Patent Application
20230361509
This application claims benefit of priority to European Patent Application No. 22172204.4 filed on May 6, 2022, the entire disclosure of which is hereby incorporated by reference.
The disclosure generally relates to connector assemblies for automotive vehicles. More particularly, this disclosure relates to a connector assembly for electrically connecting electrical conductors carrying high power currents.
An example of such a connector assembly is disclosed by US Patent Application Publication 2018/0375227 A1. When connectors are used in high voltage applications, e.g., greater than 48 volts, it is desirable to prevent accidental contact with energized terminals or conductors. More particularly, access to an electrical conductor through a cavity or passage of an insulating housing protecting this electrical conductor, should be prevented. Standards, such as International Electrotechnical Commission Standard IEC 60529, require a protection (for example the so-called IPXXB protection). To meet the requirements of the IPXXB protection for example, a test joint finger of 12 mm diameter and 80 mm length should have an adequate clearance from hazardous parts. Such a requirement limits the diameter of a cavity or passage of a housing opened on an energized electrical conductor.
However, when connectors are used in high current intensity applications, heating should be limited. Therefore, there is a need for power terminals having a large cross section. But large cross-sections may not be compatible with IPXXB protection when power terminals have to be inserted through a cavity or passage of an insulating housing.
This disclosure aims at providing a connector assembly that is compatible with both an IPXXB protection and an electrical power conduction.
This aim is at least partially achieved by the electrical connector assembly described herein. Indeed, thanks to such an electrical connector assembly, it is possible to use terminals with cross-sections that can correspond to diameters greater than 12 mm, so as to carry high-power currents, while limiting heating, but protection structure(s) create(s) an obstacle for a finger materialized by a cylindrical object of revolution with a diameter greater than, or equal, to 12 mm. This obstacle can be formed by only one protection structure or by a plurality of protection structures. The protection structures can be arranged in many ways. They can be arranged at the same level in the cavity with regard to the insertion direction. Alternatively, they can be arranged at various levels in the cavity with regard to the insertion direction.
According to one or more aspects of the present disclosure, an electrical connector includes a first housing part defining at least one cavity extending longitudinally along an insertion direction; a power terminal with a connection portion configured to be inserted, in the insertion direction, in the at least one cavity, the power terminal having an external and an internal cylindrical surface; and a first electrical conductor at least a portion of which is covered by the first housing part, and configured to be connected to the power terminal through the at least one cavity, when the power terminal is inserted in the at least one cavity, wherein the cavity has an internal surface from which protrudes at least one protection structure, wherein the at least one protection structure is configured to prevent the insertion, in the insertion direction, in the cavity, of a solid cylinder having a diameter equal to or greater than 12 mm, past the at least one protection structure, wherein at least one slot is defined in the external cylindrical surface, wherein the external cylindrical surface has a diameter greater than 12 mm, wherein each slot extends longitudinally parallel to the insertion direction and extends radially only over a portion of a thickness of the terminal between the external cylindrical surface and the internal cylindrical surface, and wherein the at least one protection structure can slide parallel to the insertion direction in at least one slot.
In some aspects of the electrical connector described in the preceding paragraph, the connection portion defines a hollow portion extending parallel to the insertion direction.
In some aspects of the electrical connector described in any one of the preceding paragraphs, the electrical connector further includes a bolt with a head and a rod, wherein the rod is engaged through the hollow portion and is screwed.
In some aspects of the electrical connector described in any one of the preceding paragraphs, the electrical connector further includes a second housing part covering at least a portion of a second electrical conductor which is electrically and mechanically connected to the first electrical conductor with the power terminal and the bolt.
In some aspects of the electrical connector described in any one of the preceding paragraphs, the first electrical conductor is a busbar.
In some aspects of the electrical connector described in any one of the preceding paragraphs, each protection structure is a rib extending parallel to the insertion direction and wherein each slot is configured to receive a rib.
In some aspects of the electrical connector described in any one of the preceding paragraphs, the at least one slot includes a plurality of slots symmetrically arranged around a central axis which is parallel to the insertion direction.
In some aspects of the electrical connector described in any one of the preceding paragraphs, the at least one cavity and the at least one protection structure are configured to meet International Electrotechnical Commission Standard IEC 60529 with regard to IPXXB protection.
In some aspects of the electrical connector described in any one of the preceding paragraphs, the external cylindrical surface extends over a cylinder having a diameter of 17.1 mm.
In some aspects of the electrical connector described in any one of the preceding paragraphs, the at least one cavity has an internal surface from which three ribs forming the at least one protection structure extend, wherein each rib terminates with a ridge arranged towards a central axis of the at least one cavity, wherein the ridges of the three ribs are arranged in a circle extending perpendicularly to the central axis, and wherein the diameter of the circle is less than or equal to 12 mm.
In some aspects of the electrical connector described in any one of the preceding paragraphs, each rib has an upper end which is at least at a distance of 43.2 mm from the first electrical conductor or any other electrically conducting part in electrical contact with the first electrical conductor and wherein the upper end is visible through a first cavity.
The present invention is now described, by way of example with reference to the accompanying drawings, in which:
An example of an electrical connector assembly 1 for an electrical power circuit of a motor vehicle is shown in
The electrical connector assembly 1 may also comprise for example a cover 29, an upper interface housing part 8, an environment part 9 (onto which the electrical connector assembly 1 is attached), a cap 10 (for protecting the first electrical conductor 6 from dust), a thermal sensor assembly 11 (connected to a circuit 12), and a bottom housing part 13.
The first housing part 2 and the second housing part 3 are made of electrically insulating material. For example, they are made of molded plastic.
As shown in
As shown in
The power terminal 4 is made of electrically conducting material. As shown in
As illustrated in
In the illustrated example, the first electrical conductor 6 and a second electrical conductor 7 are busbars. The first electrical conductor 6 and second electrical conductor 7 may be included in an electrical power circuit of a vehicle. The first electrical conductor 6 and second electrical conductor 7 may be made for example of aluminum or copper (aluminum or copper alloy) and covered by an insulating material. A portion of the first electrical conductor 6 is covered by the first housing part 2. A portion of the second electrical conductor 7 is covered by the second housing part 3. A nut 30 is screwed onto the rod 26. A first electrically conductive ring 31 is engaged and blocked into a hole made in the first electrical conductor 6. The head 27 engages a second electrically conductive ring 32 that itself is engaged and blocked into a hole made in the second electrical conductor 7. When the bolt 5 is tightened, the power terminal 4 is in electrical contact with at least the first electrically conductive ring 31 and the second electrically conductive ring 32, that are themselves electrical contact respectively in with the first electrical conductor 6 and the second electrical conductor 7. The first 6 and second 7 electrical conductors are therefore electrically connected through a round power terminal 4 having a diameter which is greater than 12 mm.
A test finger 33 is shown in
As illustrated in
Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the following claims, along with the full scope of equivalents to which such claims are entitled.
As used herein, ‘one or more’ includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above.
It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact.
The terminology used in the description of the various described embodiments herein is for the purpose of describing embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes”, “including”, “includes”, and/or “including,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
As used herein, the term “if” is, optionally, construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” is, optionally, construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context.
Additionally, while terms of ordinance or orientation may be used herein these elements should not be limited by these terms. All terms of ordinance or orientation, unless stated otherwise, are used for purposes distinguishing one element from another, and do not denote any order of arrangement, order of operations, direction or orientation unless stated otherwise.
| Number | Date | Country | Kind |
|---|---|---|---|
| 22172204.4 | May 2022 | EP | regional |
