WO2012072913A1

WO2012072913A1 - Electrical connector socket, and associated connector

Info

Publication number: WO2012072913A1
Application number: PCT/FR2011/052655
Authority: WO
Inventors: David Lantiat-Baillargue; Franck Ragot; Micaela Nazaraly; Alida Quach
Original assignee: Peugeot Citroen Automobiles Sa
Priority date: 2010-11-30
Filing date: 2011-11-16
Publication date: 2012-06-07
Also published as: FR2968139B1; FR2968139A1

Abstract

The invention relates an electrical power connector socket (1) for electrically connecting an electrical power supply module comprising a rechargeable battery for driving an electric or hybrid vehicle, comprising an electric power train and a charger on-board the vehicle, said base (1) including a first set of male and female contacts (5i, 6i), characterized in that the first set of contacts (5i, 6i) comprises a first pair of contacts of the same gender (5i) capable of supplying the electric power train of the vehicle, and a second pair of contacts of the opposite gender (6i), which are capable of receiving a supply of power from the charger in order to charge the battery.

Description

ELECTRICAL CONNECTOR HEADER AND CONNECTOR THEREFOR

The general field of the invention relates to the connection and the electrical interconnection between several electrical and electronic power devices.

The invention applies to the power connection of electric or hybrid vehicles, rechargeable, carrying an electric traction battery and a battery charger.

It relates more particularly to the electrical power connectors used to connect the charger to the battery and to connect the battery, or more specifically the power supply module comprising a housing containing the battery, to an electrical component participating in the traction of the vehicle. such as the electrical energy management module of the hybrid traction system of the vehicle, also called HPCU (English abbreviations for Hybrid Powertrain Control Unit) or even LOW (for Power Electronics Unit).

Given the power and voltages that characterize the so-called power organs (a few tens of kW and a few hundred volts), the currents involved are of the order of several hundred amperes. The electrical connections (section and cable length, bulk, ...) of these bodies are therefore often bulky and pose integration problems. They must also ensure the protection of users against high voltages. They must also allow easy disassembly of the body for example its replacement in case of failure.

It is known in the state of the art of power connectivity, separate connectors which are dedicated one, to connect the battery to the electric power train to supply the powertrain with electrical energy, and the other, to connect the battery charger to the battery to recharge the battery.

However, the multiplicity of connectors dedicated to the connection of the battery to the various bodies in the vicinity of the battery, strongly impacts the integration of the power supply module (consisting essentially of the battery) within the vehicle, its development (internal electrical architecture ) as well as its cost.

To overcome this drawback, the present invention proposes a single and compact connector that fulfills the two power supply functions introduced above. For this purpose, the invention firstly relates to an electrical power connector base for the electrical connection of a power supply module comprising an electric traction battery accumulator of an electric or hybrid vehicle, rechargeable, comprising an electric traction chain and a charger embedded in the vehicle, said base comprising a first set of male and female contacts, characterized in that the first set of contacts comprises a first pair of same-sex contacts capable of supplying the traction chain electric vehicle, and a second pair of opposite sex contacts, adapted to receive a power supply from the charger to charge the battery.

According to one characteristic, the first pair of contacts comprises male contacts and the second pair of contacts comprise female contacts.

According to another characteristic, the contacts of the first and second pairs of contacts define pins of generally cylindrical shape of circular section.

According to another characteristic, the diameter of the contacts of the first pair of contacts is greater than the diameter of the contacts of the second pair of contacts.

According to another characteristic, the base comprises a closed partition surrounding the first and second pairs of contacts and projecting from the main plane of the base.

According to another characteristic, the base further comprises an arcing safety device disposed in the vicinity of the first and second pairs of contacts of the first contact assembly within the partition.

The second object of the invention is an electrical power connector for the electrical connection of a power supply module comprising a traction electric storage battery of a rechargeable electric or hybrid electric vehicle comprising an electric traction chain and a charger embedded in the vehicle, said connector comprising a base as described above, and a removable plug comprising a second set of male and female contacts complementary to those of the first set of contacts adapted to cooperate with each other when the plug is connected on the base; said socket comprising a recess whose bottom supports the second set of contacts, the inner wall of the recess cooperating with the outer surface of the partition of the base when connecting the socket on the base; the shapes of the partition and the wall being complementary.

According to one characteristic, the socket further comprises a safety device complementary to that of the base. According to another characteristic, the complementary shapes of the partition and the wall define a polarizer and means for guiding the socket on the base at the time of connection.

The third object of the invention is a power supply module for a rechargeable electric or hybrid electric vehicle comprising an electric traction battery and a housing containing the battery, characterized in that the housing comprises a connector base. as described above.

Finally, the fourth object of the invention is an electric or hybrid vehicle, rechargeable, equipped with a battery charger, an electric traction chain and a power supply module as described above, said vehicle comprising a first beam of electric cables connecting the charger to the power supply module and a second wiring harness connecting the power supply module to the electric power train, characterized in that it comprises a single connector as described above, for connecting the charger to the power supply module via the first wiring harness, and to connect the power supply module to the electric power train via the second wiring harness.

The invention will be more understandable on reading the description which will follow, given solely by way of nonlimiting example and with reference to the drawings in which:

- Figure 1 is a front view of a power connector base according to the invention;

FIG. 2 is a perspective view of a power supply module equipped with a base according to the invention;

- Figure 3 is a partial perspective view of a connector according to the invention in its vehicle environment; and

- Figure 4 is a perspective view of the socket of the connector according to the invention equipped with its electrical cables.

In these figures, the same references are used to designate the same elements.

In the remainder of this description, the features and functions well known to those skilled in the art will not be described in detail.

FIG. 1 shows a base 1 of an electrical power connector comprising a fastening plate 2 of generally rectangular shape comprising four drilling holes 3i respectively disposed at the four corners of the plate 2 for its attachment to a support, and in particular for its mounting on a power supply module housing comprising a traction battery.

This base 1 defines a connection plane 4 which carries a set of contacts 5i and 6i and which are generally circular cylindrical in shape which we will call indifferently pins or contacts in the continuation of the description. These contacts are partially molded in the base 1.

The set of contacts 5i and 6i comprises a first pair of contacts 5i, of the same male sex, able to power a power train of an electric or hybrid vehicle, rechargeable: a first contact 51 is dedicated to the positive potential (BT +) and a second contact 52 is dedicated to a negative potential (BT-).

The set of contacts 5i and 6i comprises a second pair of contact 6i, of the same female sex, able to receive power from a battery charger to charge the battery: a first contact 61 is dedicated to the positive charging potential ( charger +), and a second contact 62 is dedicated to a negative charging potential (charger-).

In the illustrated example, the first pair of contacts 5i has male contacts 51, 52 and the second pair of contacts 6i has female contacts 61, 62 but the opposite could also be retained.

The diameter of the male contacts 51, 52 is greater than the diameter of the female contacts 61, 62. The diameter of the contacts 51, 52, 61, 62 depends on the intensity of the current flowing through the contacts 51, 52, 61, 62.

The base 1 comprises a closed partition 7, integral with the fixing plate 2, surrounding the first and second pairs of contacts 5i, 6i and projecting from the main plane, or connection plane, of the base defined by the fixing plate 4.

This partition 7 protects the male contacts 51, 52 which also protrude from the fixing plate 4 towards the outside of the housing when the base 1 is fixed on the housing.

The partition 7 also serves as guide means for the socket which makes the connection or electrical connection between the housing, the charger and the electric power train. The partition 7 also serves as a polarizer as described below.

The base 1 further comprises a safety device against electric arcs 8, disposed in the vicinity of the first and second pairs of contacts 5i, 6i of the first contact assembly inside the partition 7 and more specifically in the example described between the two male contacts 51 and 52.

This safety device 8 includes a single "pilot line" or "pilot line" in French, also known as HVIL (abbreviations for: High Voltage Interlock Line).

This safety device 8, present on most high voltage connectors (power), avoids any risk of electric arc in case of accidental disconnection of the socket. This pilot line is generally made of a copper wire traversed by a current of a few mA. The electrical continuity ensured by the wire is first interrupted before the complete disconnection of the plug and main contactors of the power module, including the battery, open automatically preventing the creation of a dangerous electric arc for the user and for nearby electrical and electronic devices.

Figure 2 shows a power supply module 9 for powering an electric power train of a rechargeable electric or hybrid vehicle (not shown).

Such a module 9 is generally located in the trunk of the vehicle, console (near driver and passenger), under the floor of the trunk or under the vehicle.

The electrical connection of the power supply module 9 is provided by the base 1 which is described above with reference to FIG.

The base 1 is fixed on the front face 1 0 of the power supply module housing 9 in the vicinity of one of its edges, in particular in the vicinity of its right edge as illustrated in FIG.

The size of the base 1, and therefore the connector, is minimal on the front face 1 0 of the housing 9 which leaves room for large openings 1 1 i for air cooling of the battery.

On the other hand, the implantation of the base 1 is advantageously chosen to limit the lengths of the cable bundles connecting the power supply module on the one hand to the onboard battery charger and on the other hand, to the components of the chain. electric traction (HPCU and electric traction machine).

FIG. 3 represents a power connector 1 2 according to the invention in its vehicle environment. The vehicle is thus partially represented here by its power supply module 9, its on-board charger 50, its electric traction chain 60 and its electric cable bundles 30 and 40.

The connector 1 2 comprises the base 1, described above, and a socket 1 3 which is described in detail with reference to FIG. 4.

The socket 1 3 comprises a hollow body of generally cylindrical shape having a recess 14 delimited by a closed outer wall 1 5 of complementary shape to that of the partition 7 of the base 1; the inner wall 1 6 of the recess 14 cooperating with the outer wall surface 1 7 (Figure 1) of the base 1 when connecting the socket 1 3 on the base 1.

The bottom 18 of the recess 14 defines a plane perpendicular to the direction of engagement of the socket 1 3 on the base 1. This plan defines the connection plan of the socket 1 3.

The bottom 18 supports a set of male contacts 18i and female 19i. The set of contacts 1 8i and 19i comprises a pair of contacts 1 8i, of the same male sex, able to receive power from the battery charger to charge the battery: a first contact 1 81 is dedicated to the positive charging potential ( charger +), and a second contact 1 82 is dedicated to a negative charge potential (charger).

The set of contacts 1 8i and 1 9i comprises a pair of contacts 5i, same-sex female, suitable for powering an electric traction train 60 of an electric or hybrid vehicle, rechargeable: a first contact 1 91 is dedicated to the potential positive (BT +) and a second contact 1 92 is dedicated to a negative potential (BT-).

In the illustrated example, the first pair of contacts has female contacts and the second pair of contacts has male contacts but the opposite could also be retained. The diameter of the female contacts is greater than the diameter of the male contacts.

The contacts 1 8i and 1 9i of the socket 1 3 are complementary to those 5i and

6i of the base 1. The socket 1 3 further comprises a safety device (not visible) complementary to that 8 of the base 1.

The outer shapes of the base 1 and the socket 13 are advantageously shaped to define a polarizer. Thus, the section of the body of the socket 1 3, and in a complementary manner, the partition 7 of the base 1, has a geometric singularity imposing a unique and reliable branch direction. Thus, considering FIG. 1, showing the base 1 in front view, and more particularly the profile of the partition 7, the latter has a generally triangular shape, the base of the triangle being substantially parallel to the upper edge of the base 1 and the tip of the triangle being oriented towards the lower edge of the base 1.

The upper part of the interior space delimited by the partition 7, is wider than the lower part of the same space. This upper part closely surrounds the pair of male contacts 5i and the lower part closely surrounds the pair of female contacts 6i. Thus, the overall size of the connector 1 2 is limited to the maximum; the thickness of the partition 7 of the base 1 and that of the wall 1 5 of the socket 1 3 remaining of the order of a few millimeters.

The rear portion 20 of the socket 13, of determined thickness, receives the ends of four cables 21-24 which are molded with the rear face of the socket.

The end portions of these stripped cables 21 - 24 (not shown) are mechanically connected to their respective contacts 1 81, 1 82, 191, 1 92, themselves partially molded in the socket 1 3.

These cables 21 -24 are arranged in two bundles of two cables 30 and 40: a first bundle of cables 30 connecting the socket 1 3 to the on-board charger 50 in the vehicle and a second cable harness 40 connecting the socket 13 to the electric power train 60 of the vehicle.

Thus, the present invention provides an advantageous solution to compact the power connections in a hybrid or electric vehicle, rechargeable, integrating into a single connector several power functions and in a condensed manner, safe and reliable.

There are many interests, but the main ones are:

- facilitate the installation, integration and assembly of the traction battery in a hybrid or electric vehicle, rechargeable;

- reduce the costs of parts and the power supply module;

- simplify the development (internal electrical architecture, module design, ...) of the battery;

- and shorten the intervention time in after-sales.

Claims

Electrical power connector socket (1) for the electrical connection of a power supply module comprising an electric traction battery of an electric or hybrid vehicle, rechargeable, comprising an electric traction chain and an on-board charger in the vehicle, said base (1) comprising a first set of male and female contacts (5i, 6i), characterized in that the first set of contacts (5i, 6i) comprises a first pair of same-sex contacts (5i) able to feed the electric traction system of the vehicle, and a second pair of contacts of the opposite sex (6i), adapted to receive a power supply from the charger to charge the battery.

Base (1) according to the preceding claim, characterized in that the first pair of contacts (5i) comprises male contacts (51, 52) and in that the second pair of contacts (6i) comprise female contacts (61, 62 ).

Base (1) according to one of the preceding claims, characterized in that the contacts (51, 52 and 61, 62) of the first and second pairs of contacts (5i and 6i) define pins of generally cylindrical shape of circular section.

Base (1) according to the preceding claim, characterized in that the diameter of the contacts of the first pair of contacts (5i) is greater than the diameter of the contacts of the second pair of contacts (6i).

Base (1) according to one of the preceding claims, characterized in that it comprises a closed partition (7) surrounding the first and second pairs of contacts (5i and 6i) and projecting from the main plane of the base (1 ).

Base (1) according to the preceding claim, characterized in that the base (1) further comprises a safety device (8) against the arcs disposed in the vicinity of the first and second pairs of contacts of the first contact assembly (5i and 6i) inside the partition (7).

Power connector (12) for the electrical connection of a power supply module comprising an electric traction battery of an electric or hybrid vehicle, rechargeable, comprising an electric traction chain and a charger embedded in the vehicle, said connector comprising a base (1) according to one of the preceding claims, and a removable plug (13) comprising a second set of male and female contacts (18i, 19i ) complementary to those of the first set of contacts (5i, 6i) adapted to cooperate with each other when the plug (13) is connected to the base (1); said socket (13) comprising a recess (14) whose bottom (18) supports the second set of contacts (18i, 19i), the inner wall (16) of the recess (14) cooperating with the outer surface of the partition (7) of the base (1) when connecting the socket (13) to the base (1); the shapes of the wall (7) and the wall (16) being complementary.

8. Connector (12) according to the preceding claim, characterized in that the plug (13) further comprises a safety device complementary to that of the base (1).

9. Connector (12) according to one of claims 7 to 8, characterized in that the complementary shapes of the partition (7) and the wall (16) define a polarizer and a guide means of the plug (13) on the base (1) at the time of connection.

10. Power supply module (9) of a rechargeable electric or hybrid electric vehicle comprising an electric traction battery and a case containing the battery, characterized in that the housing comprises a connector base (1) ( 12) according to one of claims 1 to 4.

1 1. Electric or hybrid vehicle, rechargeable, equipped with a battery charger (50), an electric traction chain (60) and a power supply module (9) according to the preceding claim, said vehicle comprising a first bundle of electric cables ( 30) connecting the charger (50) to the power supply module (9) and a second wiring harness (40) connecting the power supply module (9) to the electric power train (60), characterized in that it comprises a single connector (12) according to one of claims 7 to 9 for connecting the charger (50) to the power supply module (9) via the first wiring harness (30), and for connecting the power module supply (9) to the electric drive train (60) via the second electrical wire harness (40).