DC-DC electrical converter and motor vehicle comprising such converter

Abstract

A converter comprises: an electrical conversion circuit designed to convert a DC input voltage into a DC output voltage; an input or output connector comprising: a positive pin and a negative pin, the two pins being designed to receive an input voltage or supply an output voltage; and two flat auxiliary busbars, one being a positive flat auxiliary busbar and the other being a negative flat auxiliary busbar, each flat auxiliary busbar including a first flat portion and a second flat portion pressed against and fixed to the positive pin and the negative pin, respectively, the second flat portions being substantially parallel to each other, the first flat part of the positive flat auxiliary bus is pressed against and fixed on the flat fixed part of the positive pin, and the first flat part of the negative flat auxiliary bus is pressed against and fixed on the flat fixed part of the negative pin; and two positive and negative main busbars connected to the electrical conversion circuit and each including a flat portion pressed against and fixed to the second portion of the auxiliary busbar, respectively.

Description

Technical Field

[0001] The invention relates to a DC-DC electrical converter and to a motor vehicle comprising such a converter.

[0002] The motorized vehicle is, for example, a motorized land vehicle, a train, an aircraft, or an unmanned aircraft. The motorized land vehicle is, for example, a motor vehicle, a motorcycle, a motorized bicycle, or a motorized wheelchair. Background Art

[0003] From the prior art a DC-DC electrical converter is known, which comprises:

[0004] an electrical conversion circuit designed to convert a DC input voltage into a DC output voltage;

[0005] an input or output connector comprising two flat pins, one being a positive pin and the other being a negative pin, designed to receive an input voltage or supply an output voltage;

[0006] Two main positive and negative busbars connected to an electrical conversion circuit.

[0007] Generally speaking, in order to connect a connector to an electrical circuit, the pins of the connector are pressed against and fixed on the main busbar. Depending on the constraints for implementing the DC-DC electrical converter in its environment, the connector must have an orientation that is compatible with this environment. Therefore, each time a new product with a DC-DC electrical converter is designed, the pins of the connector and / or the main busbar must be modified to take this orientation into account. This results in significant design and production costs.

[0008] It is therefore proposed to provide a DC-DC electrical converter which allows to overcome at least some of the above mentioned problems and constraints. Summary of the invention

[0009] Therefore, a DC-DC electrical converter is proposed, the DC-DC electrical converter comprising:

[0010] an electrical conversion circuit designed to convert a DC input voltage into a DC output voltage;

[0011] An input or output connector, referred to as a first connector, comprising:

[0012] two pins, one being a positive pin and the other being a negative pin, the two pins being designed to receive an input voltage or supply an output voltage; and

[0013] Two flat auxiliary busbars, one being a positive flat auxiliary busbar and the other being a negative flat auxiliary busbar, wherein each flat auxiliary busbar comprises a first flat portion and a second flat portion respectively pressed against and fixed to the positive pin and the negative pin, wherein the second flat portions are substantially parallel to each other, e.g. coplanar, wherein the first flat portion of the positive flat auxiliary busbar is pressed against and fixed to the flat fixing portion of the positive pin, and the first flat portion of the negative flat auxiliary busbar is pressed against and fixed to the flat fixing portion of the negative pin, and comprises a connecting portion directly adjacent to the first portion and the second portion; and

[0014] Two positive and negative main busbars are connected to the electrical conversion circuit and respectively include flat portions respectively pressed against and fixed on the second portion of the auxiliary busbar.

[0015] Therefore, by means of the present invention, each time a new product is designed, only the auxiliary busbars need to be adapted to the desired orientation of the connector. The pins of the connector as well as the main busbars can remain unchanged.

[0016] The present invention may further include one or more of the following optional features in any technically feasible combination.

[0017] Optionally, the connecting portion of each auxiliary busbar comprises a folded portion, so that the first portion and the second portion of each auxiliary busbar together form a non-flat angle.

[0018] Thus, the auxiliary busbar can easily be adapted to a desired orientation by means of the fold.

[0019] Also optionally, the connecting portion of the auxiliary busbar includes a single folded portion connecting the first portion and the second portion.

[0020] This is an embodiment in which the auxiliary busbar is kept as simple as possible in order to facilitate its adaptation.

[0021] Also optionally, the connection portion of each auxiliary bus-bar is shorter than the first portion and the second portion in a current circulation direction within the auxiliary bus-bar.

[0022] The circulation direction is understood to mean the direction of the current flowing through the auxiliary busbar.

[0023] This is an advantageous embodiment as it reduces the overall size of the converter.

[0024] Still optionally, the second portion of the auxiliary bus-bar is fixed to the main bus-bar by threading in a direction of the threading, the direction of the threading being substantially perpendicular to the second portion of the auxiliary bus-bar.

[0025] Still optionally, the first portion of the auxiliary busbar is fixed to the flat fixing portion of the pin by welding.

[0026] Also optionally, the DC-DC electrical converter comprises a housing provided with a bottom having at least one flat portion, and wherein the second portion of the auxiliary busbar is substantially parallel to the flat portion of the bottom.

[0027] Also optionally, the flat fixing portions of the pins extend opposite to each other substantially parallel to each other and have opposite faces and outer faces on the other side of the opposite faces, against which the first portion of the auxiliary busbar is pressed and fixed.

[0028] Also optionally, each pin comprises a flat end portion, wherein the flat end portions extend substantially parallel to each other at a greater distance relative to each other than the fixing portion, and the connector further comprises a magnetic annulus surrounding the fixing portions of the pins.

[0029] Optionally, the connector further comprises:

[0030] a first capacitor connected between the positive pin and electrical ground, wherein this first capacitor is connected to the positive pin between the magnetic toroid and an end portion thereof; and / or

[0031] A second capacitor is connected between the negative pin and electrical ground, wherein the second capacitor is connected to the negative pin between the magnetic toroid and an end portion thereof.

[0032] Also optionally, the DC-DC electrical converter comprises a further input or output connector similar to the first connector.

[0033] “Similar” means including:

[0034] two pins, one being a positive pin and the other being a negative pin, the two pins being designed to receive an input voltage or supply an output voltage; and

[0035] Two flat auxiliary busbars, one is a positive flat auxiliary busbar and the other is a negative flat auxiliary busbar, wherein each flat auxiliary busbar includes a first flat portion and a second flat portion respectively pressed against and fixed on a positive pin and a negative pin, wherein these second flat portions are substantially parallel to each other, for example coplanar, wherein the first flat portion of the positive flat auxiliary busbar is pressed against and fixed on the flat fixing portion of the positive pin, and the first flat portion of the negative flat auxiliary busbar is pressed against and fixed on the flat fixing portion of the negative pin.

[0036] The first and second flat parts of the auxiliary busbar of this further connector then together form an angle different from the angle between the first and second flat parts of the first connector, so that the second flat part of this further connector is parallel to the second flat part of the first connector.

[0037] Also optionally, the other connector is an input connector and the first connector is an output connector.

[0038] Also optionally, the other connector is an output connector and the first connector is an input connector.

[0039] Also optionally, the positive pins and the negative pins of the two connectors are identical, in particular have the same shape.

[0040] A motor vehicle comprising a DC-DC electrical converter according to the invention is also proposed. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] The invention will be better understood from the following description which is given by way of example only and made with reference to the accompanying drawings, in which:

[0042] Figure 1 is a simplified illustration of a motor vehicle in which the present invention may be implemented;

[0043] Figure 2 yes Figure 1 A simplified three-dimensional view of a DC-DC electrical converter for a motor vehicle;

[0044] Figure 3 yes Figure 2 A 3D view of the connector of the converter;

[0045] Figure 4 yes Figure 3 3D views of the connector from different viewing angles and without the magnetic ring;

[0046] Figure 5 is with Figure 3 and Figure 4 3D view of the EMC filter associated with the connector;

[0047] Figure 6 is a 3D view of the EMC filter isolated from the connector;

[0048] Figure 7 is a view of an electromagnetic compatibility filter showing the positions of elements of a tool for securing a clamping portion;

[0049] Figure 8 There is no vertical offset of the two capacitors with Figure 7 A view similar to the view of;

[0050] Fig. 9 yes Figure 3 and Figure 4 A three-dimensional view of a connector and another connector of a DC-DC electrical converter;

[0051] Fig.10 is a 3D view of another connector and associated EMC filter;

[0052] Fig.11 is demonstrated for manufacturing Fig. 9 and Fig.10 A series of three-dimensional views of successive steps of another connector method are shown. DETAILED DESCRIPTION

[0053] Now refer to Figure 1 A motor vehicle 100 is described in which the present invention may be used.

[0054] The motor vehicle 100 comprises a propulsion system 102, such as drive wheels 104 and an electric motor 106 designed to drive the drive wheels 104. The motor vehicle 100 further comprises a battery 108 designed to supply the electric motor 106 with power.

[0055] In order to charge the battery 108 at a charging station 110 connected to a power distribution network (not shown), the motor vehicle 100 further includes an electrical socket 112 designed to be connected to the charging station 110, and a DC-DC electrical converter 114 connected between the electrical socket 112 and the battery 108 so as to convert an input voltage VIN received from the charging station 110 through the electrical socket 112 into an output voltage VOUT supplied to the battery 108.

[0056] Throughout the remainder of the description, the arrangement of the various elements of the converter 114 will refer to an arbitrary reference system including a left-right axis X, an up-down axis Y, and a front-back axis Z.

[0057] refer to Figure 2 , converter 114 will now be described in more detail.

[0058] The converter 114 first includes a housing 202, which includes a side wall 204 and a bottom 206, which together define an interior space 208 of the housing 202 and an exterior space 210 of the housing 202. The side wall 204 may also define an upper opening 212 opposite to the bottom 206. In this case, the housing 202 may further include a cover 214 designed to close the upper opening 212.

[0059] The converter 114 further includes an electrical conversion circuit 218 extending into the interior space 208 of the housing 202. The electrical conversion circuit 218 is designed to convert the input voltage VIN into an output voltage VOUT. For example, the converter 114 can be a parallel chopper (boost converter or even step-up converter), in which case the conversion circuit 218 includes, for example, a positive branch 220 and a negative branch 222 having an input side and an output side. The conversion circuit 218 includes an inductor L on the positive branch, and a switch Q1 and a capacitor C on the output side relative to the inductor L connected in parallel to each other between the positive branch 220 and the negative branch 222, and another switch Q2 on the positive branch between the switch Q1 and the capacitor C (for example, a diode passing toward the capacitor C (where its cathode is on one side of the capacitor C)). The converter 114 then further includes a control circuit 220, which is designed to control the switch Q to implement the conversion.

[0060] In order to receive the input voltage VIN, the converter 114 further comprises an input connector 224, which is accessible from the external space 210 so as to be connected to the external socket 112 through an electrical connection (not shown) having a connector at one of its ends other than the input connector 224. Thus, the input connector 224 comprises two input pins B'+, B'-: the first pin B'+ is called the positive pin so as to receive the positive potential of the input voltage VIN, and the second pin B'- is called the negative pin so as to receive the negative potential of the input voltage VIN.

[0061] In order to supply the output voltage VOUT, the converter 114 further comprises an output connector 226, which is accessible from the external space 210 so as to be connected to the battery 108 through an electrical connection (not shown) having at one of its ends a connector other than the output connector 226. Thus, the output connector 226 comprises two output pins B+, B-: the first pin B+ is referred to as the positive pin for supplying the positive potential of the output voltage VOUT, and the second pin B- is referred to as the negative pin for supplying the negative potential of the output voltage VOUT.

[0062] To connect the negative potentials together, the converter 114 includes a second main bus BP- (referred to as the negative main bus) connecting the negative input pin B′- and the negative output pin B- together and to the negative line 222 of the conversion circuit 218 .

[0063] Converter 114 further includes a positive input main bus BP'+ connecting the positive input pin B'+ to the input side of the positive branch 220 of the conversion circuit 218, and a first main bus BP+ called the positive output main bus connecting the positive output pin B+ to the output side of the positive branch 220 of the conversion circuit 218.

[0064] The converter 114 may further include a switch 228 for selectively connecting and disconnecting the positive main bus BP+, BP'+. This allows the conversion circuit 218 to be short-circuited so that the output voltage VOUT is equal to the input voltage VIN. This function is useful, for example, when the charging station 110 supplies an input voltage VIN that is already at a voltage required to charge the battery 108.

[0065] refer to Figure 3 and Figure 4 , the output connector 226 will now be described in more detail.

[0066] refer to Figure 3 , the output pins B+, B- respectively comprise, for example, two flat busbars ranging between 1 mm and 5 mm thick, for example 4 mm thick, each having a flat fixing portion B1+, B1- and a flat end portion B2+, B2-. The end portions B2+, B2- protrude toward the external space 210, for example, along the axis D (in the forward direction in the example shown), and are designed to be connected to an additional connector of the output connector 226 along this axis D. In other embodiments, the end portions B2+, B2- can have a geometry other than a flat geometry, for example, a rod geometry of a circular cross section protruding along the axis D.

[0067] The flat fixing parts B1+, B1- extend substantially parallel to each other (e.g., at the nearest 1°) (e.g., less than 10 mm apart, e.g., 4 mm apart). Similarly, the flat end parts B2+, B2- extend substantially parallel to each other (e.g., at the nearest 1°) but at a greater distance (e.g., at least twice as large, e.g., between 20 mm and 30 mm apart, e.g., 25.7 mm apart) than the flat fixing parts B1+, B1-. For example, one of the output pins B+, B- (e.g., the positive output pin B+, as in the example shown) is flat, while the other of the output pins B+, B- (e.g., the negative connection pin B-, as in the example shown) has a joint 302 between the end part B2- and the fixing part B1-, wherein this joint 302 has two bends, for example, made by folding the connection pin B- over the width of the connection pin.

[0068] The output connector 226 further includes a first electromagnetic compatibility filter. This first filter first includes, for example, a magnetic annulus 304 surrounding the output pins B+, B- and more specifically surrounding these fixed parts due to the limited space between the fixed parts B1+, B1-. The first filter further includes, for example, two capacitors C+, C-, which are respectively connected between a busbar 306 connected to an electrical ground (e.g., housing 202) and the positive output pin B+ and the negative output pin B-. For example, the positive output pin B+ includes a tab 308+ extending from the flat busbar to the capacitor C+. Similarly, the negative output pin B- may include a tab 308- extending from the flat busbar to the capacitor C-. These tabs 308+, 308- are located between the magnetic annulus 304 and the end portions B2+, B2- of the output pins B+, B-.

[0069] refer to Figure 4 The output connector 226 further includes two auxiliary busbars BA+ and BA-. The first BA+ is called the positive auxiliary busbar and is inserted between the positive pin B+ and the positive main busbar BP+. The second BA- is called the negative auxiliary busbar and is inserted between the negative pin B- and the negative busbar BP-.

[0070] Thus, each auxiliary busbar BA+, BA- comprises a first flat portion BA1+, BA1-, respectively fixed to the positive pin B+ and the negative pin B- and more specifically to its fixing portion B1+, B1-, respectively. The flat portion BA1+, BA1- of the auxiliary busbar BA+, BA- is, for example, pressed against and fixed to the face of the fixing portion B1+, B1-. For example, the fixing portion B1+, B1- has opposite faces (facing each other) and external faces on the other side of the opposite faces. Thus, the flat portion BA1+, BA1- of the auxiliary busbar BA+, BA- is, for example, pressed against and fixed to these external faces (as in the example shown).

[0071] Each auxiliary busbar BA+, BA- further comprises a second flat portion BA2+, BA2-. These second flat portions BA2+, BA2- are substantially parallel to each other (e.g., to the nearest 1°), for example, they are coplanar. Depending on the orientation of the output pins B+, B- around their axis D, each portion BA2+, BA2- can extend in the continuation of the first flat portion BA1+, BA1- (in this case, the auxiliary busbars BA+, BA- are flat) or extend at a non-flat angle (as in the example shown). In the latter case, each auxiliary busbar BA+, BA- has, for example, a folded portion P+, P- substantially parallel to (e.g., to the nearest 1°) axis D between the portions BA1+, BA2+ and BA1-, BA2-.

[0072] The flat parts BP2+, BP2- of the main busbars BP+, BP- are pressed against and fixed on the second parts BA2+, BA2- of the auxiliary busbars BA+, BA-, respectively. Since the second parts BA2+, BA2- extend in parallel, they can be fixed in a similar manner, in particular along the same fixing axis, regardless of the orientation of the output pins B+, B- around the axis D. In particular, when this fixing operation is performed by threaded connection (as in the example shown), the threaded connection can be performed along an axis perpendicular to the second parts BA2+, BA2- (vertically in the example shown). This threaded connection axis can also be used for other screws of the converter 114. Therefore, all of these threaded connection operations can be performed using the same tool, regardless of the orientation of the pins B+, B- around their axis D.

[0073] refer to Figure 5 , the converter 114 further includes a second electromagnetic compatibility filter 600 for the output connector 226 .

[0074] This electromagnetic compatibility filter 600 first includes a negative busbar LD- connected to the negative main busbar BP-. To this end, the negative busbar LD- includes, for example, a fixed terminal 602, which is fixed to the negative main busbar BP-, for example, by the same screws as the negative auxiliary busbar BA-. The electromagnetic compatibility filter 600 further includes a positive busbar LD+ connected to the positive main output busbar BP+. To this end, the busbar LD+ includes, for example, a fixed terminal 604, which is fixed to the positive main output busbar BP+, for example, by the same screws as the positive auxiliary busbar BA+. The electromagnetic compatibility filter 600 further includes a grounding busbar LD0, which is connected to an electrical ground, for example, to the housing 202. To this end, the grounding busbar LD0 includes a fixed terminal 606 fixed to the electrical ground.

[0075] The electromagnetic compatibility filter 600 further includes a capacitor C1 connected between the negative bus LD- and the ground bus LD0, a capacitor C2 connected between the positive bus LD+ and the ground bus LD0, and a capacitor C3 connected between the positive bus LD+ and the negative bus LD-. All capacitors C1, C2, C3 have respective housings of generally parallelepiped shape, for example, with horizontal upper faces parallel to each other and perpendicular to the Y-axis.

[0076] refer to Figure 6, for connection, the capacitor C1 comprises two pins C1A, C1B protruding along an axis D1A, D1B parallel to the Z axis in the example shown. Thus, the negative busbar LD- comprises a clamping portion P1A clamping the pin C1A, and the ground busbar LD0 has a clamping portion P1B clamping the pin C1B. The clamping portion P1B protrudes (i.e. is open) along an axis called the tilting axis and in a direction A1 along this axis.

[0077] Similarly, for connection, capacitor C2 includes two pins C2A, C2B protruding along axes D2A, D2B. Thus, positive busbar LD+ includes a clamping portion P2A clamping pin C2A, and ground busbar LD0 includes a clamping portion P2B clamping pin C2B. Clamping portion P2B protrudes (i.e., is open) along the same axis as the axis of clamping portion P1B (e.g., at the nearest 1°) and in direction A2. Clamping portions P1B and P2B are positioned head to tail, i.e., directions A1, A2 are opposite.

[0078] Similarly, for connection, the capacitor C3 includes two pins C3A, C3B protruding in the forward direction D3A, D3B (each of the two pins can be separated as in the example shown). Therefore, the positive busbar LD+ has a clamping portion P3A that clamps the pin C3A. This clamping portion P3A protrudes (i.e., is open) in the upward direction A3 along the vertical axis Y. The negative busbar LD- also has a clamping portion P3B that protrudes (i.e., is open) in the upward direction A3 along the vertical axis Y and clamps the pin C3B.

[0079] The ground conductor LD0 includes an elongated body 702 extending downward from the clamping portions P1B, P2B at least as far as the pin C3A. For example, the terminal 606 of the ground conductor LD0 is positioned below this pin C3A so that the elongated body 702 passes through the side of the pin C3A and between the pins C3A and C3B.

[0080] However, reference Figure 7When manufacturing the electromagnetic compatibility filter 600, each clamping portion P1A, P1B, P2A, P2B, P3A, P3B is closed on its associated pin C1A, C1B, C2A, C2B, C3A, C3B by a tool (in particular a fixed clamping portion having two elements 802, 804 designed to be placed on each side of the clamping portion P1A, P1B, P2A, P2B, P3A, P3B, respectively). The fixed clamping portion can be a clamping clamping portion, in which case the elements are designed to move toward each other so as to mechanically push the two arms of the clamping portion P1A, P1B, P2A, P2B, P3A, P3B so that they clamp the associated pin C1A, C1B, C2A, C2B, C3A, C3B. The fixed clamp may also be an electric welding clamp, in which case elements 802, 804 additionally or alternatively form electrodes for passing current through the clamps P1A, P1B, P2A, P2B, P3A, P3B and associated pins C1A, C1B, C2A, C2B, C3A, C3B to weld them together.

[0081] Therefore, in order to leave enough space for these elements 802, 804, the elongated body of the ground strap LD0 must pass at a certain distance from the clamping portion P3A.

[0082] Furthermore, in order to make the electromagnetic compatibility filter 600 as compact as possible, it is recommended that the capacitors C1 and C2 extending above the capacitor C3 are as close as possible to said capacitor C3.

[0083] In order to meet these two constraints, capacitor C1 is positioned so that its pin C1B is higher than the pin C2B of the second capacitor C2. Therefore, the opposite directions A1, A2 and direction A3 together form an angle of less than 80°, preferably less than 70°, for example 65°, which allows the elongated body 702 to have a straight end portion 801, from which the clamping portions P1B, P2B protrude substantially vertically (for example, at the nearest 1°), and which is vertically angled away from the clamping portion P3A. Therefore, it is possible to maintain a sufficient distance between the clamping portion P3A and the elongated body 702 for the elements 802, 804 of the tool (particularly element 804) to pass, while keeping the capacitor C2 low and close to the capacitor C3.

[0084] For example, capacitor C1 is positioned so that its upper face extends higher than the upper face of capacitor C2, ie to a greater height. For example, the height of the upper face of capacitor C1 is at least 5 mm, preferably at least 10 mm higher than the height of the upper face of capacitor C2.

[0085] Still for example, the legs of each capacitor C1, C2 define straight lines D1, D2. The two straight lines D1, D2 are substantially parallel (e.g., to within 1°), wherein line D1 is above line D2, e.g., at least 5 mm above it, e.g., between 5 mm and 10 mm above it.

[0086] refer to Figure 8 If capacitor C1 were positioned at the same level as capacitor C2 , the elongated body 702 would extend too close to clamp portion P1B and / or clamp portion P3A to allow tool elements 802 , 804 to pass (see dashed circle area).

[0087] refer to Fig. 9 and Fig.10 , the input connector 224 has elements similar to those of the output connector 226, for which the reference numerals of the previous figures are repeated, using "'" to distinguish them. The input pins B'+, B'- are identical to the output pins B+, B- and in particular present the same shape. The input pins B'+, B'- extend horizontally, i.e. perpendicular to the fixing direction (e.g. screw connection). Therefore, no compensation angle is required, so that the auxiliary busbars BA'+, BA'- are flat.

[0088] Furthermore, the electromagnetic compatibility filter 600' is also arranged behind the input connector 224 and has elements similar to those of the electromagnetic compatibility filter 600, for which the reference numerals of the previous figures are repeated, using "'" to distinguish them. In particular, as before, the capacitors C1', C2' are vertically offset so that the busbar LD0' passes at a distance from the clamping portion.

[0089] Reference now Fig.11 An example of a method for manufacturing the input connector 224 is described.

[0090] The output connector 226 is obtained in the same way.

[0091] During step E1, the negative pin B'- and, for example, the busbar 306' are obtained. Both are obtained, for example, using an overmolding 502' (for example overmolded), thereby exposing the portions B1'-, B2'- of the negative pin B'-. The overmolding 502' also has a through opening 504' in a portion of the overmolding 502' overmolding the portion B1'- of the negative pin B'-. In other embodiments, the overmolding 502' may be devoid of a through opening 504'.

[0092] The magnetic annulus 304 ′ is obtained during step E2 .

[0093] During step E3 , the negative pin B′—through its fixing portion B1 ′—is inserted into the magnetic annulus 304 ′, for example until the annulus 304 ′ extends around the overmoulding 502 ′, for example around the portion of the overmoulding 302 ′ having the through opening 504 ′.

[0094] During a step E4 , the negative auxiliary busbar BA′- is obtained.

[0095] During step E5, the portion BA1'- of the negative auxiliary busbar BA'- is pressed against and fixed to the fixing portion B1'- of the negative pin B'-. The fixing is carried out, for example, by welding, for example by electro-soldering and / or by depositing a silver link between the two portions BA1'-, B1'- to be fixed.

[0096] During step E6 , a positive branch B′+ is obtained comprising the portions B1 ′+, B2 ′+.

[0097] During step E7, the positive pin B'+ is inserted into the annulus 304' by its fixing portion B1'+, for example by offsetting its fixing portion B1'+ from the fixing portion B1'- of the negative pin B'- (upwards, as in the example illustrated). In particular, as in the example illustrated, the positive pin B'+ is inserted into the through opening 504' of the overmolding 502' such that the annulus 304' surrounds the fixing portion B1'+ of the positive pin B'+.

[0098] The positive auxiliary busbar BA′+ is obtained during a step E8 .

[0099] During step E9, the portion BA1'+ of the positive auxiliary busbar BA'+ is pressed against and fixed to the fixing portion B1'+ of the positive pin B'+. This fixing is facilitated by the offset between the fixing portions B1'+, B1'- of the pins B'-, B'+, which allows access from both sides. For example, the fixing is achieved by soldering.

[0100] During step E10 , the positive pin B′+ is slid down into the annular surface 304 ′ so as to place the fixing portions B1 ′+, B1 ′− opposite one another. For example, as in the example shown, the positive pin B′+ is slid down into the through opening 504 ′ of the overmolding 502 ′.

[0101] Once the connector 226 is obtained by the above-mentioned method for manufacturing the connector, this connector is assembled on the two positive main bus BP+ and the negative main bus BP- of the DC-DC voltage converter 114 according to an assembly method, and the assembly method includes: step F1 of obtaining the connector 226 according to the above-mentioned method for manufacturing the connector, and the step of pressing and fixing the flat part BP2+ of the positive main bus BP+ and the flat part BP2- of the negative main bus BP- against the second flat parts BA2+ and BA2- of the auxiliary bus BA+ and BA-, respectively.

[0102] In particular, the step of pressing and fixing the flat part BP2+ of the positive main busbar BP+ and the flat part BP2- of the negative main busbar BP- against and fixing the second part BA2+, BA2- of the auxiliary busbar BA+, BA- respectively includes: the step of fixing the second part BA2+, BA2- of the auxiliary busbar BA+, BA- to the flat part BP2+, BP2- of the main busbar BP+, BP- by threading them in a threaded connection direction basically perpendicular to the second part BA2+, BA2- of the auxiliary busbar BA+, BA-.

[0103] It should also be noted that the present invention is not limited to the embodiments described above. In fact, it will be apparent to those skilled in the art that various modifications may be made to the embodiments described above based on the teachings just disclosed to them.

[0104] In the detailed presentation of the invention provided above, the terms used should not be understood to limit the invention to the embodiments disclosed in this specification, but should be understood to include all equivalent schemes that can be foreseen by those skilled in the art by applying their general knowledge to implement the teachings just disclosed for them.

Claims

1. A DC-DC electrical converter (114), comprising: an electrical conversion circuit (218) designed to convert a DC input voltage (VIN) into a DC output voltage (VOUT); An input or output connector (226), referred to as a first connector, comprising: two pins (B+, B-), one (B+) being a positive pin and the other (B-) being a negative pin, the two pins being designed to receive the input voltage (VIN) or supply the output voltage (VOUT); and Two flat auxiliary busbars (BA+, BA-), one (BA+) being a positive flat auxiliary busbar and the other (BA-) being a negative flat auxiliary busbar, wherein each flat auxiliary busbar (BA+, BA-) comprises a first flat portion (BA1+, BA1-) and a second flat portion (BA2+, BA2-) respectively pressed against and fixed on the positive pin (B+) and the negative pin (B-), wherein these second flat portions (BA2+, BA2-) are substantially parallel to each other, for example, coplanar, wherein the first flat portion (BA1+) of the positive flat auxiliary busbar (BA+) is pressed against and fixed on the flat fixing portion (B1+) of the positive pin (B+), and the first flat portion (BA1-) of the negative flat auxiliary busbar (BA-) is pressed against and fixed on the flat fixing portion (B1-) of the negative pin (B-), and comprises a connecting portion directly adjacent to the first portion (BA1+, BA1-) and the second portion (BA2+, BA2-); and Two positive main busbars (BP+) and a negative main busbar (BP-), which are connected to the electrical conversion circuit (218) and respectively include flat parts (BP2+, BP2-) pressed against and fixed on the second part (BA2+, BA2-) of the auxiliary busbars (BA+, BA-).

2. The DC-DC electrical converter (114) according to claim 1, wherein the connection portion of each auxiliary bus bar comprises a folded portion (P+, P-) so that the first portion (BA1+, BA1-) and the second portion (BA2+, BA2-) of each auxiliary bus bar (BA+, BA-) together form a non-flat angle.

3. The DC-DC electrical converter (114) according to claim 2, wherein: The connecting portion includes a single fold (P+, P-) connecting the first portion (BA1+, BA1-) and the second portion (BA2+, BA2-) of each auxiliary bus bar (BA+, BA-).

4. The DC-DC electrical converter (114) according to any one of claims 1 to 3, wherein the connection portion of each auxiliary bus (BA+, BA-) is shorter than the first portion (BA1+, BA1-) and the second portion (BA2+, BA2-) of the auxiliary bus (BA+, BA-) in the current circulation direction within the auxiliary bus (BA+, BA-).

5. The DC-DC electrical converter (114) according to any one of claims 1 to 4, wherein: The second part (BA2+, BA2-) of the auxiliary busbar (BA+, BA-) is fixed to the main busbar (BP+, BP-) by threaded connection in the direction of the threaded connection, and the direction of the threaded connection is basically perpendicular to the second part (BA2+, BA2-) of the auxiliary busbar (BA+, BA-).

6. The DC-DC electrical converter (114) according to any one of claims 1 to 5, wherein: The first portion (BA1+, BA1-) of the auxiliary busbar (BA+, BA-) is fixed to the flat fixing portion (B1+, B1-) of the pin (B+, B-) by welding.

7. A DC-DC electrical converter (114) according to any one of claims 1 to 6, comprising a housing (202) provided with a bottom (206) having at least one flat portion, and wherein: The second portion (BA2+, BA2-) of the auxiliary busbar (BA+, BA-) is substantially parallel to the flat portion of the bottom (206).

8. The DC-DC electrical converter (114) according to any one of claims 1 to 7, wherein: The flat fixed parts (B1+, B1-) of the pins (B+, B-) extend substantially parallel to each other relative to each other, and have opposite faces and an external face on the other side of the opposite faces, and the first part (BA1+, BA1-) of the auxiliary busbar (BA+, BA-) is pressed against and fixed on the external face.

9. The DC-DC electrical converter (114) according to claim 8, wherein: Each pin (B+, B-) includes a flat end portion (B2+, B2-), wherein the flat end portions (B2+, B2-) extend substantially parallel to each other relative to each other at a greater distance than the fixed portions (B1+, B1-), and wherein the connector (224, 226) further includes a magnetic annular surface (304) surrounding the fixed portions (B1+, B1-) of the pins (B+, B-).

10. The DC-DC electrical converter (114) according to claim 9, wherein: The connector (224, 226) further comprises: a first capacitor (C+) connected between the positive pin (B+) and electrical ground, wherein the first capacitor (C+) is connected to the positive pin (B+) between the magnetic toroid (304) and its end portion (B2+); and / or A second capacitor (C-), the second capacitor being connected between the negative pin (B-) and electrical ground, wherein the second capacitor (C-) is connected to the negative pin (B-) between the magnetic toroid (304) and an end portion (B2-) thereof.

11. A DC-DC electrical converter (114) according to any one of claims 1 to 10, comprising a further input or output connector (224) similar to the first connector (226), wherein: The first flat portion and the second flat portion (BA1'+, BA1'-, BA2'+, BA2'-) of the auxiliary busbar (BA'+, BA'-) of the other connector (224) together form an angle different from the angle between the first flat portion and the second flat portion (BA1+, BA1-, BA2+, BA2-) of the first connector (226), so that the second flat portion (BA2'+, BA2'-) of the other connector (224) is parallel to the second flat portion (BA2+, BA2-) of the first connector (226).

12. The DC-DC electrical converter (114) according to claim 11, wherein: The positive pins (B+, B'+) and negative pins (B-, B'-) of the two connectors (224, 226) are identical, and in particular have identical shapes.

13. A motor vehicle comprising a DC-DC electrical converter (114) according to any one of claims 1 to 12.

Images