Electrical interconnection device for transmitting electrical power within a vehicle

Abstract

An electrical interconnection device (1) for transmitting electrical power from a first electrical component (A) of a vehicle to a second electrical component (B) of the vehicle, the electrical interconnection device (1) comprising: a first part (2) comprising a first electrical conductor (8), the first electrical conductor (8) having an internal surface defining a groove; a second part (4) more flexible than the first part (2) and connectable to an electrical component, the second part (4) comprising a second electrical conductor (20) suitable for being electrically connected to the first electrical component (A), the second electrical conductor (20) having an external surface; wherein the second electrical conductor (20) is fixed to the first electrical conductor (8) and electrically connected to the first conductor by bringing the internal surface into contact with the external surface. Figure for the abbreviation: Fig. 7

Description

Title of the invention: Electrical interconnection device for transmitting electrical power in a vehicle FIELD OF INVENTION

[0001] The present invention relates to an electrical interconnection device for transmitting electrical power in a vehicle. STATE OF THE ART

[0002] Prior art is known for electrical interconnection devices for transmitting electrical power from a first electrical component of a vehicle to a second electrical component of the vehicle, taking the form of rigid power cables, i.e., cables that are not expected to deform without external stress. Thus, a rigid power cable is, during its manufacture, shaped into a certain form, which the cable subsequently retains.

[0003] However, connecting such a rigid cable to electrical equipment can prove difficult. The inherent rigidity of the cable requires perfect alignment of the cable with the equipment in question, which constitutes a constraint. Description of the invention

[0004] An object of the invention is to provide an electrical interconnection device for transmitting electrical power from a first electrical equipment of a vehicle to a second electrical equipment of the vehicle which is easy to connect while benefiting from the advantages provided by a rigid cable, and whose manufacture is not very complex.

[0005] This objective is achieved by an electrical interconnection device for transmitting electrical power from a first electrical component of a vehicle to a second electrical component of the vehicle, the electrical interconnection device comprising: • a first part comprising a first electrical conductor, the first electrical conductor having an internal surface delimiting a hollow, • a second part more flexible than the first part and connectable to electrical equipment, the second part comprising a second electrical conductor suitable for being electrically connected to the electrical equipment, the second electrical conductor having an external surface, • in which the second electrical conductor is fixed to the first electrical conductor and electrically connected to the first conductor by bringing the inner surface into contact with the outer surface.

[0006] Since the second part of the electrical interconnection device is more flexible than the first part, it can be more easily aligned with the equipment to which the first part is to be connected. Conversely, the first part of the electrical interconnection device benefits from the advantages associated with its rigidity. Furthermore, bringing the inner surface of the first electrical conductor into contact with the outer surface of the second electrical conductor has the advantage of allowing for fastening and electrical connection between the two conductors without requiring an additional connecting piece such as a sleeve.

[0007] The proposed electrical interconnection device may also include the following optional features, taken alone or in combination whenever possible.

[0008] Preferably, the second electrical conductor is a strand.

[0009] Preferably, the second electrical conductor is fixed to the first conductor electrical by crimping, by magnetic pulse welding and / or by ultrasonic welding.

[0010] Preferably, the first part comprises a first electrical insulator extending around the first electrical conductor, and the second part comprises a second electrical insulator extending around the second electrical conductor.

[0011] Preferably, the first electrical insulator and the second electrical insulator are in one piece.

[0012] Preferably, at least one of the first electrical insulator and the second electrical insulator is cross-linked.

[0013] Preferably, at least one of the first electrical insulator and the second electrical insulator is made of a material being or comprising a polyolefin, preferably a high-density polyethylene.

[0014] Preferably, at least one of the first electrical insulator and the second electrical insulator has a temperature class equal to T3, T4 or T5.

[0015] Preferably, the device is devoid of an electromagnetic shielding layer around the first electrical insulator and / or around the second electrical insulator.

[0016] Preferably, the electrical interconnection device further comprises: a third part that is more flexible than the first part and connectable to the second electrical equipment; the third part comprising a third electrical conductor suitable for being electrically connected to the second electrical equipment; the third electrical conductor having an external surface, in which the third electrical conductor is fixed to the first electrical conductor and electrically connected to the first conductor by contacting an internal surface of the first conductor. electrical with the external surface of the third electrical conductor.

[0017] Preferably, the hollow crosses the first part from end to end and in which the internal surface which delimits the hollow is in contact with the external surface of the third electrical conductor.

[0018] A method for manufacturing the aforementioned electrical interconnection device is also proposed. The method comprises bringing the internal surface into contact with the external surface, so as to fix and electrically connect the second electrical conductor to the first electrical conductor.

[0019] Preferably, the second electrical conductor is fixed to the first electrical conductor by crimping, by magnetic pulse welding and / or by ultrasonic welding.

[0020] Preferably, the process further comprises the following steps: • heating an electrically insulating part having an internal surface delimiting a cavity, the electrically insulating part being adapted so that heating causes an expansion of the electrically insulating part increasing the diameter of the internal surface, and so that subsequent cooling of the electrically insulating part causes a contraction of the electrical insulation reducing the diameter of the internal surface, • Insertion of the first electrical conductor and the second electrical conductor into the electrically insulating piece while the electrically insulating piece is in an expanded state in which the diameter of the internal surface is greater than the diameter of an external surface of the first electrical conductor and the diameter of the external surface of the second electrical conductor, so that, after retraction of the electrically insulating piece, the internal surface of the electrically insulating piece is in contact with the external surface of the first electrical conductor. DESCRIPTION OF FIGURES

[0021] Other features, objectives and advantages of the invention will become apparent from the following description, which is purely illustrative and not limiting, and which should be read in conjunction with the accompanying drawings on which:

[0022] Fig. 1 schematically illustrates a vehicle and some components inside the vehicle.

[0023] Fig. 2, Fig. 3, Fig. 4, Fig. 5 and Fig. 6 are different cross-sectional views transverse of an electrical interconnection device according to a first embodiment, in different positions along this device.

[0024] Figure 7 is a partial longitudinal cross-sectional view of the interconnecting device. electric according to the first embodiment.

[0025] Fig. 8 is a cross-sectional view of an electrically insulating part in normal and expanded states.

[0026] Fig. 9 is a partial longitudinal sectional view showing the electrically insulating part in the expanded state and other elements of the electrical interconnection device according to the first embodiment, during its manufacture.

[0027] The [Fig. 10] is a partial longitudinal cross-sectional view of an electrical interconnection device according to a second embodiment.

[0028] The [Fig. 11] is a partial longitudinal cross-sectional view of an electrical interconnection device according to a third embodiment.

[0029] Fig. 12 is a cross-sectional view of an electrical interconnection device for a vehicle according to another embodiment.

[0030] Throughout the figures, similar elements bear identical references. DETAILED DESCRIPTION OF THE INVENTION

[0031] In what follows, reference will be made to the diameter of certain surfaces that are not necessarily of revolution. In this document, the diameter of a surface that is not of revolution should be understood as the maximum diameter of that surface. 1) Vehicle and power cable

[0032] With reference to [Fig. 1], a vehicle V comprises a first electrical equipment A, a second electrical equipment B, and an electrical interconnection device 1 for transmitting electrical power from the first electrical equipment A to the second electrical equipment B.

[0033] For example, the first electrical equipment A is a source of electrical energy, for example a battery, and the second electrical equipment is intended to be supplied with electrical energy by the first electrical equipment A via the electrical interconnection device 1. In this case, the electrical interconnection device 1 provides a power supply function.

[0034] Alternatively, the first electrical equipment A and the second electrical equipment B are internal components of a battery.

[0035] In what follows, we will focus on embodiments in which the electrical interconnection device 1 takes the form of a cable, it being understood that in other embodiments this interconnection device can take the form of a bar.

[0036] The cable 1 comprises three parts 2, 4, 6: a first part 2 (constituting an intermediate part), a second part 4 (constituting a terminal part of the cable 1 suitable for connection to the first electrical equipment A), and a third part 6 (constituting another terminal part of the cable 1 suitable for connection to the second electrical equipment B).

[0037] The first part 2 is rigid, in the sense that it tends to retain a specific shape in the absence of external stress. The first part 2 may not be straight. In particular, the first part 2 may include one or more bends, as is the case in the example shown in [Fig. 1], which includes two bends. The shape assigned to the first part 2 can be determined in advance, so that the first part 2 can be placed in a sinuous space left free within the vehicle V. Due to the rigidity of its first part 2, the installation of the cable 1 in such a location is facilitated and it remains in place.

[0038] The first part 2 can constitute a major part of the cable 1, for example at least 80% of the length of the cable 1 (measured taking into account changes of direction caused by any bends present).

[0039] The second part 4 extends the first part 2 and has an end intended to be connected to the first electrical equipment A. The second part 4 is more flexible than the first part 2. This means that there is a stress that causes deformation of the first part 2 when this stress is applied to it, but does not cause deformation of the comparatively more rigid first part 2 when the same stress is applied to it. In practice, this flexibility allows a technician to adjust the position of the second part 4 relative to the electrical equipment to be connected, thus facilitating this connection.

[0040] The third part 6 also extends the first part 2, and has an end intended to be connected to the second electrical equipment B. Thus, the first part 2 constitutes a linking part between the second part 4 and the third part 6. The third part 6 is more flexible than the first part 2.

[0041] The second part 4 and the third part 6 may have identical flexibilities (using identical materials of identical sections) or not.

[0042] With reference to [Fig.2], the first part 2 comprises a first electrical conductor 8.

[0043] The first electrical conductor 8 has an internal surface 10 delimiting a hollow 9, and an external surface 12 opposite the internal surface 10, and extending around the internal surface 10. An advantage conferred by this hollow character allows the exchange surface of the first conductor 8 with the air to be increased, compared to a more compact conductor such as a strand or a solid (non-hollow) conductor of the same conductive cross-section.

[0044] The hollow 9 passes through the first electrical conductor 8 from end to end. Thus, this hollow 9 is accessible from two opposite points, and the first electrical conductor 8 has the shape of a tube. The fact that the hollow 9 extends from end to end further increases the surface area of ​​the first conductor 8 exposed to the air.

[0045] The first electrical conductor 8 has a rectangular cross-section. By "rectangular cross-section" is meant a cross-section comprising four sides, of which the first two sides are parallel and the second two sides are parallel, the second sides being perpendicular to the first sides. Thus, in the present disclosure, a "rectangular cross-section" may include rounded corners. In this rectangular cross-section, the inner surface 10 forms a rectangular line, and the outer surface 12 forms another rectangular line.

[0046] The first part 2 also includes a first electrical insulator 14 extending around the first electrical conductor 8.

[0047] The first electrical insulator 14 comprises an internal surface 16 in contact with the external surface 12 of the first electrical conductor 8, and an external surface 18 opposite the internal surface 16.

[0048] The first electrical insulator 14 is made of a material which expands when heated.

[0049] Furthermore, the first electrical insulator 14 preferably has a temperature class equal to T3, T4 or T5, most preferably T4.

[0050] Although a T2 class insulator is conceivable, a T2 class insulator has a lower maximum operating temperature and is therefore not capable of operating at higher temperatures, and therefore cannot withstand for extended periods the heat generated by a large electric current carried in the first electrical conductor 8. The T3, T4 or T5 class insulator has a higher maximum operating temperature, which allows it to dissipate more efficiently an electric current carried by the first electrical conductor 8. Thus, at constant current, it is possible to reduce the cross-section of the first part 2.

[0051] Moreover, a T3, T4 or T5 class insulation is less expensive than a T6 class insulation.

[0052] In conclusion, temperature classes T3, T4, and T5 offer a good compromise between cost and performance. Class T4 offers an ideal compromise.

[0053] Preferably, the first electrical insulator 14 is preferably made of a material being or comprising a polyolefin, or even polyethylene.

[0054] Most preferably, this polyethylene is high-density polyethylene (HDPE). This gives the first electrical insulator 14 greater rigidity than low-density polyethylene.

[0055] The first electrical insulator 14 may be made of polyethylene. Alternatively, the first electrical insulator comprises polyethylene, ethylene-vinyl acetate (EVA), or even is made of PE and EVA.

[0056] Furthermore, the first electrical insulator 14 is cross-linked, which also contributes to increasing its rigidity, compared to a non-cross-linked insulator.

[0057] Furthermore, the first electrical insulator 14 can be flame-retardant. This flame-retardant property can be the result of charges present in the polyethylene from which this insulator is made.

[0058] The first electrical insulator 14 can form an outer layer of the cable 1. In other words, the first electrical insulator 14 forms a sheath of the cable 1, is not surrounded by another layer and is therefore visible from the outside of the cable 1. Alternatively, the cable 1 includes other layers extending around the first electrical insulator 14, for example an outer sheath, or even an additional electrical conductor between such an outer sheath and the electrical insulator.

[0059] Preferably, the first part 2 of the cable 1 is devoid of an electromagnetic shielding layer around the first electrical insulator 14.

[0060] With reference to [Fig.3], the second part 4 comprises a second electrical conductor 20 suitable for being electrically connected to the electrical equipment A.

[0061] The second electrical conductor 20 has an external surface 22.

[0062] The external surface 22 of the second electrical conductor 20 has a diameter less than that of the external surface 12 of the first electrical conductor 8.

[0063] The second electrical conductor 20 can be solid or hollow. When it is solid, the second electrical conductor 20 has no internal surface; when it is hollow, the second electrical conductor 20 has an internal surface opposite to the external surface 22, similarly to the first electrical conductor 8.

[0064] In particular, the second electrical conductor 20 can be in the form of a strand. In a manner known per se, a strand comprises a set of contiguous elements rotating about a main axis, for example in a helical manner.

[0065] Preferably, the second electrical conductor 20 is made of copper strands. This conductor construction has the advantage of being particularly flexible, and therefore contributes to the flexibility of the second part 4. Furthermore, the copper composition of the strand eliminates the risk of galvanic corrosion. Consequently, this copper strand construction helps to facilitate connection and extend the service life of the second part 4 to the first electrical equipment A.

[0066] The second part 4 also includes a second electrical insulator 24 surrounding the second electrical conductor 20.

[0067] The second electrical insulator 24 comprises an internal surface 26 opposite the external surface 22 of the second electrical conductor 20, and an external surface 28 opposite the internal surface 26.

[0068] The internal surface 26 has the same diameter as the internal surface 16 of the first electrical insulator 14. Furthermore, the external surface 28 has the same diameter to that of the external surface 18 of the first electrical insulator 14. A space 23 separates the second electrical conductor 20 from the second electrical insulator 24.

[0069] The second electrical insulator 24 is made of the same material as the first electrical insulator 14. All the information provided above relating to the material of the first electrical insulator is applicable to the second electrical insulator 24 (temperature class, nature of the material used, etc.).

[0070] The second electrical insulator 24 can form an outer layer of the cable 1. In other words, the second electrical insulator 24 forms a sheath of the cable 1, is not surrounded by another layer and is therefore visible from the outside of the cable 1. Alternatively, the cable 1 includes other layers extending around the second electrical insulator 24, for example an outer sheath, or even an additional electrical conductor between such an outer sheath and the electrical insulator.

[0071] The second electrical insulator 24 and the first electrical insulator 14 are two parts of a single piece extending along the first part 2 and the second part 4.

[0072] We saw earlier that the second part 4 was more flexible than the first part 2. This difference in flexibility can be found in particular at the level of the electrical conductors. Thus, the second electrical conductor 20 can be more flexible than the first electrical conductor 8.

[0073] Preferably, the second part 4 of the cable 1 is devoid of an electromagnetic shielding layer around the second electrical conductor 20.

[0074] Since the second part 4 of the electrical interconnection device 1 is more flexible than the first part 2, it can be more easily aligned with the first piece of equipment A. Conversely, the first part 2 benefits from the advantages associated with its rigidity. Furthermore, bringing the inner surface 10 of the first electrical conductor 8 into contact with the outer surface 22 of the second electrical conductor 20 has the advantage of allowing fixing and electrical connection between the two conductors 8, 20 without requiring an additional connecting piece such as a sleeve.

[0075] With reference to [Fig.4], the second electrical conductor 20 extends partially into the hollow 9 delimited by the first electrical conductor 8, so that the internal surface 10 of the first conductor 8 is in contact with the external surface 22 of the second conductor 20.

[0076] This contact is made in such a way as to ensure relative fixity between the first electrical conductor 8 and the second electrical conductor 20. Furthermore, this contact is direct (i.e., without any interposed element between the two surfaces 10 and 22), so as to ensure an electrical connection between the first electrical conductor 8 and the second electrical conductor 20. This relative fixity and this electrical connection can be obtained by various techniques, in particular by crimping or welding.

[0077] The external surface 22 of the second electrical conductor 20 can be complementary to the internal surface 10 of the first electrical conductor 8, so that this contact is effective all around the perimeter of the second electrical conductor 20.

[0078] With reference to [Fig.5], the third part 6 includes a third electrical conductor 30 suitable for being electrically connected to the other electrical equipment.

[0079] The third electrical conductor 30 has an external surface 32.

[0080] The external surface 32 of the third electrical conductor 30 has a diameter less than that of the internal surface 12 of the first electrical conductor 8.

[0081] The third electrical conductor 30 can be solid or hollow. When it is solid, the third electrical conductor 30 has no internal surface; when it is hollow, the third electrical conductor 30 has an internal surface opposite to the external surface 32, similarly to the first electrical conductor 8.

[0082] In particular, the third electrical conductor 30 can be in the form of a strand.

[0083] Preferably, the third electrical conductor 30 is made of copper. This material has the advantage of being particularly flexible, and therefore contributes to the flexibility of the third part 6. Consequently, this material helps to facilitate the connection of the second part 6 to the second electrical equipment B.

[0084] The third part 6 also includes a third electrical insulator 34 surrounding the third electrical conductor 30.

[0085] The third electrical insulator 34 comprises an internal surface 36 opposite the external surface 32 of the third electrical conductor 30, and an external surface 38 opposite the internal surface 36.

[0086] The internal surface 36 has the same diameter as the internal surface 16 of the first electrical insulator 14. Furthermore, the external surface 38 has the same diameter as the external surface 18 of the first electrical insulator 14. A space 33 separates the third electrical conductor 30 from the third electrical insulator 34.

[0087] The third electrical insulator 34 is made of the same material as the first electrical insulator 14. All the information provided above relating to the material of the first electrical insulator is applicable to the third electrical insulator 34 (temperature class, nature of the material used, etc.).

[0088] The third electrical insulator 34 can form an outer layer of the cable 1. In other words, the third electrical insulator 34 forms a sheath of the cable 1, is not surrounded by another layer, and is therefore visible from the outside of the cable 1. Alternatively, the cable 1 comprises other layers extending around the third electrical insulator 34, for example, an outer sheath, or even an electrical conductor additional between such an external sheath and the electrical insulation.

[0089] The third electrical insulator 34 and the first electrical insulator 14 are two parts of a single piece extending along the first part 2 and the third part 6.

[0090] We saw earlier that the third part 6 was more flexible than the first part 2. This difference in flexibility can be found in particular at the level of the electrical conductors. Thus, the third electrical conductor 30 can be more flexible than the first electrical conductor 8.

[0091] Preferably, the third part 3 of the cable 1 is devoid of an electromagnetic shielding layer around the third electrical conductor 30.

[0092] Since the third part 6 of the electrical interconnection device 1 is more flexible than the first part 2, it can be more easily aligned with the second piece of equipment B. Conversely, the first part 2 benefits from the advantages associated with its rigidity. Furthermore, bringing the inner surface 10 of the first electrical conductor 8 into contact with the outer surface 32 of the third electrical conductor 30 has the advantage of allowing for fixing and electrical connection between the two conductors 8, 30 without requiring an additional connecting piece such as a sleeve.

[0093] With reference to [Fig.6], the third electrical conductor 30 extends partially into the hollow 9 delimited by the first electrical conductor 8, so that the internal surface 10 of the first electrical conductor 8 is in contact with the external surface 32 of the third electrical conductor 30.

[0094] This contact is made in such a way as to ensure relative fixity between the first electrical conductor 8 and the third electrical conductor 30. Moreover, this contact is direct (i.e. without any interposed element between the two surfaces), so as to ensure an electrical connection between the first electrical conductor 8 and the third electrical conductor 30. This relative fixity and this electrical connection can be obtained by different techniques, in particular by crimping or welding.

[0095] The external surface 32 of the third electrical conductor 30 can be complementary to the internal surface 10 of the first electrical conductor 8, so that this contact is effective all around the third electrical conductor 30.

[0096] Figure 7 is a schematic longitudinal cross-sectional view showing the through-hole 9 into which the second electrical conductor 20 and the third electrical conductor 30 are inserted and partially extended. Of course, it is not necessary for these insertions to be so deep as to fill the entire through-hole 9, that is, such that the second electrical conductor 20 and the third electrical conductor 30 touch each other. To save conductive material, the second electrical conductor 20 and the third electrical conductor 30 30 occupy only a portion of the available space in the hollow, and thus remain at a distance from each other.

[0097] As previously stated, the first electrical insulator 14, the second electrical insulator 24, and the third electrical insulator 34 constitute different parts of an electrically insulating piece extending into the first part 2, the second part 4, and the third part 6 of the cable 1. The first part 2, the second part 4, and the third part 6 have identical external diameters. Such a constant diameter helps to make the cable easier to connect securely to other equipment.

[0098] Due to the radial thickness of the first electrical conductor 8, this electrically insulating piece can include a shoulder junctioning between the first electrical insulator 14 and the second electrical insulator 24, and another shoulder junctioning between the first electrical insulator 14 and the third electrical insulator 34 (visible in [Fig.7]).

[0099] 2) Method for manufacturing an electrical interconnection device

[0100] A method for manufacturing the electrical interconnection device 1 for vehicles described above includes the following steps.

[0101] As a preliminary step, the first electrical conductor 8, the second electrical conductor 20 and the third electrical conductor 30 were manufactured.

[0102] In an insertion step, the second electrical conductor 20 is partially inserted into the hollow delimited by the first electrical conductor 8, so that the external surface 22 of the second electrical conductor 20 is in contact with the internal surface 10 of the first electrical conductor 8.

[0103] In another insertion step, the third electrical conductor 30 is partially inserted into the hollow delimited by the first electrical conductor 8, so that the external surface 32 of the third electrical conductor 30 is in contact with the internal surface 10 of the first electrical conductor 8.

[0104] In a fixing step, a treatment is carried out to fix the second electrical conductor 20 to the first electrical conductor 8.

[0105] The treatment may include a mechanical crimping of the second electrical conductor 20 into the first electrical conductor 8. Thus, it is the application of a force which ensures this relative fixity between the first electrical conductor 8 and the second electrical conductor 20.

[0106] Alternatively, the treatment includes magnetic pulse welding. Under the effect of such magnetic pulses, bonds are created at the atomic level between the inner and outer surfaces, and these bonds make it possible to obtain the desired fixity.

[0107] In another variant, the treatment includes ultrasonic welding.

[0108] The fixation treatment performed may combine several of the aforementioned techniques.

[0109] In another fixing step, a treatment is carried out to fix the third electrical conductor 30 to the first electrical conductor 8. This treatment can be identical to that used to fix the second electrical conductor 20 to the first electrical conductor 8. The two fixing treatments can be simultaneous or consecutive.

[0110] In an electrical insulation step, the first electrical insulator 14 is positioned around the first electrical conductor 8, such that the internal surface 16 of the first electrical insulator 14 is in contact with the external surface 10 of the first electrical conductor 8. Furthermore, the second electrical insulator 24 is positioned around the second electrical conductor 20, such that the internal surface 26 of the second electrical insulator 24 is in contact with the external surface 22 of the second electrical conductor 20. In addition, the third electrical insulator 34 is positioned around the third electrical conductor 30, such that the internal surface 36 of the third electrical insulator 34 is in contact with the external surface 32 of the third electrical conductor 30.

[0111] The electrical insulation step includes the following substeps, where the first electrical insulator 14, the second electrical insulator 20 and the third electrical insulator 30 are made from a single electrically insulating piece.

[0112] Figure 8 shows an example of a hollow electrically insulating part 40.

[0113] The electrically insulating part 40 is a hollow tube extending around an axis (it is not necessary for the cross-sectional shape of this part to exactly match the cross-sectional shape of the electrical conductors). The electrically insulating part 40 has an internal surface delimiting the hollow. This internal surface has a circular profile, but this profile could alternatively be oval or rectangular. The first electrical insulator 14, the second electrical insulator 20, and the third electrical insulator 30 correspond to different parts of the part 40, and are therefore each tubes.

[0114] In a crosslinking substep, the electrically insulating part 40 undergoes crosslinking. The crosslinking has the effect of improving the finishing resistance of the part 40.

[0115] In a heating substep, the cross-linked electrically insulating piece is heated, causing it to expand and thus increasing the diameter of its internal surface, as shown in [Fig. 8]. The electrically insulating piece is then in an expanded state, and the diameter of its internal surface is greater than the diameter of the external surface of the first electrical conductor 8, the second electrical conductor 20, and the third electrical conductor 30.

[0116] In a positioning substep, the electrically insulating part 40 in its The expanded state of the electrical insulating piece is positioned around the first electrical conductor 8, the second conductor 20, and the third conductor 30 such that its internal surface faces the external surfaces 12, 22, and 32 of the electrical conductors present (see [Fig. 10]). This positioning is easily achieved given the expanded state of the electrically insulating piece.

[0117] In a cooling substep, the electrically insulating part 40 is cooled, causing a contraction that reduces the diameter of its internal surface.

[0118] During this retraction, the inner surface of the electrically insulating part 40 comes into contact with the outer surface 12 of the first electrical conductor 8, conforming to its shape. The outer surface 12 thus comes into contact with the inner surface of the part 40 over 360 degrees in a cutting plane perpendicular to the longitudinal axis of the part 40. In other words, there is a cutting plane in which contact between the part 40 and the first electrical conductor 8 is established all around the axis, over 360 degrees.

[0119] On the other hand, the internal surface of the electrically insulating part 40 does not come into contact with the external surface 22 of the first electrical conductor 20 or with the external surface 32 of the second electrical conductor 30. This results from the fact that the part 40 is rigid, this rigidity being itself obtained thanks to the material in which the part 40 is made, and improved by the cross-linking carried out upstream.

[0120] Cooling the electrically insulating part 40 can be active cooling (by immersing the electrically insulating part in a cold environment) or passive cooling (by simply ceasing heating and waiting long enough to cause shrinkage).

[0121] The preceding steps are carried out while the conductors and insulators are straight. They therefore make it possible to obtain a device 1 in the form of a cable or a straight bar.

[0122] In a shaping step, the final shape of the electrical interconnection device 1 is obtained by shaping the first part of the electrical interconnection device 1. The device 1 as shown in [Fig. 1] is thus obtained. It can then be installed in the vehicle V and connected to the electrical equipment A, B, for the purpose of transmitting electrical power from A to B (or vice versa).

[0123] During the process described above, the electrically insulating part 40 was crosslinked before being assembled with electrical conductors. Performing crosslinking at this preliminary stage is particularly easy. Indeed, it is possible to move the electrically insulating part using pulleys to expose it to a crosslinking device, which radiates radiation towards the part 40. This radiation crosslinks the wall of the part 40 opposite the crosslinking device and is also capable of to cross the hollow of part 40, and to cross-link the opposite wall of part 40. As the part is not yet assembled with conductors, such conductors do not obstruct the propagation of radiation in the hollow.

[0124] One advantage of the above process is that it allows for a cable whose external diameter does not vary, or varies very little, along its length. This gives the cable the ability to be connected repeatably and securely to electrical equipment.

[0125] This advantage is notably obtained compared to a process in which insulation is formed by extrusion. External diameter variations are due to the fact that variations in the quantity of insulation injected into the extrusion head lead to a variation in the outside diameter in the case of extrusion onto a conductor. In the case of extruding a hollow tube, these variations in the injected quantity affect the internal diameter while leaving the external diameter uniform. This uniformity with constant clamping in the connector certainly allows for homogeneous sealing from part to part. However, in the event of a variation in the external diameter (as in the case of the conductor with extrusion), the variation with constant clamping leads to variability in the sealing. The manufacture of the "empty" insulating part 40 thus allows for greater control of the outside diameter compared to insulation deposited via conventional extrusion onto a conductor.Variations in material content affect the internal (not external) diameter of the insulating tube during a manufacturing process where the tube is not supported by a conductor. 3) Manufacturing variations.

[0126] In the cable embodiment 1 discussed so far, the first electrical conductor 8 has a through-hole into which the second electrical conductor 20 and the third electrical conductor 30 are inserted and partially extend. In another embodiment, the first electrical conductor 8 is partially solid and has two mutually opposed blind holes. That is, the first conductor comprises two end portions, each having a blind hole, and a solid central portion separating the two blind holes from each other. Thus, each blind hole has a bottom that marks the boundary between the end portion in question and the solid central portion of the electrical conductor 8. The second electrical conductor 20 extends into one of the two blind holes, and the third electrical conductor 30 extends into the opposite blind hole.Thus, unlike the previous embodiment, the second electrical conductor 20 and the third electrical conductor 30 are here separated by the massive central part of the first electrical conductor 8.

[0127] A second embodiment for cable 1 is shown in [Fig. 10]. In this second embodiment, the internal surface 26 of the second electrical insulator 24 is in contact with the external surface 22 of the second electrical conductor 20. The hollows 23 and 33 are therefore absent or at least minimized. Furthermore, the surface The internal 36 of the third electrical insulator 34 is in contact with the external surface 32 of the third electrical conductor 30. In the second embodiment, the electrically insulating part 40 includes a shoulder junctioning the first electrical insulator 14 and the second electrical insulator 24, and another shoulder junctioning the first electrical insulator 14 and the third electrical insulator 34.

[0128] The cable according to the second embodiment can be obtained by a process in which the first electrical insulator 14, the second electrical insulator 24 and the third electrical insulator 34 are formed by extrusion around the electrical conductors.

[0129] A third embodiment of the cable 1 is shown in [Fig. 11]. In this third embodiment, the first electrical insulator 14 and the second electrical insulator 24 are separate parts. An additional insulating sleeve (not shown) can overlap the first electrical insulator 14 and the second electrical insulator 24 to close a gap between them. Similarly, the third electrical insulator 34 and the first electrical insulator 14 can be separate parts. Another additional insulating sleeve (not shown) can overlap the first electrical insulator 14 and the third electrical insulator 34 to close a gap between them.Instead of using such sleeves, it is also possible to have the first electrical insulator 14 cover the second electrical insulator 24 and / or the third electrical insulator 34.

[0130] The cable according to the third embodiment can be obtained by a process similar to that applied to the first embodiment, by repeating the heating steps for each of the three electrical insulators. It is possible to shrink the second electrical insulator 24 onto the second electrical conductor 20 before inserting one end of the second electrical conductor 20, left bare, into the first hollow electrical conductor 8. Similarly, it is possible to shrink the third electrical insulator 34 onto the third electrical conductor 30 before inserting one end of the third electrical conductor 30, left bare, into the first hollow electrical conductor 8.

[0131] The electrical conductors 8, 20, 30 shown in Figures 2, 3, and 4 have a rectangular cross-section. Such a cross-section promotes bending of the cable 1 in one or two preferred directions, which can facilitate the implementation of the shaping step when very specific cable shapes are desired. Figure 12 shows a variant in which the electrical conductors 8, 20, 30 have circular cross-sections. These circular cross-sections allow the cable 1 to be bent in any direction during the shaping step; thus, The cable can be easily formed into a greater number of shapes than with a rectangular cross-section. This variant is applicable to all the embodiments described above. Oval cross-sections are also possible.

Claims

Claims

1. Electrical interconnection device (1) for transmitting electrical power from a first electrical equipment (A) of a vehicle to a second electrical equipment (B) of the vehicle, the electrical interconnection device (1) comprising: • a first part (2) comprising a first electrical conductor (8), the first electrical conductor (8) having an internal surface delimiting a hollow, • a second part (4) more flexible than the first part (2) and connectable to electrical equipment, the second part (4) comprising a second electrical conductor (20) suitable for being electrically connected to the first electrical equipment (A), the second electrical conductor (20) having an external surface, • wherein the second electrical conductor (20) is fixed to the first electrical conductor (8) and electrically connected to the first conductor by bringing the internal surface into contact with the external surface.

2. Electrical interconnection device (1) according to the preceding claim, wherein the second electrical conductor (20) is a strand.

3. An electrical interconnection device (1) according to any preceding claim, wherein the second electrical conductor (20) is attached to the first electrical conductor (8) by crimping, magnetic pulse welding and / or ultrasonic welding.

4. An electrical interconnection device (1) according to any preceding claim, wherein the first portion (2) comprises a first electrical insulator (14) extending around the first electrical conductor (8), and the second portion (4) comprises a second electrical insulator (24) extending around the second electrical conductor (20).

5. Electrical interconnection device (1) according to the preceding claim, wherein the first electrical insulator (14) and the second electrical insulator (24) are in one piece.

6. Electrical interconnection device (1) according to any one of the re- claims 4 and 5, wherein at least one of the first electrical insulator (14) and the second electrical insulator (24) is crosslinked.

7. An electrical interconnection device (1) according to any one of claims 4 to 6, wherein at least one of the first electrical insulator (14) and the second electrical insulator (24) is made of a material being or comprising a polyolefin, preferably a high density polyethylene.

8. An electrical interconnection device (1) according to any one of claims 4 to 7, wherein at least one of the first electrical insulator (14) and the second electrical insulator (24) has a temperature class ranging from T3 to T5, preferably T4.

9. An electrical interconnection device (1) according to any one of claims 4 to 8, which is devoid of an electromagnetic shielding layer around the first electrical insulator (14) and / or around the second electrical insulator (24).

10. Electrical interconnection device (1) according to any one of the preceding claims, further comprising • a third part (6) more flexible than the first part (2) and connectable to the second electrical equipment (B), the third part (6) comprising a third electrical conductor (30) suitable for being electrically connected to the second electrical equipment (B), the third electrical conductor (30) having an external surface, • in which the third electrical conductor (30) is fixed to the first electrical conductor (8) and electrically connected to the first conductor by bringing an internal surface of the first electrical conductor (8) into contact with the external surface of the third electrical conductor (30).

11. Electrical interconnection device (1) according to the preceding claim, in which the hollow passes through the first part (2) from end to end and in which the internal surface which delimits the hollow is in contact with the external surface of the third electrical conductor (30).

12. Method of manufacturing an electrical interconnection device (1) for transmitting electrical power from a first electrical equipment (A) of a vehicle to a second electrical equipment (B) of the vehicle,

13.

14. • the electrical interconnection device (1) comprising: • a first part (2) comprising a first electrical conductor (8), the first electrical conductor (8) having an internal surface delimiting a hollow, • a second part (4) more flexible than the first part (2) and connectable to electrical equipment, the second part (4) comprising a second electrical conductor (20) suitable for being electrically connected to the electrical equipment, the second electrical conductor (20) having an external surface, • the method comprising bringing the internal surface into contact with the external surface, so as to fix and electrically connect the second electrical conductor (20) to the first electrical conductor (8). Method according to the preceding claim, wherein the second electrical conductor (20) is fixed to the first electrical conductor (8) by crimping, by magnetic pulse welding and / or by ultrasonic welding. A method according to any one of claims 12 and 13, further comprising the following steps: • heating an electrically insulating part having an internal surface delimiting a hollow, the electrically insulating part being adapted so that the heating causes an expansion of the electrically insulating part increasing the diameter of the internal surface, and so that subsequent cooling of the electrically insulating part causes a retraction of the electrical insulator reducing the diameter of the internal surface, • inserting the first electrical conductor (8) and the second electrical conductor (20) into the electrically insulating part while the electrically insulating part is in an expanded state in which the diameter of the inner surface is greater than the diameter of an outer surface of the first electrical conductor (8) and the diameter of the outer surface of the second electrical conductor (20), such that, after retraction of the electrically insulating part, the inner surface of the electrically insulating part is in contact with the outer surface of the first electrical conductor (8).

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