METHOD FOR MANUFACTURED A CONNECTOR, METHOD FOR ASSEMBLING A CONNECTOR THUS OBTAINED WITH TWO POSITIVE AND NEGATIVE MAIN BUS BARS OF A DC-DC VOLTAGE CONVERTER, DC-DC VOLTAGE CONVERTER THUS OBTAINED, AND MOBILE ENGINEERING SUCH A CONVERTER

Abstract

The invention relates to a method of manufacturing a connector comprising a first and a second pin (B'+, B'-) each comprising a flat fixing portion (B1'+, B1'-), a first (BA'+) and a second (BA'-) auxiliary bus bars each comprising a first flat portion (BA1'+, BA1'-) and a second flat portion (BA2'+, BA2'-) and a magnetic core (304'), said method comprising: the insertion (E3) of the second pin (B'-) into the opening of the magnetic core (304') such that its flat fixing portion (B1'-) passes through the opening of the magnetic core (304'); the fixing (E5) of the first flat portion (BA1'-) of the second auxiliary bus bar (BA'-) against the flat fixing portion (B1'-) of the second pin (BA'-);the insertion (E7) of the fixing portion (B1'+) of the first pin (B'+) into said opening so that the fixing portion of the first pin is further from said opening than the fixing portion of the second pin, then the fixing (E9) of the first flat portion (BA1'+) of the first auxiliary bus bar (BA'+) against the flat fixing portion (B1'+) of the first pin (B'+); then the sliding (E10) of the first pin (B'+) into said opening to place the flat fixing portions (B1'+, B1'-) opposite each other. Figure for the abbreviation: Fig. 11;

Description

Title of the invention: METHOD FOR MANUFACTURING A CONNECTOR, METHOD FOR ASSEMBLING A CONNECTOR THUS OBTAINED TO TWO POSITIVE AND NEGATIVE MAIN BUS BARS OF A DC-DC VOLTAGE CONVERTER, DC-DC VOLTAGE CONVERTER THUS OBTAINED AND MOBILE EQUIPMENT COMPRISING SUCH A CONVERTER Technical field of the invention

[0001] The present invention relates to a method of manufacturing a connector and a method of assembling a connector thus obtained to two main positive and negative bus bars of a DC-DC voltage converter, a DC-DC electrical converter thus obtained and a mobility device comprising such a converter.

[0002] A mobility device is, for example, a motorized land vehicle, a train, an aircraft or a drone. A motorized land vehicle is, for example, a motor vehicle, a motorcycle, a motorized bicycle or a motorized wheelchair. Technological background

[0003] A DC-DC electrical converter is known from the state of the art, comprising: - an electrical conversion circuit designed to convert an input voltage continuous into a continuous output voltage; - an input or output connector, comprising two pins, one positive and the other negative, designed to receive the input voltage or to provide the output voltage and a magnetic core surrounding the two pins of the connector; and - two main bus bars called positive and negative connected to the electrical conversion circuit.

[0004] Generally, in order to connect the connector to the electrical circuit, the connector pins are plated and fixed against the main bus bars. Depending on the implementation constraints of the DC-DC electrical converter in its environment, the connector must have an orientation adapted to this environment. Thus, each time a new product is designed with a converter DC-DC electrical wiring, it is necessary to modify the connector pins and / or the main bus bars to accommodate this orientation. This therefore results in significant design and production costs.

[0005] Furthermore, in the prior art, the volume of the connector depends on the volume of the magnetic core, the volume of the latter itself depending on the shape of the connector pins. The miniaturization of the connector is therefore limited by the corresponding volume of the magnetic core.

[0006] It may thus be desirable to provide a connector which makes it possible to overcome at least some of the aforementioned problems and constraints. Summary of the invention

[0007] There is therefore provided a method of manufacturing a connector comprising a first pin and a second pin designed to receive a voltage therebetween, each pin comprising a planar fixing portion, a first and a second auxiliary bus bar, each auxiliary bus bar comprising a first planar portion and a second planar portion and a magnetic core comprising an opening, said method comprising: - a step of obtaining the second pin and a step of obtaining the magnetic torus; - a step of inserting the flat fixing portion of the second pin into the opening of the magnetic core so that the flat fixing portion of the second pin passes through the opening of the magnetic core; - a step of obtaining the second auxiliary bus bar; - a step of fixing the first flat portion of the second bar auxiliary buses against the flat fixing portion of the second pin; - a step of obtaining the first pin and a step of obtaining the first auxiliary bus bar; - a step of inserting the flat fixing portion of the first pin into the opening of the magnetic core so that the flat fixing portion of the first pin passes through the opening of the magnetic core and is further from the opening of the magnetic core than the flat fixing portion of the second pin; then a step of fixing the first flat portion of the first auxiliary bus bar against the flat fixing portion of the first pin; then - a step of sliding the first pin into the magnetic core to place the flat fixing portions opposite each other.

[0008] Thus, thanks to the invention, with each design of a new product, only the Auxiliary busbars need to be adapted to the desired orientation of the connector. The pins of the latter, as well as the main busbars, can be left unchanged.

[0009] Furthermore, thanks to the use of auxiliary bus bars obtained independently of the pins, it is possible to reduce the size of the magnetic toroid and therefore also the size of the connector.

[0010] The invention may further comprise one or more of the following optional features, in any technically possible combination.

[0011] Optionally, the step of obtaining the second auxiliary bus bar is a step of obtaining a second auxiliary bus bar comprising a bend between the first flat portion and the second flat portion such that the first flat portion and the second flat portion of the second auxiliary bus bar form a non-flat angle between them.

[0012] Also optionally, the step of obtaining the first auxiliary bus bar is a step of obtaining a first auxiliary bus bar comprising a bend between the first flat portion and the second flat portion such that the first flat portion and the second flat portion of the first auxiliary bus bar form a non-flat angle between them.

[0013] Also optionally, the steps of attaching the first flat portions of the auxiliary bus bars to the flat attachment portions of the pins are welding steps.

[0014] Also optionally, the step of obtaining the second pin is a step of obtaining a second pin comprising a flat end portion connected by a junction to the attachment portion of the second pin, the flat end portion and the flat attachment portion of the second pin extending substantially parallel, one opposite the other.

[0015] Also optionally, the step of obtaining the first pin is a step of obtaining a first pin comprising a flat end portion connected by a junction to the fixing portion of the second pin, the flat end portion and the flat fixing portion of the first pin extending substantially parallel, one opposite the other.

[0016] Also optionally, the planar end portion and the planar attachment portion of the first pin are not coplanar.

[0017] Also optionally, the planar end portion and the planar attachment portion of the second pin are not coplanar.

[0018] Also provided is a method of assembling a connector to a first main busbar and a second main busbar of a DC-DC voltage converter connected to an electrical circuit of conversion and respectively comprising flat portions, comprising: - a step of obtaining a connector according to the method of manufacturing a connector according to the invention, and - a step of plating and fixing the flat portion of the first main bus bar and the flat portion of the second main bus bar against the second flat portions of the first and second auxiliary bus bars respectively.

[0019] Optionally, the step of fixing the flat portion of the first main bus bar and the flat portion of the second main bus bar against the second portions of the first and second auxiliary bus bars respectively comprises a step of fixing by screwing the second portions of the auxiliary bus bars to the main bus bars in a screwing direction substantially perpendicular to the second portions of the auxiliary bus bars.

[0020] Also provided is a DC-DC voltage converter obtained after assembly according to an assembly method according to the invention.

[0021] A mobility device comprising a DC-DC electric converter according to the invention is also proposed. Brief description of the figures

[0022] The invention will be better understood with the aid of the following description, given solely by way of example and with reference to the appended drawings in which: - [Fig.l] is a simplified view of a mobility device in which the invention can be implemented, - [Fig.2] is a simplified three-dimensional view of a DC-DC electric converter of the mobility device of [Fig.l], - [Fig.3] is a three-dimensional view of a connector of the converter of [Fig.2], - [Fig.4] is a three-dimensional view of the connector of [Fig.3], from a different viewing angle and in the absence of a magnetic core, - [Fig.5] is a three-dimensional view of an electromagnetic compatibility filter associated with the connector of Figures 3 and 4, - [Fig.6] is a three-dimensional view of the electromagnetic compatibility filter, isolated from the connector, - [Fig.7] is a view of the electromagnetic compatibility showing the locations of elements of a clamp fixing tool, - [Fig.8] is a view similar to that of [Fig.7] without vertical offset of two capacities, - [Fig.9] is a three-dimensional view of the connector of Figures 3 and 4 and another connector of the DC-DC electrical converter, - [Fig. 10] is a three-dimensional view of the other connector and an associated electromagnetic compatibility filter. - [Fig. 11] is a series of three-dimensional views illustrating the successive stages of a manufacturing process for the other connector shown in [Fig. 9] and 10, Detailed description of the invention

[0023] With reference to [Fig. 1], a mobility device 100 in which the invention can be used will now be described.

[0024] The mobility device 100 comprises a propulsion system 102, for example drive wheels 104 and an electric motor 106 designed to drive the drive wheels 104. The mobility device 100 further comprises a battery 108 designed to electrically power the electric motor 106.

[0025] To recharge the battery 108 at a charging station 110 connected to an electrical distribution network (not shown), the mobility device 100 further comprises an electrical outlet 112 designed to be connected to the charging station 110, as well as a DC-DC electrical converter 114 connected between the electrical outlet 112 and the battery 108, in order to convert an input voltage VIN received from the charging station 110 through the electrical outlet 112 into an output voltage VOUT supplied to the battery 108.

[0026] In the remainder of the description, the arrangement of the various elements of the converter 114 will refer to an arbitrary reference frame comprising a left-right X axis, a bottom-top Y axis and a front-rear Z axis.

[0027] With reference to [Fig. 2], the converter 114 will now be described in more detail.

[0028] The converter 114 firstly comprises a housing 202 comprising side walls 204 and a bottom 206 together defining an interior space 208 of the housing 202 and an exterior space 210 to the housing 202. The side walls 204 may further define, opposite the bottom 206, an upper opening 212. In this case, the housing 202 may further comprise a cover 214 designed to close the upper opening 212.

[0029] The converter 114 further comprises an electrical conversion circuit 218 extending in the interior space 208 of the housing 202. The electrical conversion circuit 218 is designed to convert the input voltage VIN into the output voltage VOUT. For example, the converter 114 may be a parallel chopper (“boost converter” or “step-up converter” in English), in which case the conversion circuit 218 comprises for example a positive branch 220 and a positive branch negative 222, having an input side and an output side. The conversion circuit 218 comprises an inductance L on the positive branch, as well as a switch Q1 and a capacitor C, in parallel with each other between the positive branch 220 and the negative branch 222, on the output side with respect to the inductance L, and another switch Q2 on the positive branch, between the switch Q1 and the capacitor C, for example a diode passing towards the capacitor C (its cathode on the side of the capacitor C). The converter 114 then further comprises a control circuit 220 designed to control the switch Q to carry out the conversion.

[0030] To receive the input voltage VIN, the converter 114 further comprises an input connector 224 accessible from the external space 210 in order to be connected to the external socket 112 by an electrical connection (not shown) having, at one of its ends, a connector complementary to the input connector 224. The input connector 224 thus comprises two input pins B'+, B'-: the first pin B'+ is said to be positive to receive the positive potential of the input voltage VIN and the second pin B'- is said to be negative to receive the negative potential of the input voltage VIN.

[0031] To provide the output voltage VOUT, the converter 114 further comprises an output connector 226 accessible from the external space 210 in order to be connected to the battery 108 by an electrical connection (not shown) having, at one of its ends, a connector complementary to the output connector 226. The output connector 226 thus comprises two output pins B+, B-: the first pin B+ is said to be positive to provide the positive potential of the output voltage VOUT and the second pin B- is said to be negative to provide the negative potential of the output voltage VOUT.

[0032] To connect the negative potentials together, the converter 114 comprises a second main bus bar, called negative, BP- connecting the negative input pin B' - and the negative output pin B- to each other, as well as to the negative line 222 of the conversion circuit 218.

[0033] The converter 114 further comprises a main positive input bus bar BP'+ connecting the positive input pin B'+ to the input side of the positive branch 220 of the conversion circuit 218, and a first main bus bar, called the positive output bus bar, BP+ connecting the positive output pin B+ to the output side of the positive branch 220 of the conversion circuit 218.

[0034] The converter 114 may further comprise a switch 228 for selectively connecting and disconnecting the positive main bus bars BP+, BP'+. This makes it possible to short-circuit the conversion circuit 218 so that the output voltage VOUT is equal to the input voltage VIN. This function is useful, for example, when the charging station 110 provides an input voltage VIN which is already at the voltage required for recharging battery 108.

[0035] With reference to Figures 3 and 4, the output connector 226 will now be described in more detail.

[0036] With reference to [Fig. 3], the output pins B+, B- comprise for example respectively two flat bus bars, for example with a thickness of between 1 mm and 5 mm, for example 4 mm, each having a flat fixing portion B1+, B1- and a flat end portion B2+, B2-. The end portions B2+, B2- project for example towards the external space 210 along an axis D (in the forward direction in the illustrated example) and are designed to be connected to the complementary connector of the output connector 226 along this axis D. In other embodiments, the end portions B2+, B2- could have a geometry other than flat, for example a rod geometry with a circular section projecting along the axis D.

[0037] The planar fixing portions B1+, B1- extend substantially parallel, for example to within 1°, one opposite the other, for example less than 10 mm from each other, for example 4 mm from each other. Similarly, the planar end portions B2+, B2- extend substantially parallel, for example to within 1°, one opposite the other, but at a greater distance than the planar fixing portions B1+, B1-, for example at least twice as great, for example between 20 mm and 30 mm from each other, for example 25.7 mm from each other.For example, one of the output pins B+, B- (for example the positive output pin B+, as in the illustrated example) is flat, while the other of the output pins B+, B- (for example the negative connection pin B-, as in the illustrated example) has a junction 302 between the end portion B2- and the fixing portion B1-, this junction 302 having two bends for example made by bending the connection pin B- in its width.

[0038] The output connector 226 further comprises a first electromagnetic compatibility filter. This first filter comprises, for example, first of all, a magnetic core 304 surrounding the output pins B+, B-, and more precisely the fixing portions B1+, B1- due to their small spacing. The first filter further comprises, for example, two capacitors C+, C- connected between a bus bar 306 connected to an electrical ground (for example, the housing 202) and respectively the positive output pin B+ and the negative output pin B-. For example, the positive output pin B+ comprises a tab 308+ extending from the flat bus bar to the capacitor C+. Similarly, the negative output pin B- may comprise a tab 308- extending from the flat bus bar to the capacitor C-. These pins 308+, 308- are located between the magnetic core 304 and the end portions B2+, B2- of the output pins B+, B-.

[0039] With reference to [Fig.4], the output connector 226 further comprises two bars auxiliary buses BA+, BA-. The first BA+ is called positive and is inserted between the positive pin B+ and the positive main bus bar BP+. The second BA- is called negative and is inserted between the negative pin B- and the negative bus bar BP-.

[0040] Thus, each auxiliary bus bar BA+, BA- comprises a first flat portion BA1+, BAI- fixed on the positive pin B+, respectively negative B-, and more precisely on its fixing portion B1+, respectively B1-. The flat portions BA1+, BAI- of the auxiliary bus bars BA+, BA- are for example pressed against and fixed against faces of the fixing portions B1+, B1-. For example, the fixing portions B1+, B1- have facing faces (facing each other) and external faces, on the other side of the facing faces. Thus, the flat portions BA1+, BA1- of the auxiliary bus bars BA+, BA- are for example pressed against and fixed against these external faces (as in the example illustrated).

[0041] Each auxiliary bus bar BA+, BA- further comprises a second flat portion BA2+, BA2-. These second flat portions BA2+, BA2- are substantially parallel, for example to within 1°, to each other, for example coplanar. Depending on the orientation of the output pins B+, B- around their axis D, each portion BA2+, BA2- may extend in continuity with the first flat portion BA1+, BA1- (in which case the auxiliary bus bars BA+, BA- are flat) or with a non-flat angle (as in the example illustrated). In the latter case, each auxiliary bus bar BA+, BA- has for example a fold P+, P- between the portions BA1+, BA2+ and BA1-, BA2-, substantially parallel to the axis D, for example to within 1°.

[0042] Flat portions BP2+, BP2- of the main bus bars BP+, BP- respectively are pressed against and fixed respectively against the second portions BA2+, BA2- of the auxiliary bus bars BA+, BA-. Because the second portions BA2+, BA2- extend in parallel, their fixing can be carried out in a similar manner, in particular along the same fixing axis, whatever the orientation of the output pins B+, B- around the axis D. In particular, when this fixing is done by screwing (as in the example illustrated), the screwing can be carried out along the axis perpendicular to the second portions BA2+, BA2-, vertically in the example illustrated. This screwing axis can also be used for other screws of the converter 114. Thus, the same tool can be used to carry out all these screwing operations, whatever the orientation of the pins B+, B- around their axis D.

[0043] With reference to [Fig.5], the converter 114 further comprises a second electromagnetic compatibility filter 600 for the output connector 226.

[0044] This electromagnetic compatibility filter 600 firstly comprises a negative bus bar LD- connected to the negative main bus bar BP-. For this, the negative bus bar LD- comprises for example a fixing terminal 602 fixed to the negative main bus bar BP-, for example by the same screw as the negative auxiliary bus bar BA-. The electromagnetic compatibility filter 600 further comprises a positive bus bar LD+ connected to the positive main output bus bar BP+. For this purpose, the bus bar LD+ comprises, for example, a fixing terminal 604 fixed to the positive main output bus bar BP+, for example by the same screw as the positive auxiliary bus bar BA+. The electromagnetic compatibility filter 600 further comprises a ground bus bar LD0 connected to electrical ground, for example to the housing 202. For this purpose, the ground bus bar LD0 comprises a fixing terminal 606 fixed to electrical ground.

[0045] The electromagnetic compatibility filter 600 further comprises a capacitor C1 connected between the negative bus bar LD- and the ground bus bar LD0, a capacitor C2 connected between the positive bus bar LD+ and the ground bus bar LD0, and a capacitor C3 connected between the positive bus bar LD+ and the negative bus bar LD-. All the capacitors C1, C2, C3 have, for example, respective housings of generally parallelepipedal shape with horizontal upper faces, parallel to each other, perpendicular to the Y axis.

[0046] With reference to [Fig.6], to be connected, the capacitor Cl has two pins CIA, C1B projecting along axes D1A, DIB, parallel to the axis Z in the illustrated example. Thus, the negative bus bar LD- has a clamp PI A enclosing the pin CIA and the ground bus bar LD0 has a clamp PIB enclosing the pin C1B. The clamp PIB projects, that is to say opens, along a so-called oblique axis and a direction Al on this axis.

[0047] Similarly, to be connected, the capacitor C2 has two pins C2A, C2B projecting along axes D2A, D2B. Thus, the positive bus bar LD+ has a clamp P2A enclosing the pin C2A and the ground bus bar LD0 has a clamp P2B enclosing the pin C2B. The clamp P2B projects, i.e. opens, along the same axis, for example to within 1°, as the axis of the clamp PIB, and in a direction A2. The clamps PIB and P2B are positioned head to tail, i.e. the directions A1, A2 are opposite.

[0048] Similarly, to be connected, the capacitor C3 has two pins C3A, C3B (each of which can be split as in the example illustrated) projecting in forward directions D3A, D3B. Thus, the positive bus bar LD+ has a clamp P3A enclosing the pin C3A. This clamp P3A projects, i.e. opens, in the vertical axis Y in the direction A3 upwards. The negative bus bar LD- also has a clamp P3B which projects, i.e. opens, in the vertical axis Y in the direction A3 upwards and enclosing the pin C3B.

[0049] The ground conductor LD0 comprises an elongated body 702 extending from the clamps PIB, P2B downwards, at least to the level of the pin C3A. For example, LDO ground conductor terminal 606 is located lower than this C3A pin, so that the elongated body 702 passes to the side of pin C3A and between pins C3A and C3B.

[0050] Now, with reference to [Fig. 7], during the manufacture of the electromagnetic compatibility filter 600, each clamp P1A, PIB, P2A, P2B, P3A, P3B is closed on its associated pin C1A, C1B, C2A, C2B, C3A, C3B by a tool, in particular a fixing clamp having two elements 802, 804 designed to be placed respectively on each side of the clamp P1A, PIB, P2A, P2B, P3A, P3B. The fixing clamp may be a clamping clamp, in which case the elements are designed to move towards each other to mechanically push respectively the two branches of the clamp P1A, PIB, P2A, P2B, P3A, P3B so that they clamp the associated pin C1A, C1B, C2A, C2B, C3A, C3B.The fixing clamp may also be an electric welding clamp, in which case the elements 802, 804 additionally or alternatively form electrodes for passing a current through the clamp PI A, PIB, P2A, P2B, P3A, P3B and the associated pin CIA, C1B, C2A, C2B, C3A, C3B to weld them together.

[0051] Thus, to leave sufficient space for these elements 802, 804, the elongated body of the ground bus bar LDO must pass at a distance from the clamp P3A.

[0052] Furthermore, in order for the electromagnetic compatibility filter 600 to be as compact as possible, it is desirable that the capacitors C1 and C2, which extend above the capacitor C3, be as close as possible to the latter.

[0053] To satisfy these two constraints, the capacitor C1 is placed so that its pin C1B is located higher than the pin C2B of the second capacitor C2. Thus, the opposite directions A1, A2 and the direction A3 make an angle between them of less than 80°, preferably less than 70°, for example 65°, which allows the elongated body 702 to have a straight end portion 801, from which the grippers PIB, P2B project substantially perpendicularly, for example to within 1°, which is vertically at an angle to move away from the gripper P3A. Thus, it is possible to keep a sufficient distance between the gripper P3A and the elongated body 702 for the passage of the elements 802, 804 (in particular the element 804) of the tool, while keeping the capacitor C2 low, close to the capacitor C3.

[0054] For example, the capacitor C1 is placed so that its upper face extends higher than the upper face of the capacitor C2, i.e. at a higher height. For example, the height of the upper face of the capacitor C1 is at least 5 mm, preferably at least 10 mm, higher than the height of the upper face of the capacitor C2.

[0055] Still for example, the pins of each capacitor C1, C2 define a straight line D1, D2. These two straight lines D1, D2 are substantially parallel, by example to within 1°, with line DI above line D2, for example at least 5 mm above, for example between 5 mm and 10 mm above.

[0056] With reference to [Fig.8], if the capacitor C1 were placed at the same level as the capacitor C2, the elongated body 702 would extend too close to the gripper PIB and / or the gripper P3A to allow the passage of the elements 802, 804 of the tool (see the area surrounded by dotted lines).

[0057] With reference to [Fig.9] and 10, the input connector 224 has elements similar to those of the output connector 226, for which the references of the preceding figures are repeated, with "'" to distinguish them. The input pins B'+, B'- are identical to the output pins B+, B', in particular of the same shape. The input pins B'+, B'- extend horizontally, that is to say perpendicular to the direction of fixing (for example screwing). Thus, there is no angle to compensate for, so that the auxiliary bus bars BA'+, BA'- are flat.

[0058] Furthermore, an electromagnetic compatibility filter 600' is also provided behind the input connector 224 and has elements similar to those of the electromagnetic compatibility filter 600, for which the references of the preceding figures are repeated, with "'" to distinguish them. In particular, as previously, the capacitors C1', C2' are offset vertically in order to facilitate the passage of the bus bar LD0' away from the clamp

[0059] With reference to [Fig. 11], an exemplary method of manufacturing the input connector 224 is described.

[0060] The output connector 226 is obtained by an identical process.

[0061] During a step E1, the negative pin B' - and, for example, the bus bar 306' are obtained. Both are for example obtained overmolded by an overmolding 502', leaving the portions B1'-, B2'- of the negative pin B'- visible. The overmolding 502' further has a through opening 504' in a part of the overmolding 502' overmolding the portion B1'- of the negative pin B'-. In other exemplary embodiments, the overmolding 502' could be without a through opening 504'.

[0062] During a step E2, the magnetic torus 304' is obtained.

[0063] During a step E3, the negative pin B'- is inserted, by its fixing portion Bl'-, in the magnetic core 304', for example until the core 304' extends around the overmolding 502', for example around the part of the overmolding 302' having the through opening 504'.

[0064] During a step E4, the negative auxiliary bus bar BA'- is obtained.

[0065] During a step E5, the portion BAI'- of the negative auxiliary bus bar BA'- is pressed and fixed against the fixing portion Bl'- of the negative pin B'-. The fixing is for example carried out by welding, for example by electric soldering and / or by depositing a silver link between the two portions BAI'-, Bl'- to be fixed.

[0066] During a step E6, the positive branch B' + is obtained comprising the portions Bl' +, B2' +.

[0067] During a step E7, the positive pin B'+ is inserted, by its fixing portion Bl'+, into the torus 304', by shifting, for example upwards as in the illustrated example, its fixing portion Bl'+ from the fixing portion Bl'- of the negative pin B'-. In particular, as in the illustrated example, the positive pin B'+ is inserted into the through opening 504' of the overmolding 502', so that the torus 304' surrounds the fixing portion Bl'+ of the positive pin B'+.

[0068] During a step E8, the positive auxiliary bus bar BA'+ is obtained.

[0069] During a step E9, the portion BA1' + of the positive auxiliary bus bar BA'+ is pressed against and fixed against the Bl'+ fixing portion of the positive pin B'+. This fixing is facilitated by the offset between the Bl'+, Bl'- fixing portions of the pins B'-, B'+, which allows access from both sides. The fixing is for example carried out by welding.

[0070] During a step E10, the positive pin B'+ is slid downwards into the torus 304' to place the fixing portions Bl'+, Bl'- opposite each other. For example, as in the example illustrated, the positive pin B'+ is slid downwards into the through opening 504' of the overmolding 502'.

[0071] Once the connector 226 has been obtained by the method of manufacturing a connector as described above, this connector is assembled to the two main bus bars, positive BP+ and negative BP-, of the DC-DC voltage converter 114 according to an assembly method comprising a step F1 of obtaining a connector 226 according to the method of manufacturing a connector previously described, and a step of plating and fixing the flat portion BP2+ of the main positive bus bar BP+ and the flat portion BP2- of the main negative bus bar BP- against respectively the second flat portions BA2+, BA2- of the auxiliary bus bars BA+, BA-.

[0072] In particular, this step of plating and fixing the flat portion BP2+ of the positive main bus bar BP+ and the flat portion BP2- of the negative main bus bar BP- against the second portions BA2+, BA2- of the auxiliary bus bars BA+, BA- respectively comprises a step of fixing by screwing the second portions BA2+, BA2- of the auxiliary bus bars BA+, BA- to the flat portions BP2+, BP2- of the main bus bars BP+, BP- in a screwing direction substantially perpendicular to the second portions BA2+, BA2- of the auxiliary bus bars BA+, BA-.

[0073] It will be noted elsewhere that the invention is not limited to the embodiments described above. It will indeed appear to those skilled in the art that various modifications can be made to the embodiments described above, in light of the teaching which has just been disclosed to him.

[0074] In the detailed presentation of the invention which is made above, the terms used must not be interpreted as limiting the invention to the embodiments set out in the present description, but must be interpreted to include all equivalents whose prediction is within the reach of those skilled in the art by applying their general knowledge to the implementation of the teaching which has just been disclosed to them.

Claims

Claims

1. A method of manufacturing a connector (224) comprising a first pin (B'+) and a second pin (B'-) adapted to receive a voltage therebetween, each pin comprising a planar attachment portion (B 1 '+, B1'-), a first (BA'+) and a second (BA'-) auxiliary busbar, each auxiliary busbar comprising a first planar portion (BA1'+, BAI'-) and a second planar portion (BA2'+, BA2'-) and a magnetic core (304') comprising an opening, said method comprising: - a step of obtaining (El) the second pin (B'-) and a step of obtaining (E2) the magnetic torus (304'); - a step (E3) of inserting the flat fixing portion (Bl'-) of the second pin (B'-) into the opening of the magnetic core (304') so that the flat fixing portion (Bl'-) of the second pin passes through the opening of the magnetic core (304'); - a step of obtaining (E4) the second auxiliary bus bar (BA'-); - a step of fixing (E5) the first flat portion (BAI'-) of the second auxiliary bus bar (BA'-) against the flat fixing portion (Bl'-) of the second pin (B'-); - a step of obtaining (E6) the first pin (B'+) and a step of obtaining (E8) the first auxiliary bus bar (BA'+); - a step (E7) of inserting the flat fixing portion (Bl'+) of the first pin (B'+) into the opening of the magnetic core (304') so that the flat fixing portion (Bl'+) of the first pin passes through the opening of the magnetic core and is further from the opening of the magnetic core than the flat fixing portion (Bl'-) of the second pin; then a step (E9) of fixing the first flat portion (BA1'+) of the first auxiliary bus bar (BA'+) against the flat fixing portion (Bl'+) of the first pin (B'+); then - a sliding step (E10) of the first pin (B'+) in the magnetic core (304') to place the portions of plane fixations (Bl'+, Bl'-) facing each other.

2. A manufacturing method according to claim 1, wherein the step of obtaining (E4) the second auxiliary bus bar (BA'-) is a step of obtaining a second auxiliary bus bar (BA'-) having a bend between the first flat portion (BAI'-) and the second flat portion (BA2'-) so that the first flat portion (BAI'-) and the second flat portion (BA2'-) of the second auxiliary bus bar (BA'-) make a non-flat angle between them.

3. A manufacturing method according to claim 1 or 2, wherein the step of obtaining (E8) the first auxiliary bus bar (BA'+) is a step of obtaining a first auxiliary bus bar (BA'+) having a bend between the first flat portion (BA1'+) and the second flat portion (BA2'+) so that the first flat portion (BA1'+) and the second flat portion (BA2'+) of the first auxiliary bus bar (BA'+) make a non-flat angle between them.

4. A manufacturing method according to any one of claims 1 to 3, wherein the steps of fixing (E5, E9) the first flat portions (BA1'+, BAI'-) of the auxiliary bus bars (BA'+, BA'-) to the flat fixing portions (Bl'+, Bl'-) of the pins (B'+, B'-) are welding steps.

5. A manufacturing method according to any one of claims 1 to 4, wherein the step of obtaining (El) the second pin (B'-) is a step of obtaining a second pin comprising a flat end portion (B2'-) connected by a junction to the fixing portion (Bl'-) of the second pin (B-), the flat end portion (B2'-) and the flat fixing portion (B 1'-) of the second pin (B'-) extending substantially parallel, one opposite the other.

6. A manufacturing method according to any one of claims 1 to 5, wherein the step of obtaining (E6) the first pin (B'+) is a step of obtaining a first pin comprising a flat end portion (B2'+) connected by a junction to the fixing portion of the second pin (B2'+), the flat end portion (B2'+) and the flat fixing portion (B 1 '+) of the first pin (B'+) extending substantially parallel, one opposite the other.

7. A method of assembling a connector (226) to a first main bus bar (BP+) and a second main bus bar (BP-) of a DC-DC voltage converter connected to an electrical conversion circuit (218) and respectively comprising flat portions (BP2+, BP2-), comprising: - a step of obtaining a connector (226) according to the method of manufacturing a connector according to one of claims 1 to 6, and - a step of plating and fixing the flat portion (BP2+) of the first main bus bar (BP+) and the flat portion (BP2-) of the second main bus bar (BP-) against respectively the second flat portions (BA2+, BA2-) of the first and second auxiliary bus bars (BA+, BA-).

8. An assembly method according to the preceding claim, wherein the step of fixing the flat portion (BP2+) of the first main bus bar (BP+) and the flat portion (BP2-) of the second main bus bar against the second portions (BA2+, BA2-) of the first and second auxiliary bus bars (BA+, BA-) respectively comprises a step of fixing by screwing the second portions (BA2+, BA2-) of the auxiliary bus bars (BA+, BA-) to the main bus bars (BP+, BP-) in a screwing direction substantially perpendicular to the second portions (BA2+, BA2-) of the auxiliary bus bars (BA+, BA-).

9. A DC-DC voltage converter obtained after assembly according to an assembly method according to any one of claims 7 to 8.

10. A mobility device comprising a DC-DC electrical converter (114) according to claim 9.

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