Assembly forming a threefold connection between an electrical conduction bar, a connector and an interconnector
Patent Information
- Application Number
- EP2024719232
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-03-27
- Filing Date
- 2024-03-12
- Publication Date
- 2026-02-11
AI Technical Summary
Achieving reliable and efficient electrical connections between high-voltage electrical conduction bars and electronic devices in complex environments like inverters in electric or hybrid vehicles is challenging due to mechanical stress, positioning issues, and the complexity of wired connections, which are difficult to automate and maintain over time.
A triple connection assembly using a metallic interconnector with a first end connected to the electrical conduction bar via a screw and a second end connected to an electronic device, providing mechanical fixing and electrical connection, allowing for direct connection at the input of the inverter and accommodating different positions and thermal variations.
The assembly simplifies and optimizes the connection process, reducing mechanical stress on electronic devices and ensuring reliable electrical connections, maintaining signal quality by positioning the connection close to the input or output of the inverter, thus minimizing signal disturbances.
Smart Images
Figure FR2024000030_03102024_PF_FP_ABST
Abstract
Description
[0001] Assembly forming a triple connection between an electrical conduction bar, a connector, and an interconnector
[0002]
[0001] The present invention claims priority from French application 2302893 filed on March 27, 2023, the content of which (text, drawings and claims) is incorporated herein by reference.
[0003] TECHNICAL FIELD OF THE INVENTION
[0004]
[0002] The present invention relates to the field of electrical and electronic equipment which comprises at least one electrical conduction bar and an electronic device, such as an electronic card, which must be electrically connected, for example for its power supply, to the electrical conduction bar.
[0005]
[0003] This type of electrical equipment is particularly present in electric or hybrid vehicles whose propulsion uses at least one electric motor. The present invention relates in particular, but not exclusively, to inverters particularly present in electric or hybrid vehicles.
[0006]
[0004] The present invention is thus explained below in detail within the framework of this preferred application, but is obviously applicable in numerous other applications.
[0007] STATE OF THE ART
[0008]
[0005] Electric or hybrid vehicles have a power system powered by a high-voltage battery. The high-voltage battery provides the energy required by the electric motor (or motors) to propel the vehicle.
[0009]
[0006] To control the motor, the use of an inverter, which converts the direct current from the high-voltage battery into alternating current, is well known. In particular, a polyphase inverter, for example three-phase, makes it possible to chop a direct voltage into a balanced polyphase (for example three-phase) sinusoidal voltage.
[0010]
[0007] For this purpose, the inverters comprise power modules comprising electronic switches, for example IGBTs (IGBT meaning insulated gate bipolar transistor), the opening and closing of which are controlled appropriately.
[0011]
[0008] This control is provided by an electronic power card or "driver" card. The functions of controlling the inverter system, its monitoring and its protection are provided by a control card. In certain applications, the control card and the power card can be combined into a single electronic card.
[0009] The electrical connections through which the electrical power passes through the inverter are made in the form of interconnection bars or electrical conduction bars (generally referred to by the English term "busbars").
[0012]
[0010] In this context, it may be necessary to make one or more electrical connections, or links, between the high voltage circuit and an electronic card. For example, a connection between the electrical conduction bars and the control card may be necessary, in order to ensure the electrical power supply of this card and / or for the acquisition of information on the high voltage circuit of the inverter and the system. This may allow, in particular, the observation of the voltage at the electrical conduction bars and / or the evaluation of the intensity of the currents flowing through them.
[0013]
[0011] A connection between an electrical conduction bar and an electronic card may be required for other functions. Such a connection may also be necessary for other equipment.
[0014]
[0012] Making such a connection can be complex. It must meet a certain number of constraints, starting with respecting the relative position between the electrical conduction bar and the electronic card. In particular, the physical connection between an electrical conduction bar and an electronic card located in different planes can cause mechanical stress on the electronic card which should be avoided. Relative positioning defects between the electrical conduction bar and the electronic card, as well as variations in this relative positioning and mechanical stresses linked to thermal variations in the system can increase these mechanical stresses in the system.
[0015]
[0013] The creation of a wired connection, which appears to be the simplest solution, is however industrially complex. Such a wired connection cannot be created by automated means. The reliability over time of such a wired connection is also uncertain.
[0016]
[0014] Furthermore, in a complex and cluttered environment of an inverter, it may be difficult to provide a connection area on the electrical conduction bar at the desired location, for example at the location closest to the corresponding connection point on the electronic board.
[0017]
[0015] There is therefore a need to develop a connection device between an electrical conduction bar and an electronic card (or any other electronic device) which resolves all or part of the problems mentioned above.
[0018] DISCLOSURE OF THE INVENTION
[0016] The present invention aims to remedy all or part of the drawbacks of the state of the art cited above.
[0019]
[0017] To this end, the invention relates to an assembly comprising at least one electrical conduction bar, an electrical connector, and an interconnector intended to electrically connect the electrical conduction bar to an electronic device. The interconnector is metallic. It comprises a first end shaped to be connected to the conduction bar using a first screw, and a second end shaped to be connected to the electronic device. The assembly comprises the first screw and a threaded element, the first screw being adapted to be screwed into the threaded element. The first end of the interconnector comprises an orifice adapted for the passage of the first screw and a rim around the orifice adapted to receive a head of said first screw in abutment.The first screw passes through an orifice of the electrical conduction bar and an orifice of the electrical connector, so that the first screw being screwed into the threaded element, the head of the first screw bears on said rim of the first end of the interconnector and clamps the electrical connector and the electrical conduction bar between them, thus ensuring the mechanical fixing and the electrical connection between the interconnector, the electrical conduction bar, and the electrical connector.
[0020]
[0018] A triple electrical connection is thus made between the interconnector, the electrical conduction bar, and the connector. The present invention thus makes it possible to connect an electronic device, for example an electronic card such as a control card of an inverter, to electrical conduction bars, in a simple, optimized and economical manner. Because the connection between the interconnector and the electrical conduction bar is made jointly with the connection between an electrical connector and said electrical conduction bar, this triple connection can be made directly at the input of an inverter, in particular before any filtering component. This connection can nevertheless be made, according to various embodiments of the invention, in any position in the inverter.
[0021]
[0019] A connection as close as possible to the input or output of the inverter allows incoming or outgoing information to be obtained before filtering or pollution (disturbances of the power signal).
[0022]
[0020] The interconnector may be formed, between its first end and its second end, of an elongated metal blade.
[0023]
[0021] The interconnector extending in a so-called longitudinal direction, it may comprise a transverse fold configured to allow adaptation of the length of said interconnector and / or to limit the mechanical stresses between the electrical conduction bar and the electronic device.
[0024]
[0022] The length is measured in the longitudinal direction.
[0023] The first end of the interconnector may be formed of a first planar portion, the second end of the interconnector may be formed of a second planar portion, the first planar portion and the second planar portion being parallel to each other but located in different planes.
[0025]
[0024] The threaded element may be a reported insert. Alternatively, the threaded element may be formed by the connector.
[0026]
[0025] The second end may be shaped to be connected to the electronic device using a second screw. The second end may have a hole or slot allowing the second screw to pass through.
[0027]
[0026] The second end may comprise a flap forming a connection plane orthogonal to a surface of the electronic device.
[0028]
[0027] The assembly may comprise two electrical conduction bars and two interconnectors.
[0029]
[0028] The assembly may further comprise the electronic device. The electronic device may be an electronic card.
[0030]
[0029] The invention also relates to an inverter comprising such an assembly, the electrical connector being a high voltage input connector of the inverter.
[0031] BRIEF DESCRIPTION OF THE FIGURES
[0032]
[0030] Other advantages, aims and particular characteristics of the present invention will emerge from the following non-limiting description of at least one particular embodiment of the devices and methods which are the subject of the present invention, with reference to the appended drawings, in which: Figure 1 is a partial schematic perspective view of an inverter comprising an assembly according to one embodiment of the invention; Figure 2 is a partial schematic sectional view of the inverter of Figure 1; Figure 3 is a schematic perspective view of a first embodiment of an interconnector which can be used in an assembly according to the present invention; Figure 4 is a schematic perspective view of a second embodiment of an interconnector which can be used in an assembly according to the present invention;Figure 5 is a schematic perspective view of a third embodiment of an interconnector usable in an assembly according to the present invention; Figure 6 is a schematic perspective view of a fourth embodiment of an interconnector usable in an assembly according to the present invention; Figure 7 is a schematic perspective view of a fifth embodiment of an interconnector usable in an assembly according to the present invention; Figure 8 is a partial schematic perspective view of an inverter comprising an assembly according to an embodiment of the invention in which the interconnector of Figure 4 is used; Figure 9 is a partial schematic perspective view of an inverter comprising an assembly according to an embodiment of the invention in which the interconnector of Figure 7 is used.;
[0033] Figure 10 represents, according to a schematic sectional view similar to that of Figure 2, an inverter comprising an assembly according to another embodiment of the invention.
[0034] DETAILED DESCRIPTION OF THE INVENTION
[0035]
[0031] The present description is given as a non-limiting example of embodiment.
[0036]
[0032] Figure 1 is a partial perspective view of an inverter comprising an assembly according to an embodiment of the invention. Figure 2 is a partial schematic sectional view of this inverter, and is described below in conjunction with Figure 1. Figure 1 and Figure 2 represent in particular an inverter for an electric or hybrid electric motor vehicle. The partial view of the inverter in Figure 1, as well as that in Figure 2, correspond to the area of the so-called high voltage input of the inverter, that is to say the area in which the inverter is connected to the high voltage circuit of the vehicle, which comprises a high voltage battery.
[0037]
[0033] The inverter 1 comprises a casing 2 in which the various components of the inverter 1 are arranged.
[0038]
[0034] The inverter here comprises an input filter 3, namely an electromagnetic compatibility filter generally referred to as an “EMC filter” intended to prevent disturbances in the equipment connected to the inverter power supply. This is then referred to as filtering the power signal.
[0039]
[0035] The input filter 3 is thus generally formed from a combination of one or more electrical conduction bars 4, one or more inductors and one or more capacitors.
[0040]
[0036] Each electrical conduction bar 4 must be connected to the high voltage circuit, here respectively to the positive pole and the negative pole of this circuit and of the high voltage battery. This connection ensures the electrical power supply of the inverter 1.
[0041]
[0037] An electrical connector 5, which passes through a wall of the casing 2, thus allows the connection of the electrical conduction bars 4 to the high voltage circuit.
[0042]
[0038] In the assembly shown here, an electronic card 6, namely an electronic control card or an electronic card combining the functions of control card and power card, must be electrically connected to the electrical conduction bars 4. Although the invention is described here with reference to this particular application, it may relate more generally to any connection of an electrical conduction bar to an electronic device.
[0043]
[0039] According to the present invention, this connection is made using an interconnector 7 for each of the connections to be made.
[0044]
[0040] The interconnector 7 is an electrically conductive element which has a first end 8 and a second end 9.
[0045]
[0041] The first end 8 is fixed, and is mechanically and electrically connected, to one of the electrical conduction bars 4. This fixing is carried out using a first screw 10.
[0046]
[0042] Remarkably, the first screw 10 also ensures the connection between the electrical conduction bar 4 and the electrical connector 5.
[0047]
[0043] For this, in the example shown here, the first screw 10 passes successively through: the first end 8 of the interconnector 7, which has an orifice 11 allowing the passage of the first screw 10; the electrical conduction bar 4, and the connector 5. A head 12 of the screw 10 thus comes to bear on the first end 8.
[0048]
[0044] The first screw 10 is screwed into a threaded element, which has a thread adapted to said first screw 10.
[0049]
[0045] The threaded element is here formed of an insert 13 which is attached to the assembly, in the example shown under the part of the connector to be connected to the electrical conduction bar. Alternatively, any other suitable threaded element can be used. Alternatively, the thread can be formed directly in the connector 5.
[0050]
[0046] According to an alternative embodiment, the electrical conduction bar 4 and the connector 5 can be reversed in the assembly, so that the first screw 10 then successively passes through the first end 8 of the interconnector 7, the connector 5, and the electrical conduction bar 4.
[0051]
[0047] Screwing the first screw 10 into the threaded element, the head 12 pressing on a rim 14 formed around the orifice 11 of the first end 8 of the interconnector 7, creates a tight assembly and a triple electrical connection between the interconnector 7, the electrical conduction bar 4, and the electrical connector 5.
[0052]
[0048] The second end 9 is fixed, and is mechanically and electrically connected, to the electronic card 6. This fixing is carried out using a second screw 15. To make this connection between the second end 9 and the electronic card 6, the electronic card 6 comprises a connection member 16 welded to the rest of the electronic card, and which comprises a threaded orifice adapted to cooperate with the second screw for its screwing.
[0049] It is noteworthy that, in the example shown, the connection between the interconnector 7 and the electrical conduction bar is made at the connection with the connector 5, that is to say at the input of the high voltage circuit in the inverter, upstream of any filtering component. This guarantees the quality of the signals that can be recovered by the interconnector, for example in order to determine at any time the intensity of the current flowing in the electrical conduction bars 4.
[0053]
[0050] The interconnector 7 is preferably metallic. The interconnector 7 may in particular be made of copper, for example tinned copper.
[0054]
[0051] The interconnector 7 is in the example of the embodiment shown in the form of a blade. By “blade” is meant a thin and elongated part. As can be seen in Figure 3, the interconnector 7 thus has a main direction of extension called “longitudinal”, along its largest dimension called “length” L. The interconnector 7 can thus comprise, between its first end 8 and its second end 9, a metal strip of small width I (dimension perpendicular to the length).
[0052] The interconnector 7 comprises a fold 17, according to several transverse folds
[0055] (orthogonal to the longitudinal direction). The bending 17 gives the interconnector 7 a certain adaptability, beyond the intrinsic flexibility of the blade, in particular a certain capacity to adapt in length to the distance between the connection made between on the one hand said interconnector 7, the electrical conduction bar 4, and the connector 5, and on the other hand between said interconnector 7 and the electronic card 6. This limits the mechanical forces caused by the interconnector 7 on the card, both when connecting the interconnector 7 to the card and when using it. This makes it possible in particular to compensate for the expansion and retraction of the interconnector when it undergoes thermal variations.
[0056]
[0053] Figures 3 to 7 show variants of interconnectors 7 that can be implemented within the framework of the present invention. In the variants of interconnectors shown, the first end 8 of the interconnector 7 is formed of a first planar portion, the second end 9 of the interconnector is formed of a second planar portion. The first planar portion and the second planar portion are substantially parallel to each other but located in different planes. This makes it possible to connect together an electrical conduction bar 4 and an electronic card 6 (or other electronic device) which are also located in different planes. We can thus speak of components installed at different heights in the inverter 1.
[0057]
[0054] As is clearly visible in Figure 2, the first end and the second end of the interconnector 7 are connected by a substantially straight middle portion 25 of the interconnector, ignoring the bend 17.
[0055] The angle α between the electrical conduction bar 4 and the middle portion 25 (which is also the angle between the first end 8 and the middle portion 25) can be between 0° and 120°, in particular between 40° and 100°, for example 43° or 95°.
[0058]
[0056] An angle α greater than 90° allows for significant overlap between the electrical conduction bar 4 and the electronic card 6. An exemplary embodiment in which the angle α is 95° is shown in Figure 10.
[0059]
[0057] The interconnector 7 of Figure 3 is the one used in the assembly shown in Figure 1 and Figure 2. The first end 8 has a round orifice 11, which is surrounded by a rim 14, also round, which forms a disc which has the function of a washer in the screwed assembly which connects the electrical connector 5 to the electrical conduction bar 4. Other rim shapes can be envisaged, as long as the rim allows the head 12 to rest to have the washer function. The washer function makes it possible to improve the screwing operation because it increases the distribution of the contact force of the screw. A better distribution of the contact force of the screw makes it possible to guarantee better electrical contact, and therefore better current flow.
[0060]
[0058] In the embodiment of Figure 3, the second end 9 comprises a rectangular portion comprising a hole 18 for the passage of the second screw 15. This rectangular shape makes it possible to maximize the contact surface between the second end 9 and the connection member 16. Other shapes can be used for the portion forming the second end, if it allows a sufficient contact surface to ensure a good electrical connection.
[0061]
[0059] In the embodiment of Figure 4, the first end is formed in the same manner as the first end of the interconnector of Figure 3.
[0062]
[0060] The second end 9 has a slot 19 instead of a hole 18. The slot 19 allows the second end 9 to slide under the head of the second screw while it is screwed but not tightened into the connecting member 16.
[0063]
[0061] In the embodiment of Figure 5, the first end is formed in the same way as the first end of the interconnector of Figures 3 and 4. The second end 9 has a hole 18, but could have a slot instead. The second end 9 has wings 20 which, by interaction with the connecting member 16, provide an anti-rotation function.
[0064]
[0062] In the embodiment of Figure 6, the second end 9 is formed in the same way as the second end of the interconnector of Figure 3. Just like the first end of the interconnector of Figure 3, the first end of the interconnector of Figure 6 has a round orifice 11 which is surrounded by a rim formed on the base of a round rim truncated on either side laterally so as to form flat areas 22.
[0063] In the embodiment of Figure 7, the first end 8 is formed in the same way as the second end of the interconnector of Figures 3 to 5. The second end 9 has a flap 23. The flap 23 is orthogonal to the remainder of the second end 9. The flap 23 allows, in certain embodiments, as illustrated in Figure 9, to make the electrical connection at a suitable connector.
[0065]
[0064] Obviously, the configurations of the different ends of the interconnectors of Figures 3 to 7 can be used to form other interconnectors. Other end configurations are still possible.
[0066]
[0065] Figure 8 is a partial schematic perspective view of an inverter comprising an assembly according to an embodiment of the invention in which the interconnector of Figure 4 is used. When the electronic card 6 is put in place during the assembly of the inverter 1, it can be brought with the second screws 15 prepositioned in the connection members 16. The second ends of the interconnectors 7 are then put in place by sliding them under the heads of the second screws 15.
[0067]
[0066] Figure 8 also shows how the connection of the electronic card to the electrical conduction bars 4 is made as close as possible to the input into the inverter of the high voltage circuit. Figure 8 shows in particular the input of the electrical connector 5 into the inverter 1, via insulating sheaths 21.
[0068]
[0067] Figure 9 is a partial schematic perspective view of an inverter, similar to the view of Figure 8. In this embodiment, the interconnector of Figure 7 is used. The flap 23 of the second end 9 of the interconnector 9 is inserted into the slot of a connector 24 of the electronic card 6. The connector 24 is thus adapted to receive the flap 23. In particular, the flap 24 is inserted into the connector 24 perpendicular to the plane of extension of the electronic card 6, that is to say perpendicular to one of its surfaces. The connector 24 may comprise elastic strips which make a clean contact with the flap 23, and ensure that the flap 24 and therefore the second end 9 are held in place by friction.
[0069]
[0068] Thus, within the scope of the present invention, an assembly is proposed allowing the connection between an electrical conduction bar and an electronic device using an interconnector, in which a triple screwed connection is made between a connector, the electrical conduction bar, and the interconnector. The interconnector advantageously plays the role of a washer in this connection. This simplifies the connection and the assembly range, and limits the number of parts in the assembly. The configuration of the interconnector can allow the connection of components located in different planes, and / or by causing little mechanical stress on the connected electronic device.
[0069] The invention is of particular interest in an inverter, in particular an inverter used in an electric or hybrid motor vehicle. In particular, this triple connection can be used to power a control card of the inverter.By making this triple connection at the inverter input, at the electrical connector with the high voltage circuit, the power signal that can be recovered via the interconnector (or interconnectors) is not disturbed by components, for example filtering, located in the inverter downstream of the connection.
[0070]
[0070] Nomenclature:
[0071] 1: inverter
[0072] 2: crankcase
[0073] 3: Input filter
[0074] 4: electrical conduction bar
[0075] 5: electrical connector
[0076] 6: electronic card
[0077] 7: interconnector
[0078] 8: first end
[0079] 9: second end
[0080] 10: first screw
[0081] 11: orifice
[0082] 12: head
[0083] 13: insert
[0084] 14: ledge
[0085] 15: second screw
[0086] 16: connecting organ
[0087] 17: folding
[0088] 18: hole
[0089] 19: slot
[0090] 20: wings
[0091] 21: insulating sheaths
[0092] 22: flat
[0093] 23: flap
[0094] 24: connector
[0095] 25: middle portion.
Claims
Claims 1. Assembly comprising at least one electrical conduction bar (4), an electrical connector (5), and an interconnector (7) intended to electrically connect the electrical conduction bar (4) to an electronic device, the interconnector (7) being metallic and comprising a first end (8) shaped to be connected to the electrical conduction bar (4) using a first screw (10), and a second end (9) shaped to be connected to the electronic device, the assembly comprising the first screw (10) and a threaded element, the first screw (10) being adapted to be screwed into said threaded element, the assembly being characterized in that the first end (8) of the interconnector (7) comprises an orifice (11) adapted for the passage of the first screw (10) and a rim (14) around the orifice (11) adapted to receive in support a head (12) of said first screw (10),and in that the first screw (10) passes through an orifice of the electrical conduction bar (4) and an orifice of the electrical connector (5), so that the first screw (10) being screwed into the threaded element, the head (12) of the first screw (10) bears on said rim (14) of the first end (8) of the interconnector (7), said rim having the function of a washer, and clamps the electrical connector (5) and the electrical conduction bar (4) together, thus ensuring the mechanical fixing and the electrical connection between the interconnector (7), the electrical conduction bar (4), and the electrical connector (5)., 2. Assembly according to claim 1, in which the interconnector (7) is formed, between its first end (8) and its second end (9), of an elongated metal blade.
3. Assembly according to claim 2, in which the interconnector (7) extends in a so-called longitudinal direction and comprises a transverse fold (17) configured to allow adaptation of the length of the interconnector (7) and / or to limit the mechanical constraints between the electrical conduction bar (4) and the electronic device.
4. Assembly according to one of the preceding claims, in which the first end (8) of the interconnector (7) is formed of a first flat portion, the second end (9) of the interconnector (7) is formed of a second flat portion, the first flat portion and the second flat portion being parallel to each other but situated in different planes.
5. Assembly according to one of the preceding claims, in which the threaded element is a fitted insert (13).
6. Assembly according to one of claims 1 to 4, in which the threaded element is formed by the connector.
7. Assembly according to one of the preceding claims, the second end (9) is shaped to be connected to the electronic device using a second screw (15).
8. Assembly according to claim 7 in which the second end (9) comprises a hole (18) or a slot (19) allowing the passage of the second screw.
9. Assembly according to one of claims 1 to 6, in which the second end comprises a flap (23) forming a connection plane orthogonal to a surface of the electronic device.
10. Assembly according to one of the preceding claims, comprising two electrical conduction bars (4) and two interconnectors (7).
11. Assembly according to one of the preceding claims, further comprising said electronic device and in which said electronic device is an electronic card (6).
12. Inverter (1) comprising an assembly according to claim 11, in which the electrical connector (5) is a high voltage input connector of the inverter (1).