WO2014114323A1

WO2014114323A1 - Electrical high power connection assembly

Info

Publication number: WO2014114323A1
Application number: PCT/EP2013/051137
Authority: WO
Inventors: Peter Nuetzel; Thomas Schwerin; Rainer Schmidt
Original assignee: Delphi International Operations Luxembourg S.À.R.L.
Priority date: 2013-01-22
Filing date: 2013-01-22
Publication date: 2014-07-31

Abstract

The present invention relates to an electrical high power connection assembly comprising: a connector housing with a first reception cavity and a second reception cavity, a connection member (20) at least partially inserted into the first reception cavity, and a terminal element at least partially inserted into the second reception cavity. The connection member (20) comprises a cable connection portion (21) and a terminal fastening portion (23). The electrical high power connection assembly further comprises: a bolt member (50) firmly attached to the terminal fastening portion (23), and a terminal base element (40) which supports the terminal element and movable in the connector housing between a pre-assembled position and an assembled position. In the assembled position, the terminal base element (40) is mounted to the bolt member (50).

Description

Electrical high power connection assembly

The present invention relates to an electrical high power connection assembly, in particular for the connection of high power electrical cables to electrical devices, such as further high power cables or high power batteries, especially in the field of hybrid or electrical vehicles.

The growing field of electrical and hybrid vehicles demands for new solutions for the connection of required electrical devices, such as electrical cables or electrical batteries to further electrical components.

In particular, new high power connection assemblies are needed since the high electrical powers in the range of several to tens of kilowatts, which for example are required for the operation of an electrical engine, translate into currents in the range of hundreds of amperes. Such currents can only be transmitted using relatively thick electrical cables with inner conductor diameters on the order of several millimeters.

A difficulty which arises, for example, upon assembling corresponding wire harnesses is that bending of such cables is relatively difficult.

Thus, to facilitate the installation of such high power electrical cables, specialized 90° connectors are needed. Consequently, a large number of patent applications deal with the task to provide right angle electrical connectors which can be used with such high power electrical cables.

An example of an electrical high power connection assembly is described in the European patent EP 0 858 128 B1 . Therein, an electrical high power connection assembly is described comprising one-piece rectangular contact terminals which are placed inside of a connector housing.

According to EP 0 858 128 B1 , to be optimally suited for high power applications, the contact terminals described therein are produced as a single solid piece by means of a die cast procedure. The contact terminals are provided with a female terminal portion with a plurality of contact springs for the reception of a contact pin of an electrical device. On the opposite side, the contact terminal is provided with a press fit portion for the reception of a contact pin of a further electrical device. Upon assembly, since the contact terminal according to EP 0 858 128 B1 is made from a single solid piece, the connector housing which consists of multiple parts has to be assembled around the contact terminal. A further example of an electrical high power connection assembly is described in WO 2010/029391 A1 . Therein, a rectangular contact terminal for high power applications is described which consists of a connection member and a terminal element, wherein the terminal element can be press-fittingly inserted into an opening of the connection member, thereby forming the rectangular contact terminal. According to WO 2010/029391 A1 , the connector housing consists in two housing halves. Upon assembly of the high power connection assembly, in a first step, the rectangular contact terminals are inserted into a first housing half along a first insertion direction. In a further step, the second connector half, including corresponding counter terminal elements, is mated to the first connector housing half, wherein the terminal elements and the counter terminal elements are connected. Due to the insertion of the rectangular contact terminals into the first connector housing half, this connector housing half needs to be of relatively large construction.

A still further example of an electrical high power connection assembly is described in document WO 2012/023041 A1 . Therein, a contact terminal is described which similar to the above contact terminal consists of a connection member and a terminal element which is fittingly inserted into an opening of the connection member to form a rectangular contact terminal. According to WO 2012/023041 A1 , a locking pin is provided which serves, firstly, to lock the terminal in its position in the housing and, secondly, to verify whether the terminal is correctly mounted inside of a housing or not. Thus, according to WO 2012/023041 A1 , this locking pin serves as a terminal position assurance (TPA) member. Similar as in the case described above, upon assembly the rectangular contact terminal is inserted into the connector housing as a whole, along a first inserting direction, and, thus, a relatively large insertion channel is required, which results in a relatively largely dimensioned connector housing.

Apart from this, due to the multiple part constructions of the connector housings required by the above described assemblies, for example a harness maker, i.e. the person in charge of assembling the wire harness of an electrical vehicle, is left with the responsibility to correctly assemble the connector housings.

Accordingly, it is an object of the present invention to provide an electrical high power connection assembly which allows to be assembled more easily and which is less susceptible to incorrect assembly.

It is a further object of the present invention to provide an electrical high power connection assembly which minimizes the required installation space, while, at the same time, it allows to be used for high power electrical applications, such as in the field of hybrid or electrical vehicles.

Further, it is an object of the present invention to achieve all the above advantages with an inexpensive product, wherein the electrically conductive components can be preferably made from sheet metal.

These and other objects, which become apparent upon reading the following description, are solved by electrical high power assemblies according to claim 1 .

According to the invention, an electrical high power assembly is provided which comprises a connector housing with a first reception cavity, which may define a first insertion direction, and a second reception cavity, which may define a second insertion direction. Preferably, the first insertion direction and the second insertion direction are essentially perpendicular to each other. As it will be clear to the person skilled in the art, in the context of the present invention, the term "essentially" indicates that expressions, such as perpendicular or 90°, are not to be understood in a strict mathematical sense but within the typical production tolerances. In other words, for example, perpendicular as well as 90°, both, indicate an angle of 90° +/- 20°, preferably +/- 10°, even more preferably +/- 7,5° and most preferably +/- 5°.

According to the invention, the electrical high power connection assembly further comprises a connection member, suitable to be at least partially inserted into the first reception cavity, wherein the connection member comprises a cable connection portion, suitable to be mechanically connected to an electrical cable. In a preferred embodiment, the cable connection portion is a crimping portion which can for example be crimped around the electrically conductive dismantled cable strands of an electrical cable.

Such a crimping portion provides the advantage that it allows a reliable and secure mechanical and electrical connection between the connection member and an electrical cable. However, also further connection means may be used as connection portions, such as e.g. a press-fit connection portion. The cable connection portion is therefore very robust which is a particular advantage for handling such assembly, in particular from the harness maker side. Further, the connection member may comprise a terminal fastening portion. In addition, the electrical high power connection assembly comprises a terminal element, suitable to be at least partially inserted into the second reception cavity. The terminal element is adapted to be electrically connected to a contact member of an electrical device.

For example, the electrical device may be an electrical battery for an electrical or hybrid vehicle and the contact member may be a contact terminal provided, for example, with a contact pin. Alternatively, the electrical device may be a cable and the contact member may be a contact terminal provided, for example, with a contact pin electrically and mechanically connected to the electrical cable.

Further, the electrical device may also be an electrical motor for an electrical or hybrid vehicle and the contact member a contact pin connected to such electrical motor.

According to the invention, the electrical high power connection assembly further comprises a bolt member, which can be firmly attached to the terminal fastening portion of the connection member.

For example, the terminal fastening portion may comprise a hole which is adapted to receive a portion of the bolt member such that the bolt member can be press-fittingly attached to the terminal fastening portion. Further, the bolt member may also be welded to the terminal fastening portion or firmly attached thereto by similar means.

Moreover, according to the invention, the electrical high power connection assembly comprises a terminal base element, which supports the terminal element and which can be moveable in the connector housing, such that it can be moved between a pre-assembled position and an assembled position. In an assembled position, the terminal base element is mounted to the bolt member.

The construction allows that the terminal base element may, for example, be provided already placed in the pre-assembled position, e.g. inside of the connector housing, when the components of the electrical high power connection assembly are delivered to the harness maker. Upon assembly, the harness maker is thus only required to insert the connection member with the firmly attached bolt member into the first reception cavity of the connector housing.

In a further step, an operator only needs to move the terminal base element with the terminal element supported thereon, from the pre- assembled position into the assembled position, wherein the terminal base element is easily mounted to the bolt member.

Thus, due to the provision of the terminal base element movable between the pre-assembled position and the assembled position, an easy and simple mounting procedure for assembling the electrical high power connection assembly is provided, which reduces the responsibility of the harness maker to correctly assemble more complicated components such as multiple parts of a connector housing.

Further, due to the inventive construction, a smaller diameter, e.g. of the first reception cavity, is required since, as opposed to a full contact terminal, only the connection member with the bolt member has to be inserted into this reception cavity.

In a preferred embodiment, by the interaction between the terminal base element and the bolt member, upon moving the terminal base element from the pre-assembled position into the assembled position, a terminal position assurance (TPA) function is provided. If the terminal base element is mounted to the bolt member, it is assured that both, the terminal base element and the connection member, are correctly assembled.

In a preferred embodiment, the electrical high power connection assembly is adapted to transmit an electrical power of at least 10 kW, more preferably of at least 50 kW, even more preferably of at least 100 kW, and most preferably of at least 150 kW. Thus, e.g. due to suitable dimensions of the electrically conductive components, the electrical high power connection assembly is for example adapted to transmit a current of 100 ampere at a voltage of 100 volts, and thereby a high electrical power of 10 kW.

Of course, different features, alternatives and/or embodiments of the present invention can be combined with each other in various arrangement to the extent that they are not incompatible or mutually exclusive of others.

The present invention will be better understood and other features and advantages will become apparent upon reading the following detailed description including embodiments for illustrative purposes with reference to the figures, presented as non-limitative examples, which can be used to complete the understanding of the present invention and the description and, where appropriate, contribute to its definition, in which:

• Fig. 1 shows a perspective view of a connection member, a bolt member and a terminal base element which is integrally formed with a terminal element, wherein the terminal element is covered by an insulating cap,

• Fig. 2 shows a cross-sectional view of the components of Fig. 1 ,

• Fig. 3 shows a further embodiment of a terminal base element which supports a terminal element and which is mounted to a connection member via a bolt member, wherein the connection member is connected to an electrical cable,

• Fig. 4 shows a cross-sectional view of the components of Fig. 3, • Fig. 5 shows the terminal base element of Fig. 1 which is integrally formed with the terminal element wherein the connection member is connected to an electrical cable,

• Fig. 6 shows a cross-sectional view of the components of Fig. 5, · Fig. 7A to C shows assembling steps of an electrical high power connection assembly, and

• Fig. 8 shows cross-sectional view of a connector housing suitable to receive the connection member of Fig. 1 . It should be noted that, on figures, structural and/or functional elements which are common to different embodiments may have the same reference sign. Thus, unless otherwise stated, these elements have structural, dimensional and material properties which are identical. Alternatives are indicated by an apostrophe, as e.g. terminal element 30 and 30' in Figs. 1 and 3.

Fig. 1 illustrates a connection member 20, a bolt member 50 and a terminal base element 40 in a perspective exploded view. In Fig. 2, the same view is shown in a cross-sectional view.

The connection member 20, the bolt member 50 and the terminal base element 40 are suitable to be mounted inside of a connector housing 10 as shown in Fig. 8. As illustrated in these figures, the connection member 20 comprises a cable connection portion 21 , for example in the form of a crimping portion. Specifically, the cable connection portion 21 is formed by two crimping wings which can be crimped around, for example, a dismantled wire portion of an electrical cable to establish a mechanical and electrical connection between the connection member 20 and an electrical device connected at the other end of the cable. As one may derive from Fig. 2, a terminal fastening portion 23 is provided. The terminal fastening portion 23 may be a circular opening or hole such that a portion of the bolt member 50 can, preferably by press-fitting engagement, be disposed in said opening, thereby firmly attaching the bolt member 50 to the terminal fastening portion 23 of the connection member 20.

As it will be clear to the skilled person, hereby the term "press-fittingly" indicates that initially, the opening, which is provided in the terminal fastening portion 23, is designed with a diameter which is smaller than the diameter of the corresponding portion of the bolt member 50 to such an extent that it is possible to press or squeeze the portion of the bolt member 50 into the opening. The terminal base element 40 comprises a body 41 , and preferably a contact spring 43, namely a coil spring, as it may be derived from Fig. 2.

Additionally, the terminal base element 40 may comprise a contact spring 43 and a second contact spring 44 arranged the one above the other along a axial direction of terminal base element 40. The second contact spring 44 is particularly dedicated to contact a surface of an inserted contact member, such as a contact pin, of an electrical device to establish an electrical and mechanical connection between the terminal element 30 and the electrical device.

When the terminal base element 40 is mounted to the bolt member 50, the contact spring 43 is arranged between an outer face of the bolt member 50 and an inner face 45 of the body 41 . Thereby, the contact spring 43 is biased against the outer face of the bolt member 50 and the inner face 45 of the body 41 of the terminal base element 40 to provide a particularly reliable mechanical and electrical connection. In the assembled position, the terminal base element 40 is held due to a bias of the spring element 43 resulting from a spring force.

The inner face 45 of the body 41 comprises a circular groove to receive the spring element 43.

In the shown embodiment, a terminal element 30 is formed integrally with the terminal base element 40. The terminal element 30 is partially enclosed by an insulating cap 60, the function of which will be explained in more detail in connection with Figs. 7A to 7C.

Figs. 3 and 4 show an alternative of a connection member 20'. In Figs. 3 and 4, the connection member 20' is connected to an electrical cable 70 by crimping the cable connection portion 21 around the dismantled cable strands 71 of the electrical cable 70.

In the shown embodiment, a terminal element 30' is formed as a separate piece, preferably from sheet metal, and is attached to the terminal base element 40' via a base section 33', as shown on Fig. 4, which is preferably press-fitted, more preferably is welded to the terminal base element 40'.

To this end, preferably the terminal base element 40' is provided with a ring section with an inner diameter, such that it can receive the base section 33' of the terminal element 30'. The diameter of the ring section can be chosen such that the base section 33' of the terminal element 30' can be press-fittingly inserted into the ring section. Alternatively or in addition, the base section 33' can be welded to the ring section.

Preferably, the terminal element 30' comprises a plurality of spring arms 31 ' which are arranged parallel to each other in a basically circular arrangement. As the skilled person will recognize, these spring arms 31 ' are adapted to be biased against a surface of an inserted contact member, such as a contact pin, of an electrical device to establish an electrical connection between the terminal element 30' and the electrical device. Figs. 5 and 6 illustrate the connection member 20 of Figs. 1 and 2 attached to a cable 70.

Figs. 7A to 7C show assembling steps of an electrical high power connector assembly according to the present invention. In Figs. 7A to 7C, on the left side, a longitudinally partially perspective cross-sectional view along a longitudinal direction is shown and, on the right side, a partially perspective cross-sectional view of the same elements in a plane perpendicular of the longitudinal direction. Figs. 7A to 7C show a housing part 16 of a connector housing 10, as for example, a separate insert housing part 16, which can be arranged inside a first reception cavity 1 1 of the connector housing 10, as shown in Fig. 8.

The skilled person will however understand that the housing part 16 can also be an integral part of connector housing 10 and can have any other suitable form and shape allowing the mounting of the different parts of the electrical high power connector assembly.

In Figs. 7A to 7C, one can see the connection member 20 of Figs. 1 and 2 being connected to cable 70 via the cable connection portion 21 . The bolt member 50 is fitted into the terminal fastening portion 23.

The terminal base element 40 comprises a circumferential mounting groove 46. The housing part 16 comprises a corresponding mounting element, preferably in form of a bracket 17, such that the terminal base element 40 can be held in a preliminary position as shown in Fig. 7A. Integrally formed to the terminal base element 40 is the terminal element 30, which is adapted to receive a corresponding contact element of a counter connector, which would be in the shown case a male contact pin or bolt.

The housing part 16 further comprises a stop member 18, for example in form of two flexible arms. As one can best derive from the right hand illustration of Fig. 7A, the stop member 18 prevents an insertion of the terminal base element 40 into the interior of housing part 16.

Upon assembly of connection member 20 with the housing part 16, the terminal fastening portion 23 bends the stop member 18, i.e. the two flexible arms, outwardly, as can best be derived from the right hand illustration of Fig. 7B.

As the skilled person will recognize, in the position shown in Fig. 7B, i.e. in a release position, it is now possible to dispose the terminal base element 40 inside of the housing part 16 and to achieve a mechanical and electrical connection between bolt member 50 and terminal base element 40, as shown in Fig. 7C.

As one may further derive from Fig. 7C, the insulating cap 60, which is fixed firmly to terminal element 30, is now in contact with the housing part 16, so that the construction shown in Fig. 7C is completely closed, i.e. the electrically conductive parts of terminal base element 40, terminal element 30, bolt element 50 and terminal fastening portion 23 are completely encapsulated by electrically insulating material, namely of the walls of the housing part 16 and of the insulating cap 60. As it is exemplarily shown in Fig. 8 in a cross-sectional view, the electrical high power connection assembly comprises the connector housing 10 with the first reception cavity 1 1 which defines a first insertion direction 14. Moreover, the connector housing 10 comprises a second reception cavity 13 which defines a second insertion direction 15. Preferably, the second insertion direction 15 is essentially perpendicular to the first insertion direction 14. The connection member 20 is adapted to be mounted inside of connector housing 10, when the electrical high power connection assembly is in the assembled condition. To this end, the connection member 20 is inserted into the first reception cavity 1 1 along the first insertion direction 14 and the terminal base element 40 is inserted into the second reception cavity 13 along the second insertion direction 15.

The connector housing 10 may additionally comprise the housing part 16, e.g. in the form of a separate insert element or integrally formed with the connector housing 10.

Upon assembly, in a first step, the terminal base element 40 is inserted until it reaches a preassembled position, as shown in Fig. 7A. Thereafter, the connection member 20 is inserted into cavity 1 1 until it reaches its end position, as shown in Fig. 7B. After the connection member 20 is in its end position, the terminal base element 40 can be pushed into its assembled position, as shown in Fig. 7C, wherein the electrical and mechanical connection with connection member 20 is established.

This inventive construction allows a simple and reliable 90° high power connection, which is space and cost saving.

Obviously, the present invention is not limited to embodiments which are here above described and provided only as examples. It also includes different modifications, and alternatives that may be considered by the person skill in the art as part of the present invention, including all combinations of different embodiments here above described, taken alone or in combination.

Claims

1 . Electrical high power connection assembly comprising:

• a connector housing (10) with a first reception cavity (1 1 ) and a second reception cavity (13),

• a connection member (20, 20') at least partially inserted into the first reception cavity (1 1 ),

• a terminal element (30, 30') at least partially inserted into the second reception cavity (13),

wherein the connection member (20, 20') comprises a cable connection portion (21 ) and a terminal fastening portion (23),

characterized in that the electrical high power connection assembly further comprises :

• a bolt member (50) firmly attached to the terminal fastening portion (23), and

• a terminal base element (40, 40') which supports the terminal element (30, 30') and movable in the connector housing (10) between a pre-assembled position and an assembled position,

wherein, in the assembled position, the terminal base element (40, 40') is mounted to the bolt member (50).

2. Electrical high power connection assembly according to claim 1 , characterized in that the terminal base element (40, 40') comprises a body (41 ) and at least one spring element (43, 44), arranged in between an outer face of the bolt member (50) and an inner face of the body (41 ) of the terminal base element (40, 40').

3. Electrical high power connection assembly according to claim 2, characterized in that the inner face of the body (41 ) comprises at least one circular groove, suitable to receive the spring element (43, 44).

4. Electrical high power connection assembly according to any one of the preceding claims, characterized in that the terminal fastening portion (23) comprises an opening receiving a portion of the bolt member (50), such that the bolt member (50) is preferably press-fittingly connected to the terminal fastening portion (23).

5. Electrical high power connection assembly according to any one of the preceding claims, characterized in that the terminal base element (40) is integrally formed with the terminal element (30).

6. Electrical high power connection assembly according to any one of claims 1 to 4, characterized in that the terminal element (30') is a separate element being attached to the terminal base element (40').

7. Electrical high power connection assembly according to any one of the preceding claims , characterized in that the terminal element (30') comprises a plurality of spring arms (31 ) extending from a base section of the terminal element (30').

8. Electrical high power connection assembly according to claim 7, characterized in that the spring arms (31 ) are arranged parallel to each other in a circular arrangement.

9. Electrical high power connection assembly according to any one of the preceding claims, characterized in that the connector housing (10) further comprises a housing part (16) receiving the connection member (20) and the terminal base element (40) therein.

10. Electrical high power connection assembly according to claim 9, characterized in that the housing part (16) comprises a mounting element (17) to hold the terminal base element (40).

1 1 . Electrical high power connection assembly according to claim 9 or 10, characterized in that the housing part (16) further comprises a stop member (18), suitable to block an insertion of the terminal base element (40) into the interior of housing part (16).

12. Electrical high power connection assembly according to claim 1 1 , characterized in that the stop member (18) is provided with at least one flexible arms, suitable to be bent upon full insertion of the connection member (20) into the insert part (16), to allow an insertion of the terminal base element (40) into the interior of housing part (16).

13. Electrical high power connection assembly according to any one of the preceding claims, characterized in that the terminal element (30, 30') is a female terminal, suitable to receive a corresponding male contact.

14. Electrical high power connection assembly according to any one of the preceding claims, characterized in that the electrical high power connection assembly is adapted to transmit an electrical power of at least 10 kW, more preferably of at least 50 kW, even more preferably of at least 100 kW, and most preferably of at least 150 kW.