WO2013178434A1 - Interconnection assembly for vehicle devices and method of interconnection - Google Patents

Interconnection assembly for vehicle devices and method of interconnection Download PDF

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Publication number
WO2013178434A1
WO2013178434A1 PCT/EP2013/059390 EP2013059390W WO2013178434A1 WO 2013178434 A1 WO2013178434 A1 WO 2013178434A1 EP 2013059390 W EP2013059390 W EP 2013059390W WO 2013178434 A1 WO2013178434 A1 WO 2013178434A1
Authority
WO
WIPO (PCT)
Prior art keywords
housing
devices
terminal
connection plate
assembly
Prior art date
Application number
PCT/EP2013/059390
Other languages
French (fr)
Inventor
Claude Casses
Luc MAILLET
Original Assignee
Delphi International Operations Luxembourg S.À R.L.
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
Priority to EP12305598 priority Critical
Priority to EP12305598.0 priority
Application filed by Delphi International Operations Luxembourg S.À R.L. filed Critical Delphi International Operations Luxembourg S.À R.L.
Publication of WO2013178434A1 publication Critical patent/WO2013178434A1/en

Links

Classifications

    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02Contact members
    • H01R13/04Pins or blades for co-operation with sockets
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R31/00Coupling parts supported only by co-operation with counterpart
    • H01R31/06Intermediate parts for linking two coupling parts, e.g. adapter
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2103/00Two poles

Abstract

An interconnection assembly for electrically interconnecting vehicle devices (200, 300). The assembly comprises at least one connection plate (500) and two high-power electrical devices (200, 300). The connection plate (500) has at least one terminal (560) passing through an insulating support. The housing (210 or 310) of each one of the two devices has at least one opening (230 or 330) facing an opening of the other device housing. The connection plate (500) is placed between these two openings (230, 330) so that each end of at least one terminal (560) of the connection plate (500) can be introduced in a respective opening (230 or 330) of device housing (210 or 310), for electrically connecting a respective device terminal (260, 360) of each device.

Description

INTERCONNECTION ASSEMBLY FOR VEHICLE DEVICES AND METHOD OF INTERCONNECTION

Field of the invention

The invention relates to the field of high voltage connections in vehicles, and more particularly high- voltage connections for interconnecting automobile devices supplied with high power. Background of the invention

As schematically shown on Fig. 1 , electric and hybrid vehicles 100 may comprise a battery set 200 and a power inverter 300 to convert the DC power supplied by the battery set 200 to the AC power used by the electric motors 400.

The patent application US2008/0105476 describes a connector plate mechanically and electrically interconnecting the power inverter to the electric motor. This prior art connector plate comprises bus bars attached to conductors of the connector plate and screwed to the power inverter, as well as engagement formations within which pins of the electric motor are mated.

Even though, a wiring harness is not required in this prior art assembly to connect the power inverter to the electric motor, it is desirable to provide an interconnection assembly which is even further easier and quicker to assemble.

Summary of the invention

To this aim, according to the invention, an interconnection assembly for electrically interconnecting electric devices of a vehicle is provided. Such electric devices are parts of a high power electrical circuit. These electrical devices may then be for example a battery set, a converter, an electric motor, or any other type of electric component. In such high power circuits, the voltage range may be from 100 V up to 800, depending on type of battery and number of battery cells, and the current range reaches from extremely low currents of some 10 mAmp to permanent high currents of up to 600 Amps and peak currents of up to 1.5 kAmps. The interconnection assembly according to the invention comprises at least one connection plate and two high-power electrical devices, electrically interconnected by the connection plate.

The connection plate has an insulating support with at least two faces opposite to each other. At least one terminal passes through the insulating support. The number of terminals may vary from 1 to 5 or more. Such terminals have two ends, each one of which extending from one respective of the two opposite faces of the insulating support. For example, the terminals are straight and cylindrical pins of 8mm diameter, passing through the insulating support (for example the insulating support is overmolded so as to extend, substantially in the middle of the pins, perpendicular to them). The terminals may also have any other appropriate shape (blade, male, female, etc.)

Each one of the two electrical devices has a separate housing and can be handled independently prior to mounting them in a vehicle.

Since the electrical devices have to be electrically connected in/to a high power circuit, it comprises at least one device terminal. At least one of these device terminals is advantageously accommodated inside the respective housing of each one of the two electrical devices.

The housing of each one of the two devices has an opening. Indeed, the device housings of the assembly according to the invention are advantageously designed for protecting the device terminals to be connected to another device, as long as the device is not mounted in a vehicle. In this sense, device terminals are accommodated inside (i.e. internal to) the device housing. Then, at least one opening is required, through which a terminal end (from the connector plate) is introduced for electrically connecting the device terminal accommodated inside a device housing, to another device. Such an opening is designed so as to insert a pin, a blade or any other kind of terminal for contacting a device terminal located internal to the device housing.

An advantage of this configuration is that there is no any pin or any other connecting part which sticks out of the device housing while the device is not connected.

There is consequently less risk to damage the connecting parts before or after it is mounted in the vehicle. A plug can be used for filling/ closing the opening(s) if the device is not connected.

In the assembly according to the invention, each one of two devices has a respective opening facing an opening in the other device housing. In other words, the opening of one of the two devices is opened toward the opening of the other device. Then the connection plate can be placed in-between these two openings with each terminal end extending from its opposite faces, inserted in one respective opening for contacting and electrically connecting the two devices.

The invention consequently has the advantage of avoiding the use of cables between the devices. This allows saving weight, room and costs. Power cables are usually heavy, often very rigid, and especially when they comprise large diameter cables such as those used in HV/EV systems. Connecting devices of HV/EV systems may become very burdensome. The connection plate according to the invention makes connections easier.

The invention has also the advantage of allowing the use of a connector technology for interconnecting the devices, instead of screwed electrical connections as often used for power cable connections.

Other features and advantages of the invention will be set forth in, or apparent from, the following description and of the appending drawings.

Brief description of the drawings

On the drawings:

- Figure 1 schematically represents a vehicle comprising a battery set, a power inverter, an electric motor and an electronic control unit; Figure 2 schematically represents a vehicle with an example of interconnection assembly according to the invention;

Figure 3 schematically represent a cross-section of an exemplary embodiment of interconnection assembly according to the invention;

Figure 4 is a schematic perspective view from above of an element of the assembly represented on Figs. 2 and 3;

Figure 5 is a schematic perspective view from below of the element represented on Fig. 4;

- Figure 6 is a schematic exploded view of a connector to be accommodated in the element represented on Fig. 4 and Fig. 5;

Figure 7 is a schematic perspective view of the connector represented on Fig. 6; Figure 8 is a schematic perspective view of the connection plate of the assembly represented on Figs. 2 and 3;

Figure 9 is a schematic exploded view of the connection plate of Fig. 8; and Figures 10a to lOe schematically represent the assembly process of the interconnection assembly of Figs. 2 and 3.

On the different figures, the same references signs designate like or similar elements.

Detailed description

Fig. 2 illustrates a vehicular interconnection assembly according to the invention.

The vehicle 100 of Fig. 2 comprise a battery set 200 and a power inverter 300 to convert the DC power supplied by the battery set 200 to the AC power used by the electric motor(s) 400. A connection plate 500, not shown in Fig. 2, electrically directly connects, without any wiring harness, the battery set 200 to the inverter 300. The interconnection assembly further comprises an electronic control unit (ECU) 600 connected to the battery set 200, the inverter 300 and a motor 400 for managing the power supply or consumption in these electric devices or components 200, 300 and 400.

Fig. 3 shows in greater detail the interconnection assembly according to the invention. The battery set 200 and the inverter 300 are electrically connected with a connection plate 500.

Fig. 4 illustrates a battery set 200. In this document, only one battery module is shown, but several battery modules similar to the one here described may be connected in series. The battery set 200 comprises a housing 210 on which an external connector 220 is mounted for a connection to the electric motor 400. The housing 210 has at least two openings 230. These openings 230 are open just in front of a female connector 240 accommodated in the housing 210.

As shown on Figs. 5 and 6, the female connector 240 comprises an insulating support 250, and two female terminals 260. Each female terminal 260 is made of a connection portion 270 mounted on a bus bar 280. Bus bar 280 is for instance made of a copper bus sheet metal at least 1.2 mm thick. For example, a bus bar 280 may be directly mechanically and electrically connected to a battery pole (not represented).

As shown on Figs. 6 and 7, the insulating support 250 comprises two grooves 252 each one of which respectively accommodating a connection portion 270. The distal end of each groove has a annular skirt 254 extending perpendicular to the longitudinal axis of the groove. Skirt 254 protects the elastic blades 272 of the connection portions 270, when a male terminal is mated in the female terminal 260 through an opening 230.

The insulating support 250 is mounted in the housing 210 so as to have the skirts 254 located in front of the openings 230 and to allow the insertion of the connection portions 270 in their respective groove 252 from one of the sides of the insulating support 250.

Similarly, as shown for instance on Fig. 3, a female connector 340 having an insulating support 350 and female terminals 360, is mounted in the inverter 300, with openings 330 made in the inverter housing 310 facing the female terminals 360.

The housings 210, 310 of the two electrical devices 200, 300 are independent and separate parts before assembly, so as to be handled independently while not coupled within an interconnection assembly according to the invention. Though, the female connectors 240, 340, their supports 250, 350 and their terminals 260, 360 are well protected in the housings 210, 310 and accessible only through the openings 230, 330.

Fig. 8 illustrate in greater detail the connection plate 500. The connection plate 500 comprises an insulating support 510 with at least two faces 520, 530 opposite to each other. Two cylindrical protections 522, 524 extend from and perpendicular to one 520 of these faces 520, 530. Two other cylindrical protections 532, 534 extend from and perpendicular to the other face 530. The four cylindrical protections 522, 524, 532, 534 and the insulating support 510 are a single piece made of the same insulating material. Each face 520, 530 has a recess for receiving a sealing mat 540.

Two male terminals 550, 560 are inserted through the insulating support 510. The male terminals 550, 560 are straight and cylindrical pins of 8mm diameter. One 550 of the male terminals 550, 560 is accommodated in the support and two aligned cylindrical protections 522, 532, and the other one 560 of the male terminals is accommodated in the support and two other aligned cylindrical protections 524, 534. Consequently, the two ends 552, 554 or 562, 564 of each respective terminal 550 or 560 extend from one respective of the two opposite faces 220, 230, but are protected by respective cylindrical protections 522, 532, 524 or 534.

Male terminals 550, 560 are made of copper alloy. Their tips 553, 555, 563, 565 may be respectively covered by a plastic cap 570. This configuration of the male terminals 550, 560 with their ends protected in cylindrical protections and their tips covered by a plastic cap 570, is YP2X compliant.

The cylindrical protections 522, 524, 532, 534 are designed for covering and protecting the connection portions 270, 370 of the female terminals 260, 360.

The connection plate is symmetrical with regard to a plane

Figs. 10a to lOe illustrate the assembly process according to the invention.

At a first step, a battery set 200 or module is provided with a female connector 240 located inside the housing 210 (Fig. 10a).

At a second step, a connection plate 500 is mated to the female connector 240 through the openings 230 of the battery housing 210 (Fig. 10b). Fig. 10c illustrates the female connector 240 and the connection plate 500 once mated.

At a third step, an inverter 300 is coupled to the battery set 200 through the connection plate 500. In other words, the female connector 340 of the inverter 300 is mated to the connection plate 500 to through the openings 330 of the inverter housing 310. Fig. lOe illustrates the inverter 300 and the battery set 200 once coupled, i.e. once the female connector 340 and the connection plate 500 are mated. The connection plate 500 is then sandwiched between housings of the battery set 200 and the inverter 300 and the sealing mat provides water tightness to the interconnection assembly according to the invention.

The interconnection assembly according to the invention has the advantage of having a relatively large tolerance from the mating standpoint (about 0.5 mm in both directions of the plane perpendicular to the mating directions).

While an exemplary embodiment has been presented in the foregoing description, it should be appreciated that a many variations exist. For example, the assembly according to the invention may comprise a motor (instead of the battery set), an inverter and a connection plate, or any kind of electrical device assembly comprising a connector plate and female or connectors like the ones above-disclosed, accommodated either in the connector plate or in the housings of these devices.

The interconnection assembly according to the invention may also comprise an interlock system as the ones well known by the persons skilled in the art, so as control the power supply during the electrical connection or disconnection of the devices with the connection plate 500.

Claims

Claims
1. Interconnection assembly for electrically interconnecting vehicle electric devices, the assembly comprising at least one connection plate (500) and two electrical devices (200, 300),
- wherein the connection plate (500) has an insulating support (510) with at least two faces (520, 530) opposite to each other, and has at least one terminal (550 or 560) with two ends (552, 554 or 562, 564) extending from one respective of the two opposite faces (520, 530), and
- wherein each one of the two electrical devices (200, 300) has a separate housing
(210, 310),
characterized in that
- at least one device terminal (260 or 360) is accommodated inside the respective housing (210, 310) of each one of the two electrical devices (200, 300), and in that
- the housing (210 or 310) of each one of the two devices (200, 300) has at least one opening (220 or 230) facing an opening of the other device housing and through which at least one of the terminal ends is inserted for electrically connecting a respective device terminal.
2. Interconnection assembly according to claim 1, comprising a mat seal (540) on at least one of the two opposite faces (520, 530).
3. Interconnection assembly according to claim 1 or 2, wherein at least one of the device terminals (260) is made of a connection portion (270) mounted on a bus bar (280).
4. Interconnection assembly according to one of the preceding claims, wherein the two electrical devices (200, 300) are respectively a battery set and an inverter.
5. Process for interconnecting electric devices of an electric vehicle, the process comprising the following steps:
- providing a first electrical device (200) with a female connector (240) located inside a its housing (210), - mating a connection plate (500) to the female connector (240) through at least one opening (230) of the housing (210), the connection plate (500) having an insulating support (510) with at least two faces (520, 530) opposite to each other, and at least one terminal (550 or 560) with two ends (552, 554 or 562, 564) extending from one respective of the two opposite faces (520, 530),
- coupling a second electrical device (300) to the first electrical device (200) through the connection plate (500), the second electrical device (300) having a housing (310) separate from the housing (210) of the first electrical device (200), and at least one device terminal (260 or 360) being accommodated inside the respective housing (210, 310) of each one of the two electrical devices (200, 300), and the housing (210 or 310) of each one of the two devices (200, 300) having at least one opening (220 or 230) facing an opening of the other device housing and through which at least one of the terminal ends is inserted for electrically connecting a respective device terminal.
PCT/EP2013/059390 2012-05-30 2013-05-06 Interconnection assembly for vehicle devices and method of interconnection WO2013178434A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP12305598 2012-05-30
EP12305598.0 2012-05-30

Publications (1)

Publication Number Publication Date
WO2013178434A1 true WO2013178434A1 (en) 2013-12-05

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PCT/EP2013/059390 WO2013178434A1 (en) 2012-05-30 2013-05-06 Interconnection assembly for vehicle devices and method of interconnection

Country Status (1)

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WO (1) WO2013178434A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2018530877A (en) * 2015-12-18 2018-10-18 エルジー・ケム・リミテッド Battery module, battery pack including the battery module, and automobile including the battery pack

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20080105476A1 (en) 2006-11-06 2008-05-08 Korich Mark D Power inverter connector having integrated current sensors
US20090023306A1 (en) * 2007-07-17 2009-01-22 Gm Global Technology Operations, Inc. Interface assemblies for use with inverters of vehicles
WO2009146789A1 (en) * 2008-06-03 2009-12-10 Mc Technology Gmbh Connecting element to produce an electrically conducting connection between two terminals
WO2010061063A1 (en) * 2008-11-28 2010-06-03 Siemens Transportation Systems Sas System for assembling electrical energy modules
WO2011161023A1 (en) * 2010-06-24 2011-12-29 Fci Automotive Holding Electrical connection bus
WO2011161026A1 (en) * 2010-06-24 2011-12-29 Fci Automotive Holding Electrical connector and electrical equipment comprising the same

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20080105476A1 (en) 2006-11-06 2008-05-08 Korich Mark D Power inverter connector having integrated current sensors
US20090023306A1 (en) * 2007-07-17 2009-01-22 Gm Global Technology Operations, Inc. Interface assemblies for use with inverters of vehicles
WO2009146789A1 (en) * 2008-06-03 2009-12-10 Mc Technology Gmbh Connecting element to produce an electrically conducting connection between two terminals
WO2010061063A1 (en) * 2008-11-28 2010-06-03 Siemens Transportation Systems Sas System for assembling electrical energy modules
WO2011161023A1 (en) * 2010-06-24 2011-12-29 Fci Automotive Holding Electrical connection bus
WO2011161026A1 (en) * 2010-06-24 2011-12-29 Fci Automotive Holding Electrical connector and electrical equipment comprising the same

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2018530877A (en) * 2015-12-18 2018-10-18 エルジー・ケム・リミテッド Battery module, battery pack including the battery module, and automobile including the battery pack
KR102058690B1 (en) * 2015-12-18 2019-12-23 주식회사 엘지화학 Battery moduel, battery pack comprising the battery moduel and vehicle comprising the battery pack
US10644299B2 (en) 2015-12-18 2020-05-05 Lg Chem, Ltd. Battery module, battery pack comprising battery module, and vehicle comprising battery pack

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