Electrical assembly, and method for attaching such assembly

Abstract

The object of the invention is an electrical assembly comprising a power supply filter module (2) comprising a first positive connector (21) and a second negative connector (22), and a voltage converter comprising a first positive terminal (31) and a second negative terminal (32), the first connector (21) being fastened to the first terminal (31) and covered with an encapsulation material, the second connector (22) being fastened to the second terminal (32) and covered with an encapsulation material, the second connector (22) is fastened to the second terminal (32), said assembly further comprising a deflection member (4) for deflecting said encapsulation material, said deflection member (4) protruding from the filtering module (2) or from the voltage converter (3) and extending away from and opposite the first terminal (31) in order to receive some of the encapsulation material, the deflection member (4) is configured to guide the encapsulation material between the deflection member (4) and the first terminal (31).

Description

Technical Field

[0001] The invention relates to an electrical assembly comprising a power filter module connected to a voltage converter and to a method for attaching the filter module to the voltage converter. Background Art

[0002] Voltage converters intended to be connected to a power filter module are known from the prior art. In particular, the voltage converter comprises a first positive terminal, a second negative terminal, at least one phase terminal intended to be connected to a respective phase of the motor, a first capacitor and a second capacitor respectively connected between the first positive terminal and the second negative terminal. The positive terminal and the negative terminal may be intended to be connected to the power filter module.

[0003] The power filter module particularly comprises a first positive connector and a second negative connector, which are intended to be connected to a first positive terminal of the voltage converter and a second negative terminal of the voltage converter, respectively. The first connector, the second connector, the first terminal and the second terminal are rigid elements designed to withstand a current of at least 1 A and have a thickness of at least 1 mm.

[0004] The power filter module is attached to the voltage converter, so the first positive connector and the second negative connector of the power filter module are attached to the first positive terminal and the second negative terminal of the voltage converter respectively by laser welding. This welding prevents the connector and the terminal from being coated with copper. Therefore, each connector and each terminal is left free and exposed to the external environment and environmental stress (such as salt spray), thereby causing corrosion of the connector and the terminal.

[0005] In order to overcome the above mentioned corrosion problems, it is known to deposit an adhesive or resin on top of the connector and the terminals, thereby at least partially protecting the connector and the terminals from the surrounding environment.

[0006] Furthermore, the restricted space of the first positive connector and the second negative connector of the power filter module for attachment to the first positive terminal and the second negative terminal of the voltage converter, respectively, prevents the addition of an additional adhesive or resin layer intended to further cover the connectors and terminals.

[0007] It may be considered to add a step to the production line to attach the power filter module to the voltage converter, which includes flipping the assembly over so that a second layer of adhesive or resin can be deposited over the connectors and terminals to encapsulate all connectors and terminals.

[0008] However, this additional step will increase the manufacturing time for assembly and therefore increase the manufacturing cost.

[0009] The object of the present invention is therefore to propose an electrical assembly comprising a filter module and a voltage converter which allows the adhesive and / or resin to be deposited on the connector and the terminal in a single step, ensuring complete encapsulation of at least the first positive connector of the filter module and the first positive terminal of the voltage converter, while keeping the manufacturing time and manufacturing costs for assembly unchanged. Summary of the invention

[0010] More precisely, the subject of the present invention is an electrical component comprising a power filter module and a voltage converter connected to each other. The power filter module comprises at least one capacitor, a first positive connector and a second negative connector, the connectors being rigid. The voltage converter comprises a first positive terminal and a second negative terminal, the terminals being rigid. The first positive connector of the filter module is fastened to the first positive terminal of the voltage converter, and the second negative connector of the filter module is fastened to the second negative terminal of the voltage converter. At least the first positive connector and the first positive terminal are covered with packaging material. The component also comprises a deflection member for deflecting the packaging material, the deflection member protruding from the filter module or from the voltage converter and extending away from the first positive terminal of the voltage converter and at least opposite thereto so as to receive some packaging material, the deflection member being configured to guide the packaging material between the deflection member and the first positive terminal of the voltage converter.

[0011] The deflection member receives a quantity of the encapsulating material that is conveyed between the deflection member and the first positive terminal of the voltage converter under the action of gravity. In particular, the deflection member guides the encapsulating material between the deflection member and the first positive terminal, allowing the first positive connector and the first positive terminal to be completely encapsulated by the encapsulating material. The complete encapsulation of the first positive connector and the first positive terminal by the encapsulating material prevents them from being exposed to the external environment and environmental stresses (e.g., salt spray), thereby preventing them from corroding.

[0012] Advantageously, the deflection element is made of plastic.

[0013] Advantageously, the deflection member and the filtering module are combined.

[0014] It is also advantageous if the deflection element is formed as an integral part of the filter module.

[0015] In particular, the deflection member can be a component added to the filter module or the voltage converter, or formed as an integral part of the filter module or the voltage converter. If the deflection member is formed as an integral part of the filter module or the voltage converter, it can be molded directly to the module or the converter. This makes it possible not to add additional components to the electrical assembly and thus prevents the addition of tools in its manufacture. Furthermore, during its manufacture, the cycle remains unchanged and no additional manufacturing stations are required. Therefore, the manufacturing time and the manufacturing costs remain unchanged.

[0016] Advantageously, the deflection member comprises at least one inclined portion configured to guide and urge the encapsulation material under the first positive terminal of the voltage converter.

[0017] The encapsulating material is transported under the effect of gravity in the direction of the deflection member, in particular in the direction of the inclined portion of the deflection member. The inclined portion guides the encapsulating material to areas of the first positive connector and the first positive terminal that are not yet covered by the material. Thus, by the inclined portion, the encapsulating material is pushed toward the first positive connector and the first positive terminal, allowing them to be encapsulated.

[0018] Advantageously, the inclined portion of the deflection member has an inclination angle of 30° to 60° relative to a plane perpendicular to the first positive connector and the second negative connector of the power filter module.

[0019] Also advantageously, the inclined portion of the deflection member comprises a proximal end and a distal end, the proximal end being located near the first positive connector and the distal end being remote from and opposite the first positive terminal of the voltage converter, the distal end extending a distance of 1.5 mm to 4 mm from the first positive terminal of the voltage converter.

[0020] Advantageously, the deflection member further comprises a retaining portion which protrudes from the inclined portion and has a basin shape configured to receive excess potting material.

[0021] The excess packaging material is conveyed under gravity into the holding portion of the deflection element. Thus, the holding portion makes it possible to keep the packaging material in the same place, that is, to guide it only into the area where it is to be applied.

[0022] Advantageously, the voltage converter comprises a main module and a terminal block module, the main module comprising at least a first positive terminal and a second negative terminal, the terminal block module being attached to the main module and comprising at least: a first positive terminal forming a first positive terminal of the voltage converter; and a second negative terminal forming a second negative terminal of the voltage converter; the first positive terminal of the main module and the first positive terminal of the terminal block module are at the same high potential, and the second negative terminal of the main module and the second negative terminal of the terminal block module are at the same low potential; the first positive terminal of the terminal block module is fastened to the first positive connector of the power filter module, and the second negative terminal of the terminal block module is fastened to the second negative connector of the power filter module.

[0023] The present invention also relates to a method for encapsulating a first positive connector of a power filter module and a first positive terminal of a voltage converter of an electrical component as described above, comprising the following steps: connecting the first positive connector of the power filter module and the first positive terminal of the voltage converter; connecting the second negative connector of the power filter module and the second negative terminal of the voltage converter; and encapsulating the first positive connector of the power filter module and the first positive terminal of the voltage converter by applying packaging material to the first positive connector of the power filter module and the first positive terminal of the voltage converter, a deflection component for deflecting the packaging material receiving some of the packaging material and guiding it between the deflection component and the first positive terminal of the voltage converter. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The invention will be better understood on reading the following description, which is given by way of example only, and with reference to the accompanying drawings, given by way of non-limiting examples, in which like references are given to similar objects and in which:

[0025] Figure 1 is a schematic perspective view of an electrical assembly according to the present invention, the electrical assembly comprising a filter module connected to a terminal block module of a voltage converter;

[0026] Figure 2 yes Figure 1 A schematic diagram of a filter module, wherein the cover, heat sink, electronic board and terminal block module are omitted;

[0027] Figure 3 yes Figure 2 An enlarged view of the deflection component and the connector of the filter module are specifically shown;

[0028] Figure 4 is similar to Figure 3 Schematic diagram, but from a different perspective;

[0029] Figure 5 yes Figure 1an enlarged view of the electrical assembly of the filter module, specifically showing the connector and deflection components of the filter module, and the terminals of the terminal block module of the voltage converter; and

[0030] Figure 6 is similar to Figure 5 but from a different perspective.

[0031] It should be noted that the attached drawings disclose the invention in detail to enable the invention to be implemented. Although not limiting, the attached drawings are particularly used to better define the invention when appropriate. DETAILED DESCRIPTION

[0032] The present invention relates to an electrical component 1, such as Figure 1 shown.

[0033] The electrical assembly 1 is intended to be installed in a motor vehicle, for example.

[0034] In particular, the electrical component 1 includes a power filter module 2 and a voltage converter 3 .

[0035] The power filter module 2 comprises at least one capacitor (in particular a plurality of capacitors), an electronic board, a heat sink and a cover.

[0036] The power filter module 2 includes a first positive connector 21 and a second negative connector 22 .

[0037] A first positive connector 21 and a second negative connector 22 protrude from the power filter module 2 and are intended to connect the power filter module 2 to the voltage converter 3 .

[0038] The first positive connector 21 and the second negative connector 22 are rigid. They are designed to withstand a current of at least 1 A and have a thickness of at least 1 mm.

[0039] The voltage converter 3 is intended to be connected firstly to the power filtering module 2 and secondly to a power source configured to provide a DC voltage U. The voltage converter 3 is also particularly configured to convert the DC voltage U into a phase voltage provided to an electric motor of the motor vehicle.

[0040] The voltage converter 3 includes a first positive terminal 31 and a second negative terminal 32 .

[0041] A first positive terminal 31 and a second negative terminal 32 protrude from the voltage converter 3 and are intended to connect the voltage converter 3 to the power filter module 2 .

[0042] The first positive terminal 31 and the second negative terminal 32 are rigid. They are designed to be able to withstand a current of at least 1 A and have a thickness of at least 1 mm.

[0043] According to a particular embodiment, the voltage converter 3 may comprise a main module and a terminal block module 30. The main module is attached to the terminal block module 30.

[0044] The main module includes at least a first positive terminal and a second negative terminal, and the terminal block module 30 includes at least a first positive terminal 31 forming a first positive terminal of the power converter 3 and a second negative terminal 32 forming a second negative terminal of the voltage converter 3 .

[0045] The first positive terminal of the main module and the first positive terminal 31 of the terminal block module 30 are at the same high potential, and the second negative terminal of the main module and the second negative terminal 32 of the terminal block module 30 are at the same low potential.

[0046] The first positive terminal 31 of the terminal block module 30 is configured to be fastened to the first positive connector 21 of the power filter module 2 , and the second negative terminal 32 of the terminal block module 30 is configured to be fastened to the second negative connector 22 of the power filter module 2 .

[0047] like Figure 1 , Figure 5 and Figure 6 As shown, in order to make the drawing clearer, only the terminal block module 30 of the voltage converter 3 is shown.

[0048] In particular, in the electrical assembly 1 according to the invention, the first positive connector 21 of the filter module 2 is fastened to the first positive terminal 31 of the voltage converter 3. Furthermore, the second negative connector 22 of the filter module 2 is fastened to the second negative terminal 32 of the voltage converter 3.

[0049] In particular, the first positive connector 21 of the filter module 2 is fastened to the first positive terminal 31 of the voltage converter 3 by laser welding, and the second negative connector 22 of the filter module 2 is fastened to the second negative terminal 32 of the voltage converter 3 by laser welding.

[0050] The electrical assembly 1 further includes a packaging material covering at least the first positive connector 21 and the first positive terminal 31 .

[0051] In addition, the packaging material may also cover the second negative electrode connector 22 and the second negative electrode terminal 32 .

[0052] The encapsulation material may be, for example, an adhesive or a resin, making it possible to insulate at least the first positive connector 21 and the first positive terminal 31 , thereby at least partially protecting them from the external environment and environmental stresses (eg salt spray) and therefore from corrosion.

[0053] Reference Figure 2 The electrical component 1 further comprises a deflection member 4 for deflecting the encapsulation material.

[0054] The deflection element 4 protrudes from the filter module 2 or from the voltage converter 3 .

[0055] according to Figures 2 to 6 In the example shown, the deflection element 4 is integrated with the filter module 2 , in particular the deflection element 4 protrudes from the filter module 2 .

[0056] According to a particular embodiment, the deflection member 4 is formed as an integral part of the filter module 2 .

[0057] It goes without saying that the deflection element 4 can also be combined with the voltage converter 3 and protrude from said voltage converter 3. Thus, the deflection element 4 can be formed as an integral part of the voltage converter 3.

[0058] The deflection member 4 extends away from and opposite to the first positive terminal 31 of the voltage converter 3 of the assembled electrical component 1. The deflection member 4 is configured to receive some encapsulation material and guide the encapsulation material between the deflection member 4 and the first positive terminal 31 of the voltage converter 3 of the assembled electrical component 1.

[0059] In particular, the deflection element 4 is made of plastic.

[0060] Reference Figure 3 and Figure 4 , the deflection member comprises at least one inclined portion 40 .

[0061] The inclined portion 40 is configured to guide and push the encapsulation material under the first positive terminal 31 of the voltage converter 3 .

[0062] The inclined portion 40 of the deflection member has an inclination angle of 30° to 60° relative to a plane perpendicular to the first positive connector 21 and the second negative connector 22 of the power filter module 2. This inclination facilitates the transport of the packaging material along the inclined portion 40 under the action of gravity.

[0063] Reference Figure 3 The inclined portion 40 includes a proximal end close to the first positive connector 21 and a distal end away from and opposite to the first positive terminal 31 of the voltage converter 3 .

[0064] The distal end of the inclined portion 40 extends from the first positive terminal 31 of the voltage converter 3 by a distance of 1.5 mm to 4 mm.

[0065] The deflection member 4 may further include a retaining portion 41. The retaining portion 41 protrudes from the inclined portion 40, in particular, from a distal end of the inclined portion 40. The retaining portion 41 has a basin shape and is configured to receive excess packaging material.

[0066] Excess encapsulation material is understood to mean encapsulation material which is not used for encapsulating the first positive terminal 31 and the first positive connector 21 , but which will be placed in the electrical component 1 anyway.

[0067] Thus, the encapsulating material is arranged on the first positive connector 21 and the first positive terminal 31 of the electrical component 1. The encapsulating material first covers the connector and the terminal, and then the encapsulating material is conveyed under the effect of gravity in the direction of the deflection member 4, in particular in the direction of the inclined portion 40 of the deflection member 4. The inclined portion 40 guides the encapsulating material towards the areas of the first positive connector 21 and the first positive terminal 31 that are not covered by the material. Thus, the inclined portion 40 pushes the encapsulating material towards the first positive connector 21 and the first positive terminal 31, allowing them to be completely encapsulated.

[0068] If there is excess packaging material, the excess packaging material is conveyed into the holding portion 41 under the effect of gravity.

[0069] The invention also relates to a method for packaging a first positive connector 21 of a power filter module 2 and a first positive terminal 31 of a voltage converter 3 to form an electrical component 1 .

[0070] The method comprises at least the following steps: connecting the first positive connector 21 of the power filter module 2 and the first positive terminal 31 of the voltage converter 3, then connecting the second negative connector 22 of the power filter module 2 and the second negative terminal 32 of the voltage converter 3, and finally, encapsulating the first positive connector 21 of the power filter module 2 and the first positive terminal 31 of the voltage converter 3 by applying encapsulation material to the first positive connector 21 of the power filter module 2 and the first positive terminal 31 of the voltage converter 3. The deflection member 4 for deflecting the encapsulation material receives some of the encapsulation material and guides it between the deflection member 4 and the first positive terminal 31 of the voltage converter 3.

[0071] In particular, the first positive connector 21 of the power filter module 2 and the first positive terminal 31 of the voltage converter 3 are connected by welding, in particular by laser welding. The same applies to the second negative connector 22 of the power filter module 2 and the second negative terminal 32 of the voltage converter 3.

[0072] Due to these welds, it is impossible to apply a coating on the first positive connector 21, the first positive terminal 31, the second negative connector 22, and the second negative terminal 32. Therefore, the connectors and terminals are exposed to the surrounding environment and thus to environmental stresses such as salt spray, causing them to corrode in whole or in part.

[0073] With the encapsulation method that is the subject of the present invention, an encapsulation material such as a resin or an adhesive is arranged at least on the first positive connector 21 and the first positive terminal 31, and then the encapsulation material will flow around said connectors and terminals under the action of gravity, and then reach the deflection member 4. In particular, the encapsulation material is first conveyed toward the inclined portion 40, which, due to its inclination, allows the material to be arranged on the lower part of the first positive connector 21 and the first positive terminal 31, thereby allowing said connectors and terminals to be completely encapsulated.

[0074] If there is excess packaging material, the excess packaging material is conveyed into the holding portion 41 under the effect of gravity.

[0075] The holding portion 41 thus makes it possible to keep the encapsulating material in one place, that is to say to introduce it only into the area where it is required to be applied.

[0076] Furthermore, this approach allows the first positive connector 21 and the first positive terminal 31 to be completely packaged in a single manufacturing operation. Thus, packaging is performed while maintaining the manufacturing cycle, manufacturing time, and manufacturing cost of the electrical assembly 1.

[0077] It will also be noted that the present invention is not limited to the above-described embodiments. In fact, it will be apparent to those skilled in the art that various modifications may be made to the above-described embodiments based on the teachings just disclosed to them.

[0078] In the above detailed description of the present invention, the terms used should not be understood to limit the present invention to the embodiments disclosed in this specification, but should be understood to include all equivalents that can be thought of by those skilled in the art applying their common sense to implement the teachings just disclosed to them.

Claims

1. An electrical component (1), comprising a power filter module (2) and a voltage converter (3) connected to each other, The power filter module (2) comprises at least one capacitor, a first positive electrode connector (21) and a second negative electrode connector (22), wherein the connectors are rigid; The voltage converter (3) comprises a first positive terminal (31) and a second negative terminal (32), the terminals being rigid; The first positive connector (21) of the filter module (2) is fastened to the first positive terminal (31) of the voltage converter (3), and the second negative connector (22) of the filter module (2) is fastened to the second negative terminal (32) of the voltage converter (3); At least the first positive electrode connector (21) and the first positive electrode terminal (31) are covered with packaging material; The assembly further comprises a deflection member (4) for deflecting the encapsulating material, the deflection member (4) protruding from the filter module (2) or from the voltage converter (3) and extending away from the first positive terminal (31) of the voltage converter (3) and at least opposite to the first positive terminal (31) so as to receive some of the encapsulating material, the deflection member (4) being configured to guide the encapsulating material between the deflection member (4) and the first positive terminal (31) of the voltage converter (3).

2. The electrical component (1) according to claim 1, characterized in that The deflection component (4) is made of plastic.

3. The electrical component (1) according to any one of claims 1 and / or 2, characterized in that The deflection component (4) and the filter module (2) are combined.

4. The electrical component (1) according to any one of claims 1 to 3, characterized in that The deflection member (4) is formed as an integral part of the filter module (2).

5. The electrical component (1) according to any one of claims 1 to 4, characterized in that The deflection member (4) comprises at least one inclined portion (40) configured to guide and push the encapsulation material under the first positive terminal (31) of the voltage converter (3).

6. The electrical component (1) according to claim 5, characterized in that The inclined portion (40) of the deflection component (4) has an inclination angle of 30° to 60° relative to a plane perpendicular to the first positive connector (21) and the second negative connector (22) of the power filter module (2).

7. The electrical component (1) according to any one of claims 5 and / or 6, characterized in that The inclined portion (40) of the deflection member (4) comprises a proximal end and a distal end, the proximal end being located near the first positive connector (21), the distal end being away from and opposite to the first positive terminal (31) of the voltage converter (3), and the distal end extending a distance of 1.5 mm to 4 mm from the first positive terminal (31) of the voltage converter (3).

8. The electrical component (1) according to any one of claims 5 to 7, characterized in that The deflection member (4) further comprises a retaining portion (41) which protrudes from the inclined portion (40) and has a basin shape configured to receive excess encapsulating material.

9. The electrical component (1) according to any one of claims 1 to 8, characterized in that The voltage converter (3) comprises a main module and a terminal block module (30), the main module comprising at least a first positive terminal and a second negative terminal, the terminal block module (30) being attached to the main module and comprising at least: a first positive terminal (31) forming the first positive terminal (31) of the voltage converter (3); and a second negative terminal (32) forming the second negative terminal (32) of the voltage converter (3); The first positive terminal of the main module and the first positive terminal (31) of the terminal block module (30) are at the same high potential, and the second negative terminal of the main module and the second negative terminal (32) of the terminal block module (30) are at the same low potential; The first positive terminal (31) of the terminal block module (30) is fastened to the first positive connector (21) of the power filter module (2), and the second negative terminal (32) of the terminal block module (30) is fastened to the second negative connector (22) of the power filter module (2).

10. A method for packaging the first positive connector (21) of the power filter module (2) and the first positive terminal (31) of the voltage converter (3) of the electrical component (1) according to any one of claims 1 to 9, comprising the following steps: Connecting the first positive connector (21) of the power filter module (2) and the first positive terminal (31) of the voltage converter (3); connecting the second negative electrode connector (22) of the power filter module (2) and the second negative electrode terminal (32) of the voltage converter (3); and The first positive connector (21) of the power filter module (2) and the first positive terminal (31) of the voltage converter (3) are encapsulated by applying the encapsulating material to the first positive connector (21) of the power filter module (2) and the first positive terminal (31) of the voltage converter (3), and the deflection component (4) for deflecting the encapsulating material receives some of the encapsulating material and guides it between the deflection component (4) and the first positive terminal (31) of the voltage converter (3).

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