WO2024131957A1 - 一体注塑分流器 - Google Patents

一体注塑分流器 Download PDF

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Publication number
WO2024131957A1
WO2024131957A1 PCT/CN2023/141126 CN2023141126W WO2024131957A1 WO 2024131957 A1 WO2024131957 A1 WO 2024131957A1 CN 2023141126 W CN2023141126 W CN 2023141126W WO 2024131957 A1 WO2024131957 A1 WO 2024131957A1
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WO
WIPO (PCT)
Prior art keywords
diverter
section
molded
flow divider
piece injection
Prior art date
Application number
PCT/CN2023/141126
Other languages
English (en)
French (fr)
Inventor
王超
Original Assignee
长春捷翼汽车科技股份有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 长春捷翼汽车科技股份有限公司 filed Critical 长春捷翼汽车科技股份有限公司
Publication of WO2024131957A1 publication Critical patent/WO2024131957A1/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
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/12—End pieces terminating in an eye, hook, or fork
    • 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
    • H01R13/40—Securing contact members in or to a base or case; Insulating of contact members
    • 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
    • H01R13/46—Bases; Cases
    • H01R13/50—Bases; Cases formed as an integral body
    • 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
    • H01R31/02—Intermediate parts for distributing energy to two or more circuits in parallel, e.g. splitter

Definitions

  • the present application belongs to the technical field of diverters, and specifically relates to an integral injection molded diverter.
  • the shunt includes a conductor and an insulating layer included on the conductor.
  • a fixing component is provided on the insulating layer, and the shunt is provided on the mounting base through the fixing component. That is to say, the current fixing component is a separate structure from the insulating layer, which takes a long time to process, wastes labor time and mold costs, and the overall structure is not strong. Therefore, a new solution is urgently needed in the prior art to solve the above problems.
  • One purpose of the present application is to provide an integral injection molded flow divider to solve the problem that the flow divider takes a long time to process, wastes man-hours and mold costs, and the overall structure is not strong.
  • an integral injection molded flow divider comprising: at least two flow dividers, each flow divider comprising at least three flow divider sections and an insulating layer disposed on at least a portion of the outer surface of the flow divider sections, the converging ends of the flow divider sections being connected to each other to form a converging area;
  • a fixing member fixedly connects at least two flow dividers and covers at least the intersection area
  • the fixing component is formed on the diversion section.
  • the fixing member covers at least a portion of the insulating layer and is integrally injection-molded with at least a portion of the insulating layer.
  • the insulating layer covers the fixing component and is integrally injection-molded with the fixing component.
  • a free end of the diversion section which is arranged opposite to the converging end, is provided with a connecting portion, and a through hole or a threaded hole or a stud is provided on the connecting portion.
  • a conductive wear-resistant layer is provided on the surface of the through hole, threaded hole or stud.
  • surfaces on the same side of at least two connecting parts are in the same plane.
  • the flow-dividing section includes at least one energy-absorbing portion, and the energy-absorbing portion is located between the converging end and the connecting portion.
  • the ratio of the deployed length of the energy absorbing portion to the straight-line distance between two ends of the energy absorbing portion is 1:0.05-1:0.98.
  • the two ends of the energy absorbing part respectively have a first mounting hole and at least one second mounting hole movable relative to the first mounting hole, and the ratio of the movable distance of the center point of the second mounting hole relative to the center point of the first mounting hole to the diameter of the first mounting hole is in the range of: 0.25:1-1.75:1.
  • At least the energy absorbing portion in the diversion section is made of a flexible material.
  • intersection area includes an area formed by the converging end of at least one flow dividing section overlapping the converging end of another flow dividing section.
  • the diverter section includes a first diverter section, a second diverter section and a third diverter section, and converging ends of the first diverter section, the second diverter section and the third diverter section are respectively welded to the intersection area.
  • the diverter section includes a first diverter section, a second diverter section and a third diverter section, the first diverter section and the second diverter section are an integral structure, and a converging end of the third diverter section is welded to the first diverter section and/or the second diverter section.
  • intersection areas of at least two diverters are stacked.
  • the diverter section includes a first diverter section, a second diverter section and a third diverter section, and an angle between the first diverter section and the second diverter section is 15°-90°.
  • the angle between the third diverter section and the first diverter section or the second diverter section is greater than or equal to 90°.
  • the integral injection-molded flow divider includes a first flow divider and a second flow divider, and the first flow divider section and the second flow divider section of the first flow divider and the third flow divider section of the second flow divider are located on the same side of the intersection area.
  • the ratio of the contact area between each diverter and the fixing member to the surface area of the diverter is not less than 3.5%, that is, the contact area between each diverter and the fixing member accounts for not less than 3.5% of the surface area of the diverter.
  • the fixing member and at least part of the insulating layer are integrally injection molded and covered on at least two shunts, so that two or more shunts can be protected and fixed, which not only plays an insulating role, but also makes the overall structure stable, saves injection molding costs and installation time, and improves production efficiency.
  • a connecting portion is provided at the free end of the shunt section, and a through hole or a threaded hole is provided on the connecting portion, so that the fastener can be fastened and connected to the installation position after passing through the through hole or the threaded hole.
  • the vehicle body wiring harness can be reliably fixed to realize the shunt control of the power supply of the battery pack to different electrical appliances; at the same time, the shunt has a certain energy absorption effect.
  • the vibration of the vehicle body causes the wiring harness to shake, it can absorb the vibration energy to avoid problems such as abnormal noise caused by the shaking of the wiring harness; the installation hole position of this device can also be moved within a certain distance, and even if the connected wiring harness is relatively rigid, a reliable connection can be established with it.
  • FIG1 is a schematic structural diagram of the integrated injection-molded diverter of the present application.
  • FIG. 2 is a schematic diagram of the diverter structure of the integrated injection molded diverter of the present application.
  • FIG. 3 is a schematic diagram of a bending in which the ratio of the unfolded length of the energy absorbing portion to the straight-line distance between the two ends of the energy absorbing portion is 1:0.05.
  • FIG. 4 is a schematic diagram of a bending in which the ratio of the unfolded length of the energy absorbing portion to the straight-line distance between the two ends of the energy absorbing portion is 1:0.98.
  • the integral injection molded flow divider as shown in FIG. 1 and FIG. 2 , comprises: at least two flow dividers, each flow divider comprising at least three flow divider sections and an insulating layer 5 disposed on at least a portion of the outer surface of the flow divider sections, the converging ends of the flow divider sections being connected to each other to form a converging area 7;
  • a fixing member 1 fixedly connecting at least two flow dividers and covering at least a junction area 7;
  • the fixing component 1 is formed on the flow dividing section.
  • the fixing member 1 may cover at least a portion of the insulating layer 5 and be integrally injection-molded with at least a portion of the insulating layer 5 .
  • the insulating layer 5 can cover the fixing component 1 and be integrally injection molded with the fixing component 1 .
  • the fixed component 1 and the insulating layer 5 of the diverter are separate structures, which takes a long time to process, wastes man-hours and mold costs, and the overall structure is not strong.
  • the diverter of the present application includes at least three diverter sections, which can be divided at three angles to meet different angle division requirements.
  • the diverter section includes a converging end and a free end. The free end is used to connect with the connecting part 6.
  • the converging ends of the diverter sections are interconnected to form an intersection area 7, thereby realizing electrical connection of multiple diverter sections at different angles;
  • the fixed component 1 and at least part of the insulating layer 5 are integrally injection-molded and coated on at least two diverters (it can be understood that the fixed component 1 is coated on the outside of the insulating layer 5 and is integrally molded with it to coat the diverter section, or the insulating layer 5 is coated on the outside of the fixed component 1 and is integrally molded with it to coat the diverter section).
  • Two or more diverters can be protected and fixed, which not only plays an insulating role, but also makes the overall structure stable, saves injection molding costs and installation time, and improves production efficiency.
  • a connecting portion 6 is provided at a free end of the diversion section opposite to the converging end, and a through hole or a threaded hole 4 or a stud is provided on the connecting portion 6 .
  • a connecting portion 6 is provided at the free end of the diversion section, and the connecting portion 6 is connected to the installation position.
  • a through hole or a threaded hole 4 or a stud is provided on the connecting portion 6 to facilitate the fastener to be fastened and connected to the installation position after passing through the through hole or the threaded hole 4, or to facilitate the stud to be threadedly connected to the installation hole of the installation position.
  • a conductive wear-resistant layer is provided on the surface of the through hole or threaded hole 4 or the stud.
  • This shunt is mainly electrically connected to the vehicle body wiring harness through a through hole or threaded hole 4 to transfer and distribute electrical energy. Therefore, the reliability of the conductivity of the through hole or threaded hole 4 is crucial to the stable use of this device. By setting a conductive wear-resistant layer, the reliability of the connection here can be greatly improved, avoiding problems such as poor power transmission due to harsh working environment.
  • surfaces on the same side of at least two connecting portions 6 are located in the same plane.
  • the same side surfaces of at least two connecting parts 6 (which can be understood as the lower surface as shown in Figure 1) are in the same plane, which can ensure that the overall volume of the diverter is small, occupies a small installation space, is suitable for more installation environments, can be mass-produced, and is easy to replace and maintain.
  • the flow diversion section includes at least one energy absorbing portion 3 , and the energy absorbing portion 3 is located between the intersection area 7 and the connecting portion 6 .
  • the energy absorbing part 3 is provided with a bending section so as to absorb energy when the connector is impacted.
  • the bending section can be bent according to the connection direction or the corresponding bending design can be made according to the layout of the installation environment space.
  • the energy absorbing part 3 can achieve energy absorption effects at multiple angles.
  • the ratio of the deployed length of the energy absorbing portion 3 to the straight-line distance between the two ends of the energy absorbing portion 3 is 1:0.05-1:0.98.
  • the unfolded length of the energy absorbing part 3 is the length of the plate before it is bent; the straight-line distance between the two ends of the energy absorbing part 3 is the distance between the two ends after the bending. If the straight-line distance is too short, the processed energy absorbing part 3 cannot be connected to its two ends.
  • the conductive part at the end realizes reliable electrical connection. Relatively speaking, if the aforementioned straight-line distance is too large, the energy absorption effect may be insufficient due to the small bending deformation. Therefore, in order to achieve a better use effect, the ratio between the aforementioned two distances must meet the following two conditions: the two ends of the energy absorption part 3 can be connected to the conductive part and have an energy absorption effect. For this purpose, the inventor conducted relevant experiments, and the test parameters are shown in Table 1.
  • the unfolded length of the energy absorbing part 3 is L2, and the straight-line distance between the two ends of the energy absorbing part 3 is L1.
  • Figure 3 is a schematic diagram of L2:L1 being 1:0.05. At this time, the bending degree reaches the maximum. If the bending continues, there is a risk of not being able to connect the connecting part 6 and the confluence end at both ends.
  • Figure 4 is a schematic diagram of L2:L1 being 1:0.98. At this time, the bending degree is small, resulting in a smaller energy absorption capacity. If the bending degree is smaller than this degree, the problem of being unable to absorb energy will occur.
  • the energy absorbing part 3 has a first mounting hole and at least one second mounting hole movable relative to the first mounting hole at both ends, and the ratio of the movable distance of the center point of the second mounting hole relative to the center point of the first mounting hole to the diameter of the first mounting hole is in the range of 0.25:1-1.65:1.
  • At least the energy absorbing portion 3 in the diversion section is made of a flexible material.
  • the energy absorbing part 3 is made of a flexible material, which can be bent to a suitable angle to meet different orientation requirements of the connection position and to be suitable for different installation layout spaces.
  • the diverter section includes a first diverter section 8, a second diverter section 9 and a third diverter section 10, and the converging ends of the first diverter section 8, the second diverter section 9 and the third diverter section 10 are welded and connected.
  • the shunt section includes a first shunt section 8, a second shunt section 9 and a third shunt section 10.
  • Different shunt sections face different angles to achieve branch line connection effects at different angles.
  • the converging ends of the three are welded to achieve electrical connection.
  • the diversion section includes a first diversion section 8, a second diversion section 9 and a third diversion section 10.
  • the first diversion section 8 and the second diversion section 9 are an integrated structure, and the converging end of the third diversion section 10 is welded to the first diversion section 8 and/or the second diversion section 9.
  • This diversion section includes a first diversion section 8, a second diversion section 9 and a third diversion section 10. Different diversion sections face different angles to achieve branch line connection effects at different angles.
  • the confluence end of the third diversion section 10 is welded to the first diversion section 8 and/or the second diversion section 9 to achieve electrical connection.
  • intersection regions 7 of at least two flow dividers are stacked.
  • intersection area 7 of at least two diverters is stacked, so that after the fixing component 1 and the insulating layer 5 are integrally injection-molded, the fixing component 1 wraps and fixes the stacking position, so that the intersection area 7 of the two diverters is not separated, the overall structure is stable during use, and the connection structure is not easily damaged or separated by external force.
  • the intersection area 7 includes an area formed by the converging end of at least one diverting section overlapping the converging end of another diverting section.
  • the intersection area at least includes an area formed by the converging end of the second diverting section 9 overlapping the converging end of the first diverting section 8.
  • the flow dividing section includes a first flow dividing section 8, a second flow dividing section 9 and a third flow dividing section 10.
  • the angle between the section 8 and the second diverter section 9 is 15°-90°.
  • the angle between the third diverter section 10 and the first diverter section 8 or the second diverter section 9 is greater than or equal to 90°.
  • the angle between the third diverter section 10 and the first diverter section 8 or the second diverter section 9 is greater than or equal to 90°.
  • the overall longitudinal width of the structure of the present application is small, which can save longitudinal space and better adapt to more vehicle models and installation environments.
  • the angle between the third diverter section 10 and the first diverter section 8 or the second diverter section 9 is greater than or equal to 90°, which can not only realize a 90-180° spatial arrangement on the other side of the intersection area 7, but also allow the fixed component 1 and at least part of the insulating layer 5 to be easily integrally injection molded and coated on the stacked position of the intersection area 7 of the two diverters; if the angle between the third diverter section 10 and the first diverter section 8 or the second diverter section 9 is less than 90°, it is not easy for the fixed component 1 to cover the stacked position of the intersection area 7, and even after the injection molding and coating installation is successful, if the angle between the third diverter section 10 and the first diverter section 8 or the second diverter section 9 is less
  • the integral injection-molded flow divider includes a first flow divider and a second flow divider, and the first flow divider section 8 and the second flow divider section 9 of the first flow divider and the third flow divider section 10 of the second flow divider are located on the same side of the intersection area 7 .
  • the present application meets the requirement of having at least two diversion sections at different angles on the same side of the intersection area 7, so as to realize connection in different directions on the same side of the intersection area 7.
  • the ratio of the contact area between each diverter and the fixing member 1 to the surface area of the diverter is not less than 3.5%. That is, the contact area between each diverter and the fixed component accounts for no less than 3.5% of the surface area of the diverter.
  • the ratio of the contact area between each fixing component 1 and the diverter to the surface area of the diverter was different. After the fixing component 1 and the diverter were installed, they were matched with the installation position. If the diverters were separated or the fixing component 1 was cracked and deformed after 10 consecutive installation, disassembly and matching, it was unqualified; if the diverters were not separated or the fixing component 1 was not cracked and deformed after 10 consecutive installation, disassembly and matching, it was qualified. The results are shown in Table 4.
  • Table 4 Comparison of the contact area between the diverter and the fixing component 1 and the surface area of the diverter. The influence of whether the diverters are separated during use and whether the fixing component 1 is cracked and deformed.

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  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

本申请提供了一体注塑分流器，属于分流器技术领域，包括至少两个分流器和固定构件，每一分流器包括至少三个分流段和设置在分流段至少部分外表面的绝缘层，分流段的汇流端相互连接形成交汇区域；固定构件固定连接至少两个分流器，并至少部分覆盖交汇区域；固定构件成型于分流段上。本申请的固定构件与至少部分绝缘层一体注塑成型，加工效率高，节约成本。

Description

一体注塑分流器
相关申请
本申请要求于2022年12月24日递交的申请号为202223462552.3的中国专利申请的优先权，并引用上述专利申请公开的内容作为本申请的一部分。
技术领域
本申请属于分流器技术领域，具体涉及到一体注塑分流器。
背景技术
随着新能源汽车领域的发展，高压电连接器在汽车上应用的比例越来越高，连接器作为电传输的关键使用部件，担当着连接设备，传输高压、大电流的主要职责。随着电路的越来越复杂，分流器的需求也越来迫切。目前分流器包括导电体和包括在导电体上的绝缘层，在绝缘层上设置固定构件，分流器通过固定构件设置在安装基体上。也就是说目前的固定构件为与绝缘层分体结构，加工时间长，浪费工时和模具成本，同时整体结构也不牢固。因此，现有技术中亟需一种新的方案来解决上述问题。
发明内容
本申请的一个目的是提供一种一体注塑分流器。来解决分流器加工时间长，浪费工时和模具成本，同时整体结构也不牢固的问题。
根据本申请的第一方面，提供了一种一体注塑分流器，包括：至少两个分流器，每一分流器包括至少三个分流段和设置在分流段至少部分外表面的绝缘层，分流段的汇流端相互连接形成交汇区域；
固定构件，固定连接至少两个分流器，并至少覆盖交汇区域；
固定构件成型于分流段上。
可选地，固定构件包覆至少部分绝缘层并与至少部分绝缘层一体注塑成型。
可选地，至少部分绝缘层包覆固定构件并与固定构件一体注塑成型。
可选地，分流段的与汇流端相反设置的自由端设置有连接部，连接部上设置通孔或螺纹孔或螺柱。
可选地，通孔或螺纹孔或螺柱表面设置有导电耐磨层。
可选地，至少两个连接部的同侧表面处于同一平面。
可选地，分流段中至少包含一个吸能部，吸能部位于汇流端和连接部之间。
可选地，吸能部的展开长度与吸能部两端之间的直线距离的比为1：0.05-1：0.98。
可选地，吸能部的两端分别具有第一安装孔和相对于第一安装孔可移动的至少一个第二安装孔，第二安装孔的中心点相对于第一安装孔的中心点的可移动距离与第一安装孔直径的比值范围为：0.25：1-1.75：1。
可选地，分流段中至少吸能部的材质为柔性材质。
可选地，交汇区域包括由至少一个分流段的汇流端搭接另一个分流段的汇流端形成的区域。
可选地，分流段包括第一分流段、第二分流段和第三分流段，第一分流段、第二分流段和第三分流段的汇流端分别与交汇区域焊接连接。
可选地，分流段包括第一分流段、第二分流段和第三分流段，第一分流段和第二分流段为一体结构，第三分流段的汇流端与第一分流段和/或第二分流段焊接连接。
可选地，至少两个分流器的交汇区域堆叠设置。
可选地，分流段包括第一分流段、第二分流段和第三分流段，第一分流段和第二分流段之间的夹角为15°-90°。
可选地，第三分流段与第一分流段或第二分流段之间的夹角大于等于90°。
可选地，一体注塑分流器包括第一分流器和第二分流器，第一分流器的第一分流段和第二分流段与第二分流器的第三分流段位于交汇区域的同一侧。
可选地，每个分流器与固定构件的接触面积与分流器表面积的比不小于3.5％，即每个分流器与固定构件的接触面积占分流器表面积的占比不小于3.5％。
本申请的有益效果是：固定构件与至少部分绝缘层一体注塑成型包覆在至少两个分流器上，可以将两个或者更多的分流器防护固定，不仅起到绝缘的作用，还使得整体结构稳固，也节省了注塑成本和安装时间，提高生产效率。分流段的自由端设置连接部，连接部上设置通孔或螺纹孔，便于紧固件通过通孔或螺纹孔后与安装位置紧固连接。另外，通过本文的分流器，可以对车身线束进行可靠的固定，实现电池包的电源对不同用电器的分流控制；同时该分流器具备一定的吸能效力，车身震动导致线束发生晃动时，可以吸收震动能量，避免线束晃动产生的异响等问题；此装置的安装孔位还可以在一定距离内移动，即使所连接的线束刚性较大，也能与其建立可靠连接。
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为本申请一体注塑分流器的结构示意图。
图2为本申请一体注塑分流器的分流器结构示意图。
图3为吸能部的展开长度与吸能部两端之间的直线距离的比为1：0.05的弯折示意图。
图4为吸能部的展开长度与吸能部两端之间的直线距离的比为1：0.98的弯折示意图。
图中标示如下：
1-固定构件、3-吸能部、4-通孔/螺纹孔、5-绝缘层、6-连接部、7-交汇区域、8-第一分流
段、9-第二分流段、10-第三分流段。
具体实施方式
现在将参照附图来详细描述本申请的各种示例性实施例。应注意到：除非另外具体说明，否则在这些实施例中阐述的部件和步骤的相对布置、数字表达式和数值不限制本申请的范围。
以下对至少一个示例性实施例的描述实际上仅仅是说明性的，决不作为对本申请及其应用或使用的任何限制。
对于相关领域普通技术人员已知的技术、方法和设备可能不作详细讨论，但在适当情况下，所述技术、方法和设备应当被视为说明书的一部分。
在这里示出和讨论的所有例子中，任何具体值应被解释为仅仅是示例性的，而不是作为限制。因此，示例性实施例的其它例子可以具有不同的值。
在一些实施例中，一体注塑分流器，如图1和图2所示，包括：至少两个分流器，每一分流器包括至少三个分流段和设置在分流段至少部分外表面的绝缘层5，分流段的汇流端相互连接形成交汇区域7；
固定构件1，固定连接至少两个分流器，并至少覆盖交汇区域7；
固定构件1成型于分流段上。
具体地，在一些实施例中，固定构件1可以包覆至少部分绝缘层5并与至少部分绝缘层5一体注塑成型。
当然，可以理解，在其他实施例中，至少部分绝缘层5可以包覆固定构件1并与固定构件1一体注塑成型。
目前分流器的固定构件1与绝缘层5分体结构，加工时间长，浪费工时和模具成本，同时整体结构也不牢固，本申请分流器包括至少三个分流段，可以分三个角度进行分线，满足不同的角度分线要求，分流段包括汇流端和自由端，自由端用于与连接部6连接，分流段的汇流端相互连接形成交汇区域7，实现了多个分流段不同角度方向的电连接；固定构件1与至少部分绝缘层5一体注塑成型包覆在至少两个分流器上(可以理解为，固定构件1包覆在绝缘层5外侧与其一体成型来包覆分流段，或者，绝缘层5包覆在固定构件1外侧与其一体成型来包覆分流段)，可以将两个或者更多的分流器防护固定，不仅起到绝缘的作用，还使得整体结构稳固，也节省了注塑成本和安装时间，提高生产效率。
在一些实施例中，分流段与汇流端相反设置的自由端设置连接部6，连接部6上设置通孔或螺纹孔4或螺柱。
分流段的自由端设置连接部6，连接部6与安装位置连接，连接部6上设置通孔或螺纹孔4或螺柱，便于紧固件通过通孔或螺纹孔4后与安装位置紧固连接，或者便于螺柱与安装位置的安装孔螺纹连接。
在一些实施例中，通孔或螺纹孔4或螺柱表面设置有导电耐磨层。
此分流器主要通过通孔或螺纹孔4与车身线束进行电性连接，从而进行电能的传递分配，因此，该通孔或螺纹孔4导电的可靠性对此装置的稳定使用至关重要，通过导电耐磨层的设置，可大大提升此处连接的可靠性，避免因恶劣的工作环境导致电能传输不畅等问题。
在一些实施例中，至少两个连接部6的同侧表面处于同一平面。
至少两个连接部6的同侧表面(可以理解为如图1所示的下表面)处于同一平面，可以保证分流器的整体体积小，占用安装空间小，适用更多的安装环境，可批量生产，便于更换维护。
在一些实施例中，分流段中至少包含一个吸能部3，吸能部3位于交汇区域7和连接部6之间。
吸能部3是通过设置弯曲段从而在连接器受到冲击时产生吸能的作用。可以根据连接方向的需要进行弯折，或者根据安装的环境空间的布置需要进行对应的弯折设计，吸能部3能够实现多个角度的吸能效果。
在一些实施例中，吸能部3的展开长度与吸能部3两端之间的直线距离的比为1：0.05-1：0.98。
吸能部3的展开长度为板材、尚未弯折时的长度；吸能部3两端之间的直线距离，即为形成折弯后两端之间的距离，如果前述的直线距离过于短，则加工后的吸能部3无法与其两 端的导电部实现可靠电连接，相对地，如果前述的直线距离过大，则因折弯变形较小，可能导致吸能效果不足，因此为实现较好的使用效果，前述两处距离之间的比值需满足：吸能部3两端可以与导电部连接、具有吸能效果两个条件，为此，发明人进行了相关试验，试验参数如表1所示。
表1，不同的比值对连接、吸能情况的影响
从表1可知，当吸能部3两端之间的直线距离较短，导致该比值大于1:0.05时，无法连接其两端的导电部，为不合格，而当吸能部3两端之间的直线距离较长，导致该比值小于1:0.98时，吸能部3不具备吸能效果，也不合格，因此发明人优选的比值区间为1:0.05-1:0.98。
如图3和图4所示，吸能部3的展开长度为L2，吸能部3两端之间的直线距离为L1，图3为L2:L1为1：0.05的示意图，此时折弯程度达到最大，继续折弯则有无法连接其两端的连接部6和汇流端的风险，图4为L2:L1为1：0.98的示意图，此时折弯程度较小，导致吸能的能力也较小，如果折弯程度比此程度更小，则将出现无法吸能的问题。
在一些实施例中，吸能部3的两端分别具有第一安装孔和相对于第一安装孔可移动的至少一个第二安装孔，第二安装孔的中心点相对于第一安装孔的中心点的可移动距离与第一安装孔直径的比值范围为：0.25：1-1.65：1。
发明人为了选用不同的第二安装孔的中心点相对于第一安装孔的中心点的可移动距离与第一安装孔直径的比值范围连接导电件，来测试比值是否影响连接导电件以及导电是否充分，测试结果如表2所示。
表2，第二安装孔的中心点相对于第一安装孔的中心点的可移动距离与第一安装孔直径的比是否影响连接导电件和导电是否充分：

从表2可知，第二安装孔的中心点相对于第一安装孔的中心点的可移动距离与第一安装孔直径的比值范围为小于0.25：1的时候，移动距离太小，无法调整连接到导电件；第二安装孔的中心点相对于第一安装孔的中心点的可移动距离与第一安装孔直径的比值范围大于1.65：1的时候，安装孔孔径相对大，导电接触面积小，导电不充分；只有在比为0.25：1-1.65：1区间的时候，既可以导电充分又可以实现电连接，因此发明人选取了最适合的第二安装孔的中心点相对于第一安装孔的中心点的可移动距离与第一安装孔直径的比值范围为0.25：1-1.65：1。
在一些实施例中，分流段中至少吸能部3的材质为柔性材质。
吸能部3的材质为柔性材质，柔性材质可弯折到合适的角度以配合连接位置不同的走向需求和适用不同安装布置空间。
在一些实施例中，分流段包括第一分流段8、第二分流段9和第三分流段10，第一分流段8、第二分流段9和第三分流段10的汇流端焊接连接。
本分流段包括第一分流段8、第二分流段9和第三分流段10，不同的分流段朝向不同的角度，达到不同角度的分线连接效果，这三者的汇流端焊接连接，实现电连接。
在一些实施例中，分流段包括第一分流段8、第二分流段9和第三分流段10，第一分流段8和第二分流段9为一体结构，第三分流段10的汇流端与第一分流段8和/或第二分流段9焊接连接。
本分流段包括第一分流段8、第二分流段9和第三分流段10，不同的分流段朝向不同的角度，达到不同角度的分线连接效果，第三分流段10的汇流端与第一分流段8和/或第二分流段9焊接连接，实现电连接。
在一些实施例中，至少两个分流器的交汇区域7堆叠设置。
至少两个分流器的交汇区域7堆叠设置，便于固定构件1与绝缘层5一体注塑成型后，固定构件1将堆叠位置包裹固定住，使得两个分流器的交汇区域7不分离，整体结构在使用时稳定，连接结构不易被外力拉扯损坏或者分离。
在一些实施例中，交汇区域7包括由至少一个分流段的汇流端搭接另一个分流段的汇流端形成的区域。在本实施例中，如图2所示，交汇区域至少包括由第二分流段9的汇流端搭接第一分流段8的汇流端形成的区域。
在一些实施例中，分流段包括第一分流段8、第二分流段9和第三分流段10，第一分流 段8和第二分流段9之间的夹角为15°-90°。
发明人为了测试第一分流段8和第二分流段9的夹角对分流器能否安装的影响，选取了相同的第一分流段8和第二分流段9进行测试。采用不同的夹角，模拟匹配连接安装过程，测试第一分流段8和第二分流段9具有的不同夹角对连接器的影响，测试结果如表3所示。
表3，第一分流段8和第二分流段9的不同夹角对连接器安装的影响
从表3可知，如果第一分流段8和第二分流段9具有的夹角小于15°时，两个相邻的交汇区域连接由于过近，导致Y型分流器与外界连接安装空间不够，第一分流段8和第二分流段9互相干涉，为不合格。如果第一分流段8和第二分流段9具有的夹角为大于90°，就转变成了相对的一侧第一分流段8和第二分流段9具有的夹角为小于90°，均可以保证在同一侧实现不同角度的分线需求，适用性广，因此发明人优选第一分流段8和第二分流段9具有的夹角为15°-90°。
在一些实施例中，第三分流段10与第一分流段8或第二分流段9之间的夹角大于等于90°。
第三分流段10与第一分流段8或第二分流段9之间的夹角大于等于90°本申请结构整体纵向宽度小，可以节省纵向占用的空间，更好的适配更多车型和安装环境，同时第三分流段10与第一分流段8或第二分流段9之间的夹角大于等于90°，不仅可以在交汇区域7的另一侧实现90-180°的空间布置，还可以让固定构件1与至少部分绝缘层5可以很轻松的一体注塑成型包覆在两个分流器的交汇区域7堆叠的位置上；如果第三分流段10与第一分流段8或第二分流段9之间的夹角小于90°，固定构件1不易包覆交汇区域7堆叠的位置，而且即使注塑包覆安装成功后，如果第三分流段10与第一分流段8或第二分流段9之间的夹角小于90°，固定构件1容易出现褶皱，在使用过程中容易褶皱后断裂，使用寿命减短。
在一些实施例中，一体注塑分流器包括第一分流器和第二分流器，第一分流器的第一分流段8和第二分流段9与第二分流器的第三分流段10位于交汇区域7的同一侧。
本申请满足了在交汇区域7同一侧至少有两个角度的分流段，实现交汇区域7同一侧不同方向连接的需求。
在一些实施例中，每个分流器与固定构件1的接触面积与分流器表面积的比不小于3.5％， 即每个分流器与固定构件的接触面积占分流器表面积的占比不小于3.5％。
为了验证每个分流器与固定构件1的接触面积与分流器表面积的比对分流器之间是否分离的影响及固定构件1是否开裂变形的影响。
发明人选用了相同的两个分流器和不同的固定构件1进行测试，每个固定构件1与分流器的接触面积与分流器表面积的比不同，将固定构件1与分流器安装后，将其与安装位置匹配安装，如果连续安装拆卸匹配10次，分流器之间是分离或者固定构件1开裂变形为不合格；如果连续安装拆卸匹配10次，分流器之间是不分离或者固定构件1不开裂变形为合格，结果如表4所示。
表4：分流器与固定构件1的接触面积与分流器表面积的比对使用过程中分流器之间是否分离的影响及固定构件1是否开裂变形。
从上表4中可以看出，当分流器与固定构件1的接触面积与分流器表面积的比小于3.5％时，分流器之间分离，固定构件1开裂变形，所以不合格。当分流器与固定构件1的接触面积与分流器表面积的比大于等于3.5％时，分流器之间不分离，固定构件1不发生开裂变形，所以合格。因此发明人优选每个分流器与固定构件1的接触面积与分流器表面积的比不小于3.5％。
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。本申请的范围由所附权利要求来限定。

Claims (18)

  1. 一体注塑分流器，其特征在于，包括：
    至少两个分流器，每一所述分流器包括至少三个分流段和设置在所述分流段至少部分外表面的绝缘层，所述分流段的汇流端相互连接形成交汇区域；
    固定构件，固定连接至少两个所述分流器，并至少部分覆盖所述交汇区域；
    所述固定构件成型于所述分流段上。
  2. 根据权利要求1所述的一体注塑分流器，其特征在于，所述固定构件包覆至少部分所述绝缘层并与至少部分所述绝缘层一体注塑成型。
  3. 根据权利要求1所述的一体注塑分流器，其特征在于，至少部分所述绝缘层包覆所述固定构件并与所述固定构件一体注塑成型。
  4. 根据权利要求1所述的一体注塑分流器，其特征在于，所述分流段的与所述汇流端相反设置的自由端设置有连接部，所述连接部上设置通孔或螺纹孔或螺柱。
  5. 根据权利要求4所述的一体注塑分流器，其特征在于，所述通孔或所述螺纹孔或所述螺柱的表面设置有导电耐磨层。
  6. 根据权利要求4所述的一体注塑分流器，其特征在于，至少两个所述连接部的同侧表面处于同一平面。
  7. 根据权利要求4所述的一体注塑分流器，其特征在于，所述分流段中至少包含一个吸能部，所述吸能部位于所述汇流端和所述连接部之间。
  8. 根据权利要求7所述的一体注塑分流器，其特征在于，所述吸能部的展开长度与吸能部两端之间的直线距离的比为1：0.05-1：0.98。
  9. 根据权利要求7所述的一体注塑分流器，其特征在于，所述吸能部的两端分别具有第一安装孔和相对于所述第一安装孔可移动的至少一个第二安装孔，所述第二安装孔的中心点相对于所述第一安装孔的中心点的可移动距离与所述第一安装孔直径的比值范围为：0.25：1-1.75：1。
  10. 根据权利要求7所述的一体注塑分流器，其特征在于，所述分流段中至少所述吸能部的材质为柔性材质。
  11. 根据权利要求1所述的一体注塑分流器，其特征在于，所述交汇区域包括由至少一个所述分流段的所述汇流端搭接另一个所述分流段的所述汇流端形成的区域。
  12. 根据权利要求1所述的一体注塑分流器，其特征在于，所述分流段包括第一分流段、第二分流段和第三分流段，所述第一分流段、所述第二分流段和所述第三分流段的所 述汇流端焊接连接。
  13. 根据权利要求1所述的一体注塑分流器，其特征在于，所述分流段包括第一分流段、第二分流段和第三分流段，所述第一分流段和所述第二分流段为一体结构，所述第三分流段的所述汇流端与所述第一分流段和/或所述第二分流段焊接连接。
  14. 根据权利要求1所述的一体注塑分流器，其特征在于，至少两个所述分流器的所述交汇区域堆叠设置。
  15. 根据权利要求4所述的一体注塑分流器，其特征在于，所述分流段包括第一分流段、第二分流段和第三分流段，所述第一分流段和所述第二分流段之间的夹角为15°-90°。
  16. 根据权利要求15所述的一体注塑分流器，其特征在于，所述第三分流段与所述第一分流段或所述第二分流段之间的夹角大于等于90°。
  17. 根据权利要求16所述的一体注塑分流器，其特征在于，包括第一分流器和第二分流器，所述第一分流器的所述第一分流段和所述第二分流段与所述第二分流器的所述第三分流段位于所述交汇区域的同一侧。
  18. 根据权利要求1所述的一体注塑分流器，其特征在于，每个所述分流器与所述固定构件的接触面积与所述分流器表面积的比不小于3.5％。
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