block copolymer, perfluoroalkoxyalkane, 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, polyvinyl chloride, polyethylene, polyamide,
  • Polyformaldehyde is a hard and dense material with a smooth and shiny surface. It is light yellow or white in color and can be used for a long time in the temperature range of -40°C-100°C. Its wear resistance and self-lubricating properties are also superior to those of most engineering plastics, and it also has good oil resistance and peroxide resistance.
  • Polycarbonate colorless and transparent, heat-resistant, impact-resistant, flame-retardant BI grade, has good mechanical properties within normal operating temperatures. Compared with polymethyl methacrylate, which has similar properties, polycarbonate has good impact resistance, high refractive index, good processing performance, and has very advanced flame retardant properties without the need for additives.
  • Polyamide is non-toxic, lightweight, has excellent mechanical strength, and has good wear resistance and corrosion resistance. It can replace copper and other metals in the manufacture of bearings, gears, and pumps in machinery, chemical industry, instrumentation, automobile and other industries. Leaves and other parts.
  • the conductive particles 31 are made of one or more types of metal, conductive ceramics, carbon-containing conductors, solid electrolytes, and mixed conductors.
  • the conductive particles 31 are mixed into a polymer material to form a conductive plastic, and the insulating layer 3 is integrally formed on both sides of the conductive plastic.
  • Conductive plastic has conductive properties, so the insulating layer has a shielding effect, that is, it has a shielding function. The biggest advantage is low cost, simple and practical, and wide application.
  • the insulating layer contains conductive particles in the middle, which has a shielding effect. It can replace the weaving of a shielding net. , reduces the use of shielding network preparation equipment, occupies a small area, reduces cable processing costs, reduces cable weight, simplifies the production process, shortens the production cycle, and reduces the production cost of the connector assembly.
  • the metal material includes gold, silver, copper, nickel, titanium, tin, aluminum, cadmium, zirconium, chromium, cobalt, manganese, zinc, phosphorus, tellurium, beryllium, tin-lead alloy, silver-antimony alloy, palladium , palladium-nickel alloy or silver-gold-zirconium alloy, one or more.
  • the inventor conducted experiments using the insulating layer 3 with conductive particles 31, and used conductive particles 31 of the same size and different materials to make the insulating layer. 3 samples, the conductivity was tested respectively, and the experimental results are shown in Table 2 below. In this embodiment, the conductivity of the conductive plastic is greater than 99% as an ideal value.
  • Table 2 Effect of conductive particles of different materials on the conductivity of the conductive layer formed by conductive particles in the insulating layer
  • the conductivity of the insulating layer 3 made of different conductive particles is within the ideal range.
  • phosphorus is a non-metallic material and cannot be directly used as the material of the conductive layer, but it can be added to other metals.
  • the carbon-containing conductor contains one or more of graphite powder, carbon nanotube material, graphene material, graphite silver or graphene silver.
  • Graphite powder is a mineral powder, the main component is carbon, soft, black gray; graphite powder is a good non-metallic conductive substance. Carbon nanotubes have good electrical conductivity. Since the structure of carbon nanotubes is the same as the lamellar structure of graphite, they have good electrical properties. Graphene has extremely high electrical properties. Carbon-containing conductors containing these five materials have high conductivity and good shielding properties, and can effectively achieve electromagnetic shielding of the electrical connection skeleton 1.
  • the volume proportion of the conductive particles 31 in the insulating layer 3 is 3.5%-95%.
  • the maximum diameter of the conductive particles 31 accounts for 0.1%-97% of the thickness of the insulating layer 3 .
  • the method for testing the insulation performance of the insulation layer 3 is to use an insulation withstand voltage tester to apply different AC or DC high voltages between the conductive particles 31 and the inner surface of the insulation layer 3, and between the conductive particles 31 and the outer surface of the insulation layer 3, A test to check the withstand voltage capability of the outer insulation layer 3 of the electrical connection skeleton 1. If the breakdown voltage of insulation layer 3 is less than 2.1KV, it is considered unqualified. The test results are shown in Table 4.
  • Table 4 Effect of the ratio of the diameter of conductive particles to the thickness of the insulating layer on the breakdown voltage of the insulating layer
  • the breakdown voltage of the insulating layer 3 is greater than 2.1KV, which can meet the needs.
  • the ratio of the diameter of the conductive particles 31 to the thickness of the insulating layer 3 is greater than At 97%, the breakdown voltage of the insulating layer 3 is less than 2.1KV, which cannot meet the needs. Therefore, the maximum diameter of the conductive particles 31 accounts for 97% of the thickness of the insulating layer 3 .
  • the ratio of the diameter of the conductive particles to the thickness of the insulating layer 3 is less than 0.1%, the difficulty of production increases accordingly, and it is difficult to increase the value of the breakdown voltage. Therefore, the inventor chooses that the maximum diameter of the conductive particles 31 accounts for 0.1%-97% of the thickness of the insulation layer 3.
  • the conductive particles 31 in the insulating layer 3 conduct electricity in the axial direction of the electrical connection skeleton 1 .
  • the conductive particles 31 in the insulating layer 3 conduct electricity in the axial direction of the electrical connection skeleton 1, which can ensure that the electrical connection skeleton 1 shields the magnetic field generated by the current during use, and ensures that the conductive particles can provide shielding. function to avoid affecting the use of other electrical equipment.
  • the conductive particles 31 in the insulating layer 3 conduct electricity in the circumferential direction of the electrical connection skeleton 1 .
  • the conductive particles 31 in the insulating layer 3 conduct electricity in the circumferential direction of the electrical connection frame 1, which can ensure that the conductive particles surround the electrical connection frame 1 and form a closed ring, which can ensure shielding.
  • the conductive particles 31 are continuously sandwiched between the inner surface and the outer surface of the insulating layer 3.
  • the conductive particles 31 are arranged in a cylindrical form between the inner surface and the outer surface of the insulating layer 3, which can completely shield the insulation.
  • the transfer impedance of the conductive particles 31 in the insulating layer 3 in the axial direction of the electrical connection skeleton 1 is less than 100 m ⁇ .
  • the shielding effect of the insulating layer 3 is usually characterized by the transfer impedance of the conductive particles 31 in the insulating layer 3. The smaller the transfer impedance, the better the shielding effect.
  • the transfer impedance of the insulation layer 3 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, that is:
  • the inventor sets the transfer impedance of the conductive particles 31 in the insulating layer 3 to be less than 100 m ⁇ .
  • the insulation withstand voltage value of the inner and outer surfaces of the insulating layer 3 against the conductive particles is greater than 2.1KV.
  • the working voltage of the electrical connection frame 1 is generally between 500V and 600V, and the detection voltage for the insulating layer 3 is three times the working voltage. Therefore, the inventor chooses the insulation between the inner surface and the outer surface of the insulating layer 3.
  • the withstand voltage value is greater than 2.1KV, which can effectively ensure that the insulation layer is not broken down by high voltage during use.
  • the material of the inner shell 4 contains conductive metal or a polymer material containing conductive particles.
  • the conductive particle material contains one or more of metal, conductive ceramics, carbon-containing conductors, solid electrolytes, and mixed conductors; the polymer material contains tetrastyrene, polyvinyl chloride, polyethylene, polyethylene, etc.
  • polymer materials containing different conductive particles can be selected as needed.
  • the metal material of the conductive particles includes gold, silver, copper, nickel, titanium, tin, aluminum, cadmium, zirconium, chromium, cobalt, manganese, zinc, phosphorus, tellurium, beryllium, tin-lead alloy, silver antimony One or more alloys, palladium, palladium-nickel alloy or silver-gold-zirconium alloy.
  • the inventor used the inner shell 4 to conduct experiments. Conductive particles of the same size and different materials were used to make samples of the inner shell 4, and the conductivity was tested respectively.
  • the experimental results As shown in Table 6 below, in this embodiment, the conductivity of the inner shell 4 is greater than 99%, which is an ideal value.
  • the conductivity of the inner shell 4 made of different conductive particles is within the ideal range.
  • phosphorus is a non-metallic material and cannot be directly used as the material of the inner shell, but it can be added to other metals. Forming alloys to improve the electrical conductivity and mechanical properties of the metal itself. Therefore, the inventors set the conductive particles to contain gold, silver, copper, nickel, titanium, tin, aluminum, cadmium, zirconium, chromium, cobalt, manganese, zinc, tin-lead alloy, silver-antimony alloy, palladium, and palladium-nickel alloy. Or one or more types of silver, gold, and zirconium alloys.
  • the carbon-containing conductor of the conductive particles contains one or more of graphite powder, carbon nanotube materials, graphene materials, graphite silver or graphene silver.
  • Graphite powder is a mineral powder, the main component is carbon, soft, black gray; graphite powder is a good non-metallic conductive substance. Carbon nanotubes have good electrical conductivity. Since the structure of carbon nanotubes is the same as the lamellar structure of graphite, they have good electrical properties. Graphene has extremely high electrical properties. Carbon-containing conductors containing these five materials have high conductivity and good shielding properties, and can effectively achieve electromagnetic shielding of the connection terminal 5 .
  • the inner shell 4 is electrically connected to the conductive particles.
  • the electromagnetic interference generated during use of the electrical connection skeleton 1 can be shielded to prevent affecting other electronic equipment used as the control system. normal use to avoid traffic accidents, property losses and casualties caused by electromagnetic interference failure of the control system.
  • the insulating layer 3 is at least partially provided with a notch 32 in the connector 2.
  • the notch The conductive particles 31 are exposed in 32; the inner shell 4 is provided with protrusions 21 at corresponding positions, and the protrusions 21 are matched and connected with the notches 32 and are electrically connected with the conductive particles.
  • the inner shell 4 is generally installed inside the shell of the connector 2 and formed integrally.
  • the inner shell 4 can be made of conductive plastic material and injection molded together with the outer shell of the connector 2 .
  • the inner shell 4 is connected to the conductive layer formed by adding conductive particles to the insulating layer 3.
  • the notches 32 can be provided on the insulating layer 3 and the protrusions 21 can be provided at the corresponding positions of the inner shell.
  • the electrical connection between the inner shell 4 and the conductive layer formed by the conductive particles 31 is achieved through the protrusions 21 and the recesses 32 . In this way, electromagnetic interference generated during use of the electrical connection frame 1 is shielded.
  • the conductive layer formed by the conductive particles 31 in the recess 32 can also be protruded to form a protrusion on the outer surface of the insulating layer 3, and the inner shell 4 is provided with a corresponding groove, and the groove is electrically connected to the protrusion. Realizing the electrical connection between the conductive layer and the inner shell 4 can also achieve the function of shielding the electromagnetic interference generated by the electrical connection skeleton 1 during use.
  • the insulating layer 3 is formed with notches or protrusions exposing the conductive particles, which may be annular grooves or annular protrusions, so that the electrical connection between the two is more stable and sufficient.
  • the impedance between the conductive particles 31 and the inner shell 4 is less than 80 m ⁇ .
  • the transfer impedance of the inner shell 4 is less than 100 m ⁇ .
  • Table 8 Effect of transfer impedance of inner shell 4 on shielding performance
  • the connector 2 further includes a shielding connection device 6, and the shielding connection device 6 has at least one insertion portion. 61 and a contact portion 62.
  • the insertion portion 61 is inserted along the outer peripheral surface of the insulating layer 3 and is electrically connected to the conductive particles 31.
  • the contact portion 62 is electrically connected to the inner shell 4.
  • the shielding connection device 6 is installed between the inner shell 4 and the conductive layer formed by the conductive particles in the insulating layer 3, and is used to electrically connect the conductive layer and the inner shell 4, thereby shielding the electrical connection skeleton 1 and the connection terminal 5. Electromagnetic interference generated during the power-on process.
  • the conductive layer and the inner shell 4 can be electrically connected more firmly through the shielding connection device 6, so that a more stable shielding effect between the two can be achieved. This makes the shielding function of the connector 2 more complete and the shielding effect better.
  • the assembly difficulty between the inner shell 4 and the electrical connection skeleton 1 is also reduced.
  • the vertical length of the insertion portion 61 along the radial direction of the electrical connection frame 1 is less than the thickness of the insulating layer 3 .
  • the insertion portion 61 is inserted into the insulating layer 3 to electrically connect with the conductive particles 31 but does not penetrate the insulating layer 3 .
  • the contact part 62 is cylindrical, and at least one insertion part 61 is provided inside the cylindrical shape.
  • the outer wall of the cylindrical contact part 62 is in contact with the The inner surface of the inner shell 4 is electrically connected.
  • the contact portion 62 is a cylindrical conductive elastic piece.
  • the conductive elastic piece is electrically connected to the inner shell 4 and exerts an elastic force on the inner shell 4 to ensure that the inner shell 4 and the contact portion 62 are more closely connected to prevent falling off. This makes the shielding function of connector 2 more complete and the shielding effect better.
  • the contact portion 62 is columnar, and the contact portion 62 is inserted into the inner shell 4 and is electrically connected to the inner shell 4 .
  • corresponding notches can be provided inside the inner shell 4, and the notches of the inner shell 4 are connected to the cylindrical contact portion 62 to ensure that the shielding connection device 6 and the inner shell 4 are connected more closely, so that the connection between the two is The shielding function is more complete and the shielding effect is better.
  • the contact portion 62 is an elastic piece, and at least part of the outer surface of the elastic piece is electrically connected to the inner surface of the inner shell 4 .
  • the contact portion 62 is a conductive elastic piece, which is at least partially elastic.
  • the conductive elastic piece is electrically connected to the inner shell 4 to form a complete shielding structure.
  • One end of the conductive spring piece is fixed with the electrical connection insertion part 61, the insertion part 61 is electrically connected to the conductive layer formed by the conductive particles 31, and the other end is in contact with the inner shell 4 and is electrically connected; the contact part 62 can also have connected embedded conductive layers at both ends.
  • the insertion part 61 in the middle, the conductive elastic piece with a middle protrusion, the middle protruding position is electrically connected to the inner shell 4, and the outer diameter of the protruding position of the conductive elastic piece is larger than the inner diameter of the connection position of the inner shell 4, so that after the connector 2 is assembled , the conductive shrapnel is tightly connected with the inner shell 4 by elastic force.
  • the impedance between the shielding connection device 6 and the conductive particles 31 is less than 80 m ⁇ , and the impedance between the shielding connection device 6 and the inner shell 4 is less than 80 m ⁇ .
  • the shielding performance value is less than 40dB, which does not meet the ideal value requirements.
  • the impedance value between the shielding connection device 6 and the conductive particles 31 is less than 80 m ⁇ , the shielding performance values all meet the ideal value requirements, and the trend is getting better and better. Therefore, the inventor sets the impedance between the shielding connection device 6 and the conductive particles 31 to be less than 80 m ⁇ .
  • the inventor used a similar method to set the impedance between the shielding connection device 6 and the inner shell 4 to be less than 80 m ⁇ .
  • the thickness of the insulating layer 3 is 0.1mm-3.8mm.
  • Figure 6 shows an axial cross-sectional view of the electrical connection skeleton 1 covered with the insulation layer 3.
  • Figure 7 shows a radial cross-section of the electrical connection skeleton 1 covered with the insulation layer 3.
  • the breakdown voltage of the insulation layer 3 is less than 2.1KV, which cannot meet the needs.
  • the thickness ratio of the insulation layer 3 is greater than 3.8mm, the breakdown voltage of the insulation layer increases.
  • the increase in the thickness of the insulation layer 3 also increases the cost of raw materials.
  • the increase in the thickness of the insulation layer 3 will also increase the wire diameter. The increase in wire diameter will make the cable less easy to bend. At this time, adding the insulation layer The thickness of 3 has no practical significance. It cannot meet the needs, so the inventor sets the thickness of the insulation layer to 0.1mm-3.8mm.
  • the cross-sectional shape of the electrical connection skeleton 1 is circular, elliptical, rectangular, polygonal, A-shaped, B-shaped, D-shaped, M-shaped, N-shaped Shape, O shape, S shape, E
  • the cross-sectional shape of the electrical connection skeleton 1 can be specifically designed according to the wiring space in the vehicle to facilitate the wiring in the vehicle and the operator to assemble the vehicle.
  • the cross-sectional shape of the electrical connection skeleton 1 is a polygon, and the corners of the polygon are all chamfered or rounded.
  • the corners of the electrical connection skeleton 1 with a polygonal cross-section are all chamfered or rounded, which can facilitate the connection between the electrical connection skeleton 1 and the connection terminal, so that the two are electrically connected during welding or crimping.
  • the connection between the skeleton 1 and the connection terminal is stronger, the contact area is larger, and the conduction current is better; it prevents the contact area between the electrical connection skeleton 1 and the connection terminal from being too small during the connection, resulting in excessive resistance, causing heating or even It can also prevent the occurrence of burning accidents; it can also prevent casualties and property losses caused by the edges formed by the two adjacent sides of the polygon from scratching the insulation layer during use.
  • the cross-sectional area of the electrical connection skeleton is 3.5mm 2 -240mm 2 .
  • the cross-sectional area of the electrical connection skeleton 1 determines the current that the electrical connection skeleton 1 can conduct. Generally, the electrical connection skeleton 1 that realizes signal conduction has a smaller current and the cross-sectional area of the electrical connection skeleton 1 is also smaller. For example, with The minimum cross-sectional area of the electrical connection skeleton 1 for transmitting signals can reach 3.5mm 2 , and the electrical connection skeleton 1 for realizing power conduction has a large current, and the cross-sectional area of the electrical connection skeleton 1 is also large, such as automobile battery wiring harness, electrical connection The maximum cross-sectional area of the skeleton 1 reaches 240mm 2 .
  • the electrical connection frame includes at least one bending portion.
  • a bending portion can be provided on the electrical connection frame 1 as needed to meet the need to change the direction of the electrical connection frame 1 during the wiring process on the vehicle.
  • the bending portion facilitates the operator's wiring and reduces the need for vehicle wiring.
  • the processing man-hours can reduce vehicle production costs and increase market competitiveness.
  • a vehicle of the present application includes a connector assembly of the above-mentioned new shielding material.

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Abstract

本申请公开了一种新型屏蔽材料的连接器总成及车辆，包括电连接骨架及与所述电连接骨架两端连接的连接器，所述连接器中包含连接端子和具有屏蔽效能的内壳，所述电连接骨架两端分别与所述连接端子电连接，所述电连接骨架外周包覆绝缘层，所述绝缘层径向中含有导电粒子，所述导电粒子至少一处密度不均匀的分布在所述绝缘层内。本申请的一种新型屏蔽材料的连接器总成，绝缘层中含有导电粒子代替编制屏蔽网，减少屏蔽网编制设备的使用，占地面积小，降低了线缆的加工成本，同时降低了连接器的生产成本。

Description

新型屏蔽材料的连接器总成及车辆
相关申请
本申请要求2022年3月14日递交的、申请号为202210250047.8、专利名称为“新型屏蔽材料的连接器总成及车辆”的中国发明专利的优先权，该专利的所有内容在此全部引入。
技术领域
本申请涉及汽车电器技术领域，更具体地，涉及新型屏蔽材料的连接器总成及车辆。
背景技术
随着新能源汽车的越来越普及，为新能源汽车充电的设备和设施也随之发展起来，新能源汽车上的连接器总成由于要达到驱动大功率电机的要求，传输电流都比较大，连接器总成上的高压线缆的直径也随之增大。目前大部分连接器总成上的高压线缆都使用多芯的铜线缆，重量大，价格高，成为限制新能源汽车普及的障碍。另外，多芯的线缆虽然较柔软，能够方便加工和布线，都是由于线径过粗，重量较大，在汽车行驶过程中线缆会频繁摩擦车壳，导致线缆的绝缘层破损，造成高压放电，轻则损坏车辆，重则会造成严重的交通事故。
为了降低电磁干扰的影响，导电线缆通常采用屏蔽网进行电磁干扰的屏蔽，目前常用的屏蔽网是采用金属丝编制而成，需要在线缆生产设备中增加屏蔽编织机，设备价格高，占地面积大，导致屏蔽线缆价格居高不下。
因此，汽车电器技术领域亟需一种价格低，寿命长的屏蔽线缆以及新型屏蔽材料的连接器总成。
本申请内容
本申请的一个目的是提供一种新型屏蔽材料的连接器总成的新技术方案。
根据本申请的第一方面，提供了一种新型屏蔽材料的连接器总成，包括电连接骨架及与所述电连接骨架两端连接的连接器，所述连接器中包含连接端子和具有屏蔽效能的内壳，所述电连接骨架两端分别与所述连接端子电连接，所述电连接骨架外周包覆绝缘 层，所述绝缘层径向中含有导电粒子，所述导电粒子至少一处密度不均匀的分布在所述绝缘层内。
根据本申请的第二方面，提供了一种车辆，包含如上所述的新型屏蔽材料的连接器总成。
本申请的有益效果是：
1、使用刚性体电连接骨架，可减小线缆直径，减轻线缆重量，使线缆安装方便，减少与车壳的摩擦，延长了连接器总成的使用寿命。
2、绝缘层径向含有导电粒子，具有屏蔽作用，以此代替编制屏蔽网，减少屏蔽网编制设备的使用，占地面积小，降低了线缆的加工成本，减轻了线缆重量，简化了生产流程，缩短了生产周期，同时降低了连接器总成的生产成本。
3、在绝缘层的内表面与外表面之间夹持导电粒子，此时，绝缘层的内表面与外表面具有绝缘作用，导电粒子形成的导电层，具有屏蔽作用，不需要在绝缘层外侧单独设置屏蔽网，简化了生产工艺，不需要增加生产设备，并且提高生产效率。
4、在内壳和导电粒子形成的导电层之间设置屏蔽连接装置，能够先将导电层与屏蔽连接装置固定并电连接，再组装屏蔽连接装置与内壳接触并电连接，提高屏蔽连接的稳定性，降低加工难度，同时可保证绝缘层中的导电层与内壳之间连接更牢固，屏蔽效果更好。
5、导电粒子至少一处密度不均匀的分布在绝缘层，这样可以根据整车EMC(电磁兼容)需求而进行有针对性的绝缘层设置，在满足屏蔽要求的情况下，有些地方采用导电粒子密度低的绝缘层，能够大幅的节约成本。
通过以下参照附图对本申请的示例性实施例的详细描述，本申请的其它特征及其优点将会变得清楚。
附图说明
被结合在说明书中并构成说明书的一部分的附图示出了本申请的实施例，并且连同其说明一起用于解释本申请的原理。
图1为本申请一种新型屏蔽材料的连接器总成的结构示意图；
图2为本申请一种新型屏蔽材料的连接器总成的内壳与导电粒子连接的剖视图；
图3为本申请另一种新型屏蔽材料的连接器总成的内壳与导电粒子连接的剖视图；
图4为本申请一种新型屏蔽材料的连接器总成的屏蔽连接装置的结构示意图；
图5为本申请一种新型屏蔽材料的连接器总成的另一种屏蔽连接装置的结构示意图；
图6为本申请中绝缘层包覆电连接骨架的轴向截面图；
图7为本申请中绝缘层包覆电连接骨架的径向截面图；
图8为本申请中屏蔽连接装置包覆带有绝缘层的电连接骨架的径向截面图。
【附图标记说明】：
1、电连接骨架；2、连接器；3、绝缘层；4、内壳；5、连接端子；6、屏蔽连接
装置；31、导电粒子；32、凹口；21、凸起；61、插入部；62、接触部。
具体实施方式
下面将结合本申请实施例中的附图，对本申请实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本申请一部分实施例，而不是全部的实施例。基于本申请中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本申请保护的范围。
本申请的一种新型屏蔽材料的连接器总成，如图1至图8所示，包括电连接骨架1及与所述电连接骨架1两端连接的连接器2，所述连接器2中包含连接端子5和具有屏蔽效能的内壳4，所述电连接骨架1两端分别与所述连接端子5电连接，所述电连接骨架1外周包覆绝缘层3，所述绝缘层3径向中含有导电粒子31，所述导电粒子31至少一处密度不均匀的分布在所述绝缘层内。
具体实施时，为了降低电磁干扰的影响，导电线缆通常采用屏蔽网进行电磁干扰的屏蔽，目前常用的屏蔽网是采用金属丝编制而成，需要在线缆生产设备中增加屏蔽编织机，设备价格高，占地面积大，同时增加了生产工序，导致屏蔽线缆价格居高不下。
电连接骨架1多用于在车内传输大电流，在电流经过时会产生较大的电磁场，为了防止大电流产生的电磁场对汽车中的电器进行电磁干扰，影响其他电器的正常工作，因此需要将大电流产生的电磁场进行电磁屏蔽。数据通信线缆则相反，其内部传输电磁信号，这个电磁信号会被外界的电磁场干扰，从而导致电磁信号失真，无法有效的传递信号，因此需要电磁屏蔽来屏蔽外界的电磁场干扰。
电磁屏蔽主要是使用屏蔽体来防止高频电磁场的影响，从而有效地控制电磁波从某一区域向另一区域进行辐射传播。基本原理是采用低电阻值的导体材料制作屏蔽 体，利用电磁波在屏蔽体表面的反射，在屏蔽体内部的被吸收以及在传输过程中的被损耗而产生屏蔽作用。除了电连接骨架1需要进行电磁屏蔽，其与连接器2及连接端子5的连接处也是需要特别进行电磁屏蔽的地方，本申请的电连接骨架1的两端各自与一连接器2及一连接端子5连接，将这些连接处设置在内壳4内，内壳4与电连接骨架1外侧的绝缘层3中的导电粒子31形成的导电层电连接，从而达到完整屏蔽的效果。
为简化生产流程，缩小线缆线径以及降低生产成本，本申请中，绝缘层径向含有导电粒子，由导电粒子形成导电层，此时，绝缘层具有了屏蔽作用，以此代替编制屏蔽网，减少屏蔽网编制设备的使用，占地面积小，降低了线缆的加工成本，减轻了线缆重量，简化了生产流程，缩短了生产周期，同时降低了连接器总成的生产成本。在绝缘层3的内表面与外表面之间夹持导电粒子31，此时，绝缘层3的内表面与外表面具有绝缘作用，导电粒子31形成的导电层的具有屏蔽作用，不需要在绝缘层3外侧单独设置屏蔽网，简化了生产工艺，不需要增加较多的设备，并且提高生产效率。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述连接端子5的材质含有铜或铜合金，所述电连接骨架1材质含有铝或铝合金，所述电连接骨架1通过焊接或压接的方式与所述连接端子电连接。
具体实施时，铜或铜合金导电率高，并且耐摩擦，而且目前大多数的用电装置的接电部分材质都是铜，因此需要使用材质含有铜或铜合金的连接端子5进行插拔连接，连接端子5可以广泛应用于各种电传输场景。采用铝或铝合金材质的电连接骨架1，具有刚性好、质量轻、传输效率高的优点，特别适合大电流的传输。
采用纯铝或铝含量在90％以上的铝合金代替现有技术中通常使用的铜导体，由于铝的密度仅为铜的三分之一，而根据电气性能实心导体电阻率的差异，在满足相同导电性能的前提下，铝与铜的线径比只相差1.28倍，铝材重量只有相同载流量铜材的一半，在不增加电缆装车空间的情况下，可大大减轻线材重量，有利于实现车体的轻量化。而且采用比重小，材质价格便宜的铝导体(包括铝芯或其合金材料)代替比重大，材质价格高的铜导体，可减少材料成本和运输成本，节约机动车辆的生产成本。优选地，所述铝合金是铝含量在90％以上的铝铜合金或铝镁合金或铝锂合金或铝锰合金或铝锌合金或铝硅合金。
电连接骨架1通过焊接与连接端子5连接，所采用的焊接方式，包括电阻焊接、摩擦焊接、超声波焊接、弧焊、激光焊接、电子束焊接、压力扩散焊接、磁感应焊接的一种或几种，是采用集中热能或压力，使连接端子5和电连接骨架1接触位置产生熔融连接，焊接方式连接稳固，可以实现异种材料的连接，由于接触位置相融，导电效果更好。
电阻焊接方式，是指一种利用强大电流通过电极和工件间的接触点，由接触电阻产生热量而实现焊接的一种方法。
摩擦焊方式，是指利用工件接触面摩擦产生的热量为热源，使工件在压力作用下产生塑性变形而进行焊接的方法。
超声波焊接方式，是利用高频振动波传递到两个需焊接的物体表面，在加压的情况下，使两个物体表面相互摩擦而形成分子层之间的熔合。
弧焊方式，是指以电弧作为热源，利用空气放电的物理现象，将电能转换为焊接所需的热能和机械能，从而达到连接金属的目的，主要方法有焊条电弧焊、埋弧焊、气体保护焊等。
激光焊接方式，是利用高能量密度的激光束作为热源的一种高效精密焊接方法。
摩擦焊接方式，是指利用工件接触面摩擦产生的热量为热源，使工件在压力作用下产生塑性变形而进行焊接的方法。
电子束焊接方式，是指利用加速和聚焦的电子束轰击置于真空或非真空中的焊接面，使被焊工件熔化实现焊接。
压力焊接方式，是对焊件施加压力，使接合面紧密地接触产生一定的塑性变形而完成焊接的方法。
磁感应焊接方式，是两个被焊工件在强脉冲磁场作用下，产生瞬间高速碰撞，材料表层在很高的压力波作用下，使两种材料的原子在原子间距离内相遇，从而在界面上形成稳定的冶金结合。是固态冷焊的一种，可以将属性相似或不相似的传导金属焊接在一起。
压接方式，压接是将电连接骨架1与连连接端子5装配后，使用压接机，将两者冲压为一体的生产工艺。压接的优点是量产性，通过采用自动压接机能够迅速大量的制造稳定品质的产品。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述电连接骨架为刚性体，所述电连接骨架的抗拉强度大于75MPa。
目前大部分连接器总成上的充电线缆都使用多芯的铜线缆，重量大，价格高，成为限制新能源汽车普及的障碍。另外，多芯的线缆虽然较柔软，能够方便加工和布线，但是由于线径过粗，重量较大，在汽车行驶过程中线缆会频繁摩擦车壳，导致线缆的绝缘层破损，造成高压放电，轻则损坏车辆，重则会造成严重的交通事故。因此本申请使用刚性体的电连接骨架1的线缆形式替代多芯线缆结构，使线缆能够固定在车壳上，不会随着汽车振动与车壳摩擦，延长连接器的使用寿命，减少事故发生率。电连接骨架1可以为单芯的铜棒，铝棒或者铝扁带。
刚性体是指在运动中和受力作用后，形状和大小不变，而且内部各点的相对位置不变的物体。绝对刚性体实际上是不存在的，只是一种理想模型，因为任何物体在受力作用后，都或多或少地变形，如果变形的程度相对于物体本身几何尺寸来说极为微小，在研究物体运动时变形就可以忽略不计。所以，由刚性体材料制成的电连接骨架1在使用过程中，产生的形变量微乎其微，可忽略不计，刚性体的抗拉强度越大，其变形量越小。
为了验证电连接骨架1的抗拉强度，对电连接骨架1拉断时的拉力值，折弯的扭矩以及振动过程中是否发生异响的影响，发明人选用了相同尺寸规格的，使用不同抗拉强度的电连接骨架1样件，对电连接骨架1拉断时的拉力值，折弯时的扭矩和振动过程中的异响进行测试。
电连接骨架1的拉力值的测试方法：使用万能拉力测试机，将电连接骨架1，两端分别固定在万能拉力测试机的拉伸治具上，并以50mm/min的速度进行拉伸，记录最终拉断时的拉力值，在本实施例中，拉力值大于1600N为合格值。
电连接骨架1的扭矩测试方法：使用扭矩测试仪，将电连接骨架1以相同的半径，相同的速度弯折90°的时候，测试弯折过程中电连接骨架1变形的扭矩值，在本实施例中，扭矩值小于60N·m为优选值。
电连接骨架1是否会出现异响，试验方法为选择相同尺寸规格的，使用不同抗拉强度的电连接骨架1样件，相同规格的连接器2组装在一起，固定在振动试验台上，在振动试验过程中，观察电连接骨架1是否会出现异响。
表1：不同的抗拉强度对电连接骨架1的拉力值，扭矩值以及异响的影响

从上表1中可以看出，当电连接骨架1抗拉强度为小于75MPa时，电连接骨架1拉断时的拉力值小于1600N，此时电连接骨架1本身的强度不高，受到较小外力时容易拉断，造成电连接骨架1功能失效，从而无法起到电能传输的目的。
另一方面，由于电连接骨架1的抗拉强度值越大，电连接骨架1越不易发生形变，所以振动试验过程中，电连接骨架1越不容易相对两端连接的连接器2振动而产生异响，相反，电连接骨架1的抗拉强度值越小，电连接骨架1越容易发生形变，所以振动试验过程中，电连接骨架1越容易相对两端连接的连接器2振动而产生异响。从上表1中可以看出，当电连接骨架1抗拉强度为小于等于75MPa时，电连接骨架1在振动试验过程中会产生异响。所以发明人优选电连接骨架1的抗拉强度大于75MPa
同时，在表1中也能看出，当电连接骨架1抗拉强度为大于480MPa时，电连接骨架1折弯90°时的扭矩值大于60N·m，此时，电连接骨架1不容置折弯。因此，发明人进一步优选电连接骨架1抗拉强度为大于75MPa且小于等于480MPa。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述电连接骨架1至少部分含有柔性体，所述柔性体为多芯线缆或编织线缆或多层薄板叠加的软排。
具体实施时，电连接骨架1中的柔性体部分，也可以设定为多芯线缆或编织线缆或多层薄板叠加的软排，这样可方便在汽车车身上安装时进行布线，此时，电连接骨架1的弯曲性优异，方便安装及存储。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述绝缘层3的材质含有四苯乙烯、聚氯乙烯、聚乙烯、聚酰胺、聚四氟乙烯、四氟乙烯/六氟丙烯共聚物、乙烯/四氟乙烯共聚物、聚丙烯、聚偏氟乙烯、聚氨酯、聚对苯二甲酸、聚氨酯弹性体、苯乙烯嵌段共聚物、全氟烷氧基烷烃、氯化聚乙烯、聚亚苯基硫醚、聚苯乙烯、交联聚烯烃、乙丙橡胶、乙烯/醋酸乙烯共聚物、氯丁橡胶、天然橡胶、丁苯橡胶、丁腈橡胶、硅橡胶、顺丁橡胶、异戊橡胶、乙丙橡胶、丁基橡胶、氟橡胶、聚氨酯橡胶、聚丙烯酸酯橡胶、氯磺化聚乙烯橡胶、氯醚橡胶、氯化聚乙烯橡胶、氯硫橡胶、苯乙烯 丁二烯橡胶、丁二烯橡胶、氢化丁腈橡胶、聚硫橡胶、交联聚乙烯、聚碳酸酯、聚砜、聚苯醚、聚酯、酚醛树脂、脲甲醛、苯乙烯-丙烯腈共聚物、聚甲基丙烯酸酯、聚甲醛树酯中的一种或几种。
下面举例说明材料的特性。
聚甲醛是一种表面光滑、有光泽的、硬而致密的材料，呈淡黄或白色，可在-40℃-100℃温度范围内长期使用。它的耐磨性和自润滑性也比绝大多数工程塑料优越，又有良好的耐油、耐过氧化物性能。
聚碳酸酯，无色透明，耐热，抗冲击，阻燃BI级，在普通使用温度内都有良好的机械性能。同性能接近的聚甲基丙烯酸甲酯相比，聚碳酸酯的耐冲击性能好，折射率高，加工性能好，不需要添加剂就具有很高级的阻燃性能。
聚酰胺，具有无毒、质轻、优良的机械强度，具有较好的耐磨性及耐腐蚀性，可代替铜等金属应用在机械、化工、仪表、汽车等工业中制造轴承、齿轮、泵叶及其他零件。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述导电粒子31材质含有金属、导电陶瓷、含碳导体、固体电解质、混合导体的一种或几种。
具体实施时，导电粒子31掺入高分子材料中形成导电塑料，在导电塑料两侧一体成型绝缘层3。导电塑料具有导电性能，所以，绝缘层具有了屏蔽作用，即具有屏蔽功能，最大优点是成本低，简单实用且适用面广，绝缘层中间含有导电粒子，具有屏蔽作用，以此代替编制屏蔽网，减少屏蔽网编制设备的使用，占地面积小，降低了线缆的加工成本，减轻了线缆重量，简化了生产流程，缩短了生产周期，同时降低了连接器总成的生产成本。
进一步的，所述金属的材质含有金、银、铜、镍、钛、锡、铝、镉、锆、铬、钴、锰、锌、磷、碲、铍、锡铅合金、银锑合金、钯、钯镍合金或银金锆合金的一种或几种。
为了论证不同金属的材质对绝缘层3中导电粒子31的导电率的影响，发明人采用带有导电粒子31的绝缘层3进行了试验，使用相同规格尺寸、不同材质的导电粒子31制作绝缘层3的样件，分别测试导电率，实验结果如下表2所示，在本实施例中，导电塑料的导电率大于99％为理想值。
表2：不同材质的导电粒子对绝缘层中导电粒子形成的导电层的导电率的影响

从上表2可以看出，选用的不同导电粒子制作的绝缘层3，导电率都在理想值范围内，另外，磷是非金属材料，不能直接作为导电层的材质，但是可以添加到其他金属中形成合金，提高金属本身的导电和机械性能。因此，发明人设定导电粒子的材质含有金、银、铜、镍、钛、锡、铝、镉、锆、铬、钴、锰、锌、锡铅合金、银锑合金、钯、钯镍合金和银金锆合金。
进一步的，所述含碳导体含有石墨粉、碳纳米管材料、石墨烯材料，石墨银或石墨烯银中的一种或几种。
石墨粉是一种矿物粉末，主要成分为碳单质，质软，黑灰色；石墨粉是很好的非金属导电物质。碳纳米管具有良好的导电性能，由于碳纳米管的结构与石墨的片层结构相同，所以具有很好的电学性能。石墨烯更是具有极高的电学性能，含有这五种材料的含碳导体导电率高，屏蔽性能好，能够很好的实现对电连接骨架1的电磁屏蔽。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述绝缘层3中的所述导电粒子31的体积占比为3.5％-95％。
如果导电粒子31的体积占绝缘层3体积比例过小，则导电率不足，达不到理想的屏蔽效果。因此发明人对不同导电粒子的体积占比的绝缘层进行了测试，如果导电粒子的导电率小于99％为不合格，测试结果如表3所示。
表3：不同导电粒子的体积占比对绝缘层中导电粒子导电率的影响
从表3可知，当绝缘层中的导电粒子占比小于3.5％时，绝缘层3中导电粒子31的导电率小于99％，不能够满足需要，而当绝缘层3中导电粒子31占比大于95％后导电率并无增加，且所需工艺也越来越高，因此发明人优选所述绝缘层3中导电粒子的体积占比为3.5％-95％。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述导电粒子31最大直径占所述绝缘层3厚度的0.1％-97％。
如果单个导电粒子31最大直径占比过大，则导电粒子31容易刺穿绝缘层，使得绝缘层内表面及外表面不具有绝缘作用，因此发明人对不同直径导电粒子31生产的绝缘层3进行了测试。
绝缘层3的绝缘性能的测试方法，使用绝缘耐电压测试仪，将不同交流或直流高压施加在导电粒子31与绝缘层3内表面之间，以及导电粒子31与绝缘层3外表面之间，以检查电连接骨架1外侧绝缘层3所能承受耐压能力的试验。绝缘层3被击穿的电压小于2.1KV为不合格，测试结果如表4所示。
表4：导电粒子的直径占所述绝缘层厚度比值对绝缘层的击穿电压的影响
从表4可知，导电粒子31直径占所述绝缘层3厚度比值小于97％时，绝缘层3的击穿电压大于2.1KV，能够满足需要，导电粒子31直径占所述绝缘层3厚度比值大于97％时，绝缘层3的击穿电压小于2.1KV，不能够满足需要，因此，所述导电粒子31最大直径占所述绝缘层3厚度的97％。另外，导电粒子直径占所述绝缘层3厚度比值小于0.1％时，生产难度也相应的增大，且击穿电压的数值也难以再增加，所以，发明人选择导电粒子31最大直径占所述绝缘层3厚度的0.1％-97％。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述绝缘层3中的所述导电粒子31在所述电连接骨架1的轴向方向导电。
具体实施时，绝缘层3中的导电粒子31在所述电连接骨架1的轴向方向导电，能够保证电连接骨架1在使用的过程中屏蔽掉电流产生的磁场，保证导电粒子可以起到屏蔽作用，以避免影响其他用电设备的使用。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述绝缘层3中的所述导电粒子31在所述电连接骨架1的周向方向导电。
具体实施时，所述绝缘层3中的所述导电粒子31在所述电连接骨架1的周向方向导电，能够保证导电粒子环绕电连接骨架1四周，形成闭合的圆环，能够保证屏蔽掉电连接骨架1在使用的过程中电流产生的磁场。
具体实施时，绝缘层3内表面与外表面之间连续不间断的夹持导电粒子31，导电粒子31以圆筒状的形式设置在绝缘层3内表面与外表面之间，能够完全屏蔽绝缘层3套设的电连接骨架1使用过程中产生的磁场。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述绝缘层3中的所述导电粒子31在所述电连接骨架1的轴向方向的转移阻抗为小于100mΩ。
通常用绝缘层3中的导电粒子31转移阻抗来表征绝缘层3的屏蔽效果，转移阻抗越小，屏蔽效果越好。绝缘层3的转移阻抗定义为单位长度屏蔽体感应的差模电压U与屏蔽体表面通过的电流Is之比，即：
ZT＝U/IS，所以可以理解为，绝缘层3的转移阻抗将导电粒子31导通的电流转换成差模干扰。转移阻抗越小越好，即减小差模干扰转换，可以得到较好的屏蔽性能。
为了验证不同转移阻抗值的导电粒子31对屏蔽效果的影响，发明人选用相同规格的电连接骨架1、连接器2和连接端子5，采用不同转移阻抗值的导电粒子31，制作了一系列的样件，分别测试屏蔽效果，实验结果如下表5所示，在本实施例中，屏蔽性能值大于40dB为理想值。
屏蔽性能值测试方法为：测试仪器对电连接骨架1输出一个信号值(此数值为测试值2)，在绝缘层3外侧设置探测装置，此探测装置探测到一个信号值(此数值为测试值1)。屏蔽性能值＝测试值2-测试值1。
表5：绝缘层中的导电粒子的转移阻抗对屏蔽性能的影响
从上表5可以看出，当绝缘层3中的导电粒子31的转移阻抗大于100mΩ时，绝缘层3的屏蔽性能值小于40dB，不符合理想值要求，而绝缘层3中的导电粒子31的转移阻抗为小于100mΩ时，绝缘层3的屏蔽性能值全部符合理想值要求，而且趋势越来越好，因此，发明人设定绝缘层3中的导电粒子31的转移阻抗为小于100mΩ。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述绝缘层3的内表面和外表面针对所述导电粒子的绝缘耐压值大于2.1KV。
具体实施时，电连接骨架1的工作电压一般为500V至600V之间，针对绝缘层3的检测电压为工作的电压的3倍，所以，发明人选择绝缘层3的内表面和外表面的绝缘耐压值大于2.1KV，可有效保证绝缘层在使用中不被高压击穿。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述内壳4的材质含有导电金属或包含导电颗粒的高分子材料。
进一步的，所述导电颗粒材质含有金属、导电陶瓷、含碳导体、固体电解质、混合导体的一种或几种；所述高分子材料的材质含有四苯乙烯、聚氯乙烯、聚乙烯、聚酰胺、聚四氟乙烯、四氟乙烯/六氟丙烯共聚物、乙烯/四氟乙烯共聚物、聚丙烯、聚偏氟乙烯、聚氨酯、聚对苯二甲酸、聚氨酯弹性体、苯乙烯嵌段共聚物、全氟烷氧基烷烃、氯化聚乙烯、聚亚苯基硫醚、聚苯乙烯、交联聚烯烃、乙丙橡胶、乙烯/醋酸乙烯共聚物、氯丁橡胶、天然橡胶、丁苯橡胶、丁腈橡胶、硅橡胶、顺丁橡胶、异戊橡胶、乙丙橡胶、丁基橡胶、氟橡胶、聚氨酯橡胶、聚丙烯酸酯橡胶、氯磺化聚乙烯橡胶、氯醚橡胶、氯化聚乙烯橡胶、氯硫橡胶、苯乙烯丁二烯橡胶、丁二烯橡胶、氢化丁腈橡胶、聚硫橡胶、交联聚乙烯、聚碳酸酯、聚砜、聚苯醚、聚酯、酚醛树脂、脲甲醛、苯乙烯-丙烯腈共聚物、聚甲基丙烯酸酯、聚甲醛树酯中的一种或几种。
具体实施时，可以根据需要选择含有不同导电颗粒的高分子材料。
进一步的，所述导电颗粒的金属的材质含有金、银、铜、镍、钛、锡、铝、镉、锆、铬、钴、锰、锌、磷、碲、铍、锡铅合金、银锑合金、钯、钯镍合金或银金锆合金的一种或几种。
为了论证不同导电颗粒对内壳4的导电率的影响，发明人采用内壳4进行了试验，使用相同规格尺寸、不同材质的导电颗粒制作内壳4的样件，分别测试导电率，实验结果如下表6所示，在本实施例中，内壳4的导电率大于99％为理想值。
表6：不同材质的导电颗粒对内壳的导电率的影响
从上表5可以看出，选用的不同导电颗粒制作的内壳4，导电率都在理想值范围内，另外，磷是非金属材料，不能直接作为内壳的材质，但是可以添加到其他金属中形成合金，提高金属本身的导电和机械性能。因此，发明人设定导电颗粒的材质含有金、银、铜、镍、钛、锡、铝、镉、锆、铬、钴、锰、锌、锡铅合金、银锑合金、钯、钯镍合金或银金锆合金的一种或几种。
进一步的，所述导电颗粒的含碳导体含有石墨粉、碳纳米管材料、石墨烯材料、石墨银或石墨烯银中的一种或几种。
石墨粉是一种矿物粉末，主要成分为碳单质，质软，黑灰色；石墨粉是很好的非金属导电物质。碳纳米管具有良好的导电性能，由于碳纳米管的结构与石墨的片层结构相同，所以具有很好的电学性能。石墨烯更是具有极高的电学性能，含有这五种材料的含碳导体导电率高，屏蔽性能好，能够很好的实现对连接端子5的电磁屏蔽。
本申请的新型屏蔽材料的连接器总成的一实施例中，如图2至图5所示，所述内壳4与所述导电粒子电连接。
具体实施时，通过将内壳4与绝缘层3中加入导电粒子形成的导电层电连接，可将电连接骨架1在使用过程中产生的电磁干扰屏蔽掉，防止影响其他作为控制系统的电子设备的正常使用，避免控制系统因电磁干扰失灵造成交通事故，财产损失以及人员伤亡。
本申请的新型屏蔽材料的连接器总成的一实施例中，如图2至图3所示，所述绝缘层3在所述连接器2内，至少部分设置凹口32，所述凹口32内显露出所述导电粒子31；所述内壳4对应位置设置凸起21，所述凸起21与所述凹口32匹配连接并与所述导电粒子电连接。
具体实施时，内壳4一般是安装在连接器2的壳体内部并形成一体，在一种实施方式中，内壳4可以采用导电塑料材质，与连接器2的外壳一起注塑成型。电连接骨架1与连接器2装配时，内壳4与绝缘层3中加入导电粒子形成的导电层连接，可通过在绝缘层3上设置凹口32，在内壳对应处设置凸起21，通过凸起21与凹口32实现内壳4与导电粒子31形成的导电层之间的电连接。以此屏蔽电连接骨架1在使用中产生的电磁干扰。
具体实施时，也可将凹口32内的导电粒子31形成的导电层突出与绝缘层3的外表面形成凸起，内壳4对应的设置凹槽，通过凹槽与凸起的电连接，实现导电层与内壳4电连接，同样可实现屏蔽电连接骨架1在使用中产生的电磁干扰的作用。
为使内壳4与导电层接触更加充分，以使的连接器2的屏蔽功能更完整，屏蔽效果更好。绝缘层3上形成显露出导电粒子凹口或凸起，可以为环状凹槽或环状凸起，使得二者之间的电连接的更稳定充分。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述导电粒子31与所述内壳4之间的阻抗小于80mΩ。
为了验证导电粒子31形成的导电层与内壳4之间的阻抗值对屏蔽效果的影响，发明人选用相同规格的电连接骨架1、连接器2、内壳4和连接端子5，选用不同的导电粒子31与内壳4之间的阻抗，制作了一系列的样件，分别测试屏蔽效果，实验结果如下表7所示，在本实施例中，屏蔽性能值大于40dB为理想值。
屏蔽性能值测试方法为：测试仪器对电连接骨架1输出一个信号值(此数值为测试值2)，在内壳4外侧设置探测装置，此探测装置探测到一个信号值(此数值为测试值1)。屏蔽性能值＝测试值2-测试值1。
表7：导电粒子与内壳之间的阻抗对屏蔽性能的影响
从表7可以看出，当导电粒子31与内壳4之间的阻抗值大于80mΩ时，屏蔽性能值小于40dB，不符合理想值要求，而导电粒子31与内壳4之间的阻抗值为小于80mΩ时，屏蔽性能值全部符合理想值要求，而且趋势越来越好，因此，发明人设定导电粒子31与内壳4之间的阻抗为小于80mΩ。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述内壳4的转移阻抗为小于100mΩ。
为了验证不同转移阻抗值的内壳4对屏蔽效果的影响，发明人选用相同规格的电连接骨架1、连接器2和连接端子5，采用不同转移阻抗值的内壳4，制作了一系列的样件，分别测试屏蔽效果，实验结果如下表8所示，在本实施例中，屏蔽性能值大于40dB为理想值。
屏蔽性能值测试方法为：测试仪器对电连接骨架1输出一个信号值(此数值为测试值2)，在内壳4外侧设置探测装置，此探测装置探测到一个信号值(此数值为测试值1)。屏蔽性能值＝测试值2-测试值1。
表8：内壳4的转移阻抗对屏蔽性能的影响
从上表7可以看出，当内壳4的转移阻抗值大于100mΩ时，内壳4的屏蔽性能值小于40dB，不符合理想值要求，而内壳4的转移阻抗值为小于100mΩ时，内壳4的屏蔽性能值全部符合理想值要求，而且趋势越来越好，因此，发明人设定内壳4的转移阻抗为小于100mΩ。
本申请的新型屏蔽材料的连接器总成的一实施例中，如图4至图5所示，所述连接器2还包括屏蔽连接装置6，所述屏蔽连接装置6具有至少一个的插入部61和接触部62，所述插入部61沿所述绝缘层3外周表面插入并与所述导电粒子31电连接，所述接触部62与所述内壳4电连接。
具体实施时，屏蔽连接装置6安装在内壳4与绝缘层3中导电粒子形成的导电层之间，用于电连接导电层与内壳4，以此屏蔽电连接骨架1以及连接端子5在通电过程中产生的电磁干扰。通过屏蔽连接装置6可更为牢固的电连接导电层与内壳4，使得二者之间具有更为稳定的屏蔽效果。使连接器2的屏蔽功能更完整，屏蔽效果更好，同时，通过屏蔽连接装置6的设置，也使得内壳4与电连接骨架1之间的组装难度降低。
进一步的，所述插入部61沿所述电连接骨架1的径向方向的垂直长度小于所述绝缘层3的厚度。
具体实施时，插入部61插入绝缘层3中与导电粒子31电连接，但不刺破绝缘层3。
进一步的，如图4和图8所示，所述接触部62为圆筒状，所述圆筒状的内部设置至少一个所述插入部61，圆筒状的接触部62的外壁与所述内壳4的内表面电连接。
具体实施时，接触部62为圆筒状的导电弹片，导电弹片与内壳4电连接，并对内壳4施加一弹力，保证内壳4与接触部62连接的更为紧密，防止脱落，使得连接器2的屏蔽功能更完整，屏蔽效果更好。
进一步的，如图5所示，所述接触部62为柱状，所述接触部62插入所述内壳4并与所述内壳4电连接。
具体实施时，可在内壳4内部对应设置凹口，内壳4的凹口与柱状的接触部62连接，保证屏蔽连接装置6与内壳4连接的更为紧密，使得二者之间的屏蔽功能更完整，屏蔽效果更好。
进一步的，所述接触部62为弹片，所述弹片的至少部分外表面与所述内壳4的内表面电连接。
具体实施时，接触部62为导电弹片，导电弹片至少部分具有弹性，导电弹片与内壳4电连接，从而形成完整的屏蔽结构。导电弹片一端固定电连接插入部61，插入部61电连接在导电粒子31形成的导电层上，另一端与内壳4接触并电连接；接触部62也可以两端均具有连接埋入导电层中的插入部61，中间凸起的导电弹片，中间凸起位置与内壳4电连接，导电弹片凸出位置的外径，要大于内壳4连接位置的内径，这样在连接器2组装之后，导电弹片依靠弹力与内壳4紧密的连接在一起。
进一步的，所述屏蔽连接装置6与所述导电粒子31之间的阻抗小于80mΩ，所述屏蔽连接装置6与所述内壳4之间的阻抗小于80mΩ。
为了验证屏蔽连接装置6与所述导电粒子31之间的阻抗值对屏蔽效果的影响，发明人选用相同规格的电连接骨架1、连接器2、内壳4和连接端子5，选用不同的屏蔽连接装置6与导电粒子31之间的阻抗，制作了一系列的样件，分别测试屏蔽效果，实验结果如下表9所示，在本实施例中，屏蔽性能值大于40dB为理想值。
屏蔽性能值测试方法为：测试仪器对电连接骨架1输出一个信号值(此数值为测试值2)，在屏蔽连接装置6外侧设置探测装置，此探测装置探测到一个信号值(此数值为测试值1)。屏蔽性能值＝测试值2-测试值1。
表9：屏蔽连接装置与所述导电粒子之间的阻抗对屏蔽性能的影响

从表可以看出，当屏蔽连接装置6与所述导电粒子31之间的阻抗值大于80mΩ时，屏蔽性能值小于40dB，不符合理想值要求，而屏蔽连接装置6与所述导电粒子31之间的阻抗值为小于80mΩ时，屏蔽性能值全部符合理想值要求，而且趋势越来越好，因此，发明人设定屏蔽连接装置6与所述导电粒子31之间的阻抗为小于80mΩ。
发明人用类似的方法设定了屏蔽连接装置6与内壳4之间的阻抗小于80mΩ。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述绝缘层3的厚度为0.1mm-3.8mm。
如图6所示为绝缘层3包覆电连接骨架1的轴向截面图，如图7所示为绝缘层3包覆电连接骨架1的径向截面图，绝缘层3的厚度越小，则绝缘层3耐受的击穿电压越小，相反，绝缘层3的厚度越厚，则绝缘层3耐受的击穿电压越大，绝缘层3被击穿后，则不具有绝缘作用，因此发明人对不同厚度的绝缘层3进行了测试。
绝缘层3的绝缘性能的测试方法，使用绝缘耐电压测试仪，将不同交流或直流高压施加在电连接骨架1与绝缘层3之间，以检查电连接骨架1外侧绝缘层3所能承受耐压能力的试验。绝缘层3被击穿的电压小于2.1KV为不合格，测试结果如表10所示。
表10：绝缘层厚度对绝缘层的击穿电压的影响
从表10可知，绝缘层3厚度比值小于0.1mm时，绝缘层3的击穿电压小于2.1KV，不能够满足需要，绝缘层3厚度比值大于3.8mm时，绝缘层的击穿电压增长趋势趋于平缓，同时由于绝缘层3厚度增加，也使得原料成本增加，而且，绝缘层3的厚度增加，同样会使线径增大，线径增大会使线缆不易弯曲，此时，增加绝缘层3的厚度已经没有实际意义。不能够满足需要，因此，发明人设定绝缘层的厚度为0.1mm-3.8mm。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述电连接骨架1横截面形状为圆形、椭圆形、矩形、多边形、A形、B形、D形、M形、N形、O形、S形、E 形、F形、H形、K形、L形、T形、U形、V形、W形、X形、Y形、Z形、P形、半弧形、弧形、波浪形中的一种或几种。
具体实施时，电连接骨架1横截面形状可根据车内布线空间具体设计，以方便车内布线以及操作人员组装车辆。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述电连接骨架1的截面形状为多边形，所述多边形的角全部倒角或倒圆。
具体实施时，截面为多边形形状的电连接骨架1的角全部倒角或倒圆，可方便电连接骨架1与连接端子之间连接，使得二者之间在通过焊接或者压接时，电连接骨架1与连接端子之间连接的更为牢固，接触面积更大，导通电流更好；防止电连接骨架1与连接端子之间因连接时接触面积过小，导致电阻过大，引起发热甚至发生燃烧事故；也可防止在使用过程中，因多边形相邻的两条边形成的棱边划破绝缘层造成人员伤亡以及财产损失。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述电连接骨架的横截面积为3.5mm2-240mm2。
电连接骨架1的横截面积决定电连接骨架1所能导通的电流，一般情况下，实现信号导通的电连接骨架1，电流较小，电连接骨架1截面积也较小，例如用于传输信号的电连接骨架1最小截面积可达到3.5mm2，而实现电源导通的电连接骨架1，电流较大，电连接骨架1横截面积也较大，例如汽车蓄电池线束，电连接骨架1最大截面积达到240mm2。
本申请的新型屏蔽材料的连接器总成的一实施例中，所述电连接骨架包括至少一个弯折部。
具体实施时，可根据需要，在电连接骨架1上设置弯折部，以满足在车辆上布线的过程中，需要改变电连接骨架1的方向处有弯折部，方便操作人员布线，减少车辆的加工工时，能够降低车辆的生产成本，增加市场竞争力。
本申请的一种车辆，包含上述的新型屏蔽材料的连接器总成。
虽然已经通过例子对本申请的一些特定实施例进行了详细说明，但是本领域的技术人员应该理解，以上例子仅是为了进行说明，而不是为了限制本申请的范围。本领域的技术人员应该理解，可在不脱离本申请的范围和精神的情况下，对以上实施例进行修改。

Claims (34)

  1. 一种新型屏蔽材料的连接器总成，包括电连接骨架及与所述电连接骨架两端连接的连接器，其特征在于，所述连接器中包含连接端子和具有屏蔽效能的内壳，所述电连接骨架两端分别与所述连接端子电连接，所述电连接骨架外周包覆绝缘层，所述绝缘层径向中含有导电粒子，所述导电粒子至少一处密度不均匀的分布在所述绝缘层内。
  2. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述连接端子的材质含有铜或铜合金，所述电连接骨架材质含有铝或铝合金，所述电连接骨架通过焊接或压接的方式与所述连接端子电连接。
  3. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述电连接骨架为刚性体，所述电连接骨架的抗拉强度大于75MPa。
  4. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述电连接骨架至少部分含有柔性体，所述柔性体为多芯线缆或编织线缆或多层薄板叠加的软排。
  5. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述绝缘层的材质含有四苯乙烯、聚氯乙烯、聚乙烯、聚酰胺、聚四氟乙烯、四氟乙烯/六氟丙烯共聚物、乙烯/四氟乙烯共聚物、聚丙烯、聚偏氟乙烯、聚氨酯、聚对苯二甲酸、聚氨酯弹性体、苯乙烯嵌段共聚物、全氟烷氧基烷烃、氯化聚乙烯、聚亚苯基硫醚、聚苯乙烯、交联聚烯烃、乙丙橡胶、乙烯/醋酸乙烯共聚物、氯丁橡胶、天然橡胶、丁苯橡胶、丁腈橡胶、硅橡胶、顺丁橡胶、异戊橡胶、乙丙橡胶、丁基橡胶、氟橡胶、聚氨酯橡胶、聚丙烯酸酯橡胶、氯磺化聚乙烯橡胶、氯醚橡胶、氯化聚乙烯橡胶、氯硫橡胶、苯乙烯丁二烯橡胶、丁二烯橡胶、氢化丁腈橡胶、聚硫橡胶、交联聚乙烯、聚碳酸酯、聚砜、聚苯醚、聚酯、酚醛树脂、脲甲醛、苯乙烯-丙烯腈共聚物、聚甲基丙烯酸酯、聚甲醛树酯中的一种或几种。
  6. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述导电粒子材质含有金属、导电陶瓷、含碳导体、固体电解质、混合导体的一种或几种。
  7. 根据权利要求6所述的新型屏蔽材料的连接器总成，其特征在于，所述金属的材质含有金、银、铜、镍、钛、锡、铝、镉、锆、铬、钴、锰、锌、磷、碲、铍、锡铅合金、银锑合金、钯、钯镍合金或银金锆合金的一种或几种。
  8. 根据权利要求6所述的新型屏蔽材料的连接器总成，其特征在于，所述含碳导体含有石墨粉、碳纳米管材料、石墨烯材料、石墨银或石墨烯银中的一种或几种。
  9. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述绝缘层中的所述导电粒子的体积占比为3.5％-95％。
  10. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述导电粒子最大直径占所述绝缘层厚度的0.1％-97％。
  11. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述绝缘层中的所述导电粒子在所述电连接骨架的轴向方向导电。
  12. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述绝缘层中的所述导电粒子在所述电连接骨架的周向方向导电。
  13. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述绝缘层中的所述导电粒子在所述电连接骨架的轴向方向的转移阻抗为小于100mΩ。
  14. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述绝缘层的内表面和外表面针对所述导电粒子的绝缘耐压值大于2.1KV。
  15. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述内壳的材质含有导电金属或包含导电颗粒的高分子材料。
  16. 根据权利要求15所述的新型屏蔽材料的连接器总成，其特征在于，所述导电颗粒材质含有金属、导电陶瓷、含碳导体、固体电解质、混合导体的一种或几种；所述高分子材料的材质含有四苯乙烯、聚氯乙烯、聚乙烯、聚酰胺、聚四氟乙烯、四氟乙烯/六氟丙烯共聚物、乙烯/四氟乙烯共聚物、聚丙烯、聚偏氟乙烯、聚氨酯、聚对苯二甲酸、聚氨酯弹性体、苯乙烯嵌段共聚物、全氟烷氧基烷烃、氯化聚乙烯、聚亚苯基硫醚、聚苯乙烯、交联聚烯烃、乙丙橡胶、乙烯/醋酸乙烯共聚物、氯丁橡胶、天然橡胶、丁苯橡胶、丁腈橡胶、硅橡胶、顺丁橡胶、异戊橡胶、乙丙橡胶、丁基橡胶、氟橡胶、聚氨酯橡胶、聚丙烯酸酯橡胶、氯磺化聚乙烯橡胶、氯醚橡胶、氯化聚乙烯橡胶、氯硫橡胶、苯乙烯丁二烯橡胶、丁二烯橡胶、氢化丁腈橡胶、聚硫橡胶、交联聚乙烯、聚碳酸酯、聚砜、聚苯醚、聚酯、酚醛树脂、脲甲醛、苯乙烯-丙烯腈共聚物、聚甲基丙烯酸酯、聚甲醛树酯中的一种或几种。
  17. 根据权利要求16所述的新型屏蔽材料的连接器总成，其特征在于，所述导电颗粒的金属的材质含有金、银、铜、镍、钛、锡、铝、镉、锆、铬、钴、锰、锌、磷、碲、铍、锡铅合金、银锑合金、钯、钯镍合金或银金锆合金的一种或几种。
  18. 根据权利要求16所述的新型屏蔽材料的连接器总成，其特征在于，所述导电颗粒的含碳导体含有石墨粉、碳纳米管材料、石墨烯材料、石墨银或石墨烯银中的一种或几种。
  19. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述内壳与所述导电粒子电连接。
  20. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述绝缘层在所述连接器内，至少部分设置凹口，所述凹口内显露出所述导电粒子；所述内壳对应位置设置凸起，所述凸起与所述凹口匹配连接并与所述导电粒子电连接。
  21. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述导电粒子与所述内壳之间的阻抗小于80mΩ。
  22. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述内壳的转移阻抗为小于100mΩ。
  23. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述连接器还包括屏蔽连接装置，所述屏蔽连接装置具有至少一个的插入部和接触部，所述插入部沿所述绝缘层的外周表面插入并与所述导电粒子电连接，所述接触部与所述内壳电连接。
  24. 根据权利要求23所述的新型屏蔽材料的连接器总成，其特征在于，所述插入部沿所述电连接骨架的径向方向的垂直长度小于所述绝缘层的厚度。
  25. 根据权利要求23所述的新型屏蔽材料的连接器总成，其特征在于，所述接触部为圆筒状，所述圆筒状的内部设置至少一个所述插入部，所述圆筒状的外壁与所述内壳的内表面电连接。
  26. 根据权利要求23所述的新型屏蔽材料的连接器总成，其特征在于，所述接触部为柱状，所述接触部插入所述内壳并与所述内壳电连接。
  27. 根据权利要求23所述的新型屏蔽材料的连接器总成，其特征在于，所述接触部为弹片，所述弹片的至少部分外表面与所述内壳的内表面电连接。
  28. 根据权利要求23所述的新型屏蔽材料的连接器总成，其特征在于，所述屏蔽连接装置与所述导电粒子之间的阻抗小于80mΩ，所述屏蔽连接装置与所述内壳之间的阻抗小于80mΩ。
  29. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述绝缘层的厚度为0.1mm-3.8mm。
  30. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述电连接骨架横截面形状为圆形、椭圆形、矩形、多边形、A形、B形、D形、M形、N形、O形、S形、E形、F形、H形、K形、L形、T形、U形、V形、W形、X形、Y形、Z形、P形、半弧形、弧形、波浪形中的一种或几种。
  31. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述电连接骨架的截面形状为多边形，所述多边形的角全部倒角或倒圆。
  32. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述电连接骨架的横截面积为3.5mm2-240mm2。
  33. 根据权利要求1所述的新型屏蔽材料的连接器总成，其特征在于，所述电连接骨架包括至少一个弯折部。
  34. 一种车辆，其特征在于，包含如权利要求1-33任一项所述的新型屏蔽材料的连接器总成。
PCT/CN2023/081259 2022-03-14 2023-03-14 新型屏蔽材料的连接器总成及车辆 WO2023174246A1 (zh)

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