Patent Application
20240030664
The subject matter herein relates generally to power harnesses.
Electrical connectors are used to electrically connect various components within a system, such as a vehicle. For example, a plug connector may be mated with a header connector. Each connector holds contacts that are mated when the plug connector is coupled to the header connector. The plug connector typically includes power cables terminated to the contacts of the plug connector, which extend from the plug connector to another component. The cable harness is typically heavy and cumbersome to assemble within the vehicle. A need remains for a power harness that eliminates the used of power cables and cable harnesses.
In one embodiment, a power harness is provided and includes a plug housing having a chamber extending between a terminating end and a mating end configured to be mated with a header connector of the power harness. The plug housing includes a bore passing through the housing at the mating end. The power harness includes a power contact received in the chamber. The power contact has a mating portion at the mating end of the plug housing. The mating portion includes a separable mating interface configured to be plugged into a header contact stack of header contacts of the header connector when the mating end is mated with the header connector. The power contact has a terminating portion at the terminating end of the plug housing. The terminating portion includes a weld pad. The power harness includes a busbar extending from the chamber at the terminating end. The busbar is welded to the weld pad at the terminating portion of the power contact. The power harness includes a threaded bolt received in the bore and passes through the plug housing. The threaded connector configured to be threadably coupled to a threaded connector of the header connector to secure the plug housing to the header connector.
In another embodiment, a power harness is provided and includes a plug housing having housing walls that define a chamber. The plug housing includes a top and a bottom. The plug housing includes sides that extend between the top and the bottom. The plug housing has a mating end at the bottom configured to be mated with a header connector of the power harness. The plug housing includes a terminating end. The power harness includes a power contact received in the chamber. The power contact has a mating portion at the mating end of the plug housing. The mating portion is planar along a power contact plane. The mating portion includes a separable mating interface configured to be plugged into a header contact stack of header contacts of the header connector when the mating end is mated with the header connector. The power contact has a terminating portion at the terminating end of the plug housing. The terminating portion includes a weld pad. The power harness includes a busbar having an inner portion and an outer portion. The inner portion is located in the chamber and is welded to the weld pad at the terminating portion of the power contact. The outer portion extends from the terminating end of the plug housing. The outer portion extends along a busbar plane. The busbar plane is oriented non-parallel to the power contact plane.
In a further embodiment, a power harness is provided and includes a header connector including a header housing holding header contacts arranged in a header contact stack. Each header contact includes a pair of spring beams flanking a gap at a mating end of the header contact. The gaps of the header contacts are aligned in the header contact stack. The power harness includes a plug connector coupled to the header connector. The plug connector includes a plug housing has a chamber extending between a terminating end and a mating end configured to be mated with the header connector. The plug connector includes a power contact received in the chamber. The power contact has a mating portion at the mating end of the plug housing. The mating portion includes a separable mating interface configured to be plugged into the gaps of the header contacts to mate with the spring beams of each header contact in the header contact stack. The power contact has a terminating portion at the terminating end of the plug housing. The terminating portion includes a weld pad. The plug connector includes a busbar extends from the chamber at the terminating end. The busbar is welded to the weld pad at the terminating portion of the power contact. The plug connector includes a threaded bolt passing through the plug housing and is threadably coupled to the header connector to secure the plug connector to the header connector.
In various embodiments, the power system 100 may be part of a vehicle, such as an electric vehicle. The first component 104 may be a battery of the vehicle and the second component 106 may be a powered device of the vehicle, such as an inverter or motor of the vehicle or a vehicle subsystem, such as a charging inlet, a heater, a compressor, or another vehicle subsystem. The power system 100 may be used in other applications other than electric vehicles in alternative embodiments.
In an exemplary embodiment, the connectors 200, 400 are mechanically connected using threaded components, such as a threaded bolt received in a threaded insert, to connect the connectors 200, 400. In an exemplary embodiment, the connectors 200, 400 are compact or low profile, such as occupying not much more space (for example, height and/or width and/or length) than the corresponding busbar(s) 202. In an exemplary embodiment, the connectors 200, 400 are sealed connectors forming a sealed interface therebetween. The plug connector 200 is sealed to the busbar 202. The header connector 400 is sealed to the component 106. The connectors 200, 400 are sealed to each other using an environmental seal at the mating interface. The threaded fasteners may additionally be sealed within the connectors 200, 400. In an exemplary embodiment, the connectors 200, 400 are touch safe, wherein any and all live conductive elements are insulated to prevent short circuiting, sparking, arcing or injury from touching the live element. The connectors 200, 400 are touch safe both in the mated conditions and the unmated condition. In an exemplary embodiment, the connectors 200, 400 are vibration resistant to maintain a reliable electrical connection along the power transmission line. In an exemplary embodiment, the connectors 200, 400 may be mated at various orientations relative to each other. For example, the busbars 202 may extend away from the connection at different angles, such as 180°, 90° or at other angles. While a single interface is illustrated in
The plug connector 200 includes the busbars 202, a housing 230 receiving the ends of the busbars, power contacts 270 (shown in
The header connector 400 includes contact assemblies 402 and a housing 430 holding the contact assemblies 402. The contact assemblies 402 are configured to be connected to the power contacts 270. The contact assemblies 402 are configured to be electrically connected to the electrical component 106, such as to supply power to the electrical component 106. The housing 430 may hold a threaded insert, such as a threaded socket, to mate with the threaded bolt 300.
Each contact assembly 402 includes header contacts 404 arranged in one or more header contact stacks 406 and a header power contact 408 coupled to the header contact stacks 406. The header contacts 404 electrically connect the header power contact 408 to the power contact 270 (
In an exemplary embodiment, the busbar 202 is a flat metal busbar. The busbar 202 may be a jacketed busbar such that the busbar 202 is touchsafe. The busbar 202 may be a solid core busbar, such as an extruded metal busbar. Alternatively, the busbar 202 may be a stranded or braided flat cable. In an exemplary embodiment, a busbar seal 212 is provided surrounding the busbar 202. The busbar seal 212 may be sealed to the busbar jacket. The busbar seal 212 is configured to be sealed against the housing 230. The busbar seal 212 may be a rubber material in various embodiments. Optionally, multiple busbar seals 212 may be used to seal to the various components. In an exemplary embodiment, a busbar ferrule 214 is provided to secure the busbar 202 to the housing 230. The busbar ferrule 214 may be secured to the housing 230 by a latch, clip, fastener or other securing element. The busbar ferrule 214 may retain the busbar seal 212 in the housing 230.
The housing 230 is manufactured from a dielectric material, such as a plastic material. Optionally, the housing 230 may be an injection molded part. In various embodiments, the housing 230 is a multi-piece housing. For example, the housing 230 may include an outer shell and a housing insert received in the outer shell. Alternatively, the housing 230 may be a single piece housing.
The housing 230 includes walls forming a chamber 232 that receives the busbars 202, the power contacts 270, and the threaded bolt 300. In an exemplary embodiment, the housing 230 includes a top 234 and a bottom 236. The housing 230 includes sides 238 extending between a front 240 and a rear 242. The housing 230 includes an opening 244 at the rear 242 providing access to the chamber 232. The busbars 202 are received in the opening 244. The busbar ferrule 214 may be plugged into the opening 244 and coupled to the housing 230 at the rear 242. The busbar seal 212 may be sealed to the interior surface of the housing 230 at the opening 244. In an exemplary embodiment, the bottom 236 defines a mating end 250 of the housing 230 and the rear 242 defines a terminating end 252 of the housing 230. Other orientations are possible in alternative embodiments. The mating end 250 is configured to be mated to the header connector 400.
In an exemplary embodiment, the housing 230 includes a contact channel 246 in the chamber 232 that receives the power contact 270. The contact channel 246 is aligned with the opening 244 to receive the power contact 270 with the busbar 202 from the opening 244. The contact channel 246 receives the power contact 270 in a rear-to-front loading direction as the power contact 270 is loaded into the housing 230 from the rear 242. In the illustrated embodiment, the contact channel 246 is located at the front 240.
In an exemplary embodiment, the housing 230 includes a busbar channel 248 in the chamber 232 that receives the busbar 202. The busbar channel 248 is aligned with the opening 244 to receive the busbar 202 from the opening 244. The busbar channel 248 receives the busbar 202 in a rear-to-front loading direction as the busbar 202 is loaded into the housing 230 from the rear 242. In the illustrated embodiment, the busbar channel 248 is located at the rear 242. The busbar channel 248 may be larger than the contact channel 246 because the busbar 202 may be larger than the power contact 270.
The power contact 270 is a metal conductor, such as an aluminum or copper conductor. The power contact 270 may be an extruded metal contact in various embodiments. Alternatively, the power contact 270 may be hot forged or stamped and formed. The power contact 270 may be plated or coated in various embodiments. The power contact 270 extends between a terminating end 272 and a mating end 274. The mating end 274 is configured to be mated with the corresponding power contact of the header connector 400. The terminating end 272 is configured to be terminated to the busbar 202. The power contact 270 includes a weld pad 276 at the terminating end 272. The busbar 202 is welded to the weld pad 276 at the terminating end 272. Other types of terminations may be used in alternative embodiments.
In the illustrated embodiment, the power contact 270 is rectangular. However, the power contact 270 may have other shapes in alternative embodiments. The power contact 270 includes a mating edge 280 at the mating end 274. The mating edge 280 may be the bottom edge in various embodiments. The power contact includes a first surface 282 and a second surface 284 opposite the first surface 282. The mating edge 280 extends between the first and second surfaces 282, 284. The mating edge 280 is configured to be plugged into the mating contact of the header connector 400 to electrically connect the power contact 270 to the mating contact of the header connector 400. The first and second surfaces 282, 284 define mating surfaces configured to be electrically connected to the mating contact of the header connector 400.
In an exemplary embodiment, the power contact 270 includes a tab 286 extending from the first surface 282 and/or the second surface 284. The tab 286 is used to secure the power contact 270 in the housing 230, such as in the contact channel 246. The tab 286 may be deflectable.
In an exemplary embodiment, the busbar 202 includes a notch 208 at the bottom of the busbar 202. The notch 208 shortens the busbar 202, such as to a height that is generally equal to the height of the power contact 270. For example, the busbar 202 has a height 220 and a thickness 222. The notch 208 reduces the height 220 at the end. In the illustrated embodiment, the notch 208 reduces the height by approximately 25%. The power contact 270 has a height 290 and a thickness 292. The power contact 270 has a power contact centerline 294 centered along the height 290 between the top and the bottom of the power contact 270. The busbar 202 has a busbar centerline 224 centered along the height 220 between the top and the bottom of the busbar 202. In an exemplary embodiment, the busbar centerline 224 is offset from the power contact centerline 294. For example, the busbar centerline 224 is shifted downward relative to the power contact centerline 294. The busbar 202 is shifted downward relative to the power contact 270 to reduce the profile (for example, overall height) of the assembly and thus the plug connector 200.
In the illustrated embodiment, the header contacts 404 are dual socket contacts having sockets at both ends of the header contacts 404. Other types of contacts may be used in alternative embodiments. Each header contact 404 includes spring beams 410, 412 on opposite sides of a gap 414 at a first mating end 416 of the header contact 404. The gap 414 defines a socket configured to receive the bottom edge 280 of the power contact 270. For example, the power contact 270 is plugged into the gap 414 from above in a mating direction when the plug connector 200 is mated to the header connector 200. The spring beams 410, 412 engage the first and second surfaces 282, 284 of the power contact 270 to electrically connect the header contact 404 to the power contact 270. Each header contact 404 includes spring beams 420, 422 on opposite sides of a gap 424 and a second mating end 426 of the header contact 404. The gap 424 defines a socket configured to receive the top edge of the header power contact 408. The spring beams 420, 420 to engage the side surfaces of the header power contact 408 to electrically connect the header contact 404 to the header power contact 408. The header contacts 404 are arranged in the header contact stack 406 such that the gaps 414, 424 are aligned with each other to receive the power contact 270 and the header power contact 408. The header contacts 404 may be independently movable within the header contact stack 406 to interface with the power contacts 270 and/or the header power contact 408.
The channels 246, 248 are defined by walls 260 of the housing 230. In an exemplary embodiment, the walls 260 of the housing 230 include a step 262 between the power contact channel 246 and the busbar channel 248. The step 262 positions the bottom of the power contact channel 246 at a vertical height above the position of the busbar channel 248. A portion of the busbar channel 248 is located below the power contact channel 246, which allows the busbar 202 to be positioned at a lower vertical height to reduce the overall height or profile of the system. For example, the bottom 236 of the housing 230 at the terminating end 252 may be located below the bottom 236 of the housing 230 at the mating end 250. For example, the opening 244 at the bottom 236, which receives a portion of the header connector 400, may be located above the bottom 236 of the housing 230 at the rear 242. By shifting the terminating end 252 downward, the overall profile of the plug housing 230 may be reduced (for example, compared to the top of the chassis on which the header connector 400 is mounted).
With reference back to
In the illustrated embodiment, a terminating portion 207 of the busbar 202 (for example, initial length of the busbar 202 from the end terminated to the power contact 270) is oriented vertically. The terminating portion 207 of the busbar exits the housing 230 in the vertical orientation. In an exemplary embodiment, the busbar 202 further includes a twisted portion 208 downstream of the terminating portion 207. The busbar 202 is twisted through the twisted portion 208 to orient a downstream portion 209 of the busbar 202 nonparallel to the power contact 270. In the illustrated embodiment, the busbar 202 is twisted 90° through the twisted portion 208 such that the downstream portion 209 is oriented perpendicular to the terminating portion 207. However, the busbar 202 may be twisted greater or less than 90° in alternative embodiments. The busbar 202 (along the downstream portion 209) extends along a busbar plane, which is a horizontal plane. The twisted portion 208 helps reduce the effects of vibration of the busbar 202 at the mating interface with the header contacts 404. For example, the effects of vibration of the busbar 202 are greatest in the same direction as the stiffest direction of the busbar 202. The vibration of the busbar 202 is thus greatest side-to-side due to the width of the busbar 202 along the downstream portion 209 being in a side-to-side direction rather than a top-to-bottom direction. The vibration of the busbar 202 is thus perpendicular to the mating direction with the header contacts 404, which reduces wear or sliding between the header contacts and the power contact 270.
It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. 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 appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. § 112(f), unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
This application claims the benefit of U.S. Provisional Application No. 63/390,331 filed Jul. 19, 2022 titled CONNECTOR FOR SOLID BUSBAR, the subject matter of which is herein incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63390331 | Jul 2022 | US |
