Sliding clamp for busbars of an electric vehicle battery system and vehicle comprising such clamp

Abstract

The invention relates to a fastener (10) for positioning conductors of an electric vehicle charging system, the fastener comprises: - a head (20) with a flat surface (21); - two elongated legs (30; 40), a first leg (30) extending from the head (20), a second leg (40) attached to the head (20) or to the first leg (30), each leg (30, 40) having a respective face (39) arranged opposite the other leg (39), each leg (30) having a respective stop means (33) projecting towards the other leg (40), these means being arranged opposite each other, a cavity (51) is formed between the faces (39; 49) of the legs (30; 40), the cavity being bounded by the stop means (33; 43), a length (H2) of the second leg (40) beyond the stop means (43) is greater than a length (H1) of the cavity (51).

Description

[0001] The present invention claims priority from French application No. 2211592 filed on 08.11.2022.

[0002] The invention relates to charging systems in electric or hybrid electric vehicles, and in particular those comprising a battery module and a pair of insulatingly sheathed conductors, called bus bars, running along the battery module. The invention further relates to a means for positioning the bus bars against a battery module in such a charging system. A system for positioning conductors in a known electric vehicle charging system is described in US2021184197A.

[0003] In a known electric vehicle charging system structure comprising a battery module, a metal bracket (serving both for cable attachment, protection of a corner of the battery module, and mounting of an electronic control unit on the battery module), and a pair of busbars electrically connected to the battery module, adhesive tape is used to permanently fix the busbars in position against the metal bracket. However, the adhesive tape is not very durable and tends to detach under the stresses to which the busbars are subjected during electric vehicle use. The busbars then eventually move away from their initially assigned position, creating a risk of interference between the busbars and their surroundings, and thus a risk of electrical short circuits.

[0004] One objective of the invention is to remedy the ineffectiveness of adhesive tape in resisting over time.

[0005] To achieve this objective, the invention proposes an attachment for positioning conductors of an electric or hybrid electric vehicle charging system, comprising: a head having at least one flat surface; a first leg and a second leg, each elongated in shape, the first leg extending from the head, the second leg being attached to a unit formed by the head and the first leg, the first leg having a first face and the second leg having a second face arranged opposite the first face, the first leg comprising a first arresting means projecting towards the second leg, and the second leg comprising a second arresting means projecting towards the first leg, the arresting means of the first leg and the second leg being arranged opposite each other, a receiving housing being jointly formed by the first leg and the second leg between the first face and the second face, and delimited by said arresting means in a direction opposite to the head, a length of a distal section of the second leg extending beyond the second arresting means, measured from the second arresting means, being greater than a length of the receiving housing measured between the second arresting means and a bottom surface of the receiving housing opposite the second arresting means.

[0006] Such a fastener can be easily installed and secured on the bus bars of an electric or hybrid vehicle charging system. Advantageously, the fastener according to the invention eliminates the need for adhesive tape previously used in positioning the bus bars and resolves the positioning problems it caused. It ensures the correct positioning of the bus bars one above the other and secures them against a support provided by the vehicle's charging system. This fixed positioning of the bus bars also eliminates friction between them and surrounding components within the vehicle. This prevents the bus bars from being pulled off or torn, thus eliminating the risk of short circuits.

[0007] Furthermore, the invention improves the efficiency of busbar assembly by reducing the time spent positioning them. Indeed, the fastener can be installed very simply in two steps: by snapping it onto a pair of overlapping busbars and then sliding it until the head of the fastener is forced behind a support (for example, a metal one) and / or until a distal part of one of the legs is forced between one of the busbars and a floor or chassis element.

[0008] Advantageously, according to the invention, the fastener can be made of fiber-reinforced plastic, preferably carbon or glass.

[0009] Advantageously, according to the invention, the stopping means are each in the form of a tooth with a triangular cross-section.

[0010] Advantageously, according to the invention, the head and the first leg can be arranged in alignment with each other.

[0011] Advantageously, according to the invention, the second leg can be longer than the first leg and / or the first stopping means can be disposed at a distal end of the first leg.

[0012] Advantageously, according to the invention, the first leg and at least one proximal section of the second leg bearing the second face can extend in a respective extension plane, the extension planes being substantially parallel to each other.

[0013] The invention also relates to a charging system for electric or hybrid electric vehicles, comprising an attachment as described above and two metal bars intended to each form a busbar type conductor, the attachment receiving housing being suitable for receiving one of the two metal bars.

[0014] Advantageously, the charging system for electric or hybrid electric vehicles may include: a battery module; a metal bracket having a flat contact surface oriented towards the battery module when the metal bracket is mounted on the battery module; and, a pair of bus bars having a first bus bar arranged above a second bus bar along the battery module, the pair of bus bars being mounted against the battery module.

[0015] The attachment can then be snapped onto the first busbar so that: the flat surface of the head is in contact with the flat contact surface of the metal support, the first omnibus bar is disposed in the receiving housing, the attachment being held on the first omnibus bar by the stopping means; the second leg is also disposed along the second omnibus bar, preferably against the second omnibus bar.

[0016] The invention also relates to an electric or hybrid electric vehicle comprising a charging system as described above.

[0017] Advantageously, in the electric or hybrid electric vehicle, when the attachment is snap-mounted onto the first bus bar, an external surface of the second leg outside the receiving housing can be in contact with a chassis or floor element of the electric or hybrid electric vehicle.

[0018] The invention will be further detailed by describing non-limiting embodiments, and based on the accompanying figures illustrating variants of the invention, in which: [ Fig.1 ] is a view showing in detail a positioning attachment according to the invention; [ Fig.2 ] schematically illustrates an electric vehicle power supply system, including the positioning attachment of the Fig. 1 as well as a battery module, a sheet metal cable fixing bracket and two bus bars.

[0019] With reference to the Fig. 1 A 10-point attachment is described. As illustrated in Fig. 1 , attachment 10 is in a resting state, i.e. not mounted in a third structure.

[0020] In this document, the term "electric vehicle" can refer to both electric vehicles and hybrid electric vehicles, that is to say, vehicles with a first source of energy in the form of electricity, and a second source of energy, distinct from the first source of energy (for example, but not limited to, a hydrocarbon such as gasoline, diesel, bioethanol, etc.).

[0021] Furthermore, in this document, the terms "internal" and "external" are to be understood as referring to an orientation of an element towards an interior or exterior of the attachment 10.

[0022] Finally, in this document, the expression "substantially parallel" refers to faces or walls extending in planes generally aligned with each other or up to 20° apart.

[0023] The fastener 10 comprises a head 20 and two legs 30 and 40. The head and the two legs 30 and 40 are formed as a single piece.

[0024] The head 20 is generally flat here. The head 20 has at least one flat face 21. The flat face 21 is intended to form a contact region with an external element, such as the metal support 8 described later with reference to the Fig. 2 Optionally and not limited to, as illustrated, head 20 is rectangular in shape.

[0025] Legs 30 and 40 are each elongated. Preferably, as illustrated in Fig. 1 , legs 30 and 40 are generally flat.

[0026] The first leg 30 preferably extends from one side of the head 20. As illustrated, but not limited to, the first leg 30 is preferably arranged in line with the flat head 20 (as seen in Fig. 1 ).

[0027] The first leg 30 comprises a main section 31 extending to a distal end 32. The main section 31 extends between an internal face 38 and an external face 39. The internal face 38 and the external face 39 are preferably substantially flat and / or substantially parallel to each other.

[0028] The main section 31 includes a stop means 33, projecting from the inner face 38. Here, the stop means 33 is also disposed at the distal end 32. In the embodiment shown, the stop means 33 is a snap-on tooth.

[0029] The ratcheting tooth 33 has an insertion surface 34 and a stopping surface 35. The insertion surface 34 is inclined with respect to the general extension plane of the main section 31. The insertion surface 34 is also oriented opposite to the head 20 with respect to the main section 31. The stopping surface 35 is oriented substantially transversely to the main section, and in the direction of the head 20 with respect to the main section 31.

[0030] The second leg 40 has a proximal section 41 and a distal section 42. In the illustrated embodiment, the second leg 40 also has an optional junction section 46, connecting the proximal section 41 to the assembly 25 formed by the head 20 and the first leg 30 (that is to say to either the head 20 and the first leg 30, or to a connection zone between the head 20 and the first leg 30).

[0031] The junction section 46 is generally flat and rectangular in shape. On one side, the junction section 46 is attached to the main section 31 of the first leg 30. On the other side, opposite the first, the junction section 46 is attached to the proximal section 41 of the second leg 40. The junction section 46 extends transversely, for example, perpendicularly, on one side to the first leg 30 and on the other to the proximal section 41 of the second leg 40. Thus, the second leg 40 is L-shaped, with the junction section 46 forming the short leg, while the proximal section 41 and distal section 42 form the long leg.

[0032] Alternatively, the second leg is exempt from the junction section 46, the proximal section 31 then being directly connected to the assembly 25, for example by a locally curved form of the proximal section 41.

[0033] The junction section 46 of the leg 40 prevents contact between the bus bar 9a and the metal support 8 to protect the bus bar 9a from any risk of wear to its electrical protection.

[0034] The proximal section 41 extends between an inner face 49 and an outer face 50. The inner face 49 and the outer face 50 are preferably substantially flat and / or substantially parallel to each other. The distal section 42 extends from an end of the proximal section 41 opposite the head 20. The proximal section 41 is defined here as being closer to the head 20 than the distal section 42.

[0035] Preferably, but not limited to, the main section 31 of the first leg 30 and the proximal section 41 of the second leg 40 generally extend in a plane of extension P1 and P2, respectively, in a substantially parallel manner. Furthermore, the proximal section 41 and the distal section 42 extend, but not limited to, substantially in the same plane. In an alternative not shown, the distal section 42 may be slightly curved or inclined, for example, towards the first leg 30 and / or the distal end 32 of the first leg 30.

[0036] The second leg 40 has a stop means 43. The stop means 43 is formed at the meeting between the proximal section 41 and the distal section 42. For convenience of description, it is considered here that the stop means 43 belongs to the proximal section 41.

[0037] In the embodiment shown, the locking means 43 is a ratchet tooth. As illustrated, the ratchet tooth 43 may, but is not limited to, have a shape similar to the ratchet tooth 33.

[0038] Thus, the click tooth 43 also has an insertion surface 44 and a stop surface 45. The insertion surface 44 is oriented opposite to the head 20 with respect to the proximal section 41. The stop surface 45 is oriented substantially transversely to the main section 31, and in the direction of the head 20 with respect to the proximal section 41.

[0039] As can be seen from the description above, the second leg 40 is longer than the first leg 30. More precisely, in the illustrated embodiment, the length H1 of the main section 31 of the first leg is substantially the same as the length H2 of the proximal section 41 of the second leg 40. The shorter of the possible lengths H1 and H2 will be considered to be the length of the receiving housing 51, the lengths H1 and H2 preferably being equal.

[0040] Furthermore, the stopping means 33 is positioned directly opposite the stopping means 43. The stopping means 33 is thus projecting towards the second leg 40. The stopping means 43 is projecting towards the first leg 30.

[0041] Furthermore, face 38 of the first leg 30 and face 48 of the second leg 40 are opposite each other.

[0042] A receiving housing 51 is thus formed between the face 38 and the face 48. Opposite the head 20, the receiving housing 51 extends to the stopping means 33 and 43. As will be detailed later, the receiving housing 51 is designed to receive a bus bar 9a or 9b of an electric vehicle charging system 4.

[0043] An implementation of the attachment 10 in an electric vehicle 4 is described below as an example.

[0044] The electric vehicle 4 includes a charging system 5 and a floor or chassis element 6.

[0045] The charging system 5 includes a battery module 7 (of roughly parallelepiped shape), a metal support 8 and a pair of conductors 9.

[0046] The battery module 7, of a type known in itself, serves as the electrical power source for driving the electric vehicle 4.

[0047] The metal bracket 8 covers one corner of the battery module 7. The metal bracket serves both as a fixing piece for various components (not shown: electronic control unit and wiring connection elements, etc.) of the electric vehicle 4 and as a protective piece for one corner of the battery module 7.

[0048] The conductors 9 are the aforementioned bus bars 9a and 9b. Bus bars 9a and 9b form a positive and a negative electrical conductor, respectively. Bus bars 9a and 9b provide the electrical connection between the battery module 7 and the electrical consumers of the electric vehicle 4 (motor(s), equipment, etc.; not shown).

[0049] In the example illustrated and described above, the bus bars 9a and 9b are each generally rectangular in cross-section. The fastener is therefore designed so that the receiving housing 51 is sized to correspond in shape to the bus bar 9a. Advantageously, the fastener 10 can snap onto the bus bar 9a. Furthermore, an internal surface 53 of the distal section 42 can come against the second bus bar 9b to ensure its stability in the vehicle 4 after assembly.

[0050] The fastener 10 is made of fiber-reinforced plastic, such as carbon or glass fiber. This material gives the fastener 10 sufficient flexibility to snap onto the busbar 9a by spreading the legs 30 and 40 and then returning them to their initial position, while also ensuring sufficient rigidity and surface finish to allow the fastener 10 to slide in a direction C following the extension direction of the busbars 9a and 9b, and to be press-fitted between the busbars 9a and 9b and third-party components such as the metal support 8 and the floor or chassis element 6. Furthermore, this material offers significant durability, covering the lifetime of the electric vehicle. Finally, its smooth texture allows the fastener to slide smoothly on the metal busbars 9a and 9b.

[0051] It is noted that the second leg 40 is longer than the vertical dimension of two busbars (i.e., top-bottom in the normal orientation of a vehicle). Thus, the external surface 52 of the second leg 40 is suitable for contacting the floor or chassis element 6 so as to be press-fitted both onto the busbars 9a and 9b and against the floor or chassis element 6.

[0052] Note that the fastener 10 may lack either of the locking means 33 or 43 and thus have only one of the two. Preferably, however, the fastener 10 includes both locking means 33 and 43 for better grip of the fastener 10 and improved stability of the assembly when the fastener 10 is mounted on the bus bar 9a.

[0053] It is noted that the head 20 has a width L1 greater than the width L2 of the first leg 30 and than the width L3 of the second leg 40. The stability of the head 20 against the metal support 8 is therefore optimal.

Claims

1. Fastener (10) for positioning conductors (9a, 9b) of a charging system (5) of an electric vehicle or electric hybrid vehicle (4), comprising: - a head (20) having at least one flat surface (21); - a first leg (30) and a second leg (40), each of elongate shape, the first leg (30) extending from the head (20), the second leg (40) being attached to an assembly (25) formed by the head (20) and the first leg (30), the first leg (30) comprising a first face (39) and the second leg (40) comprising a second face (49) arranged facing the first face (39), the first leg (30) comprising a first shutdown means (33) projecting in management from the second leg (40), and the second leg (40) comprising a second shutdown means (43) projecting in management from the first leg (30), the shutdown means (33; 43) of the first leg (30) and of the second leg (40) being arranged facing each other by report to each other, a receipt housing (51) being formed jointly by the first leg (30) and the second leg (40) between the first face (39) and the second face (49), and defined by said shutdown means (33; 43) in a direction opposite the head (20), a length (H 3) of a distal section (42) of the second leg (40) that extends beyond the second shutdown means (43), measured from the second shutdown means (43), being greater than a length (H 1; H 2) of the receipt housing (51) measured between the second shutdown means (43) and a bottom surface (48) of the receipt housing (51) opposite the second shutdown means (43).

2. Fastener (10) according to claim 1, wherein the fastener (10) is made of plastic loaded of fibres, preferably carbon or glass.

3. Fastener (10) according to any one of Claims 1 to 2, wherein the shutdown means (33; 43) are each in the shape of a tooth with a triangular section.

4. Fastener (10) according to any one of claims 1 to 3, characterised in that the head (20) and the first leg (30) are arranged in alignment with each other.

5. Fastener (10) according to any one of claims 1 to 4, wherein the second leg (40) is longer than the first leg (30) and / or wherein the first shutdown means (33) is arranged at a distal end (32) of the first leg (30).

6. Fastener (10) according to any one of Claims 1 to 5, characterised in that the first leg (30) and at least one proximal section (41) of the second leg (40) bearing the second face (49) extend in a respective extension drawing (P1; P2), the extension drawings (P1; P2) being substantially parallel to each other.

7. Charging system (5) for an electric or hybrid electric vehicle (4), characterised in that it comprises a fastener (10) according to any one of claims 1 to 6 and two metal bars (9a, 9b) each intended to form a conductor of the bus bar type, the receipt housing (51) of the fastener (10) being able to accommodate one of the two metal bars (9a, 9b).

8. Charging system (5) for an electric or hybrid electric vehicle (4) according to claim 7, characterised in that the charging system (5) comprises: - a battery module (7); - a metal support (8) having a flat contact surface (80) facing the battery module (7) when the metal support (8) is mounted on the battery module (7); and pair of bus bars (9 a, 9 b) comprising a first bus bar (9 a) arranged above a second bus bar (9 b) along the battery module (7), the pair of bus bars (9 a, 9 b) being mounted against the battery module (7), wherein the fastener (10) is snap-fastened to the first bus bar (9 a) so that: - the planar surface (21) of the head (20) is in contact with the planar contact surface (80) of the metal support (8), - the first bus bar (9 a) is arranged in the receipt housing (51), the fastener (10) being retained to the first bus bar (9 a) by the shutdown means (33; 43), - the second leg (40) is also arranged along the second bus bar (9 b), preferably against the second bus bar (9 b).

9. Electric or hybrid electric vehicle (4) comprising a charging system (5) according to Claim 7 or 8.

10. Electric or hybrid electric vehicle (4) according to claim 9, wherein, when the fastener (10) is mounted snap-fastened on the first bus bar (9 a), an outer surface (52) of the second leg (40) outside the receipt housing (51) bears against a chassis or floor element (6) of the electric or hybrid electric vehicle (4).