Terminal for flat power cable, connection assembly or connector comprising such terminal

Abstract

A terminal (2) for a flat power connector cable (3) for automotive applications. The terminal (2) comprises an electrically conductive contact device (5), a first branch (11) and a second branch (12), the branches (11, 12) being formed in a same connection plate (6). The first branch (11) extends in a first plane. The first branch (11) comprises an attachment device (15) configured to connect the contact device (5) to the first branch (11). The second branch (12) comprises a solder surface (16) configured to be electrically connected to a flat power cable (3). A connection assembly (1) comprising such a terminal (2). A power connector comprising such a terminal (2). A method of manufacturing such a power connector.

Description

Technical Field

[0001] This disclosure relates to the field of electrical connectors for motor vehicles. For example, such connectors are used in charging sockets or inlets to supply power (particularly direct current) to batteries in electric or plug-in hybrid vehicles. Background Technology

[0002] Currently, power connectors consist of terminals that are mechanically and electrically connected to round cables or busbars. These round cables or busbars serve as distribution elements to transmit electricity between terminals of a charging socket or inlet (or any other device) and, for example, a battery and / or a motor and / or a converter and / or an inverter. The shape of these distribution elements is important for managing temperature rise caused by high-intensity current passing through the terminals and these distribution elements. It should be noted that excessive temperature rise can damage the integrity of the connector, or even the integrity of other components of the vehicle, or even the integrity of the vehicle itself. Temperature control circuitry can temporarily interrupt or suspend charging for this purpose, but in this case, charging time will be prolonged. To avoid or limit such interruptions, distribution elements such as round cables or busbars can be used as heat sinks. Their shape can then be determined to optimize heat dissipation in the terminals. For this purpose, they can be sized, even designed to be oversized, which will have a significant impact, especially on the following aspects: - The amount of material required to manufacture them - Their dimensions and the dimensions of the connectors they are integrated into or connected to. -The price of these components and the price of the connectors they are integrated into or connected to. - Their weight and the weight of the connectors they are integrated into or connected to, etc. Summary of the Invention

[0003] The present invention proposes a terminal designed to at least partially mitigate at least one of the aforementioned disadvantages (size, price, weight, etc.).

[0004] This terminal is a terminal for a flat power connector cable used in motor vehicles. The flat power cable is made of, for example, one of the following materials: aluminum-based material, copper-based material, aluminum alloy, copper alloy, etc. The flat power cable has, for example, a width between 50 mm and 120 mm and a thickness between 0.5 mm and 1.5 mm. The terminal includes at least one conductive contact device, a first branch, and a second branch, wherein the first and second branches are formed by a single connecting plate of conductive material. The first branch extends longitudinally substantially in a first plane (parallel to the first plane) between a first end and a second end. The first branch includes an attachment device configured to connect or secure the contact device to the first branch. The contact device extends substantially perpendicular to the first plane between a fixed end and a free end connected to the first branch. The second branch is connected to a first end of the first branch and extends substantially longitudinally in a direction at a non-zero angle (e.g., 90° or close to 90°) to the first branch. The second branch also includes a solder surface configured to be electrically connected to the flat power cable.

[0005] Therefore, due to this terminal, and especially due to the welded surface on the second branch, flat power cables can be used instead of cables or busbars with circular cross-sections. For the same cable cross-sectional area (i.e., essentially for the same current transmission intensity), flat cables offer a larger outer circumferential surface area (i.e., a larger perimeter) than cables with circular cross-sections. The same applies to busbars with rectangular cross-sections, as they are thicker than flat cables. Therefore, flat power cables dissipate heat better and provide a better radiator.

[0006] Furthermore, depending on its thickness, a flat cable occupies less space than a cable with a circular cross-section or a busbar, and it can be more flexible than a cable with a circular cross-section or a busbar. This can save space and / or make it easier to integrate into connectors and / or their surrounding environment.

[0007] Advantageously, the first and second branches extend in mutually perpendicular directions. This type of configuration has the advantage that the terminals can be more easily integrated into the connector, and / or the connector can be designed more simply. In practice, this facilitates the use of two identical terminals. Furthermore, using identical terminals reduces the number of parts to be designed and managed. Various different tools and / or equipment are not required for their manufacture. When two identical terminals are integrated into a single connector, an advantageous layout can be achieved by arranging their second branches above and below the pin connections of the two terminals, respectively. In this case, a compact arrangement can also be obtained when the first and second branches are perpendicular to each other.

[0008] Advantageously, a first end of the first branch connects to the second branch at a joint, the joint being arranged asymmetrically with respect to the length of the second branch. This allows the pins to be moved closer or further apart (depending on design and / or interface standard requirements) while the joint is moved along the second branch, without loss of any total length. For example, advantageously, the second branch has a first portion between the joint and a first free end and a second portion between the joint and a second free end, the second free end being opposite the first free end along the length of the second branch, the first portion being shorter than the second portion.

[0009] Advantageously, both the first and second branches extend within (parallel to) the first plane. This simplifies the terminal manufacturing process (because the plate can be cut—e.g., by simple stamping—without subsequent bending or machining). It also facilitates a more uniform distribution of current lines, which helps limit heat generation. In this case, for example, the solder surface extends in a second plane perpendicular to the first plane. In this case, the solder surface essentially corresponds to a cross-section of the plate perpendicular to the first plane. This again makes the connector design more compact and simpler. In particular, this allows the connector length to be increased (in a direction parallel to the longitudinal direction of the pins), especially when it is a straight connector (this increase is reflected in another dimension when the connector is angled). However, according to a variation, the solder surface may extend in a second plane parallel to the first plane (e.g., in a right-angle connector), or at other angles between the first and second planes.

[0010] According to another aspect, this disclosure relates to a connection assembly comprising the terminals disclosed herein and a flat power cable soldered to a soldering surface. It may be advantageous to use the entire or at least the maximum length of a second branch. For example, the flat power cable has a width greater than or equal to 90% of the length of the second branch. For example, the width of the flat power cable is between 50 mm and 120 mm (more specifically, for example, between 60 mm and 100 mm), and the length of the second branch is substantially equal to that width.

[0011] According to another aspect, this disclosure relates to a connection assembly including a power connector comprising at least two terminals as disclosed herein, wherein respective second branches of the two terminals are symmetrically arranged about a median plane about a longitudinal axis of a contact device passing through each of the two terminals, such that the solder surfaces of the two terminals are parallel (and above and below the median plane, respectively).

[0012] According to another aspect, this disclosure relates to a method of manufacturing a power connector, wherein at least one terminal as disclosed herein is provided, a flat power cable having a width between 50 mm and 120 mm (more particularly, for example, between 60 mm and 100 mm) is provided, and the free end of the flat power cable is soldered to a soldering surface. For example, the soldering is performed by resistance welding, laser welding, or ultrasonic welding.

[0013] Advantageously, in this method, two terminals as disclosed herein are provided and housed in a connector housing, the respective second branches of the two terminals being symmetrically arranged about the mid-plane of the longitudinal axis of the contact device passing through each of the two terminals, such that the solder surfaces of the two terminals are parallel. Attached Figure Description

[0014] Other features and advantages of the invention will become apparent from the detailed description and the accompanying drawings, in which: - Figure 1 A schematic perspective view of a connection assembly is shown, which includes two power terminals, each power terminal connecting to a corresponding flat power cable; and - Figure 2 It shows Figure 1 A schematic perspective view of the connecting components shown from another angle. Detailed Implementation

[0015] exist Figure 1 and Figure 2 An example of a connection assembly 1 is shown. According to this example, the connection assembly 1 includes two terminals 2, each terminal 2 connecting to a flat power cable 3. Each flat cable 3 includes a conductive core 3a embedded in an insulating sheath 3b. Advantageously, the conductive core 3a is solid; in other words, it is not composed of strands. The two terminals 2 are housed in a housing 4 of an electrical connector for motor vehicles. This electrical connector, for example, is configured to establish a connection with a charging plug (not shown). Figure 1 and Figure 2 Only a portion of the wall of the housing 4 is shown. Advantageously, the housing 4 is made of molded plastic material. The housing 4 may optionally include other elements (not shown). For example, the housing 4 may include one or more housing components 4 (e.g., an inner housing and an outer housing). The housing 4 may also receive, support, or house one or more shielding elements, one or more sealing devices (e.g., interface seals, and / or one or more seals that ensure a seal around a flat cable, etc.), auxiliary docking devices, etc.

[0016] According to this example, terminal 2 is a male terminal. Each terminal 2 specifically includes a contact device 5 and a connecting plate 6 (or, the terminal may be a female terminal, which differs from the illustrated terminal primarily in the shape and / or structure of its contact device 5). The contact device 5 and the connecting plate 6 are made of a conductive material. For example, the contact device 5 is in the form of a machined rod. Alternatively, according to a variation not shown, the contact device 5 is formed into a hollow tube by cutting and rolling. The contact device 5 extends between a free end 7 and a fixed end 8. The contact device 5 includes a contact portion 9 toward the free end 7, which is configured to establish an electrical connection with the female terminal 2 of a mating connector (not shown). The contact device 5 is fixed to the connecting plate 6 via its fixed end 8.

[0017] For example, the diameter of contact device 5 is 8 millimeters (but it can vary by a few millimeters).

[0018] For example, the connecting plate is 6 mm thick, ranging from 4 to 7 mm.

[0019] Contact device 5 and connecting plate 6 can be made of the same or different materials. When they are made of different materials, specific materials best suited to their respective manufacturing, function, use, and / or characteristics can be selected. For example, even if contact device 5 and connecting plate 6 are made of copper alloy, contact device 5 can be made of a copper alloy suitable for its machinability and / or its wear resistance during various connection cycles. On the other hand, connecting plate 6 can be made of another copper alloy with better thermal and electrical conductivity and / or better solderability with the material constituting the conductive core 3a of the flat cable 3. Figure 1 and Figure 2 In the example shown, each contact device 5 is secured to the connecting plate 6 by a screw 10, which is screwed into a thread machined into the body of the contact device 5. Alternatively, according to a variation not shown, the fixed end 8 of the contact device 5 is flattened in a plane parallel to the longitudinal axis of the contact device 5, and the connecting plate 6 is fastened to the contact device 5 using bolts passing through the flattened portion of the connecting plate 6 and the fixed end 8. According to other variations, still not shown, each contact device 5 can be fastened to the connecting plate 6 in other ways: welding, press fitting, etc. Alternatively, according to another variation, the contact device 5 and the connecting plate 6 are formed from the same single piece.

[0020] The connecting plate 6 has a first branch 11 and a second branch 12, for example, which is cut from a sheet of conductive material. Figure 1 and Figure 2 In the example shown, the first branch 11 and the second branch 12 extend vertically perpendicular to each other in the same plane (parallel to the same plane).

[0021] The first branch 11 extends in the plane between the first end 13 and the second end 14. The first branch 11 includes attachment devices 15 configured to fix the contact device 5. In the example shown, these attachment devices 15 are formed by through holes through which the screw 10 can pass.

[0022] The second branch 12 has a welding surface 16 configured for electrical connection to the flat power cable 3. This welding surface 16 extends in a second plane perpendicular to the first plane. In this case, the welding surface 16 corresponds to the edge of the connecting plate 6 (i.e., the cross-section of the connecting plate 6 located at the edge of the connecting plate 6). Therefore, the thickness of the connecting plate 6 can be selected not only to make it suitable for conducting large currents and / or to form sufficient heat sinks, but also to enable it to establish a reliable connection with the flat cable 3. Alternatively, according to an example not shown, the connecting plate 6 is bent and / or configured such that the second branch 12 extends substantially in a plane perpendicular to the plane of the first branch 11. This configuration may have the advantage of presenting a welding surface 16 larger than the welding surface corresponding to the edge of the connecting plate 6. For example, the flat power cable 3 has a width greater than or equal to 90% of the length of the second branch 12. For example, the width of the flat power cable 3 is between 60 mm and 100 mm. Optionally, the welding surface 16 may be coated with a material that improves the solderability of the conductive core 3a of the flat power cable 3 to the second branch 12. For example, the solder surface 16 is plated with a nickel layer covering at least a portion of the solder surface 16 (particularly when the connecting plate is made of a copper-based material), and the nickel layer is at least partially covered with a silver plating. More typically, the solder surface 16 may be plated with one or more metal layers selected from silver, tin, nickel, or alloys including one or more of these metals.

[0023] according to Figure 1 and Figure 2 In the example shown, the first branch 11 connects to the second branch 12 at a joint 17, which is asymmetrically arranged relative to the length of the second branch 12. More specifically, according to this example, the second branch 12 has a first portion 18 between the joint 17 and a first free end 19 and a second portion 20 between the joint 17 and a second free end 21, the second free end 21 being opposite the first free end 19 along the length of the second branch 12, and the first portion 18 being shorter than the second portion 20. Alternatively, according to a variation not shown, the first portion 18 and the second portion 20 may be of the same length, or the length of either the first portion 18 or the second portion 20 may be equal to the length of the second branch 12 (in other words, in this case, one of the two portions 18 or 20 is absent).

[0024] According to the example, the connecting assembly 1 includes two terminals 2. The respective second branches of these two terminals 2 are arranged symmetrically about the mid-plane of the contact device 5 passing through each of the two terminals 2. Therefore, the welding surfaces 16 of the two terminals 2 are parallel. Figure 1 and Figure 2 As can be seen, the two terminals 2 are arranged end-to-end. Therefore, the respective first branches 11 of the two terminals 2 extend substantially parallel to each other in opposite directions from their first ends 13 toward their second ends 14, and the second branch 12 of one terminal 2 passes over the first branch 11 of the other terminal 2, and vice versa. This allows for greater compactness without reducing the length of the second branch 12. According to other variations not shown, other angles, other orientations, etc., can be envisioned to define the respective geometries of the first branch 11 and the second branch 12, to define the positions of the terminals 2 relative to each other, etc. According to other variations not shown, the connecting assembly 1 includes one or more terminals 2 as disclosed above. According to another embodiment, the terminal 2 is a female terminal instead of a male terminal, and the rod of the contact device 5 is replaced by a contact cage connected to the fixed end 8.

[0025] Flat cable 3 has at least the following advantages: It ensures better heat exchange than round cables or busbars. - Compared to round cables or busbars, its cross-section (and material quantity) can be reduced.

[0026] Connector plate 6 has at least one of the following advantages: - No bending operation, - Improves heat transfer (e.g., compared to cable crimped sections). - The shape facilitates welding and automation of the manufacturing process.

Claims

1. A terminal (2) of a flat power connector cable (3) for a motor vehicle, comprising a conductive contact (5), a first branch (11) and a second branch (12), wherein the first branch (11) and the second branch (12) are formed in the same connecting plate (6) made of a conductive material, the first branch (11) extending in a first plane between a first end (13) and a second end (14), the first branch (11) including an attachment (15) configured to connect the contact (5) to the first branch (11), the contact (5) extending perpendicular to the first plane between a fixed end (8) and a free end (7) connected to the first branch (11), the second branch (12) being connected to the first end (13) of the first branch (11) and extending longitudinally in a direction forming a non-zero angle with the first branch (11), the second branch (12) further including a solder surface (16) configured to be electrically connected to a flat power cable (3).

2. The terminal (2) according to claim 1, characterized in that, The first branch (11) and the second branch (12) extend in mutually perpendicular directions.

3. The terminal (2) according to claim 1 or 2, characterized in that, The first end (13) of the first branch (11) is connected to the second branch (12) at a joint (17), which is arranged asymmetrically with respect to the length of the second branch (12).

4. The terminal (2) according to claim 3, characterized in that, The second branch (12) has a first portion (18) between the joint (17) and the first free end (19) and a second portion (20) between the joint (17) and the second free end (21), the second free end (21) being opposite to the first free end (19) along the length of the second branch (12), the first portion (18) being shorter than the second portion (20).

5. The terminal (2) according to any one of the preceding claims, characterized in that, Both the first branch (11) and the second branch (12) extend in the first plane.

6. The terminal (2) according to any one of the preceding claims, characterized in that, The welding surface (16) extends in a second plane perpendicular to the first plane.

7. A connection assembly (1) comprising a terminal (2) according to any one of claims 1 to 6 and a flat power cable (3) welded to the welding surface (16).

8. The connecting component (1) according to claim 7, characterized in that, The flat power cable (3) has a width that is greater than or equal to 90% of the length of the second branch (12).

9. The connecting component (1) according to claim 7 or 8, characterized in that, The width of the flat power cable (3) is between 50 mm and 120 mm.

10. A power connector comprising at least two terminals (2) according to any one of claims 1 to 6, wherein, The corresponding second branch (12) of each of the two terminals (2) is arranged symmetrically about the mid-plane of the longitudinal axis of the contact device (5) passing through each of the two terminals (2), such that the welding surfaces (16) of the two terminals (2) are parallel.

11. A method for manufacturing an electrical connector, wherein, Provide at least one terminal (2) according to any one of claims 1 to 6, provide a flat power cable (3) having a width between 50 mm and 120 mm, and weld the free end of the flat power cable (3) to the welding surface (16).

12. A method for manufacturing an electrical connector, wherein, Two terminals (2) according to claim 3 or 4 are provided and housed in a connector housing (4), wherein the corresponding second branch (12) of each of the two terminals (2) is arranged symmetrically about the mid-plane of the longitudinal axis of the contact device (5) passing through each of the two terminals (2), such that the welding surfaces (16) of the two terminals (2) are parallel.

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