CN117730630A

CN117730630A - Voltage conversion system and method for producing such a voltage conversion system

Info

Publication number: CN117730630A
Application number: CN202280048428.6A
Authority: CN
Inventors: A·科亚; E·泰隆; P·斯马尔
Original assignee: Valeo Systemes de Controle Moteur SAS
Current assignee: Valeo Systemes de Controle Moteur SAS
Priority date: 2021-05-10
Filing date: 2022-05-10
Publication date: 2024-03-19
Also published as: WO2022238359A1; FR3122801B1; EP4338559A1; FR3122801A1

Abstract

The present disclosure relates to a voltage conversion system (1000) comprising: a voltage converter (100); -a housing (200) comprising a cooling device, said voltage converter (100) being positioned inside said housing (200) so as to be in thermal contact with said cooling device; and an electrical connector (300) comprising a first bus bar (310) and a second bus bar (330), the electrical connector (300) being designed to electrically connect the voltage converter (100) to at least one electrical network via the first bus bar (310) and the second bus bar (330); the system (1000) is characterized in that it further comprises at least one electrical connection portion (400) comprising a first connection bus bar (450), said first connection bus bar (450) being electrically and mechanically connected to said first bus bar (310), said first connection bus bar (450) being in thermal contact with said cooling means via the outside of said housing (200).

Description

Voltage conversion system and method for producing such a voltage conversion system

Technical Field

The present disclosure relates to a voltage conversion system with which a motor vehicle is intended to be equipped. The present disclosure also relates to a method for manufacturing such a voltage conversion system.

Background

Known voltage conversion systems include: a voltage converter; a housing comprising a cooling device, the voltage converter being positioned inside the housing so as to be in thermal contact with the cooling device; an electrical connector.

In such systems, the electrical connector is designed to electrically connect the voltage converter to at least one electrical network via the first and second bus bars.

However, in such voltage conversion systems, as the power handled by the voltage converter increases, the heat generated in the electrical connector may become excessive.

To solve this problem, it is known to increase the size of the electrical connector. Thus, with this solution, it is necessary to use different electrical connectors to produce voltage conversion systems handling different powers.

Alternatively, a single voltage conversion system may also be used to handle various powers by: the electrical connector is sized to handle the highest power of the power that can be handled by the voltage conversion system. The electrical connectors must therefore be oversized to withstand thermal stresses, which makes the solution relatively expensive when the voltage conversion system is used for a lower power than considered when sizing the voltage conversion system.

It is an object of the present disclosure to at least partially alleviate the above-mentioned problems.

Disclosure of Invention

To this end, according to a first aspect of the present disclosure, there is provided a voltage conversion system comprising:

the voltage of the power supply is converted to a voltage,

a housing comprising a cooling device, a voltage converter being located inside the housing to be in thermal contact with the cooling device, and an electrical connector comprising a first bus bar and a second bus bar, the electrical connector being designed to electrically connect the voltage converter to at least one electrical network via the first bus bar and the second bus bar,

the system further includes at least one electrical connection portion including a first linking bus bar electrically and mechanically connected to the first bus bar, the first linking bus bar in thermal contact with the cooling device via an exterior of the housing.

In the context of the present disclosure, a bus bar is a low impedance conductor, such as a metal bar, e.g. a bar made of copper.

Since the first link bus bar is in thermal contact with the cooling device via the outside of the housing, it is possible to cool the first link bus bar, which limits the heat generation of the first link bus bar and the heat generation of the electrical connector to which the first link bus bar is electrically and mechanically connected.

By virtue of the present disclosure, a voltage conversion system capable of handling various powers without adapting an electrical connector can be obtained.

Thus, the electrical connector is sized for the lowest of the powers that the voltage converter will handle, and in order to handle higher than the lowest of the powers, the voltage conversion system comprises an electrical connection portion that cools the electrical connector.

The voltage conversion system according to the present disclosure may further comprise one or more of the following optional features taken alone or in any technically possible combination.

According to a first feature, the electrical connector is secured to the housing.

According to another feature, the voltage converter is a DC-to-DC voltage converter.

According to another feature, the voltage converter is a DC-to-AC voltage converter. According to another feature, the electrical connector further comprises a first connection terminal and a second connection terminal, the first bus bar and the second bus bar being mechanically and electrically connectable to the at least one electrical network via the first connection terminal and the second connection terminal, respectively, the first linking bus bar being electrically and mechanically connected to the first bus bar via the first connection terminal.

According to another feature, the electrical connector further comprises a first connection terminal and a second connection terminal, the first bus bar and the second bus bar being mechanically and electrically connectable to the at least one electrical network via the first connection terminal and the second connection terminal, respectively.

According to another feature, the first linking bus bar is electrically and mechanically connected to the first bus bar via a first connection terminal.

According to another feature, the first connection terminal is a metal stud, for example made of steel.

According to another feature, the second connection terminal is a metal stud, for example made of steel.

According to another feature, the voltage conversion system further comprises a second electrical connection portion comprising a second linking bus bar electrically and mechanically connected to the second bus bar, the second linking bus bar being in thermal contact with the cooling device via the outside of the housing.

According to another feature, the second linking bus bar is electrically and mechanically connected to the second bus bar via a second connection terminal.

According to another feature, the housing further comprises a carrying tray able to define a first volume of the housing with respect to a second volume of the housing through which a cooling fluid is intended to flow for cooling said voltage converter, said voltage converter being positioned in the second volume.

According to another feature, the housing comprises a cooling fluid inlet, a cooling fluid outlet, and the first volume comprises at least one cooling channel connecting the cooling fluid inlet to the cooling fluid outlet.

According to another feature, the housing comprises a bottom and a peripheral side wall surrounding the bottom, and the cooling channel is at least partially delimited by the carrying tray and/or the bottom and/or the peripheral side wall and/or by at least one wall extending between the bottom and the carrying tray.

According to another feature, the housing comprises the at least one wall extending between the bottom and the carrying tray.

According to another feature, the peripheral side wall comprises a first face facing the outside of the casing, said peripheral side wall extending between the bottom and the carrying tray, a portion of the carrying tray extending substantially perpendicular to the first face of the peripheral side wall, said portion comprising a through hole arranged to receive an electrical connector, the carrying tray comprising a second face on which the voltage converter is positioned and a first face opposite to the second face of the carrying tray, the electrical connector being fastened to the second face of the carrying tray.

According to another feature, the peripheral side wall, the carrying tray and the at least one wall extending between the bottom and the carrying tray are made of the same material and are integrally formed, for example by a casting process.

According to another feature, the first link bus bar is in thermal contact with the cooling means via the outside of the housing, for example by means of a thermally conductive link element, a thermally conductive paste or a thermal pad (or "gap pad").

According to another feature, the second link bus bar is in thermal contact with the cooling means via the outside of the housing, for example by means of a thermally conductive link element, a thermally conductive paste or a thermal pad.

According to another feature, the thermally conductive linking element may also be electrically insulating.

According to another feature, the cooling device comprises a base having a first face intended to receive the heat emitted by the voltage converter to be dissipated and at least one fin located on a second face of the base opposite to the first face, the first face of the base facing the inside of the casing, the first linking bus bar being in thermal contact with the second face of the base.

According to another feature, the electrical connection portion further comprises a first connection terminal, the first and second linking bus bars being mechanically and electrically connectable to the at least one electrical network via the first and second connection terminals, respectively.

According to another feature, the electrical connection portion further comprises a second connection terminal, the first and second linking bus bars being mechanically and electrically connectable to the at least one electrical network via the second connection terminal and the second connection terminal, respectively.

According to a second aspect of the present disclosure, there is also provided a process for manufacturing a voltage conversion system according to the first aspect of the present disclosure, the process comprising:

a voltage converter is obtained which is connected to the power source,

a housing is obtained comprising a cooling device,

positioning the voltage converter within the housing such that the voltage converter is in thermal contact with the cooling device,

obtaining an electrical connector comprising a first bus bar and a second bus bar and designed to electrically connect the voltage converter to at least one electrical network via the first bus bar and the second bus bar,

an electrical connection portion comprising a first link bus bar is obtained,

electrically and mechanically connecting the first linking bus bar to the first bus bar, an

The first link bus bar is brought into thermal contact with the cooling device via the outside of the housing.

Optionally, the manufacturing process includes fastening the electrical connector to the housing.

The present disclosure will be better understood from the following description, given by way of non-limiting example only, with reference to the following drawings:

drawings

Fig. 1 is a top view of a voltage conversion system according to a first embodiment of the present disclosure.

Fig. 2 is a three-dimensional exploded view of the voltage conversion system shown in fig. 1.

Fig. 3 is a three-dimensional exploded view of a top portion of a housing of the voltage conversion system shown in fig. 1.

Fig. 4 is a view of a bottom portion of a housing of the voltage conversion system shown in fig. 1.

Fig. 5 shows an electrical connector in which the voltage conversion system of fig. 1 is not overmolded.

Fig. 6 is a three-dimensional exploded view of a voltage conversion system according to a second embodiment of the present disclosure.

Fig. 7 shows in flow chart form the individual steps of a process for manufacturing the voltage conversion system of fig. 1.

Detailed Description

Fig. 1 shows a top view of a voltage conversion system 1000 in a first embodiment of the present disclosure.

As shown in fig. 2, the voltage conversion system 1000 includes a voltage converter 100 designed to convert a first voltage V1 into a second voltage V2, a housing 200 including a cooling device intended to cool the voltage converter 100, an electrical connector 300, and an electrical connection portion 400.

In the example described herein, the electrical connector 300 is further secured to the housing 200. In other words, the electrical connector 300 is a portion that is separated from the housing 200 before being assembled with the housing 200.

In the example described herein, the voltage converter 100 is a DC-to-DC voltage converter. The voltage converter is intended to be placed on a vehicle in order to convert a voltage between a first electrical network and a second electrical network of the vehicle. Typically, the first electrical network is a low voltage network delivering a first voltage V1 below 30V (e.g. about 24V or 12V) and the second electrical network is a high voltage network delivering a second voltage V2 above 30V (e.g. 48V).

In the example described herein, voltage converter 100 includes a circuit board 110 that includes a plurality of voltage choppers (not shown in fig. 2) connected in parallel. Each of the voltage choppers includes an inductor and two transistors that function as electronic switches. In the example described herein, the two transistors are MOSFETs (MOSFETs represent metal oxide semiconductor field effect transistors). As a variant, these transistors may also be IGBTs (IGBTs represent insulated gate bipolar transistors) or power FETs (FETs represent field effect transistors) made of gallium nitride (GaN).

It is known that such a voltage converter 100 can handle various operating powers depending on the number of voltage choppers placed in parallel.

Referring to fig. 3 and 4, the case 200 includes a bottom 210, a peripheral sidewall 220 surrounding the bottom 210, a carrying tray 230, and a cooling device intended to cool the voltage converter 100.

The peripheral sidewall 220 extends between the bottom 210 and the carrying tray 230 and includes a first face that faces the exterior of the housing 200.

In the example described herein, the bottom 210 takes the form of a cover that sits on the support surface of the peripheral side wall 220 and is secured to the peripheral side surface 220, for example, by friction stir welding.

As a variant, the cover may be screwed onto the bearing surface of the peripheral side wall 220, the seal being interposed between the cover and the peripheral side wall 220.

The carrying tray 230 defines a first volume PV1 of the housing 200 through which a cooling fluid (e.g. water) is intended to flow to cool the voltage converter 100, and a second volume PV2 of the housing 200 in which the voltage converter 100 is mounted.

Thus, the carrying tray 230 comprises a first face facing the first volume PV1 and a second face facing the second volume PV2, the second face being opposite to the first face.

Further, the voltage converter 100 is positioned on and fastened to the second face, for example by means of screws. As a variant, the voltage converter 100 is fastened to the second face by riveting or even by gluing.

The housing 200 further comprises a cooling fluid inlet 240 and a cooling fluid outlet 250, while the first volume is constituted by a cooling channel connecting the cooling fluid inlet 240 to the cooling fluid outlet 250.

In the embodiment described herein, the cooling channel is defined by a first face of the load-bearing tray 230, the bottom 210, the peripheral side wall 220, and a wall 260 extending between the bottom 210 and the load-bearing tray 230.

In this way, the cooling fluid flows through the cooling channels and thus allows the voltage converter 100 to be cooled below the carrier tray 230 supporting the voltage converter 100.

Thus, the cooling channel, the cooling fluid inlet, the cooling fluid outlet and the carrying tray form a means for cooling the voltage converter 100.

Further, a portion 235 of the carrier tray 230 extends substantially perpendicular to the first face of the peripheral sidewall 220, the portion 235 comprising a through hole 236 arranged to receive the electrical connector 300 for fastening the electrical connector 300 to the second face of the carrier tray 230.

In the example described herein, the peripheral side wall 220, the carrying tray 230 and the wall 260 are made of the same material and are integrally formed, for example, from a metal such as aluminum, for example, by a casting process. In other words, the peripheral side wall 220, the carrying tray 230 and the wall 260 form a single metal part, which is made of, for example, aluminum and is produced by, for example, a casting process. As a variant, the peripheral side wall 220, the carrying tray 230 and the wall 260 may be parts produced separately before assembly.

Referring to fig. 5, the electrical connector 300 includes a first positive bus bar 310, a second positive bus bar 320, and a negative bus bar 330, the negative bus bar 330 being intended to be connected to electrical ground.

In the example described herein, the first positive bus bar 310 is made of metal (e.g., copper). Also, the second positive bus bar 320 is made of metal (e.g., copper). Finally, negative bus bar 330 is also made of metal (e.g., copper).

In the example described herein, the first positive bus bar 310, the second positive bus bar 320, and the negative bus bar 330 are further formed as a single piece, i.e., they are made of the same material and are integrally formed.

The electrical connector 300 is designed to electrically connect the voltage converter 100 to a first electrical network via a first positive bus bar 310 and a negative bus bar 330 and to a second electrical network via a second positive bus bar 320 and a negative bus bar 330.

It will be appreciated that in the depicted example, the first positive bus bar 310, the second positive bus bar 320, and the negative bus bar 330 are designed to withstand at least 10A/mm ² Is a rigid electrical conductor of the current density of (a).

Therefore, when the voltage converter 100 converts the first voltage V1 into the second voltage V2, the first voltage V1 is provided between the first positive bus bar 310 and the negative bus bar 330, and the second voltage V2 is provided between the second positive bus bar 320 and the negative bus bar 330.

In the example described herein, the first positive connection terminal is secured to the flat section of the first end of the first positive bus bar 310, the second positive connection terminal is secured to the flat section of the first end of the second positive bus bar 320, and the negative connection terminal is secured to the flat section of the first end of the negative bus bar 330.

In the example described herein, the first positive connection terminal, the second positive connection terminal, and the negative connection terminal are studs 312, 322, 332, respectively. The studs 312, 322, 332 are threaded and are made of metal (e.g., steel).

The first positive and negative connection terminals allow the bus bars 310, 330 to be mechanically fastened to the power supply cable in order to electrically connect these bus bars 310, 330 to the first electrical network. Thus, the electrical connector 300 and the power supply cable are dimensioned for a first power transmitted by the voltage converter 100 to the first electrical network, the first power corresponding to the number N1 of choppers.

Likewise, the second positive and negative connection terminals allow the bus bars 320, 330 to be mechanically fastened to the power supply cable in order to electrically connect these bus bars 320, 330 to the second electrical network.

For example, the cable is fastened to one of these bus bars by: the threaded stud of the bus bar is inserted into the eyelet of the lug of the cable, and then a nut is threaded onto the threaded stud to press the lug against the bus bar to electrically connect the bus bar and the lug.

The electrical connector 300 further includes a magnetic ring 340 surrounding the first positive bus bar 310, the second positive bus bar 320, and the negative bus bar 330.

First positive bus bar 310, second positive bus bar 320, and negative bus bar 330 are at least partially overmolded with an insulating material 350 (not visible in fig. 5 but visible in fig. 2), such as an insulating plastic.

In the example described herein, after the first positive bus bar 310, the second positive bus bar 320, and the negative bus bar 330 have been overmolded, the magnetic ring 340 is installed around the three bus bars 310, 320, 330.

In the example described herein, the electrical connector 300 is secured within the housing 200 in the portion 235 thereof, such as by screws, to the second face of the carrier tray 230 by inserting the electrical connector 300 into the through-hole 236 through the second face of the carrier tray 230.

More precisely, the first ends of the first positive bus bar 310, the second positive bus bar 320, and the negative bus bar 330 are inserted into the through holes 236 on the side of the second face of the loading tray 230 such that the ends are located outside the case 200. In order to ensure sealing tightness between the electrical connector 300 and the housing 200, a seal surrounding the through-hole 236 may be inserted between the electrical connector 300 and the housing 200 when the electrical connector 300 is fastened to the housing 200.

Referring to fig. 2, the electrical connection part 400 includes a link bus bar 450, a first connection terminal, and a second connection terminal.

In the example described herein, the first and second terminals are threaded studs 420, 430, respectively, that are secured to the flat portion of the link bus bar 450. The studs 420, 430 are made of metal (e.g., steel).

In the example described herein, the link bus bar 450 is generally T-shaped, with the first and second terminals each secured to a different end of the transverse bar of the T. The link bus bar 450 also includes a through hole 410 at the base of the T that allows the link bus bar 450 to be mechanically connected to the first positive bus bar 310.

As a variant, the link bus bar 450 may be generally Y-shaped, with a first and a second terminal secured to one end of each arm of the Y, respectively. The link bus bar 450 also includes a through hole 410 at the base of Y that allows the link bus bar 450 to be mechanically connected to the first positive bus bar 310.

In yet another variation, the link bus bar 450 may be generally I-shaped, with the first and second terminals secured to the vertical bars of the I, respectively. The link bus bar 450 also includes a through hole 410 at the base of I that allows the link bus bar 450 to be mechanically connected to the first positive bus bar 310.

The link bus bar 450 is fastened to the first positive bus bar 310 by: the threaded stud 312 is inserted into the through-hole 410 and then a nut is threaded onto the threaded stud 312, thereby pressing the link busbar 450 against the first positive busbar 310.

The link bus bar 450 and the negative bus bar 330 can thus be mechanically and electrically connected to the first electrical network via the first and negative connection terminals, respectively, and via the second and negative connection terminals, respectively.

The use of two terminals allows the link bus bar 450 to be mechanically and electrically secured to the first electrical network by two different power cables.

Thus, the current through each of the two cables is reduced, so that the cables heat less, other things being equal.

Further, in the example described, the electrical connection portion 400 is fastened to at least one external face of the housing 200, for example by means of screws. As a variant, the electrical connection portion 400 may be fastened to at least one external face of the housing 200 by riveting or even by adhesive bonding.

Alternatively or optionally, the electrical connection portion 400 may also be fastened to the electrical connector 300, e.g. to the overmold 350, e.g. by screws.

Further, when the electrical connection portion 400 is fastened to the housing 200 and/or the electrical connector 300, the link bus 450 is in thermal contact with the cooling device of the housing 200 via the outside of the housing 200.

In the example described herein, the link bus bar 450 is in thermal contact with the exterior of the housing 200 via a thermally conductive element (e.g., a thermal pad placed between the exterior surface of the housing 200 and the surface of the link bus bar 450).

In the depicted example, three thermal pads 510, 520, and 530 (only thermal pads 510 and 530 are visible in fig. 1) are placed between the housing 200 and the link bus bar 450.

As a variant, the heat conducting element may be a heat conducting paste.

Furthermore, the heat conducting element may also be electrically insulating.

In the example described herein, the link bus 450 is in thermal contact with the bottom 210 and the peripheral side wall 220 of the housing 200.

In this way, the cooling fluid flows through the cooling channels and thus contacts the bottom 210 and the peripheral sidewall 220 allowing the link bus bar 450 to be cooled.

By virtue of this thermal contact with the cooling means of the housing 200 via the outside of the housing 200, the link bus bar 450 can be cooled, which limits the heat generation of the link bus bar, the heat generation of the two connection terminals, the heat generation of the cables connected to the two connection terminals, and the heat generation of the electrical connector 300.

In other words, with the present disclosure, the current density that can flow through the link bus bar and through the first positive bus bar 310 can be significantly increased.

Thus, different power levels to be transferred to the first electrical network may be addressed without changing the dimensions of the electrical connector 300 and the housing 200.

For a first power level, the voltage converter 100 includes a first number N1 of choppers, and the first electrical network is connected to the positive connection terminal of the first positive bus bar by a single cable. In other words, the system 1000 is capable of delivering the first power level without using the electrical connection 400.

For a second power level, which is higher than the first power level, the voltage converter 100 comprises a second number N2 of choppers, which is higher than the first number N1, and the first electrical network is connected by two cables to two different connection terminals of the linking bus bar 450, which linking bus bar 450 itself is connected to the positive connection terminal of the first positive bus bar.

It is noted that with the present disclosure, one or more cables having the same dimensions may be used for the first power level and the second power level.

Alternatively, the cooling device may comprise a heat sink comprising a base and at least one fin (not shown in the figures). The base of the heat sink comprises a first face intended to receive the heat emitted by the voltage converter 100 to be dissipated and a second face opposite to the first face. The at least one fin is located on the second face. In other words, the first face of the base is directed towards the interior of the housing and the second face of the base is directed towards the exterior of the housing. For example, the bottom 210 of the housing 220 may form such a base. In the example described herein, the link bus bar 450 is in thermal contact with the second face of the base (i.e., with the outer portion of the bottom 210) via the thermally conductive element (i.e., the thermal pad) and via the side wall 220 of the housing 200.

Fig. 6 shows a three-dimensional exploded view of a voltage conversion system 1000' in a second embodiment of the present disclosure.

In the description of the second embodiment, the same or similar elements as those of the first embodiment are denoted by the same reference numerals.

In this second embodiment, the voltage conversion system 1000 'comprises a second electrical connection portion 500 and the housing 200' differs from the housing 200 in that the portion 235 'carrying the tray 230' comprises a fastening point 238 to which the second electrical connection portion 500 is fastened, for example by means of a screw.

The second electrical connection portion 500 includes a second linking bus bar 550 connected by a first end to the threaded stud 320 of the negative bus bar of the electrical connector 300 and by a second end to the fastening point 238.

In the example described herein, the second bus bar 550 also includes two connection terminals at its second end. The two terminals are threaded metal studs 520, 530, made of steel for example, fastened to the flat portion of the second end of the second link bus bar 550.

The second link bus bar 550 also includes a through hole 510 at a first end thereof. The secondary bus bar 550 is fastened to the stud 320 by: the stud 320 is inserted into the through-hole 510 and then a nut is threaded onto the threaded stud 320, thereby pressing the second link bus bar 550 against the negative bus bar 330.

The first and second linking bus bars 450, 550 are thus mechanically and electrically connectable to the first electrical network via the first and second wire terminals 420, 520, respectively, and via the second and second wire terminals 430, 530, respectively.

The use of two connection terminals 520, 530 allows the second linking bus bar 550 to be mechanically and electrically fastened to the first electrical network by two different power supply cables.

In addition, the second link bus bar 550 is fastened to the loading tray 230 'by a heat conductive member (e.g., thermal paste) interposed between the second link bus bar 550 and the loading tray 230'. The heat conducting element may also be electrically insulating.

In the embodiment described herein, the second link bus 550 is in thermal contact with the carrying tray 230 'of the housing 200'.

In this way, the cooling fluid flows through the cooling channels and thus contacts the carrier tray 230' allowing the second link bus 550 to be cooled.

By virtue of this thermal contact with the cooling means of the housing 200' via the outside of the housing, the second link bus bar 550 can be cooled, which limits its heating.

Referring to fig. 7, one example of a process 2000 for manufacturing the voltage conversion system 1000 will now be described.

In step E2100, the voltage converter 100 is obtained.

In step E2200, a housing 200 including a cooling device is obtained.

In step E2300, the voltage converter 100 is positioned in the housing 200 such that the voltage converter 100 is in thermal contact with the cooling device.

In step E2400, an electrical connector 300 is obtained, which comprises a first positive bus bar 310 and a negative bus bar 330 and is designed to electrically connect the voltage converter 100 to at least one electrical network via the first positive bus bar 310 and the negative bus bar 330.

In step E2500, the electrical connector 300 is fastened to the housing 200.

In step E2600, an electrical connection portion 400 including a link bus bar 450 is obtained.

In step E2700, the link bus bar 450 is electrically and mechanically connected to the first positive bus bar 310 of the electrical connector 300.

In step E2800, the link bus 450 is brought into thermal contact with a cooling device via the outside of the case 200.

It should also be noted that the present disclosure is not limited to the embodiments described above. In particular, it will be apparent to those skilled in the art that various modifications can be made to the embodiments described above in light of the teachings just disclosed to them.

For example, the voltage converter may be a DC-to-AC voltage converter, and the electrical connector may only be capable of electrically connecting the voltage converter 100 to the second electrical network. In other words, in this exemplary embodiment, the electrical connector would include a single positive bus bar whose connection terminals would connect to a first linking bus bar of the electrical connection portion, which itself connects to the housing of the electrical conversion system to cool it.

According to another example, the voltage conversion system 100 may have no cooling channels and include only a heat sink. In this embodiment, the bottom 210 is the same part as the carrying tray 230.

Furthermore, the terms used in the claims should not be construed as being limited to the elements of the above embodiments, but rather must be construed to include any equivalent elements whose provision is within the ability of a person skilled in the art to apply her or his general knowledge.

Claims

1. A voltage conversion system (1000, 1000') comprising:

a) A voltage converter (100),

b) A housing (200, 200 ') comprising a cooling means, said voltage converter (100) being located inside said housing (200, 200') so as to be in thermal contact with said cooling means, and

c) An electrical connector (300) comprising a first bus bar (310) and a second bus bar (330), the electrical connector (300) being designed to electrically connect the voltage converter (100) to at least one electrical network via the first bus bar (310) and the second bus bar (330),

the system (1000, 1000 ') further comprises at least one electrical connection portion (400) comprising a first linking bus bar (450), the first linking bus bar (450) being electrically and mechanically connected to the first bus bar (310), the first linking bus bar (450) being in thermal contact with the cooling device via the outside of the housing (200, 200').

2. The voltage conversion system (1000, 1000') of the preceding claim, wherein the electrical connector (300) further comprises a first connection terminal (312) and a second connection terminal (332), the first bus bar (310) and the second bus bar (330) being mechanically and electrically connectable to the at least one electrical network via the first connection terminal (312) and the second connection terminal (332), respectively, the first linking bus bar (450) being electrically and mechanically connected to the first bus bar (310) via the first connection terminal (312).

3. The voltage conversion system (1000') according to any of the preceding claims, further comprising a second electrical connection portion (500) comprising a second linking bus bar (550), the second linking bus bar (550) being electrically and mechanically connected to the second bus bar (330), the second linking bus bar (550) being in thermal contact with the cooling device via an exterior of the housing (200).

4. The voltage conversion system (1000, 1000 ') according to any of the preceding claims, wherein the housing (200, 200 ') further comprises a carrying tray (230, 230 ') being able to define a first volume (PV 1) of the housing (200, 200 ') with respect to a second volume (PV 2) of the housing (200, 200 '), through which a cooling fluid is intended to flow for cooling the voltage converter (100), the voltage converter (100) being positioned in the second volume.

5. The voltage conversion system (1000, 1000 ') according to the preceding claim, wherein the housing (200, 200') comprises a cooling fluid inlet (240), a cooling fluid outlet (250), and the first volume (PV 1) comprises at least one cooling channel connecting the cooling fluid inlet (240) to the cooling fluid outlet (250).

6. The voltage conversion system (1000, 1000 ') according to the preceding claim, wherein the housing comprises a bottom (210) and a peripheral side wall (220) surrounding the bottom (210), and wherein the cooling channel is at least partially delimited by the carrying tray (230, 230 ') and/or the bottom (210) and/or the peripheral side wall (220) and/or by at least one wall (260) extending between the bottom (210) and the carrying tray (230, 230 ').

7. The voltage conversion system (1000, 1000 ') according to the preceding claim, wherein the peripheral side wall (220) comprises a first face facing towards the outside of the housing (200), the peripheral side wall (220) extending between the bottom (210) and the carrying tray (230, 230'), one portion (235, 235 ') of the carrying tray (230, 230') extending substantially perpendicular to the first face of the peripheral side wall (220), the portion (235, 235 ') comprising a through hole (236) arranged to receive the electrical connector (300), the carrying tray (230, 230') comprising a second face and a first face opposite to the second face of the carrying tray (230, 230 '), the voltage converter (100) being positioned on the second face, the electrical connector (300) being fastened to the second face of the carrying tray (230, 230').

8. The voltage conversion system (1000, 1000 ') according to any of claims 6 to 7, wherein the peripheral side wall (220), the carrying tray (230, 230 ') and the at least one wall (260) extending between the bottom (210) and the carrying tray (230, 230 ') are made of the same material and are integrally formed, for example by a casting process.

9. The voltage conversion system (1000, 1000 ') according to any of the preceding claims, wherein the first linking bus bar (450) is in thermal contact with the cooling means via an outside of the housing (200, 200'), for example by a thermally conductive linking element, a thermally conductive paste or a thermal pad (510, 530).

10. The voltage conversion system (1000, 1000') according to any of the preceding claims, wherein the cooling device comprises a base having a first face intended to receive heat emitted by the voltage converter (100) to be dissipated and at least one fin located on a second face of the base opposite to the first face, the first face of the base facing towards the inside of the housing, the first link bus bar (450) being in thermal contact with the second face of the base.

11. The voltage conversion system (1000, 1000') according to any of the preceding claims, wherein the electrical connection portion (400) further comprises a first connection terminal (420), the first and second connection bus bars (450, 330) being mechanically and electrically connectable to the at least one electrical network via the first and second connection terminals (420, 332), respectively.

12. The voltage conversion system (1000, 1000') according to the preceding claim, wherein the electrical connection portion (400) further comprises a second connection terminal (430), the first linking bus bar (450) and the second bus bar (330) being mechanically and electrically connectable to the at least one electrical network via the second connection terminal (430) and the second connection terminal (332), respectively.

13. A process (2000) for manufacturing a voltage conversion system (1000, 1000'), comprising:

a) Obtaining (E2100) a voltage converter (100),

b) Obtaining (E2200) a housing (200, 200') comprising cooling means,

c) Positioning (E2300) a voltage converter within the housing (200, 200') such that the voltage converter (100) is in thermal contact with the cooling device,

d) Obtaining (E2400) an electrical connector (300) comprising a first bus bar (310) and a second bus bar (330) and designed to electrically connect the voltage converter (100) to at least one electrical network via the first bus bar (310) and the second bus bar (330),

e) Obtaining (E2600) an electrical connection portion (400) comprising a first linking bus bar (450),

f) Electrically and mechanically connecting (E2700) the first linking bus bar (450) to the first bus bar (310), and

g) The first linking bus bar (450) is brought into thermal contact (E2800) with the cooling device via the outside of the housing (200, 200').