Electrical equipment and housing components thereof

Abstract

The present invention relates to an electrical device and a housing element thereof, wherein the housing element is configured to accommodate at least one electrical conductor, wherein the at least one electrical conductor is configured to form an external terminal of the electrical device; and to accommodate at least one power component, which is suitable for being electrically connected to the electrical conductor and converting direct current into alternating current, and the housing element includes a receiving member suitable for receiving the electrical conductor by sliding.

Description

Technical Field

[0001] The present invention relates to an element for a housing of an electrical device. More specifically, the present invention relates to the field of high voltage electrical installations for electric and hybrid vehicles.

[0002] In particular, the object of the invention is to facilitate the mounting of an electrical conductor on a housing element of an electrical device, in particular for a vehicle. Background Art

[0003] As is well known, an electric or hybrid vehicle comprises an electric drive system powered by a high-voltage battery through an on-board high-voltage electrical system and a plurality of auxiliary electrical facilities powered by a low-voltage battery through an on-board low-voltage electrical system. The high-voltage battery supplies power to the electric drive system, which in turn provides propulsion of the vehicle. More specifically, to control the electrical devices driving the wheels of the vehicle, it is known to use an inverter, which implements the conversion of the direct current provided by the high-voltage battery into one or several alternating control currents, such as sinusoidal currents.

[0004] In known solutions, the inverter is in the form of a housing on which a power module and an electronic control unit are mounted. The inverter comprises a body comprising electrical components through which the electric drive motor passes. The electronic control unit comprises electronic components enabling control of the power module.

[0005] For the purpose of connecting the power module to the high-voltage battery, the power module includes an electrical conductor called "positive potential" connected to the positive potential of the high-voltage battery, and an electrical conductor called "negative potential" connected to the negative potential of the high-voltage battery. In addition, in the case of a three-phase motor, the inverter includes three electrical conductors called "phase conductors" that enable the power module to be connected to the motor, thereby controlling the motor by using three currents (called "phase currents") generated by the inverter according to the direct current supplied by the high-voltage battery, and the three currents have a two-by-two phase change, for example, 120°.

[0006] These phase conductors are in the form of strips which are cut and subsequently folded, and which are made of an electrically conductive material, for example copper. The dimensions (and in particular the thickness) of these phase conductors depend on the intensity of the current circulated by them. Therefore, when the inverter is used to control an electrical device driving the wheels of a vehicle, relatively thick phase conductors (for example with a thickness greater than 2 mm) must be used to allow the circulation of high-intensity currents, for example greater than 100 Amps. However, when the inverter is used to store energy generated by the electrical device during a braking phase of the vehicle in a high-voltage battery, phase conductors of reduced thickness (for example with a thickness less than 1 mm) can be used, since in this case the intensity of the current circulating in the phase conductors is reduced, for example less than 50 Amps.

[0007] According to the known solution, the phase conductors are first fixed to the electronic control module by screwing onto it in order to make it electrically connected, and are subsequently overmolded with elements of the inverter housing made of plastic material. With this fixing method, the manufacture of the inverter is expensive, complex and time-consuming, which is a disadvantage. Moreover, this permanent fixing method does not allow the manufacture of the inverter to be optimized based on its intended application, i.e. based on whether it is to be used to control an electrical device or to store energy. In particular, when the conductors are overmolded, the type of electrical conductor cannot be changed depending on the intended application, which is another disadvantage.

[0008] Therefore, there is a need for a simple, reliable and effective solution that allows easy installation and replacement of different types of phase conductors, in particular phase conductors with different thicknesses. Summary of the invention

[0009] Therefore, a first object of the present invention is a housing element of an electrical device, specifically for a hybrid or electric vehicle, the housing element being configured to accommodate at least one electrical conductor, the at least one electrical conductor being configured to form an external terminal of the electrical device; and at least one electrical component suitable for being electrically connected to the electrical conductor and converting direct current into alternating current thereby, it being noteworthy that the housing element includes a receiving member configured to accommodate the electrical conductor by sliding.

[0010] The electrical conductor may be a metal strip, preferably folded. The electrical conductor may include a first end configured to be electrically connected to the power component and a second end configured to be electrically connected to a second electrical device, such as an electrical apparatus, such as a three-phase motor.

[0011] The receiving member enables a connection of the sliding connection type to the electrical conductor. This connection makes it very easy to mount the conductor on the housing element. In particular, it is very easy for an operator to manually insert the electrical conductor into the receiving member. The use of such a receiving member avoids having to overmould the electrical conductor in the material of the housing element, which on the one hand facilitates and speeds up the manufacture of the electrical device and on the other hand facilitates maintenance operations since the electrical conductor can be easily removed or inserted into the housing element. Furthermore, the use of a sliding connection enables the electrical conductor to be mounted on the housing element in a removable manner and with different thicknesses, in particular depending on the intended application of the electrical device and the intensity of the current to be circulated in the electrical conductor.

[0012] Preferably, the receiving member comprises at least one pair of walls extending parallel to each other.

[0013] In one embodiment, the receiving member comprises a plurality of pairs of walls, preferably three pairs of walls, to insert three electrical conductors, in particular to enable connection of the electrical device to a three-phase electrical installation.

[0014] In a preferred manner, walls of the plurality of walls extend parallel to each other.

[0015] According to one aspect of the invention, each pair of walls comprises a first wall and a second wall extending parallel to each other, the first wall comprising an edge extending in the direction of the second wall, and the second wall comprising an edge extending in the direction of the first wall, so as to guide the sliding of the phase conductor. For each pair of walls, the walls and their edges thus form two rails for guiding and supporting the electrical conductor.

[0016] Advantageously, the receiving member comprises at least one terminating end configured to define a terminating point for sliding of the electrical conductor.

[0017] In another advantageous manner, the receiving member is configured to allow a force-fitting of the electrical conductor. This force-fitting advantageously allows the electrical conductor to be securely blocked in the housing element. This force-fitting can be achieved by adapting the thickness of the guide and support rails to the thickness of the electrical conductor or by adding a blocking portion to the receiving member.

[0018] Advantageously, at least one of the first wall and the second wall comprises a domed carving. The term "domed carving" is used to describe excess material thickness or ribs configured to adjust the fit of the receiving member to the phase conductor. Embodiments of the domed carving provide effective blocking of the phase conductor based on its force fit.

[0019] Advantageously, each of the first and second walls comprises at least one circular engraving in order to form the blockage even more efficiently.

[0020] In a preferred manner, at least one circular engraving is made from the material of the first wall or the second wall to facilitate the manufacture of the housing element.

[0021] According to one aspect of the invention, the housing element forms a side wall of the housing, preferably a single wall, on which the receiving member is located.

[0022] Advantageously, the wall of the receiving member extends from the side wall perpendicularly to said side wall and the edge extends parallel to said side wall to ensure a robust blocking of the electrical conductor.

[0023] According to one aspect of the invention, the first wall and the second wall of each pair of walls extend over at least half the height of the side wall, preferably over at least 80% of the height of the side wall, and more preferably over at least 90% of the height of the side wall or over its entire height. This provides an effective blockage for each phase conductor between the first wall and the second wall.

[0024] In a preferred embodiment, the strap feature is at least partially "U" shaped.

[0025] In a still more preferred manner, the receiving member is made from the material of the side wall to facilitate the manufacture of the housing element (ie by moulding).

[0026] Still more preferably, the housing element is formed from a single block, which makes it strong, easy to handle during assembly operations, and easy to manufacture, in particular by molding.

[0027] According to one aspect of the invention, the housing element is made of a plastic material, which makes it light, strong and easy to manufacture, in particular by molding. In particular, the housing element is made of an electrically insulating material.

[0028] The invention also relates to an electrical device, in particular an electrical device for a hybrid or electric vehicle, comprising a housing as described above and at least one electrical conductor configured to form an external terminal of the electrical device, the conductor comprising a strip mounted in the housing element by insertion in a receiving member of the housing element.

[0029] Advantageously, the electrical device comprises at least one electrical component having at least one electrical terminal and mounted in the housing element, wherein the electrical conductor comprises a central portion introduced into a receiving member, the receiving member extending a first end and a second end, the first end being fastened to the electrical terminal of the electrical component to achieve electrical connection, the second end forming an external electrical terminal of the electrical device.

[0030] Advantageously, the electrical device comprises a plurality of electrical conductors introduced into corresponding receiving members and a plurality of electrical components forming a power module, each electrical conductor being connected to a corresponding terminal of said power module.

[0031] According to one aspect of the invention, the power module is capable of converting direct current into a plurality of alternating currents, called "phase currents", which circulate between the power module and the electrical device through a plurality of phase conductors. The term "power module is capable of converting direct current into a plurality of alternating currents" is used to describe the fact that the power module can be configured to convert direct current into a plurality of alternating currents and / or to convert a plurality of alternating currents into direct current.

[0032] In a preferred embodiment, the electronic module comprises a main body.

[0033] According to one aspect of the invention, each electrical conductor is fastened to the body by means of a power module.

[0034] Advantageously, the body of the power module comprises electrical components through which energy for powering the electric motor passes.

[0035] Preferably, the electrical apparatus is an inverter configured to be electrically connected to the electrical device or the high voltage battery through an electrical conductor.

[0036] According to another aspect of the invention, an electrical device comprises an electronic control unit of the power module, the electronic control unit being coupled to the power module.

[0037] Advantageously, the electronic control unit comprises electronic components enabling control of said power module.

[0038] The invention also relates to an electric or hybrid vehicle comprising an electrical device, such as a motor device, powered by a high voltage battery via an on-board high voltage electrical system; and an electrical apparatus, as described above, connected to the electrical device. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The invention will be better understood on reading the following description, which is provided by way of example only and with reference to the accompanying drawings, provided by way of example and not limitation, in which like reference numerals refer to similar items, and in which:

[0040] Figure 1 is a perspective view of an embodiment of an inverter according to the present invention.

[0041] Figure 2 Is Figure 1 A partial perspective view of a unit formed by an electronic module of an inverter, a first positive potential conductor, a first negative potential conductor and a fixing rod.

[0042] Figure 3 is a perspective view of a set of phase conductors.

[0043] Figure 4 yes Figure 1 A perspective view of a housing element of an inverter.

[0044] Figure 5 It is shown Figure 3 The receiving member and the phase conductor Figure 4 Partial perspective and close-up views of housing elements.

[0045] Figure 6 yes Figure 5 On the housing element Figure 3 A perspective view of a set of phase conductors.

[0046] Figure 7 It is installed with Figure 3 The phase conductor Figure 5 A top view of a housing element.

[0047] Figure 8 yes Figure 7 Partial perspective and close-up views of housing elements of an inverter.

[0048] Fig. 9 It is installed with Figure 3 The phase conductor Figure 5A perspective view of a housing element.

[0049] It should be noted that the accompanying drawings provide detailed views of the invention to illustrate embodiments thereof, said drawings can of course also be used to better define the invention as required. DETAILED DESCRIPTION

[0050] In the detailed description provided below, the present invention describes its application to an electric or hybrid vehicle without limiting the scope of the present invention.

[0051] In the example described below, specifically, the vehicle includes an electric device, an electric apparatus to form an inverter, a high-voltage battery, an on-board high-voltage electrical system, a low-voltage battery, a low-voltage electrical system, and a plurality of auxiliary electrical facilities.

[0052] The electric device according to the present invention is described below in its embodiment for an inverter without limiting the scope of the present invention. Therefore, it should be noted that the electric device may be, for example, an on-board charger or a DCDC converter other than an inverter.

[0053] The on-board low-voltage electrical system connects the low-voltage battery to a plurality of auxiliary electrical facilities so that the low-voltage battery supplies power to the auxiliary electrical facilities, such as the on-board computer, the window lift motor, the multimedia system, etc. The low-voltage battery usually delivers a voltage of about 12 volts, 24 volts or 48 volts. The low-voltage battery is charged from the high-voltage battery through a DC voltage to DC voltage converter (commonly known as a DC-DC converter).

[0054] The on-board high-voltage electrical system connects the high-voltage battery to the inverter so that the high-voltage battery supplies power to the electrical device through the inverter. The high-voltage battery generally supplies a voltage ranging from 100 volts to 900 volts, preferably from 100 volts to 500 volts. The electric power charging of the high-voltage battery is achieved by connecting the battery to an external power grid, such as a household AC power grid, through the high-voltage electrical system of the vehicle.

[0055] The electric device is a rotating electric device, preferably provided to drive the wheels of the vehicle using power supplied by a high voltage battery. More specifically, the electric device is an AC electric device powered by a multi-phase current source. For example, the electric device may be an AC motor. In the preferred example described below, the electric device is powered by a three-phase current source, without limiting the scope of the invention.

[0056] In this example, the control of the electrical device is achieved by means of an inverter. The inverter converts the direct current supplied by the high-voltage battery into three alternating control currents, such as sinusoidal currents. In other words, the purpose of the inverter is to convert the input direct current delivered by the high-voltage battery into a three-phase current capable of controlling the electrical device. Conversely, in another operating mode, the electrical device can also supply three alternating currents to the inverter so that the inverter converts them into direct current that can be used to charge the high-voltage battery.

[0057] exist Figure 1 In the example shown in FIG. 1 , the inverter 1 includes a housing 5 in which a (refer to FIG. 1 ) is installed. Figure 2 ) power module 10, an electronic control unit (not shown for clarity), and a plurality of electrical conductors 30, 40, 111, 112, 113. The electronic control unit includes components that implement the components of the control power module 10. More specifically, the electronic control unit controls the power unit 10 so that it converts the direct current supplied by the high-voltage battery, which defines the direct current voltage from the first electrical conductor 30 and the second electrical conductor 40, into three alternating current phase currents to control the motor (or vice versa).

[0058] refer to Figures 1 to 3 The power module 10 includes a main body 100, on which electrical conductors 30, 40, 111, 112, and 113 are fastened. In addition, the power module 10 includes power components 30, through which electrical energy passes to power the electrical device, specifically, the power components are configured to convert direct current into alternating current or vice versa. These power components may include electronic switches, such as semiconductor transistors, arranged in a circuit to achieve a controlled passage of power from a high-voltage battery to the electrical device. Specifically, the power components are bare semiconductor chips for which the main body 100 provides an enclosure. Reference Figure 2 The power module 10 includes nine external electrical terminals. Specifically, the nine external electrical terminals form three phase ports 121, 122, and 123, each of which transmits a motor control phase current, and three external positive electrical terminals 124 (only one of which is shown in FIG. Figure 2 in the middle) and three external negative electrical terminals (not shown).

[0059] exist Figures 1 to 3 In the example shown in , the inverter 1 includes: a first electrical conductor 30, configured to electrically connect the inverter 1 to the positive potential of a high-voltage battery (not shown); a second electrical conductor 40, configured to electrically connect the inverter 1 to the negative potential of the high-voltage battery; and three "phase" conductors 111, 112, and 113, provided to electrically connect the inverter 1 to an electrical device.

[0060] refer to Figure 2 , each electrical conductor 30, electrical conductor 40 is in the form of a strip, and three fixing elements 301, fixing elements 401 extend from the strip. The two fixing elements 301, fixing elements 401 positioned at the end of each electrical conductor 30, electrical conductor 40 enable the electrical conductor 30, electrical conductor 40 to be fixed to the corresponding external electrical terminals (positive pole 124 and negative pole, respectively) of the power module 10 using screws 131. The openings of the central fixing elements 301, central fixing elements 401 of the first electrical conductor 30 and the second electrical conductor 40, respectively, remain free to enable connection of the positive terminal and the negative terminal of the high-voltage battery at a later stage. Figure 2 As shown in FIG, the inverter 1 further comprises an electrically insulating fixing rod 50, which separates the first electrical conductor 30 from the second electrical conductor 40, and in particular prevents a short circuit between the first electrical conductor 30 and the second electrical conductor 40. For this purpose, the fixing rod 50 is preferably made of a plastic material (eg, PBT GF30).

[0061] Each phase conductor 111, 112, 113 realizes the electrical connection of a phase of the electrical device controlled by the inverter 1 to the power module 10. It should be noted that in another embodiment, the inverter 1 may include different amounts of phase conductors 111, 112, 113, specifically amounts based on the number of phases of the electrical device controlled by the inverter 1.

[0062] Each phase connector 111, 112, 113 is mounted on the corresponding phase port 121, 122, 123 using a fixing member such as a screw (not shown). Each phase conductor 111, 112, 113 passes through an opening of the housing 5 to connect the inverter 1 to the electrical device, and specifically, to allow AC power to circulate between the power module 10 and the electrical device.

[0063] Reference Figures 3 to 6 Each phase conductor 111, 112, 113 is in the form of a single blocking portion, i.e., is formed by a single part. This part is in the form of a strip formed of a conductive material. In this preferred embodiment, the phase conductor 111, 112, 113 is made of a conductive material, such as copper, steel or aluminum.

[0064] The thickness of the phase conductors 111, 112, 113 can be selected based on their intended use and, in particular, based on the intensity of the current passing through them. Advantageously, the thickness of the phase conductors 111, 112, 113 ranges from 0.5 mm to 3 mm. Preferably, the thickness of the phase conductors 111, 112, 113 is approximately 1 mm, 1.5 mm or 2 mm. Advantageously, the phase conductors 111, 112, 113 can also be treated with an anti-wear surface coating, for example made of tin and / or nickel for material compatibility or to increase the current.

[0065] In the example shown in the drawings, each electrical conductor 111, 112, 113 comprises a central portion 111A, 112A, 113A, from which a first fixed end 111B, 112B, 113B and a second fixed end 111C, 112C, 113C extend perpendicularly but in opposite directions. The first fixed end 111B, 112B, 113B is configured to be connected to a port phase 121, 122, 123 of the power module 10, for example, by means of a screw. For this purpose, the first fixed end 111B, 112B, 113B is in the form of a planar portion, which is suitable for contacting a planar portion of the phase port 121, 122, 123. The second fixed end 111C, 112C, 113C is configured to be connected to a phase conductor (not shown) of an electrical device. For this purpose, the second fixing end 111C, the fixing end 112C, the fixing end 113C are in the form of a planar portion which is suitable for contacting a planar portion of a phase conductor of the electrical device.

[0066] It should be noted that in this non-limiting example, the second ends 111C, 113C of the phase conductors 111 and 113 are arranged closer to the second end 112C of the centrally located phase conductor 112, which is located in an extension of the central portion 112A of the central phase conductor 112. This results in the second ends 111C, 112C, 113C of the phase conductors 111, 112, 113 being closer so that they can be connected to corresponding phase conductors (arranged in a similar manner) of the electrical device. However, in particular, the second ends 111C, 112C, 113C may be formed in different ways depending on the environment in which the inverter 1 is to be installed.

[0067] like Figure 1As shown in FIG. 1 , the housing 5 includes a housing element 5-1 and a cover 5-2 mounted on the housing element 5. The housing 5 also includes a bottom ( Figure 1 ). Figure 1 In the example shown in, as described above, the inverter 1 also includes two signal connectors 5-31, a signal connector 5-32 and a power connector 5-4 mounted on the cover 5-2 of the housing 5 in a non-limiting manner. The signal connectors 5-31 and 5-32 are configured to enable, for example, the exchange of data signals between the components of the inverter 1 and the outside of the inverter 1 using a controller of the vehicle. Specifically, these signal connectors 5-31 and 5-32 can be connected to an electronic control unit (not shown) installed in the housing element 5-1. The power connector 5-4 is configured to connect the inverter 1 to a power cable, for example, connected to the on-board low-voltage power network so as to power the electronic control unit.

[0068] Reference Figure 4 , the housing element 5-1 is in the form of a single block formed by molding an electrically insulating plastic material. The housing element 5-1 includes a side wall 5-10 in the form of a U-shaped band and a support element 5-11 configured to support the power module 10 and the electronic control unit. In this example, specifically, the support element 5-11 includes a longitudinal beam 5-11A, which realizes the main body 100 of the power module 10 and the electronic control unit.

[0069] refer to Figures 5 to 9 The housing element 5 comprises receiving means which, in this example, enable the fixing of the phase conductors 111, 112, 113 by force fit. These receiving means are formed from the material of the side walls 5-10 and comprise three pairs of rails each suitable for accommodating the phase conductors 111, 112, 113.

[0070] More specifically, each pair of rails includes a first wall 5-12A and a second wall 5-12B extending parallel to each other and perpendicular to the side wall 5-10 to secure the phase conductors 111, 112, 113. In this example, the first wall 5-12A and the second wall 5-12B of each pair of walls 5-12A, 5-12B extend substantially over the entire height of the side wall 5-10.

[0071] Preferably, each of the first wall 5-12A and the second wall 5-12B of each pair of walls 5-12A and 5-12B includes at least one round die carved decoration 5-120. This round die carved decoration 5-120 forms an excess material thickness to help adjust the insertion between each pair of walls 5-12A and 5-12B and the corresponding phase conductors 111, 112, and 113 so as to effectively fix them to each other. In this example, the round die carved decoration 5-120 is formed by the material of the first wall 5-12A and the second wall 5-12B of each pair of walls 5-12A and 5-12B.

[0072] Also in the example shown, the first wall 5-12A includes an edge 5-12A1 extending parallel to the side wall 5-10 in the direction of the second wall 5-12B, and the second wall 5-12B also includes an edge 5-12B1 extending parallel to the side wall 5-10 in the direction of the first wall 5-12A.

[0073] During assembly of the inverter, the power module 10 and the electronic control unit are assembled first.

[0074] Then, each phase conductor 111, 112, 113 is force-matched by sliding between each pair of walls 5-12A, 5-12B so that the phase conductor is blocked by the circular mold carving decoration of the first wall 5-12A and the second wall 5-12B of each pair of walls 5-12A, 5-12B.

[0075] Subsequently, each phase conductor 111 , 112 , 113 is screwed to the corresponding phase port 121 , 122 , 123 to electrically connect the conductor to the phase port 121 , 122 , 123 of the power module 10 .

[0076] The edges 5 - 12A1 , 5 - 12B1 of each pair of walls 5 - 12A, 5 - 12B further enable maintaining the phase conductors 111 , 112 , 113 between the first wall 5 - 12A and the second wall 5 - 12B.

[0077] The cover 5-2 and the bottom of the housing 5 can then be fastened to the housing element 5-1 in order to close the housing and, for example, seal the inverter 1. The phase conductors 111, 112, 113 of the inverter 1 can then be electrically connected to an electrical device, and the positive and negative potential electrical conductors 30, 40 can be connected to the high-voltage battery of the vehicle.

[0078] The invention is not limited to the examples described above. The figures show specific embodiment examples combining several embodiments. However, the features of each embodiment may be independent of each other in various modes, or they may be combined, as shown in the claims.

Claims

1. A housing element of an electrical device, the housing element being configured to accommodate at least one electrical conductor and at least one electrical component, the at least one electrical conductor being configured to form an external terminal of the electrical device; the at least one electrical component being adapted to be electrically connected to the electrical conductor, the housing element being characterized in that: It comprises a receiving member adapted to receive the electrical conductor by sliding, wherein The receiving member includes at least one pair of walls extending parallel to each other, The pair of walls comprises a first wall and a second wall extending parallel to each other, the first wall comprising an edge extending in the direction of the second wall, and the second wall comprising an edge extending in the direction of the first wall, so as to guide the sliding of the electrical conductor, The housing element forms a side wall of the housing, the receiving member being positioned on the side wall, The wall extends from the side wall perpendicularly to the side wall, and the edge extends parallel to the side wall, The first wall and the second wall extend over at least half the height of the side wall. 2 . The housing element of an electrical device according to claim 1 , wherein the receiving member comprises at least one terminating end configured to terminate the sliding of the electrical conductor. 3 . The housing element of an electrical device according to claim 1 , wherein the receiving member is configured for a force fit of the electrical conductor.

4. An electrical device comprising a housing element as claimed in any one of claims 1 to 3 and at least one electrical conductor, the at least one electrical conductor being configured to form an external terminal of the electrical device, the electrical conductor comprising a strip which is mounted in the housing element by being inserted into a receiving member of the housing element.

5. The electrical device according to claim 4 comprises at least one electrical component, which is installed in the housing element and has at least one electrical terminal, wherein the electrical conductor comprises a central part introduced into the receiving member, a first end and a second end extending from the central part, the first end being fastened to the electrical terminal of the electrical component to achieve electrical connection, and the second end forming an external electrical terminal of the electrical device.

6. The electrical device according to claim 4, comprising a plurality of electrical conductors and a plurality of power components, wherein the plurality of electrical conductors are introduced into the corresponding receiving members, the plurality of power components form a power module, and each electrical conductor is connected to a corresponding terminal of the power module. 7 . The electric equipment according to claim 4 , the electric equipment being an inverter, the inverter being provided to be electrically connected to an electric device through the electric conductor.

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