CN105408170A - 具有连接器化隔离壁的高电压电气中心 - Google Patents

具有连接器化隔离壁的高电压电气中心 Download PDF

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CN105408170A
CN105408170A CN201480041762.4A CN201480041762A CN105408170A CN 105408170 A CN105408170 A CN 105408170A CN 201480041762 A CN201480041762 A CN 201480041762A CN 105408170 A CN105408170 A CN 105408170A
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D·S·艾考恩
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Abstract

一种例如高电压电气中心的电气组件(10)，其控制电动或混合电动交通工具的电池组和推进系统之间的电力流动。组件(10)包括：多个电连接器(14)，被配置成接纳和匹配于多个相应的配对连接器；以及壳体，其包含被互连至多个电连接器(14)的多个电气设备。壳体包括限定多个连接器护罩的隔离壁(12)，所述多个连接器护罩轴向地围住多个电连接器(14)中的每个连接器。每个连接器护罩被配置成接纳相应的配对连接器的连接器本体。多个连接器护罩与隔离壁(12)形成整体。隔离壁(12)并且由此的护罩可由复合导电材料形成，所述复合导电材料包含介电基质内的导电纤维。

Description

具有连接器化隔离壁的高电压电气中心
发明背景
全电动和混合电动交通工具配有包含在典型地是金属盒的导电壳体内的电池组。去往/来自电池的功率流动通过高电压电气中心被导通和截止并路由通过高电压电气中心，所述高电压电气中心包含诸如继电器、预接触器、保险丝和电路板之类的电气设备。壳体的功能之一是提供去往和来自这些电气设备的EMI屏蔽。路由至由电池供电的交通工具设备的经屏蔽电缆必须通过壳体壁。允许电缆通过壳体壁的孔必须不得降低盒的屏蔽效率。
在一些现有技术的电池组中，通过螺纹紧固件2将连接器头1安装至穿过壳体的壁4切割出的孔图案(apatternofholes)3，如图1所示。包含导电屏蔽件或“罐(can)”(未示出)并与导电电池组壳体和配对的经屏蔽连接器形成电接触的屏蔽头连接器5由此闭合或维持经屏蔽连接器的连接元件上的电磁屏蔽。
发明背景章节中讨论的主题不应当仅仅因为其出现在发明背景章节而被视为现有技术。类似地，发明背景章节中提到的问题或与发明背景章节的主题关联的问题不应当被视为之前在现有技术中已认识到的。背景技术章节中的主题仅表示不同的方法，其本身也可以是发明。
发明概述
根据本发明的一个实施例，提供了一种电气组件。该电气组件包括：多个电连接器，被配置成接纳和匹配于多个相应的配对连接器；以及壳体，其包含互连至多个电连接器的多个电气设备。壳体包括限定多个连接器护罩的隔离壁。多个连接器护罩轴向地围住多个电连接器中的每个连接器。每个连接器护罩被配置成接纳相应的配对连接器的连接器本体。多个连接器护罩与隔离壁(bulkhead)形成整体。
隔离壁并且由此的多个连接器护罩由复合导电材料形成。复合导电材料包含介电基质材料内的导电纤维。
在本发明的另一实施例中，提供了一种电池组组件。该电池组组件包括壳体，所述壳体由导电金属材料形成并限定包含多个电气设备的腔并在壳体的壁内限定孔。电池组组件也包括接纳在孔内的隔离壁。隔离壁包括多个电连接器，这些电连接器被配置成接纳并匹配于多个相应的配对连接器。隔离壁限定多个连接器护罩，这些连接器护罩轴向地围住多个电连接器中的每个连接器。每个连接器护罩被配置成接纳相应的配对连接器的连接器本体。多个连接器护罩与隔离壁形成整体。多个电连接互连至多个电气设备。
隔离壁并且由此的多个连接器护罩由复合导电材料形成。隔离壁通过导电紧固件附连至壳体。复合导电材料包含散布在介电基质材料内的导电纤维。
在本发明的又一实施例中，提供了一种电连接器组件。该电连接器组件包括隔离壁，其被配置成接纳在由导电金属材料形成的壳体限定的孔内。该壳体限定包含多个电气设备的腔。隔离壁包括多个电连接器，这些连接器被配置成接纳和匹配于多个相应的配对连接器。隔离壁限定多个连接器护罩，这些连接器护罩轴向地围住多个电连接器中的每个连接器。每个连接器护罩被配置成接纳相应的配对连接器的连接器本体。多个连接器护罩整合到隔离壁。多个电连接器被配置成电连接至多个电气设备。
隔离壁并且由此的多个连接器护罩由复合导电材料形成。隔离壁通过导电紧固件附连至壳体。复合导电材料包含介电基质材料内的导电纤维。
在阅读下面的本发明的优选实施例的详细描述后，本发明进一步的特征和优势将更为清楚地显现，所述优选实施例仅借助非限制性示例并参照附图给出。
附图简述
现在参照附图借助示例描述本发明，在附图中：
图1是根据现有技术的高电压电气中心的隔离壁和连接器的分解立体图；
图2是根据一个实施例的高电压电气中心的立体图；以及
图3是根据一个实施例的图2的高电压电气中心的隔离壁的内表面的分解立体图；以及
图4是根据一个实施例的包括图2的高电压电气中心的电池组模块的分解立体图。
具体实施方式
这里给出了一种高电压电气中心，其包含诸如继电器、预接触器、保险丝和电路板之类的电气设备并包括由导电塑料模制而成以形成连接器化隔离壁(connectorizedbulkhead)。该高电压电气中心被安装至并纳入到电动交通工具电池组中并包含开关电路，所述开关电路用来控制电池组和交通工具电气推进系统之间的高电压连接。该高电压电气中心相比现有技术减少了所需的唯一组件的数目。该高电压电气中心还相比现有技术减少了构建电池组所需的总组装劳动。此外，该高电压电气中心可作为电池容纳部件的一部分包括于此，由此省去了现有技术所需的电缆。
图2示出例如高电压电气中心(HVEC)的电气组件的一个非限制示例，该电气组件总体由附图标记10标示。组装件10包括具有数个电连接器14的连接器隔离壁12，这些电连接器14被配置成与相应的配对电连接器(未示出)匹配以将组装件10互连至交通工具电气推进系统(未示出)。隔离壁12限定数个连接器护罩(shroud)或头部16，它们轴向地围住每个组装件的电连接器44。如图3所示，这些头部16被配置成接纳相应的配对连接器的连接器本体18。头部16与隔离壁12形成整体。
隔离壁12和头部16由导电复合材料形成，例如在PA、丙烯腈-丁二烯-苯乙烯(ABS)或聚碳酸酯(PC)基质中的镀镍碳或不锈钢纤维。这些材料可从宾夕法尼亚的华盛顿堡的ElectriPlast公司获得。隔离壁12可通过诸如注射模制之类的工艺形成。
如图3所示，组装件10也包括电磁屏蔽件24或由诸如压印并折叠的金属板之类的导电材料形成的“罐”。电磁屏蔽件24被设置在隔板12的连接器头16内并被配置成互连至相应连接器内的相应电磁屏蔽件，由此为连接器和相应配对连接器的导电元件提供屏蔽。由于隔离壁12的头部16是导电的，因此它们能够为连接器和相应的配对连接器的导电元件提供电磁屏蔽。形成电磁屏蔽件24的设计、材料和制造方法是本领域内技术人员熟知的。
如图3所示，组装件10包括：外壳26，其被配置成容纳高电压开关器件22；以及保险丝28；内部连接器30；布线(未示出)；总线条(busbar)(未示出)；螺栓(未示出)；螺母(未示出)；端子位置确保(TPA)装置(未示出)；传感器(未示出)；以及组装件10中的其他组件。外壳26由热塑性材料——例如PBT或NUYLON(尼龙)材料——形成。
组装件10也包括柔性(compliant)密封件32以提供组装件10和电池组壳体之间的环境密封。密封件32可与隔离壁12共模制成。
如图4所示，组装件10可被整合到电动或混合电动交通工具的电池组模块34中。电池组模块34包含数个电池模块36，这些电池模块36被互连以分别提供比任一电池模块36更大的电压和/或更大的电流容量。电池模块36通过布线线束38或总线条配置互连。电池模块36包含在由诸如铝之类的导电材料形成的壳体40内，所述壳体40围住模块36并提供对电池模块36/来自电池模块36的环境保护、电气隔离和电磁屏蔽。壳体40限定孔42，组装件10接纳在孔42中。电池组的布线线束/总线条38电连接至组装件10。组装件10的电气设备(例如继电器、预接触器)控制电功率流去往和来自电池组中的电池模块36。组装件10也为电池组提供至电气推进系统和控制电子器件的经屏蔽电连接。
因此，提供了诸如高电压电气中心之类的电气组装件10，该电气组装件10具有带整体地形成的连接器头16的隔离壁12。隔离壁12提供的优势是相比现有技术减少了组装件10中的唯一组件的数目并减少了将分立的头部附连至隔离壁12所需的组装时间。由导电塑料模制隔离壁12也允许更复杂的几何形状以在电池组外壳内包含电磁能量。这也更容易允许形成沟槽以将密封件32容纳在隔离壁12内和/或允许密封件32与隔离壁12共模制而成。
尽管已按照高电压电气中心的优选实施例对本发明进行了描述，但不打算使本发明受此限制，相反本发明仅受下面给出的权利要求书限制。此外，“第一”、“第二”等术语的使用不表示任何顺序的重要性，相反，“第一”、“第二”等术语被用来将一个要素与另一要素区别开。此外，“一”、“一个”等术语的使用不表示数量限制，而是表示存在至少一个所述的项。

Claims (10)

1.一种电气组装件(10)，包括：
多个电气连接器(14)，被配置成接纳和匹配于多个相应的配对连接器；
外壳(26)，其包含被互连至所述多个电连接器(14)的多个电气设备，所述外壳包括隔离壁(12)，所述隔离壁(12)限定轴向地围住所述多个电连接器(14)中的每个连接器的多个连接器护罩(16)，每个连接器护罩(16)被配置成接纳所述相应的配对连接器的连接器本体，所述多个连接器护罩(16)与所述隔离壁(12)形成整体。
2.如权利要求1所述的电气组装件(10)，其特征在于，所述隔离壁(12)，并且由此的所述多个连接器护罩(16)由复合导电材料形成。
3.如权利要求2所述的电气组装件(10)，其特征在于，所述复合导电材料包含介电基质材料内的导电纤维。
4.一种电池组组装件(34)，包括：
壳体(40)，其由导电金属材料形成并限定包含多个电气设备(36)的腔并且在所述壳体(40)的壁内限定孔(42)，
接纳在所述孔(42)内的隔离壁(12)，所述隔离壁(12)包括多个电连接器(14)，所述电连接器(14)被配置成接纳和匹配于多个相应的配对连接器，其中所述隔离壁(12)限定轴向地围住所述多个电连接器(14)中的每个连接器的多个连接器护罩(16)，每个连接器护罩(16)被配置成接纳相应的配对连接器的连接器本体，其中所述多个连接器护罩(16)与所述隔离壁(12)形成整体并且其中所述多个电连接器(14)互连至所述多个电气设备(36)。
5.如权利要求4所述的电池组组装件(34)，其特征在于，所述隔离壁(12)，并且由此的所述多个连接器护罩(16)由复合导电材料形成，其中所述隔离壁(12)通过导电紧固件附连至壳体(40)。
6.如权利要求5所述的电池组组装件(34)，其特征在于，所述壳体(40)由导电金属材料形成并且所述隔离壁(12)通过导电紧固件附连至所述壳体(40)。
7.如权利要求6所述的电池组组装件(34)，其特征在于，所述复合导电材料包含介电基质材料内的导电纤维。
8.一种电连接器组装件(10)，包括：
隔离壁(12)，被配置成接纳在由壳体限定的孔内，所述壳体由导电金属材料形成，所述壳体限定包含多个电气设备的腔，所述隔离壁(12)包括多个电连接器(14)，所述电连接器(14)被配置成接纳并匹配于多个相应的配对连接器，其中所述隔离壁(12)限定轴向地围住所述多个电连接器(14)中的每个连接器的多个连接器护罩(16)，每个连接器护罩(16)被配置成接纳相应的配对连接器的连接器本体，其中所述多个连接器护罩(16)与所述隔离壁(12)形成整体，并且其中所述多个电连接器(14)被配置成电连接至所述多个电气设备。
9.如权利要求8所述的电连接器组装件，其特征在于，所述隔离壁(12)，并且由此的所述多个连接器护罩(16)由复合导电材料形成，其中所述隔离壁(12)通过导电紧固件附连至所述壳体。
10.如权利要求9所述的电连接器组装件，其特征在于，所述复合导电材料包含介电基质材料内的导电纤维。
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