WO2016098033A1

WO2016098033A1 - Connector for connecting the end of a wire to a terminal

Info

Publication number: WO2016098033A1
Application number: PCT/IB2015/059707
Authority: WO
Inventors: Augustin Bellet; Benoit WALME; Florian LE MAOUT; Rafal PISAREK
Original assignee: Valeo Japan Co., Ltd.
Priority date: 2014-12-19
Filing date: 2015-12-17
Publication date: 2016-06-23
Also published as: EP3235065A1; CN107646159A; FR3030917A1; FR3030917B1; JP2017539067A

Abstract

Connector (20) for electrically connecting the end of at least one wire (40) to a terminal (4) comprising at least one terminal pin (70), the connector (20) comprising: - a connector housing (21, 30) adapted to receive the end of the at least one wire (40), - means for fixing the end of the at least one wire (40) inside the connector housing (21, 30), wherein the connector housing (21, 30) comprises a passage for allowing the at least one terminal pin (70) to enter the interior of the connector housing (21, 30) and to electrically contact (41) the end of the at least one wire (40), the connector (20) further comprising: - a releasable cover (21) adapted to close off the connector housing (21, 30) to envelop the end of the at least one wire (40) inside the assembly (10) of the connector housing (21, 30) and the releasable cover (21), the connector housing (21, 30) and the releasable cover (21) defining at least one groove (22) for receiving and fixing the at least one wire (40), the at least one groove (22) being partially open to allow entry of the at least one wire (40) into the groove (22) via said opening of the groove (22).

Description

CONNECTOR FOR CONNECTING THE END OF A WIRE TO A TERMINAL

Technical Field

The present invention relates to a connector adapted for electrically connecting an assembly comprising an electrical motor and a compressor of a cooling system for a vehicle, such as a car, to an electrical power source. More specifically, the present invention relates to a connector for electrically connecting the end of a wire to a terminal, wherein the connector comprises a housing adapted to receive the end of at least one wire and means for fixing the end of the wire inside the housing. Background of the Invention

The connector according to the present invention is adapted for use in the refrigerant circuit in a motor vehicle. The connector is particularly adapted to connect an electrically driven compressor to a power source.

Conventionally, this compressor is of a mechanical type and its rotation is driven by a belt or pulley which is connected to the internal combustion engine of the vehicle. The number of hybrid vehicles, that is to say vehicles with either an internal combustion engine coupled to an electric motor or fully electric vehicles is constantly increasing because of the scarcity of fossil fuels that are used for the internal combustion engines.

The mechanical energy which is normally available in case of internal combustion engines to power the compressor is less available in hybrid cars and even completely absent in the case of a fully electrical vehicle. Moreover, for reasons of overall efficiency, the preferred solution for driving a compressor in a hybrid or electric vehicle is an electrical motor instead of a belt or pulley. A complicating factor is that a particular vehicle model of a manufacturer can be sold in a first version with an internal combustion engine provided with a mechanical compressor and in a second version with an electric propulsion type engine which requires the use of an electrical compressor. These two types of compressors, mechanical and electrical, are based on different technologies, which require the use of different lubricants. The presence of high electric potential in an electric compressor requires the use of a dielectric lubricant with electrical insulation properties which are superior to those of a conventional lubricant used in a mechanical compressor. Dielectric lubricants are more expensive than conventional lubricants used for a mechanical compressor. Moreover, if both lubricants are used for different versions of a vehicle produced on the same production platform, manufacturers need to manage the presence and use of both types of lubricants during assembly of the vehicles. In order to avoid problems with either the use of lubricants in a refrigerant circuit in a vehicle or any problems during production and assembly of vehicles, the invention proposes a connector which provides both electrical contact and sealing to connect an electrical motor for a mechanical compressor to a power source. The aim is to allow the use of said electrical motor in an environment comprising a conventional, non-dielectric lubricant.

In the prior art, it is known to use a specific sealed connector comprising a plurality of wires introduced via wire guides in the connector wherein the wires comprise contacts clamped onto the extremities of said wires. During the assembly process, the contacts in the connector must be correctly aligned with passages provided in the connector for allowing the terminal to enter the connector and make electrical contact with the contacts. Each passage needs to be provided with proper sealing. The production of said known connector is relatively time consuming and therefore relatively expensive.

In the industry, especially in the car industry, there is a constant need for improving the performance of car parts and reducing production time and production costs.

Therefore, it appears that there is a need for an improved connector specifically adapted to electrically connect an electrically driven compressor. Summary of the Invention

In one aspect, the present invention is directed to a connector for electrically connecting the end of at least one wire to a terminal comprising at least one terminal pin, the connector comprising:

- a connector housing adapted to receive the end of the at least one wire,

- means for fixing the end of the at least one wire inside the connector housing, wherein the connector housing comprises a passage for allowing the at least one terminal pin to enter the interior of the connector housing and to electrically contact the end of the at least one wire, the connector further comprising:

- a releasable cover adapted to close off the connector housing to envelop the end of the at least one wire inside the assembly of the connector housing and the releasable cover, the connector housing and the releasable cover defining at least one groove for receiving and fixing the at least one wire, the at least one groove being partially open to allow entry of the at least one wire into the groove via said opening of the groove.

According to an embodiment of the invention, the opening of the at least one groove is provided with chamfers to facilitate the entry of the at least one wire in the at least one groove. According to an embodiment of the invention, the at least one groove is provided in the releasable cover and wherein upon assembly of the connector housing and the releasable cover, the connector housing is adapted to at least partially close off the opening of the at least one groove.

According to an embodiment of the invention, the releasable cover is provided with means for receiving a contact clamped to the end of the at least one wire inside the connector housing. According to an embodiment of the invention, the releasable cover comprises a gasket with at least one aperture, the gasket being adapted to be positioned in the releasable cover to have the at least one aperture of the gasket in line with the passage in the connector housing, wherein the gasket is adapted to form a seal around at least one sleeve around a terminal pin once the terminal pin is received inside the connector housing.

According to an embodiment of the invention, the gasket comprises a flexible material, such as rubber. According to an embodiment of the invention, the releasable cover of the connector is provided with positioning means for the gasket, said positioning means comprising protrusions, the gasket being provided with corresponding positioning holes for receiving said protrusions. According to an embodiment of the invention, the releasable cover comprises a recess adapted to receive the gasket, wherein the gasket has a corresponding form to fill at least partially said recess.

According to an embodiment of the invention, the recess of the releasable cover and the gasket are asymmetrically shaped. According to an embodiment of the invention, the connector housing is adapted to close off the recess in the releasable cover to thereby allow the fixing of the gasket in the recess between the connector housing and the releasable cover. Brief Description of the Drawings

Reference will now be made, by way of example, to the accompanying drawings, in which: Figure 1 is a schematic illustration of an assembly of an electrical motor and a compressor, wherein the assembly comprises a connector according to the invention,

Figure 2 shows a connector according to the invention according to an exemplary embodiment,

Figure 3 shows a cross-section of the connection between the connector and a terminal, Figure 4 shows a gasket used as a sealing in the connector in top view, Figure 5 shows the gasket according to Figure 4 in cross-section, Figure 6 shows the fixing of phase wires inside wire grooves of the connector,

Figure 7 shows a detail of the housing, the releasable cover and the wire grooves, and

Figure 8 shows the sequence of the assembly of the housing, the releasable cover and the connector. Detailed Description of the Invention

While specific embodiments of the invention will be described in detail below, it will be appreciated that the invention may be practiced otherwise than as described. The descriptions and examples below are intended to be illustrative, not limiting. Thus, it will be apparent to one skilled in the art that modifications may be made to the invention as described without departing from the scope of the disclosure. Figure 1 schematically shows an assembly 10. Typically, the assembly 10 can be used in a thermodynamic circuit, for example a cooling or heating circuit used in a vehicle, such as a car. The assembly 10 comprises an electrical motor 1 connected to a mechanical compressor 2. The assembly 10 further comprises a control module 3 for operating the motor 1 and the mechanical compressor 2. The assembly comprises a terminal 4 to tightly and electrically connect the motor to control module 3. In Figure 1, terminal 4 comprises three terminal pins, as an example, for making electrical contact. A wall member 5 defines a specific sealed envelope around the motor 1. The terminal 4 protrudes in the wall member 5 as shown in more detail in Figure 3.

In the present disclosure, the terms "terminal" and "terminal pin" are used. The term "terminal" refers to the plug which protrudes from the compressor and on which a connector can be fixed. The term "terminal pin" is used to refer to the metal part of the terminal which is adapted to make electrical contact.

Figure 2 shows a connector 20 according to the invention, comprising a connector housing 30. Pluralities of contacts (visible by transparency of connector housing 30) are located inside the connector housing 30. Each contact may be clamped onto the end of a wire (not shown) such as a motor phase wire. The connector 20 is adapted to be connected to the terminal 4. Once the connector 20 is fixed on the terminal 4, each terminal pin of the terminal 4 is in electrical contact with the contacts inside the connector 20. The connector 20 also comprises a releasable cover 21 to maintain the contacts inside the connector housing 30 and to receive contacts in their respective positions. The connector housing 30 and the releasable cover 21 are adapted to allow fixing of the releasable cover 21 on the connector housing 30 by means of, for example, a snap fit. The releasable cover 21 also comprises a plurality of grooves 22, such as three grooves, to allow a corresponding number of phase wires to enter the connector 20. As shown in more detail in Figure 6, the grooves 22 comprise an opening such as an open end to allow easy assembly of the phase wires inside the grooves 22. Thus, the structure of the releasable cover 21 guarantees that the wires are received and fixed in a correct position inside the grooves 22. The releasable cover 21 and the connector housing 30 are formed to close at least partially the open end of the grooves 22 to keep the phase wires 40 inside the grooves 22. The assembly of the connector housing 30 and the releasable cover 21 provides an improved insulation distance around the wires received in the grooves 22. This will be discussed in more detail with reference to Figure 7.

In Figure 3, a cross-section of the connection between a connector 20 and the terminal 4 is shown. The terminal 4 ensures a perfectly sealed connection through wall 5 and comprises a set of three terminal pins 70. Figure 3 shows only two terminal pins 70. Each terminal pin 70 comprises an insulator 51 which generally comprises glass. The insulator 51 prevents leakage and electrical contact between each terminal pin 70 and a terminal plate 53. The protruding end of each terminal pin 70 further comprises a sleeve 52 which determines the exact distance between the wall member 5 and the connector 20. The sleeve 52 generally comprises a ceramic material.

The connector 20 is adapted to be fixed on the protruding end of the terminal pins 70 to allow electrical contact between the terminal 4 and the plurality of wires 40. The extremity of each wire 40 is provided with a contact 41. The contact 41 is normally clamped onto the end of a wire 40 and is adapted to contact the terminal pin 70 to allow electrical contact. Inside the releasable cover 21, a recess 24 is available for receiving a gasket 60 or insert. The shape of the recess 24 corresponds to the form of the gasket 60 to allow the positioning of the gasket 60 inside the recess 24. The gasket 60 operates as a seal to provide proper sealing around the sleeve 52 to avoid any current leakage between contact 41 and terminal plate 53. The gasket 60 comprises any suitable material, such as rubber. HNBR or EPDM are commonly used for this purpose in refrigerating applications. In Figures 3, 4 and 5, the gasket 60 is adapted to seal the contact with a terminal 4 comprising three terminal pins 70.

Figure 4 shows a top view of the gasket 60. The gasket 60 comprises an asymmetric form with a main body 61 and a protruding lip 62. The asymmetric form and the presence of the protruding lip 62 thus provide a foolproof means or poka yoke shape to allow assembly of the gasket 60 in only one correct position inside the recess 24. This means, for instance, that the gasket 60 cannot be assembled upside down.

Protruding lip 62 can confirm the presence of the gasket 60 inside the connector 20 as it is visible from the outside. This allows for visible inspection after the assembly to ensure that the gasket 60 is inside and properly positioned.

The gasket 60 comprises three apertures 63, 64, 65 wherein each aperture 63, 64, 65 allows the passage of a terminal pin 70 and a corresponding ceramic sleeve 52. The size and the position of the respective holes 63, 64, 65 are adapted to coincide with the position of the corresponding terminal pins 70 and sleeves 52. The gasket 60 further comprises positioning holes 66, 67, 68. The positioning holes 66, 67, 68 are through holes which are adapted to be positioned on matching protrusions (not shown) present on the bottom of the recess 24 in the releasable cover 21. The three matching through holes 66, 67, 68 and protrusions (not shown) allow proper positioning of the gasket 60 inside the connector 20. In Figure 5, a cross-section of the gasket 60 is shown along the line A-A of Figure 4. The cross-section of Figure 5 shows the main aperture 64, the positioning hole 66 and the specific form of the wall part of the main hole 64. Figure 5 shows that the asymmetric gasket 60 is positioned with lips 65 facing the connector housing 30 to ensure sealing.

In Figure 6, the connector 20 is shown with three phase wires 40, 40', 40" in three different positions. Figure 6 shows the positions during the assembly process of the phase wires 40, 40', 40" in the respective grooves 22. As the grooves 22 are open on one side, assembly of the phase wires 40, 40', 40" is relatively easy in that a phase wire 40, 40', 40" can be pressed in one of the respective grooves 22. The opening of the various grooves 22 is slightly smaller than the outer diameter of the phase wires 40, 40', 40". Thus, each phase wire 40, 40', 40" is pushed inside a groove 22 using a determined amount of force. Once each phase wire 40, 40', 40" is respectively positioned inside a groove 22, the phase wire cannot slip out easily. The grooves 22 are each provided with a chamfer of approximately 30° to allow an opening of the grooves 22 of approximately 60° to allow phase wires 40, 40', 40" to enter grooves 22. The opening of the grooves 22 and the specific dimensions of said grooves 22 require the wires 40, 40' and 40" to be pressed inside the grooves 22. The presence of a 60° chamfer provides an important aid during the assembly of the connector 20. Indeed, as the different wires 40, 40', 40" each comprise at their end a contact 41, the fixing of the contacts 41 on the wires 40, 40', 40" can be completed before the wires 40, 40', 40" are fixed inside the grooves 22. Thus, contrary to grooves disclosed in the prior art having the form of through holes, in the present invention there is no need for the wires to be forwarded through the grooves prior to fixing the contacts 41 at the respective ends of the wires. Thus, the opening of the grooves 22 as in the present invention advantageously makes it possible to avoid technical constraints for the fixing of the contacts 41. This functionality also greatly facilitates any repair work, in case the releasable cover 21 is damaged and can no longer ensure its function. Figure 7 shows in perspective that the grooves 22 are open in order to receive the phase wires 40, 40', 40". Once the connector housing 30 and the releasable cover 21 are assembled, the connector housing 30 covers part LI of the grooves 22 of the releasable cover 21 to maintain the wires 40, 40', 40" inside the grooves 22 during use. At the same time, the presence of the cover over distance LI, allows for a minimum needed distance between contact 41 positioned in the center and the casing to avoid any current leakage. Figure 7 shows the length L which corresponds to the length of the grooves 22. Typically, LI covers at least a third of the indicated length L of the grooves 22. Typically, L has a value of around 12.4 millimetres (mm). LI has a value of around 5 millimetres (mm). Figure 8 shows the sequence of three assembly steps 80, 82, 84 of the connector housing 30 and the releasable cover 21. In assembly steps 80 and 82, for the purpose of clarity a part of the connector housing 30 is removed to show certain elements described below. For the purpose of clarity, the other elements of the connector are not shown in Figure 8. In assembly step 80, the connector housing 30 and the releasable cover 21 are placed in a position to allow assembly. As shown in step 80, the interior of the releasable cover 21 comprises an angled surface 26 adapted to contact the forward end 35 of the housing 30. As shown in assembly step 82, the forward end 35 is guided by the angled surface 26 towards an end position by forwarding the connector housing 30. As shown in assembly step 84, the housing 30 and the releasable cover 21 are fully assembled. The trailing end 37 is provided with a small ridge which is fixed by means of a notch 27 of the releasable cover 21 to allow said trailing end to be fixed by means of a snap lock.

The role of the connector 20 is to electrically connect the motor 1 to a control module 3. Thus, the connection of said connector 20 on the set of terminals 4 is critical because the terminal 4 pass through the wall member 5 of the connector housing 21 around the motor 1. The connector 20 of the present invention provides a proper sealing once the connector 20 is put in place to guarantee a secured connection.

Claims

Connector (20) for electrically connecting the end of at least one wire (40) to a terminal (4) comprising at least one terminal pin (70), the connector (20) comprising:

- a connector housing (30) adapted to receive the end of the at least one wire (40),

- means for fixing the end of the at least one wire (40) inside the connector housing (30),

wherein the connector housing (30) comprises a passage for allowing the at least one terminal pin (70) to enter the interior of the connector housing (30) and to electrically contact the end of the at least one wire (40), the connector (20) further comprising:

- a releasable cover (21) adapted to close off the connector housing (30) to envelop the end of the at least one wire (40) inside the assembly of the connector housing (30) and the releasable cover (21), the connector housing (30) and the releasable cover (21) defining at least one groove (22) for receiving and fixing the at least one wire (40), the at least one groove (22) being partially open to allow entry of the at least one wire (40) into the groove (22) via said opening of the groove (22).

Connector (20) according to claim 1, wherein the opening of the at least one groove (22) is provided with chamfers to facilitate the entry of the at least one wire (40) in the at least one groove (22).

Connector according to claim 1 or 2, wherein the at least one groove (22) is provided in the releasable cover (21) and wherein upon assembly of the connector housing (30) and the releasable cover (21), the connector housing (30) is adapted to at least partially close off the opening of the at least one groove (22).

4. Connector (20) according to any preceding claim, wherein the releasable cover (21) is provided with means for receiving a contact (41) clamped to the end of the at least one wire (40) inside the connector housing (30).

5. Connector (20) according to any preceding claim, wherein the connector (20) comprises a gasket (60) with at least one aperture (63, 64, 65), the gasket (60) being adapted to be positioned in the releasable cover (21) to have the at least one aperture (63, 64, 65) of the gasket (60) in line with the passage in the connector housing (30), wherein the gasket (60) is adapted to form a seal around the at least one sleeve (52) around a terminal pin (70) once the terminal (4) is received inside the connector housing (30).

6. Connector (20) according to claim 5, wherein the gasket (60) comprises a flexible material, such as rubber.

7. Connector (20) according to claim 5 or 6, wherein releasable cover (21) of the connector (20) is provided with positioning means for the gasket (60), said positioning means comprising protrusions, the gasket (60) being provided with corresponding positioning holes (66, 67, 68) for receiving said protrusions.

8. Connector (20) according to any of claims 5 to 7, wherein the releasable cover (21) comprises a recess (24) adapted to receive the gasket (60), wherein the gasket (60) has a corresponding form to fill at least partially said recess (24).

9. Connector (20) according to claim 8, wherein the recess (24) of the releasable cover (21) and the gasket (60) are asymmetrically shaped.

10. Connector (20) according to claim 8 or 9, wherein the connector housing (30) is adapted to close off the recess (24) in the releasable cover (21) upon assembly to thereby allow the fixing of the gasket (60) in the recess (24) between the connector housing (30) and the releasable cover (21).