Connection channel for high-voltage applications in a motor vehicle

Abstract

Connection channel (1) for high-voltage applications in a motor vehicle, wherein the connection channel (1) for guiding a flexible conductor (3) between an HV interface (2) and an energy module (4) is formed from two partial channels (10, 11) arranged at an angle (W) to each other, and wherein one of the partial channels (10, 11) has a groove (N) serving as a guide rail and the other partial channel (10, 11) has a spring (F) engaging with the groove (N), wherein the groove (N) and spring (F) are formed such that the spring (F) is movable along the groove (N).

Description

[0001] The invention relates to the connection of high-voltage interfaces within a vehicle, in particular the provision of tolerance compensation for assembly.

[0002] Electrical connections between multiple electrical conductors, e.g., in a battery, are known, for example, from documents DE 10 2017 210 425 A1, WO 2022 / 073 945 A1, and DE 10 2020 211 091 A1. Connecting an electrical conductor between the busbar and the high-voltage interface (HV interface) can be achieved using a rigid arrangement. While this allows for good positioning, it does not compensate for tolerances. Alternatively, the connection can be made using flexible conductors between the busbar and the high-voltage interface (HV interface), which allows for good tolerance compensation but not precise positioning.

[0003] Therefore, an object of this invention is to provide a connection between the busbar and the high-voltage interface (HV interface) that enables both positioning and tolerance compensation. This object is achieved according to the invention by the features of the independent claims. Advantageous embodiments are the subject of the dependent claims.

[0004] A connection channel for high-voltage applications in a motor vehicle is proposed, wherein the connection channel for guiding a flexible conductor between an HV interface and an energy module is formed from two sub-channels arranged at an angle to each other, and wherein one of the sub-channels has a groove serving as a guide rail and the other sub-channel has a spring which engages with the groove, wherein the groove and spring are formed such that the spring is movable along the groove.

[0005] Furthermore, it is provided that the groove is wider than the tongue and that an outer wall of the groove is formed with a preload in the direction of the tongue.

[0006] Furthermore, it is provided that the groove has a length that corresponds to the sum of the length of the spring and a specified tolerance distance.

[0007] Furthermore, it is stipulated that the tolerance range will be less than one centimeter.

[0008] Furthermore, it is provided that the groove has at least one detent at one upper end area.

[0009] Furthermore, it is planned that the angle at which the partial channels are arranged to each other will be 90 degrees.

[0010] Furthermore, a system is proposed comprising an HV interface, a power module, the connection channel, and a flexible conductor which is guided in the connection channel and is electrically contacted at one end with an HV busbar of the HV interface and at the other end with a busbar of the power module.

[0011] Furthermore, a motor vehicle featuring the system is proposed.

[0012] Further features and advantages of the invention will become apparent from the following description of exemplary embodiments of the invention, with reference to the figures in the drawing, which shows details of the invention, and from the claims. The individual features can be implemented individually or in any combination in a variant of the invention.

[0013] Preferred embodiments of the invention are explained in more detail below with reference to the accompanying drawing. Fig. Figure 1 shows a schematic sectional view of a connecting channel according to an embodiment of the present invention. Fig. Figure 2 shows a schematic sectional view of a system consisting of a connection channel, HV interface and energy module according to an embodiment of the present invention. Fig. Figure 3 shows a schematic sectional view in the AA direction from Fig. 2. Fig. 4 shows a detailed view of D from Fig. 3. Fig. Figure 5 shows a schematic sectional view in the BB direction from Fig. 2.

[0014] In the following figure descriptions, identical elements or functions are marked with the same reference symbols.

[0015] The basic concept of the invention is to provide an improved connection option in high-voltage (HV) applications in the automotive sector between the energy module 4, more precisely its busbar 40, and the high-voltage interface (HV interface) 2, which, for example, has a socket 20 and an HV busbar 21, of an (HV) energy storage device 5 of a motor vehicle. This connection option is intended to provide tolerance compensation T (z-direction in the figures) for the mounting of the (housing) cover 50 to the (HV) energy storage device 5, as well as simultaneously enabling the most precise possible positioning of the HV interface 2.

[0016] The proposed connection option is formed as connection channel 1 and in Fig. Figure 1 is shown schematically. It is part of the (HV) storage unit 5. Here, a side view of a proposed connection channel 1 is shown, which is formed from two sub-channels 10, 11 arranged at an angle W to each other. The connection channel 1 serves to guide a flexible conductor 3, which connects the HV interface 2 to the energy module 4. Its function is explained below with reference to the diagram in Figure 1. Fig. Systems 2 to 5 shown are described in detail.

[0017] The in Fig. The system shown in Figure 2 as a schematic sectional view essentially represents the (HV) storage unit 5 with (housing) cover 50. The (HV) storage unit 5 includes an HV interface 2, the aforementioned connection channel 1, and an energy module 4 with several energy cells connected via a busbar 40.

[0018] The HV interface 2, for example, has a socket 20 with an HV busbar 21 as an electrical connection to one end of a flexible conductor 3 within the connection channel 1. Part of the socket 20 protrudes through the (housing) cover 50 in the (z-direction) to provide a connection to the outside of the (HV) storage unit 5. The socket 20 typically points towards the interior of the vehicle, and its housing 22 is attached to the (housing) cover 50, for example, by screws.

[0019] The flexible conductor 3 is guided within the connection channel 1 and electrically connected at one end to the HV busbar 21 and at the other end to the busbar 40 of the power module 4 (as part of the (HV) storage unit 5). Since the path between the HV busbar 21 and the busbar 40 is not straight due to the geometric arrangement of the socket 21 and the power module 4, the flexible conductor 3 must be guided in an arc. For this reason, the connection channel 1 is also angled (with an angle W). It is made of a rigid material such as plastic and therefore provides good positioning.

[0020] To enable the required tolerance compensation T (in the z-direction), the connecting channel 1 is designed to be two-part. It therefore has two sub-channels 10 and 11, which are arranged at an angle W to each other, as shown in Fig. 1 and Fig. Figure 2 shows that in the embodiment shown, the angle W is at least approximately 90 degrees. In the area where the two partial channels 10 and 11 merge, they are movably connected in the z-direction. This is achieved by providing a type of tongue-and-groove connection, as shown in the sectional views of the Fig. 3 and Fig. 5 shown. In Fig. 3 is a section in the AA direction of the in Fig. The system shown in section 2 is illustrated. Fig. 5 is a cut in the BB direction of the in Fig. 2 systems shown.

[0021] The tongue-and-groove connection is achieved by having one of the partial channels (in the illustrated embodiment, this is partial channel 11) in its housing a groove N serving as a guide rail, and the other partial channel (in the illustrated embodiment, this is partial channel 10) having a spring F in the form of a rib that engages in the groove N and is movable within it (in the z-direction). To allow the spring F to move within the groove N, the groove N is wider (x-direction) than the spring F. The tolerance range S (see detailed view in Fig. 5), which can be traveled in this way, advantageously corresponds at most to the tolerances known for the system and is usually a few millimeters. Therefore, the maximum tolerance distance S provided is less than one centimeter. For this purpose, the groove advantageously has a length L. N (in the z-direction) that sums the length L F the spring F (in the z-direction) and the tolerance distance S.

[0022] To enable precise guidance (position and angular offset) in the x-direction, in one embodiment the groove N has a preload V. Advantageously, the outer wall of the housing of the sub-channel (here sub-channel 11) is inclined towards groove N so that the wall of sub-channel 10, which forms the spring F, is clamped there. This is described in detail in Fig. 4 shown, which is a detailed view D from Fig. 3 shows.

[0023] As in Fig. As can be seen in Figure 5, the groove N is open in the z-direction so that the partial channel 10, which contains the spring F, can be inserted during assembly. To limit the tolerance range S and prevent the partial channel 10 with the spring F from extending out of the groove N, a detent 6 is provided in one embodiment in the region of the open end of the groove N of the partial channel 11. This detent prevents the spring F from extending out of the groove N in the z-direction by acting as a block. The detent 6 can be designed in various ways. For example, it can be formed (partially) circumferentially from the outer wall of the groove N of the partial section 11 and be movable such that it yields (-z) when the spring F is inserted, allowing the spring F to pass through, but does not yield in the other direction (+z). As shown in Figure 5, the groove N is open in the z-direction. Fig. As can be seen in 5, the detent 6 can define the tolerance distance S, i.e., the distance between the lower end of the detent 6 and the upper end of the spring F defines the tolerance distance S.

[0024] By providing the connection channel 1 equipped with groove N and tongue F, both precise positioning (in the x-direction) and tolerance compensation T in the z-direction can be achieved, which facilitates the assembly of the overall system and improves the interface connection.

[0025] The flexible conductor, for example in the form of a cable, braided wire, or multilayer, serves to conduct electrical current. It is routed in connection channel 1.

[0026] Depending on the geometric arrangement of the socket 21 and the energy module 4 relative to each other, the angle W can also be other than essentially 90 degrees, advantageously being an obtuse angle.

[0027] The terms busbar and current rail are essentially identical and refer to a rail made of an electrically conductive material, used for high-current distribution. They are sometimes also called busbars.

[0028] The connecting channel 1 is advantageously located in the Fig. The system shown in section 1 is used. The system is part of a (HV) storage unit 5, which is used in a motor vehicle. Reference symbol list 1 connection channel 10, 11 sub-channels 2 HV interface 20 sockets 21 HV-Busbar 22 Housing socket 3 flexible ladders 4 Energy module 40 busbar 5 (HV) storage units 50 (housing) covers 6. Locking mechanism F spring L F Length of spring N Nut L N Length of groove S tolerance range V Preload W Shop

Claims

[1] Connection channel (1) for high-voltage applications in a motor vehicle, wherein the connection channel (1) for guiding a flexible conductor (3) between an HV interface (2) and an energy module (4) is formed from two partial channels (10, 11) arranged at an angle (W) to each other, and wherein one of the partial channels (10, 11) has a groove (N) serving as a guide rail and the other partial channel (10, 11) has a spring (F) engaging with the groove (N), wherein the groove (N) and spring (F) are formed such that the spring (F) is movable along the groove (N). [2] Connecting channel according to claim 1, wherein the groove (N) is wider than the spring (F) and an outer wall of the groove (N) is formed with a preload (V) in the direction of the spring (F). [3] Connecting channel according to claim 1 or 2, wherein the groove (N) has a length (L N ) exhibits which is the sum of the length (L F ) of the spring (F) and a predetermined tolerance distance (S). [4] Connecting channel according to claim 3, wherein the tolerance distance (S) is less than one centimeter. [5] Connecting channel according to one of the preceding claims, wherein the groove (N) has at least one detent (6) at an upper end region thereof. [6] Connecting channel according to one of the preceding claims, wherein the angle (W) at which the partial channels (10, 11) are arranged relative to each other is 90 degrees. [7] System comprising an HV interface (2), a power module (4), a connection channel (1) according to one of the preceding claims, and a flexible conductor (3) which is guided in the connection channel (1) and is electrically contacted at one end with an HV busbar (21) of the HV interface (2) and at another end with a busbar (40) of the power module (4). [8] Motor vehicle comprising the system according to claim 7.

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