Electrical bond between two busbars

Abstract

The invention relates to an electrical junction (1) comprising a housing (2), a screw (3) and a nut (4), wherein the housing (2) is able to accommodate the end of an upper busbar (B1) and the end of a lower busbar (B2), the upper busbar (B1) comprising a first hole (H1) and the lower busbar (B2) comprising a second hole (H2), the axis (A2) of the second hole being aligned with the axis (A1) of the first hole (H1), the two busbars (B1, B2) being assembled by engaging the screw (3) with the two holes (H1, H2) and tightening the nut (4), so that the two busbars (B1, B2) are pressed against each other, wherein the junction (1) further comprises a first insulating element (5) which is overall cylindrical, intended to be inserted into the two holes (H1, H2) and hollow to accommodate the screw (3), so as to prohibit any contact between the two busbars (B1, B2) and the screw (3).

Description

Technical Field

[0001] This invention relates to an electrical connection between two busbars. Background Technology

[0002] A busbar is an electrical conductor designed to carry high-intensity current. For this purpose, it is made of metallic materials, such as copper or aluminum. A busbar implies a rigid component.

[0003] To connect / disconnect two busbars, a coupling is used. Due to the high current carrying capacity, a large contact surface is required, and this contact must be mechanically secured. This is typically achieved by screwing the two busbars together.

[0004] According to one embodiment, both busbars can include holes, and screws can be inserted into these holes and secured with nuts.

[0005] For safety reasons, any part of the busbar must be protected in accordance with IP2X requirements, which means that the conductive surfaces of the busbar must be protected to prevent any contact between them and any body parts of a living organism.

[0006] This is typically achieved by keeping the busbar away from the joint, usually through an insulating sheath that completely surrounds the busbar. However, at the joint, any such insulation must be removed to ensure electrical contact between the two busbars.

[0007] Therefore, the connector must provide IP2X protection for this contact.

[0008] Because screws and nuts are metal components, they are typically energized to provide sufficient contact force and to press against the busbar. According to existing technology, the coupling places the screws and nuts in an energized state. This means that the screws need to be protected, for example, through overmolding. This solution is costly and bulky. Summary of the Invention

[0009] The present invention provides an alternative in which the screws and nuts do not come into electrical contact with any busbar, thereby eliminating any need for protection of the screws or nuts.

[0010] Therefore, the present invention relates to an electrical connector comprising a housing, a screw, and a nut, wherein the housing is capable of accommodating the ends of an upper busbar and a lower busbar, the upper busbar including a first hole along a first axis, and the lower busbar including a second hole, wherein when the two busbars are engaged into the housing, the second axis of the second hole is aligned with the first axis of the first hole, and the two busbars are assembled by engaging the screw with the two holes and tightening the nut, thereby pressing the two busbars against each other, wherein the connector further includes a first insulating member, which is integrally cylindrical for insertion into the two holes and is hollow to accommodate the screw, thereby preventing any contact between the two busbars and the screw.

[0011] Some specific features or embodiments that can be used alone or in combination include: The electrical connection also includes a second insulating element, which includes a third hole engaged by a screw and disposed between the nut and the lower female connector to prevent any contact between the lower female connector and the nut. - The first and second insulating components are made of PPSGF40 plastic material. The housing includes a generally cylindrical chamber with a top opening for receiving a first insulator. The first insulator is slidable relative to the chamber along an axis parallel to the axis of the holes when two busbars are engaged into the housing, such that the first insulator can engage both holes in the following positions: an outer position, in which the first insulator is removed from the housing and does not engage either hole; an intermediate position, in which the first insulator engages only the first hole of the upper busbar; and a final position, in which the first insulator engages both holes. The housing and the first insulator include at least one latch capable of selectively engaging / disengaging and a corresponding number of recesses to lock the first insulator relative to the housing in an intermediate and / or final position. The bottom of the chamber is designed to tightly accommodate the nut, preventing rotation of the nut along the chamber's axis. The housing and the second insulator include at least one latch capable of selectively engaging / disengaging, and a corresponding number of recesses to lock / unlock the second insulator relative to the housing, thereby securing the nut in the bottom of the chamber. The housing also includes an upper slot for receiving the end of an upper busbar, the upper slot being generally perpendicular to the axis and including at least one latch capable of selectively locking / unlocking the end of the upper busbar when it is fully inserted into the upper slot; and a lower slot for receiving the end of a lower busbar, the lower slot being generally perpendicular to the axis and including at least one latch capable of selectively locking / unlocking the end of the lower busbar when it is fully inserted into the lower slot. - When the upper busbar is fully inserted into the upper slot, the first axis of the first hole is aligned with the axis, and when the lower busbar is fully inserted into the lower slot, the second axis of the second hole is aligned with the axis.

[0012] The present invention also relates to a method for assembling such an electrical connector, comprising the following steps: Insert the nut into the bottom of the chamber. - Place and lock the second insulating element in the chamber. Insert the upper busbar into the upper slot of the housing. - Place the first insulating element in the chamber and slide it to the middle position to fix the upper busbar. Insert the lower busbar into the lower slot of the housing. - Slide the first insulator to its final position to secure the upper and lower busbars. Insert the screw into the first insulating part and screw the screw into the nut. Attached Figure Description

[0013] Other features, details and advantages of the invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings, wherein: Figure 1 An electrical connector with two busbars is shown in a 3D view. Figure 2 The electrical connector is shown in an exploded perspective view. Figure 3 The casing is shown in a 3D view. Figure 4 The assembly is shown in a sectional perspective view, with the first insulating member in the middle position. Figure 5 The assembly is shown in a sectional perspective view, with the first insulator in its final position. Figure 6 The second insulating element, locked in place, is shown in a top view. Figure 7 The sectional perspective view shows the shell with the first motherboard as seen from a top view. Figure 8 The sectional perspective view shows the shell with the first motherboard as seen from a side view. Figure 9 The housing and first busbar are shown in a 3D view before insertion. Figure 10 The 3D view shows the housing and the first busbar after insertion and before locking. Figure 11 The housing, the first busbar after locking, and the second busbar before insertion are shown in a 3D view. Figure 12 The housing and the second busbar are shown in a 3D view after the second busbar has been inserted and locked. Detailed Implementation

[0014] One object of the present invention is an electrical connector 1. The electrical connector 1 includes a housing 2, a screw 3, and a nut 4. The housing 2 is configured to receive the end of an upper busbar B1 and the end of a lower busbar B2. The upper busbar B1 includes a first hole H1 along a first axis A1. The lower busbar B2 includes a second hole H2 along a second axis A2, wherein when the busbars B1 and B2 are engaged in the housing 2, the second axis A2 is aligned with the first axis A1.

[0015] Once connected to housing 2, two busbars B1 and B2 are assembled by engaging the two holes H1 and H2 with screws 3 and tightening nuts 4. When screws 3 are tightened toward nuts 4, they press busbars B1 and B2 together to ensure electrical contact between them.

[0016] When screws 3 and nuts 4 are tightened, they will typically come into contact with either busbar B1 or B2. Since screws 3 and nuts 4 are metal parts, they will also typically be energized when busbars B1 and B2 are energized.

[0017] However, according to one feature, the coupling 1 also includes a first insulating member 5. The first insulating member 5 is generally cylindrical. Therefore, the first insulating member 5 can be inserted into the two holes H1, H2. Furthermore, the first insulating member 5 is a hollow structure and can accommodate the screw 3. Since the first insulating member 5 is placed between the screw 3 and the busbars B1, B2, it advantageously prevents any contact between the busbars B1, B2 and the screw 3. Because the first insulating member 5 is made of an insulating material such as plastic, the screw 3 will not be energized even if current flows through the busbars B1, B2.

[0018] Therefore, IP2X protection becomes simpler. Busbars B1 and B2 still require protection to prevent any possible contact with body parts. This is achieved by housing 2 surrounding the ends of busbars B1 and B2, where they are not sheathed. However, screw 3 does not need protection because it is unlikely to be energized.

[0019] As shown in the figure, the first insulating member 5 includes a first tubular lower portion 5b. The lower portion 5b is intended to engage with two holes H1 and H2 and is engaged by a screw 3. The first insulating member 5 includes a second tubular upper portion 5a. The upper portion 5a is concentric with the lower portion 5b. The upper portion 5a is intended to surround the screw head of the screw 3. Between these two portions 5a and 5b, the first insulating member 5 also includes a shoulder 5c, such that when tightened, the screw head of the screw 3 can press against the upper busbar B1 without contacting it.

[0020] According to another feature, the electrical connector 1 also includes a second insulator 6. The second insulator 6 is generally flat. It includes a third hole 7. The third hole 7 is capable of receiving the screw 3. Since the second insulator 6 is located between the nut 4 and the nearest busbar, i.e., the lower busbar B2, it advantageously prevents any contact between the lower busbar B2 and the nut 4. Since the second insulator 6 is made of an insulating material such as plastic, the nut 4 will not be energized even if current flows through the busbars B1 and B2.

[0021] The two insulating components 5 and 6 can be made of any insulating material. According to another feature, they can advantageously be made of PPSGF40 plastic material. This PPSGF40 material exhibits high dimensional stability, very good chemical resistance, and good electrical and thermal insulation properties.

[0022] In this application, a key characteristic of PPS GF40 is its insensitivity to dimensional changes under the influence of temperature and time. This is advantageous because when screw 3 is tightened, insulators 5 and 6 are subjected to tightening torque. This characteristic prevents torque loss after heating or aging of insulators 5 and 6.

[0023] According to another feature, the housing 2 includes an integrally cylindrical chamber 10. The chamber 10 includes a top opening. The chamber 10 is preferably closed at its bottom 10b. The chamber 10 is slidably capable of accommodating a first insulator 5. The first insulator 5 is slidable relative to the chamber 10 along a generally vertical axis A of the chamber. When the busbars B1 and B2 are fully engaged in the housing 2, the axis A of the chamber is aligned with the axes A1 and A2 of the holes. Therefore, the first insulator 5 can engage holes H1 and H2. These three axes also correspond to the axes of the screws 3.

[0024] The first insulator 5 is slidable along the cavity 10 between three different positions. The first position is the external position, in which the first insulator 5 is outside the housing 2. In this external position, more specifically as follows: Figure 2 and Figure 10 As shown, the first insulating element 5 does not engage with any of the holes H1 or H2.

[0025] The second position is the middle position. In this middle position, more specifically, as... Figure 4 and Figure 11 As shown, the first insulating member 5 only engages with the first hole H1 of the upper busbar B1.

[0026] The third position is the final position. In this final position, more specifically, as... Figure 5 and Figure 12 As shown, the first insulating element 5 is connected to two holes H1 and H2.

[0027] According to another feature, the housing 2 and the first insulating member 5 include at least one latch 8 capable of selectively engaging / disengaging and a corresponding number of recesses 9, 9i, 9f. When the latch 8 engages in the corresponding recesses 9, 9i, 9f, the first insulating member 5 is locked relative to the housing 2, in an intermediate or final position, respectively.

[0028] As shown in the figure, the latch 8 is supported by the housing 2, and recesses 9, 9i, and 9f are drilled into the first insulating member 5. The latch 8 includes ends capable of selectively engaging the recesses 9, 9i, and 9f. The latch 8 is an elastic member. In the stationary state, the latch 8 engages with the recesses 9, 9i, and 9f. Its elasticity allows it to disengage. Therefore, the latch 8 is in the default engaged / locked state.

[0029] The first insulating member 5 includes a first series of recesses 9i, corresponding to and defining the intermediate position. The first insulating member 5 also includes a second series of recesses 9f, corresponding to and defining the final position.

[0030] As an alternative, the latch 8 can be carried by the first insulating member 5, while the recesses 9, 9i, and 9f can be drilled into the housing 2; a combination of the two is also possible.

[0031] According to another feature, the bottom 10b of the chamber 10 can tightly accommodate the nut 4, thereby preventing the nut 4 from rotating along its axis A. For example, as shown, for the hexagonal nut 4, the bottom 10b of the chamber 10 is advantageously hexagonal and tightly fitted relative to the nut 4.

[0032] According to another feature, the housing 2 and the second insulator 6 include at least one latch 11 capable of selectively engaging / disengaging and a corresponding number of recesses 12. This allows the second insulator 6 to be selectively locked / unlocked relative to the housing 2. This ensures the closure of the bottom 10b of the chamber 10. The closure secures the nut 4 within the chamber 10. Due to the elasticity of the latch 11 material, the second insulator 6 can be selectively locked and unlocked. The latch 11 can be located on the second insulator 6 or on the housing 2. As shown, the latch 11 can be located on both simultaneously. The corresponding recesses 12 are also present.

[0033] According to another characteristic, more specifically, such as Figure 3 , 7 As shown in Figures 8, 9, and 11, the housing 2 includes an upper slot 13 and a lower slot 15.

[0034] The upper slot 13 is capable of accommodating the end of the upper busbar B1. The upper slot 13 is substantially perpendicular to the axis A of the chamber. The upper slot 13 preferably includes at least one latch 14, which can selectively lock / unlock the end of the upper busbar B1 when the upper busbar B1 is fully inserted into the upper slot 13. More specifically as... Figure 7 As shown, latch 14 locks upper busbar B1 by blocking shoulder B1b of upper busbar B1.

[0035] The lower slot 15 is capable of receiving the end of the lower busbar B2. The lower slot 15 is substantially perpendicular to the axis A of the chamber. The lower slot 15 preferably includes at least one latch 16, which is capable of selectively locking / unlocking the end of the lower busbar B2 when the lower busbar B2 is fully inserted into the lower slot 15. As not shown, the latch 16 locks the lower busbar B2 by blocking the shoulder of the lower busbar B2.

[0036] According to another feature, when the upper busbar B1 is fully inserted into the upper slot 13, the axis A1 of the first hole H1 is aligned with the axis A of the chamber. When the lower busbar B2 is fully inserted into the lower slot 15, the axis A2 of the second hole H2 is aligned with the axis A of the chamber. This allows the screw 3, which is also aligned with the axis A of the chamber, to engage the two holes H1 and H2, and to assemble the two busbars B1 and B2 while tightening the nut 4.

[0037] The present invention also relates to a method for connecting two busbars B1 and B2 using such an electrical connector 1. The method includes the following steps.

[0038] In the first step, nut 4 is inserted into the bottom 10b of chamber 10. In the second step, the second insulator 6 is placed and locked in chamber 10 to secure nut 4. In the third step, the end of upper busbar B1 is inserted into the upper slot 13 of housing 2. This insertion continues until a stop is encountered upon full insertion, at which point, if at least one latch 14 is present, locks upper busbar B1 in place. In the fourth step, first insulator 5 is inserted into chamber 10. First insulator 5 is slid to the middle position. This inserts the lower part 5b into the first hole H1, thereby securing upper busbar B1 in housing 2. In the fifth step, lower busbar B2 is inserted into the lower slot 15 of housing 2. This insertion continues until a stop is encountered upon full insertion, at which point, if at least one latch 16 is present, locks lower busbar B2 in place. In the sixth step, first insulator 5 is slid to the final position. This inserts the lower part 5b into the second hole H2, thereby securing both the upper busbar B1 and the lower busbar B2. In the seventh step, the screw 3 is inserted into the first insulating member 5 along its axis A and screwed into the nut 4.

[0039] While presently preferred embodiments of the invention have been shown and described, it should be clearly understood that the invention is not limited thereto, but can be embodied and practiced in various ways within the scope of the following claims.

[0040] List of reference numerals

[0041] 1: Connector, 2: Shell, 3: Screws 4: Nuts 5: First insulating component, 5a: Upper part, 5b: lower part, 5c: Shoulder area 6: Second insulating component, 7: Third hole, 8: Bolt, 9: Dent, 9f: Final pit, 9i: A pit in the middle, 10: Chamber, 10b: The bottom of the chamber. 11: Bolt, 12: pit, 13: upper notch, 14: Bolt, 15: lower notch, 16: Bolt, A: The axis of the chamber. A1, A2: The axis of the hole. B1: Upper motherboard, B1a: Shoulder area B2: Lower motherboard, H1: First hole, H2: Second hole.

Claims

1. An electrical coupling (1), comprising a housing (2), a screw (3), and a nut (4), wherein, The housing (2) is capable of accommodating the end of the upper busbar (B1) and the end of the lower busbar (B2). The upper busbar (B1) includes a first hole (H1) along a first axis (A1), and the lower busbar (B2) includes a second hole (H2) along a second axis (A2). When the two busbars (B1, B2) are joined to the housing (2), the second axis (A2) is aligned with the first axis (A1) of the first hole (H1). The two busbars (B1, B2) are assembled by engaging the screw (3) with the two holes (H1, H2) and tightening the nut (4), thereby pressing the two busbars (B1, B2) against each other. The connecting member (1) is characterized in that the connecting member (1) further includes a first insulating member (5), which is cylindrical in shape and is used to insert into the two holes (H1, H2), and is hollow to accommodate the screw (3), thereby preventing any contact between the two busbars (B1, B2) and the screw (3).

2. The electrical connector (1) according to claim 1, characterized in that, It also includes a second insulating element (6), which includes a third hole (7) engaged by the screw (3) and is disposed between the nut (4) and the lower busbar (B2) to prevent any contact between the lower busbar (B2) and the nut (4).

3. The electrical connector (1) according to claim 2, characterized in that, The first insulating element (5) and the second insulating element (6) are made of PPS GF40 plastic material.

4. The electrical connector (1) according to any one of claims 1 to 3, characterized in that, The housing (2) includes a generally cylindrical chamber (10) with a top opening for accommodating the first insulating member (5), which is capable of sliding relative to the chamber (10) along an axis (A) of the chamber parallel to the axes (A1, A2) of the holes when the two busbars (B1, B2) are engaged in the housing (2), such that the first insulating member (5) can engage the two holes (H1, H2) in the following positions: an external position in which the first insulating member (5) is removed from the housing (2) and does not engage any of the two holes (H1, H2); an intermediate position in which the first insulating member (5) engages only the first hole (H1) of the upper busbar (B1); and a final position in which the first insulating member (5) engages the two holes (H1, H2).

5. The electrical connector (1) according to claim 4, characterized in that, The housing (2) and the first insulating member (5) include at least one latch (8) capable of selectively engaging / disengaging and a corresponding number of recesses (9i, 9f) to lock the first insulating member (5) relative to the housing (2) in the intermediate position and / or the final position.

6. The electrical connector (1) according to any one of claims 1 to 5, characterized in that, The bottom (10b) of the chamber (10) is able to tightly accommodate the nut (4) to prevent the nut (4) from rotating along the axis (A) of the chamber (10), and the housing (2) and the second insulator (6) include at least one latch (11) that can be selectively engaged / disengaged and a corresponding number of recesses (12) to lock / unlock the second insulator (6) relative to the housing (2), thereby securing the nut (4) in the bottom (10b) of the chamber (10).

7. The electrical connector (1) according to any one of claims 1 to 6, characterized in that, The housing (2) further includes an upper slot (13) for receiving the end of the upper busbar (B1), the upper slot (13) being generally perpendicular to the axis (A) and including at least one latch (14) capable of selectively locking / unlocking the end of the upper busbar (B1) when the upper busbar (B1) is fully inserted into the upper slot (13); and a lower slot (15) for receiving the end of the lower busbar (B2), the lower slot (15) being generally perpendicular to the axis (A) and including at least one latch (16) capable of selectively locking / unlocking the end of the lower busbar (B2) when the lower busbar (B2) is fully inserted into the lower slot (15).

8. The electrical connector (1) according to claim 7, characterized in that, When the upper busbar (B1) is fully inserted into the upper slot (13), the first axis (A1) of the first hole (H1) is aligned with the axis (A), and when the lower busbar (B2) is fully inserted into the lower slot (15), the second axis (A2) of the second hole (H2) is aligned with the axis (A).

9. A method for assembling an electrical connector (1) according to any one of claims 1 to 8, comprising the following steps: - Insert the nut (4) into the bottom (10b) of the chamber (10), - Place and lock the second insulating element (6) in the chamber (10), - Insert the upper busbar (B1) into the upper slot (13) of the housing (2), - Place the first insulating member (5) in the chamber (10) and slide the first insulating member (5) to the middle position to fix the upper busbar (B1). - Insert the lower busbar (B2) into the lower slot (15) of the housing (2), - Slide the first insulating member (5) to its final position to fix the upper busbar (B1) and the lower busbar (B2). Insert the screw (3) into the first insulating member (5) and screw the screw (3) into the nut (4).

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