High voltage power distributor

Abstract

The present disclosure relates to a high-voltage power distributor, comprising an insulated high-voltage power cable, a fuse mechanically connected to a fuse holder, and a bus bar electrically connected between the cable and the fuse. The fuse, the fuse holder, the bus bar, and the cable are accommodated in a housing.

Description

Technical Field

[0001] The present disclosure relates to a high voltage power distributor for providing a high voltage power cable with an articulated and fused power connection for use as a power source for auxiliary automotive equipment. Background Art

[0002] The increase in popularity of electric vehicles has resulted in an increase in the production of high voltage power cables having a wiring harness structure that requires a robust and repeatable articulated connection including a high voltage fuse. Figure 5 A conventional solution for an articulated connection of high-voltage power cables is shown, in which two high-voltage main cables A and B and an auxiliary outlet cable C are connected to each other by welding to form an articulated portion D. The auxiliary outlet cable C, which has a reduced thickness compared to the main power cables A and B, is welded to the articulated portion D at its first end, and at its second end, the auxiliary outlet cable C is connected to a fuse E to which auxiliary vehicle equipment can be connected. Due to the flexible connection between the main power cables A and B and the fuse E via the auxiliary outlet cable C, this articulated connection requires manual assembly work and is prone to loosening.

[0003] Therefore, there is a need to provide a stable and robust solution for a high voltage power distributor that can be manufactured at low cost for use in automotive applications. Summary of the Invention

[0004] The present disclosure provides a high voltage power distributor and a method for manufacturing the high voltage power distributor. Implementations are given in the specification and drawings.

[0005] In one aspect, the present disclosure relates to a high-voltage power distributor comprising: a high-voltage power cable; a fuse mechanically connected to a fuse holder; and a bus bar electrically connected to the cable at a first end and electrically connected to the fuse at a second end. Furthermore, a housing is provided for housing at least a portion of the cable, the fuse, the fuse holder, and the bus bar.

[0006] The high-voltage power distributor according to this embodiment provides a stable and robust device comprising only a small number of components, thereby allowing for short assembly and processing times. Since bus bars are provided within the power distributor and between the cables and fuses, a robust assembly is provided that can be used to splice high-voltage cables to provide power to auxiliary vehicle equipment.

[0007] According to one embodiment, the cable remains uninterrupted within the housing, and the busbar is connected to the uninsulated section of the cable. This embodiment avoids cutting the cable and / or connecting both ends of the cable to a third cable leading to the fuse. In this embodiment, the busbar only needs to be connected to the uninsulated section of the cable to provide the hinge, resulting in only one interface between the cable and the busbar. This also achieves a high pullout force.

[0008] According to another embodiment, the busbar is welded to the cable, for example, by ultrasonic welding. In this embodiment, there is no need for clamps or the like for electrical connection between the busbar and the cable, and welding of the busbar to the cable can be performed without manual labor. Furthermore, the welding process is simple and does not require bending the cable or positioning the cable ends.

[0009] According to another embodiment, the fuse holder includes a slot for receiving the end of a busbar. Due to the provision of the slot, the busbar can be positioned within the fuse holder without requiring further adjustments to connect the busbar and fuse, such as with screws and nuts. Furthermore, receiving the busbar within the slot provides for a stable fixation of the busbar within the fuse holder.

[0010] According to another embodiment, the slot supports the busbar at its four sides, which improves the fixing of the busbar in the fuseholder.

[0011] According to another embodiment, at least one biasing spring element is positioned between the fuse holder and the housing. This provides an anti-vibration solution, as the spring element biases the fuse holder against the housing, preventing relative movement between the two. If the spring forces of the at least two spring elements are oriented perpendicular to each other, any vibrations are effectively prevented. According to one embodiment, the spring element is connected to the fuse holder, for example, integrally formed therewith.

[0012] According to another embodiment, the fuse holder is L-shaped so that the bus bar and the fuse can be oriented at a 90° angle to each other. If this is the case, the fuse holder and the fuse can be arranged parallel to the cable, with the bus bar extending transversely to the cable and the fuse.

[0013] According to another embodiment, the cable extends substantially in a straight line through the housing. This facilitates the manufacture of the device, avoids any undesirable bends and allows a compact design of the dispenser.

[0014] According to another embodiment, the bus bar includes an enlarged welding platform. Such a welding platform can be provided, for example, by increasing the width of the bus bar at the end of the bus bar that is welded to the cable compared to the other end of the bus bar that is connected to the fuse.

[0015] According to another embodiment, the fuse is rigidly connected to the cable (eg by means of a bus bar), thereby achieving a robust and stable assembly of cable, bus bar and fuse. This is in contrast to a flexible connection (eg by means of a cable).

[0016] In another aspect, the present invention relates to a method of manufacturing a high-voltage power distributor as described above, wherein the insulation material of an insulated high-voltage power cable is partially removed, a bus bar is electrically connected to an uninsulated section of the cable at a first end thereof, and the bus bar is electrically connected to a fuse at a second end thereof. Furthermore, the fuse is connected to a fuse holder, and the cable, bus bar, fuse, and fuse holder are housed in a housing.

[0017] According to one embodiment, the bus bar is inserted into the slot of the fuse holder before establishing an electrical connection between the bus bar and the fuse.

[0018] According to another embodiment, the fuse holder and fuse are inserted into the housing while the spring element is biased between the fuse holder and the housing. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Exemplary embodiments and functions of the present disclosure are described herein with reference to the accompanying drawings.

[0020] Figure 1 schematically shows an exploded view of a high voltage power distributor;

[0021] Figure 2 A side view of a fuse holder is schematically shown;

[0022] Figure 3 Schematically shows Figure 2 A top view of the fuse holder;

[0023] Figure 4 Schematically shows the Figure 3 A cross-sectional view taken along line IV-IV of ; and

[0024] Figure 5 A prior art articulation solution is schematically shown. DETAILED DESCRIPTION

[0025] Figure 1 An exploded view of a high voltage power distributor for automotive applications is shown, comprising an insulated high voltage power main cable 10, a fuse 12 mechanically connected to a fuse holder 14, and a bus bar 16 having a first end electrically connected to the main cable 10 and a second end electrically connected to the fuse 12. In addition, a housing is provided which comprises two parts 18 and 20 and houses at least a portion of the main cable 10 and the fuse 12, the fuse holder 14 and the bus bar 16. Although Figure 1The main cable 10 is illustrated as not extending outside the housing, but it is apparent that the main cable 10 may be guided through the housing, for example to extend through the outer end of the housing. In other embodiments, the main cable 10 may be provided with terminals for connecting the main cable 10 to other cables.

[0026] like Figure 1 As shown, the main cable 10 is generally insulated and extends continuously in a generally straight line through the housings 18, 20. However, the main cable 10 includes an uninsulated section 22 from which the insulation has been removed, and to which the busbars 16 are welded, such as by ultrasonic welding.

[0027] The bus bar 16 is made of metal and is generally strip-shaped, with a mounting hole 24 provided at one end thereof. A welding platform 26 having a rectangular shape and an enlarged width compared to the rest of the strip-shaped bus bar 16 is provided at the other end thereof.

[0028] The fuse holder 14 is integrally formed of an electrically insulating material with two nuts 28 and 30 overmolded therein to receive screws 32 and 34 , respectively, for mounting the fuse 12 to the fuse holder 14 .

[0029] like Figure 1 and Figure 3 As shown, the fuse holder 14 is generally L-shaped, wherein one (longer) leg of the L-shape accommodates the fuse 12, while the other (shorter) leg provides a slot 36 for accommodating the end of the bus bar 16. The slot 36 has a rectangular cross-section corresponding to the cross-section of the bus bar 16, whereby the slot 36 supports the bus bar 16 on four sides of the slot 36. The slot 36 is formed by a base 38, two side walls 40 and 42, and two wings 44 and 46 that prevent the bus bar 16 from rotating relative to the fuse holder 14.

[0030] like Figure 2 and Figure 3 As illustrated, the base 38 of the slot 36 is provided with two parallel slide rails 41 and 43 for supporting the busbar. When the busbar 16 is inserted into the slot 36, the wings 44 and 46 are slightly biased so that the busbar 16 is pressed against the slides 41 and 43.

[0031] Furthermore, it can be seen that the bus bar 16 can be inserted into the slot 36 of the fuse holder 14 until the mounting hole 24 is aligned with the through hole of the fuse 12, thereby allowing the screw 34 to be inserted through the fuse 12 and the bus bar 16 to connect with the nut 30. Similarly, when the screw 32 is threaded into the nut 28, the screw 32 is used to connect the terminal 29 of the auxiliary outlet cable (not shown) to the fuse 12. The auxiliary outlet cable can exit the cylindrical section 19 of the housing 18 through the outlet opening 23.

[0032] from Figure 1 It can be seen that the housing portion 18 includes a cylindrical section 19 adapted to accommodate the assembly of the terminal 29, the fuse holder 14, and the fuse 12. To prevent relative movement of the assembly within the cylindrical section 19 of the housing portion 18, a side wall 15 ( Figure 3 ), the fuse holder 14 is provided with integrally formed spring elements 48 and 50. A further spring element 51 is provided on the adjacent side wall 17 of the fuse holder, wherein the spring forces of the two spring elements 48 and 50 on the one hand and the spring force of the spring element 51 on the other hand are oriented perpendicularly to each other in order to exclude vibrations of the fuse and the fuse holder relative to the housing. Figure 3 ) is provided with another spring element 53 ( Figure 2 and Figure 3 When the housing is fully closed, the spring element 53 pushes against the wall of the housing portion 20 to prevent the fuse holder 14 and the fuse 12 from moving within the housing.

[0033] like Figure 4 As shown, the fuse holder 14 includes a container 13 having a semicircular cross-section with a radius R, and the container 13 is used to accommodate the fuse 12.

[0034] To provide a watertight seal, a single, one-piece seal 52 is interposed between the two housing portions 18 and 20, which can be connected to each other by means of clips 54 at housing portion 20 engaging hooks 56 at housing portion 18. Finally, covers 60 and 62 can be clipped onto housing portions 18 and 20, with seals 64 and 66 provided between the respective covers 60, 62 and housing portions 18 and 20.

[0035] To manufacture the above-described high voltage power distributor, the insulating material of the insulated high voltage power mains cable 10 is partially removed to provide a non-insulated section 22. Thereafter, the section 22 is welded to the welding platform 26 of the bus bar 16, wherein the bus bar is oriented in a generally rectangular manner relative to the main cable 10, as shown in FIG. Figure 1 As shown. Thereafter, bus bar 16 is inserted into slot 36 of fuse holder 14, and fuse 12 is electrically connected to bus bar 16 by screwing screw 34 into nut 30. This also provides a fixed and reliable mechanical connection between bus bar 16, fuse holder 14, and fuse 12. At the other end of fuse 12, screw 32 is used to connect terminal 29 of the auxiliary outlet cable to fuse 12 and also provide a mechanical connection between fuse 12 and fuse holder 14.

[0036] Thereafter, a stable assembly is provided comprising the main cable 10, bus bar 16, fuse holder 14, fuse 12 and terminal 29. Thereafter, the assembly is inserted into the housing portion 18 while biasing the spring elements 48, 50 and 51 between the fuse holder 14 and the housing portion 18.

[0037] Finally, the housing can be closed by snapping the housing part 20 onto the housing part 18 .

[0038] The disclosed power distributor provides for a 25 mm 2 , 35mm 2 , 50mm 2 , 70mm 2 or 95mm 2 The outlet opening 23 for the auxiliary outlet cable can be designed to accommodate a cable with a cross-sectional area of ​​4mm 2 or 6mm 2 The cross-sectional area of ​​the auxiliary outlet cable. The fuse can have a value of 40A.

Claims

1. A high voltage power distributor, comprising: Insulated high voltage power cable (10), a fuse (12) mechanically connected to a fuse holder (14); a bus bar (16) electrically connected to the cable (10) at a first end of the bus bar and electrically connected to the fuse (12) at a second end of the bus bar; as well as a housing that houses at least a portion of the cable (10), the fuse (12), the fuse holder (14), and the bus bar (16), At least one biasing spring element is provided between the fuse holder (14) and the housing.

2. The high voltage power distributor according to claim 1, in, The cable (10) is uninterrupted in the housing, and the busbar (16) is connected to the non-insulated section (22) of the cable (10).

3. The high voltage power distributor according to claim 1 or 2, in, The bus bar (16) is welded to the cable (10).

4. The high voltage power distributor according to claim 1 or 2, in, The fuse holder (14) includes a slot (36) for receiving an end of the bus bar (16).

5. The high voltage power distributor according to claim 4, in, The slot (36) supports the bus bar (16) at four sides of the slot (36).

6. The high voltage power distributor according to claim 1 or 2, in, At least two biasing spring elements are arranged between the fuse holder (14) and the housing, and the spring forces of the spring elements are oriented perpendicularly to each other.

7. The high voltage power distributor according to claim 1 or 2, in, The fuse holder (14) is L-shaped.

8. The high voltage power distributor according to claim 1 or 2, in, The cable (10) extends generally linearly through the housing.

9. The high voltage power distributor according to claim 1 or 2, in, The busbar (16) extends transversely to the cable (10).

10. The high voltage power distributor according to claim 1 or 2, in, The bus bar (16) includes an enlarged welding platform (26).

11. The high voltage power distributor according to claim 1 or 2, in, The fuse (12) is rigidly connected to the cable (10).

12. A method of manufacturing a high voltage power distributor according to any one of claims 1 to 11, the method comprising the following steps: Partially removing insulation material from an insulated high voltage power cable (10), electrically connecting a bus bar (16) at a first end thereof to a non-insulated section (22) of the cable (10), and electrically connecting the bus bar to a fuse (12) at a second end thereof, Connecting the fuse (12) to a fuse holder (14); Accommodating the cable (10), the bus bar (16), the fuse (12) and the fuse holder (14) in a housing; as well as At least one biasing spring element is disposed between the fuse holder (14) and the housing.

13. The method according to claim 12, wherein: Before establishing an electrical connection between the bus bar (16) and the fuse (12), the bus bar (16) is inserted into the slot (36) of the fuse holder (14).

14. The method according to claim 12 or 13, wherein: The fuse holder and the fuse are inserted into the housing while a spring element is biased between the fuse holder (14) and the housing.

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