Electrical assembly comprising a power filtering module connected to a voltage converter and method of assembling such an assembly.

Abstract

The present invention relates to an electrical assembly comprising a power filtering module (2) comprising a first positive connector (21) and a second negative connector (22), and a voltage converter comprising a first positive terminal (31) and a second negative terminal (32), the first connector (21) being fixed to the first terminal (31) and being covered by a coating substance, and the second connector (22) being fixed to the second terminal (32), said assembly also comprising a deflection member (4) for said coating substance, said deflection member (4) projecting from the filtering module (2) or from the voltage converter (3) and extending at a distance from and facing the first terminal (31), so as to receive a portion of the coating substance, said deflection member (4) being configured to guide the coating substance between the deflection member (4) and the first terminal (31). Abstract figure: Figure 6

Description

Title of the invention: Electrical assembly comprising a power filtering module connected to a voltage converter and method of assembling such an assembly. Technical field

[0001] The present invention relates to an electrical assembly comprising a power filtering module connected to a voltage converter as well as a method of assembling said filtering module to said voltage converter. STATE OF THE ART

[0002] Known from the prior art is a voltage converter intended to be connected to a power filtering module. In particular, the voltage converter comprises a first positive terminal, a second negative terminal, at least one phase terminal intended to be connected to a corresponding phase of an electrical machine, a first capacitor and a second capacitor connected respectively between the first positive terminal and the second negative terminal. The positive and negative terminals may be intended to be connected to a power filtering module.

[0003] The power filtering module comprises, in particular, a first positive connector and a second negative connector, intended to be connected respectively to the first positive terminal of the voltage converter and to the second negative terminal of the voltage converter. The first connector, the second connector, the first terminal and the second terminal are rigid elements designed to withstand electric currents of at least 1 A, and having a thickness of at least 1 mm.

[0004] The assembly of the power filtering module with the voltage converter, and therefore of the first positive connector and the second negative connector of the power filtering module with respectively the first positive terminal and the second negative terminal of the voltage converter, is carried out by laser welding. Such welding prevents the coating of the connectors and terminals, made of copper. Thus, each of the connectors and each of the terminals is left free, exposed to the external environment and to environmental constraints such as salt spray for example, thus causing corrosion of the connectors and terminals.

[0005] To overcome the aforementioned corrosion problem, it is known to deposit glue or resin on top of the connectors and terminals and thus to protect, at least partially, said connectors and said terminals from the surrounding environment.

[0006] Furthermore, the restricted space requirement at the level of the first positive connector and the second negative connector of the power filter module assembled with respectively the first positive terminal and the second negative terminal of the voltage converter prevents the addition of an additional layer of glue or resin to further cover the connectors and terminals.

[0007] It could be envisaged to add a step on the production line for assembling the power filtering module with the voltage converter consisting of turning the assembly over to deposit a second layer of glue or resin at the connectors and terminals so as to coat all of the connectors and terminals.

[0008] However, this additional step would increase the production time of the assembly and therefore increase the production cost.

[0009] Thus, the invention aims to propose an electrical assembly comprising a filtering module and a voltage converter allowing the application of glue and / or resin at the connectors and terminals in a single step ensuring the complete coating of at least the first positive connector of the filtering module and the first positive terminal of the voltage converter, while maintaining the production time of the assembly and the production cost unchanged. PRESENTATION OF THE INVENTION

[0010] More specifically, the invention relates to an electrical assembly comprising a power filtering module and a voltage converter connected to each other. The power filtering module comprises at least one capacitor, a first positive connector and a second negative connector, said connectors being rigid. The voltage converter comprises a first positive terminal and a second negative terminal, said terminals being rigid. The first positive connector of the filtering module is fixed to the first positive terminal of the voltage converter, and the second negative connector of the filtering module is fixed to the second negative terminal of the voltage converter. At least said first positive connector and said first positive terminal are covered by a coating substance.Said assembly further comprising a deflection member for said coating substance, said deflection member projecting from the filtering module or from the voltage converter and extending at a distance from and opposite at least the first positive terminal of the voltage converter, so as to receive a portion of the coating substance, said deflection member being configured to guide the coating substance between the deflection member and the first positive terminal of the voltage converter.

[0011] The deflection member receives a portion of the coating substance, which by gravity flows between the deflection member and the first positive terminal of the voltage converter. In particular, the deflection member guides the coating substance between the deflection member and the first positive terminal, allowing the complete coating by the coating substance of the first positive connector and said first positive terminal. The complete coating by the coating substance of the first positive connector and said first positive terminal prevents their exposure to the external environment and to environmental constraints such as salt spray for example, thus preventing their corrosion.

[0012] Advantageously, the deflection member is made of plastic.

[0013] Advantageously, the deflection member and said filtering module are integral.

[0014] Advantageously, the deflection member is made of a material with said filtering module.

[0015] In particular, the deflection member can be either a part added to the filtering module or to the voltage converter, or be integrally formed with the filtering module or with the voltage converter. In the case where the deflection member is integrally formed with the filtering module or with the voltage converter, it can be directly molded with the latter. This makes it possible not to add an additional part to the electrical assembly and therefore to prevent the addition of a tool during its manufacture. Furthermore, during its manufacture, the cycle remains unchanged and no additional manufacturing station is necessary. Thus the production time remains unchanged, as does the production cost.

[0016] Advantageously, the deflection member comprises at least one inclined portion configured to guide and push the coating substance under the first positive terminal of the voltage converter.

[0017] By gravity, the coating substance is conveyed towards the deflection member and in particular towards the inclined portion of said deflection member. This inclined portion guides the coating substance towards an area not yet covered by the substance of the first positive connectors, first positive terminal. Thus, by means of this inclined portion, the coating substance is pushed towards the first positive connector and first positive terminal, which allows them to be coated.

[0018] Advantageously, the inclined portion of the deflection member has an inclination of between 30° and 60° relative to a plane perpendicular to the first positive connector and to the second negative connector of said power filtering module.

[0019] Advantageously again, the inclined portion of the deflection member comprises a proximal end located near the first positive connector and a distal end located at a distance from and opposite the first positive terminal of the voltage converter, said distal end extending at a distance of between 1.5 mm and 4 mm from the first positive terminal of the voltage converter.

[0020] Advantageously, the deflection member further comprises a retaining portion, projecting from the inclined portion and having a bowl shape configured to receive a surplus of coating substance.

[0021] By gravity, the excess coating substance flows into the retaining portion of the deflection member. Thus, the retaining portion makes it possible to keep the coating substance in the same place, that is to say to channel it only into the area where it is desired to be applied.

[0022] Advantageously, the voltage converter comprises a main module and a terminal module, the main module comprising at least a first positive terminal and a second negative terminal, the terminal module being assembled to the main module and comprising at least a first positive terminal forming the first positive terminal of the voltage converter; and a second negative terminal forming the second negative terminal of the voltage converter; the first positive terminal of the main module and the first positive terminal of the terminal module being at the same high potential, the second negative terminal of the main module and the second negative terminal of the terminal module being at the same low potential; the first positive terminal of the terminal module being fixed to the first positive connector of the power filtering module and the second negative terminal of the terminal module being fixed to the second negative connector of the power filtering module.

[0023] The invention also relates to a method for coating the first positive connector of the power filtering module and the first positive terminal of the voltage converter of the electrical assembly as described previously, comprising the following steps: connecting the first positive connector of the power filtering module and the first positive terminal of the voltage converter; connecting the second negative connector of the power filtering module and the second negative terminal of the voltage converter;and coating the first positive connector of the power filter module and the first positive terminal of the voltage converter by applying the coating substance to said first positive connector of the power filter module and to said first positive terminal of the voltage converter, the coating substance deflecting member receiving a portion of said coating substance and guiding it between the deflecting member and the first positive terminal of the voltage converter. ; PRESENTATION OF FIGURES

[0024] The invention will be better understood on reading the following description, given solely by way of example, and referring to the appended drawings given by way of non-limiting examples, in which identical references are given to similar objects and in which:

[0025] [Fig.l] is a schematic perspective representation of the electrical assembly according to the invention comprising a filtering module connected to a terminal module of a voltage converter;

[0026] [Fig.2] is a schematic representation of the filter module of [Fig.l], where the cover, a heat sink, an electronic card and the terminal module have been omitted;

[0027] [Fig.3] is an enlargement of [Fig.2], making the connectors of the filter module and the deflection member particularly visible;

[0028] [Fig.4] is a schematic representation similar to [Fig.3], but from another perspective angle;

[0029] [Fig. 5] is an enlargement of the electrical assembly of [Fig. 1], making particularly visible the connectors of the filter module and the deflection member as well as the terminals of the terminal module of the voltage converter; and

[0030] [Fig.6] is a schematic representation similar to [Fig.5], but from another perspective angle.

[0031] It should be noted that the figures set out the invention in detail to enable the invention to be implemented; although not limiting, said figures serve in particular to better define the invention where appropriate. DETAILED DESCRIPTION OF THE INVENTION

[0032] The invention relates to an electrical assembly 1, as shown in [Fig.l].

[0033] The electrical assembly 1 is for example intended to be installed in a vehicle at car.

[0034] In particular, the electrical assembly 1 comprises a power filtering module 2 and a voltage converter 3.

[0035] The power filtering module 2 comprises at least one capacitor, in particular a plurality of capacitors, an electronic card, a heat sink and a cover.

[0036] The power filtering module 2 comprises a first positive connector 21 and a second negative connector 22.

[0037] The first positive connector 21 and the second negative connector 22 protrude from the power filter module 2 and are intended to connect the power filter module 2 to the voltage converter 3.

[0038] The first positive connector 21 and the second negative connector 22 are rigid. They are designed to withstand electric currents of at least 1 A, and have a thickness of at least 1 mm.

[0039] The voltage converter 3 is intended to be connected on the one hand to the power filtering module 2 and on the other hand to a configured electrical power source to deliver a direct voltage U. The voltage converter 3 is further configured in particular to convert the direct voltage U into phase voltages delivered to an electrical machine of a motor vehicle.

[0040] The voltage converter 3 comprises a first positive terminal 31 and a second negative terminal 32.

[0041] The first positive terminal 31 and the second negative terminal 32 protrude from the voltage converter 3 and are intended to connect the voltage converter 3 to the power filter module 2.

[0042] The first positive terminal 31 and the second negative terminal 32 are rigid. They are designed to withstand electric currents of at least 1 A, and have a thickness of at least 1 mm.

[0043] According to a particular embodiment, the voltage converter 3 may comprise a main module and a terminal module 30. The main module is assembled with the terminal module 30.

[0044] The main module comprises at least a first positive terminal and a second negative terminal and the terminal module 30 comprises at least a first positive terminal forming the first positive terminal 31 of the power converter 3 and a second negative terminal forming the second negative terminal 32 of the voltage converter 3.

[0045] The first positive terminal of the main module and the first positive terminal 31 of the terminal module 30 are at the same high potential and the second negative terminal of the main module and the second negative terminal 32 of the terminal module 30 are at the same low potential.

[0046] The first positive terminal 31 of the terminal block module 30 is configured to be attached to the first positive connector 21 of the power filter module 2 and the second negative terminal 32 of the terminal block module 30 is configured to be attached to the second negative connector 22 of the power filter module 2.

[0047] As shown in Figures 1, 5 and 6, only the terminal module 30 of the voltage converter 3 has been shown for greater readability of the figures.

[0048] In particular, in the electrical assembly 1 according to the invention, the first positive connector 21 of the filtering module 2 is fixed to the first positive terminal 31 of the voltage converter 3. In addition, the second negative connector 22 of the filtering module 2 is fixed to the second negative terminal 32 of the voltage converter 3.

[0049] In particular, the fixing of the first positive connector 21 of the filtering module 2 to the first positive terminal 31 of the voltage converter 3 and the fixing of the second negative connector 22 of the filtering module 2 to the second negative terminal 32 of the voltage converter 3 are carried out by laser welding.

[0050] The electrical assembly 1 further comprises a coating substance, covering at least the first positive connector 21 and the first positive terminal 31.

[0051] Furthermore, this coating substance can also cover the second negative connector 22 and the second negative terminal 32.

[0052] The coating substance may for example be glue or even resin, making it possible to isolate at least the first positive connector 21 and the first positive terminal 31, so as to protect them at least in part from the external environment and from environmental constraints such as salt spray for example and thus from corrosion.

[0053] With reference to [Fig.2], the electrical assembly 1 further comprises a deflection member 4 for the coating substance.

[0054] The deflection member 4 projects from the filtering module 2 or from the voltage converter 3.

[0055] According to the example illustrated in Figures 2 to 6, the deflection member 4 is integral with the filtering module 2, in particular the deflection member 4 projects from the filtering module 2.

[0056] According to a particular embodiment, the deflection member 4 is made in one piece with the filtering module 2.

[0057] It goes without saying that the deflection member 4 can also be integral with the voltage converter 3 and project from said voltage converter 3. Also the deflection member 4 can be made in one piece with the voltage converter 3.

[0058] The deflection member 4 extends at a distance from and opposite the first positive terminal 31 of the voltage converter 3 of the assembled electrical assembly 1. The deflection member 4 is configured to receive a portion of the coating substance and to guide the coating substance between the deflection member 4 and the first positive terminal 31 of the voltage converter 3 of the assembled electrical assembly 1.

[0059] In particular, the deflection member 4 is made of plastic.

[0060] With reference to figures 3 and 4, the deflection member comprises at least one inclined portion 40.

[0061] This inclined portion 40 is configured to guide and push the coating substance under the first positive terminal 31 of the voltage converter 3.

[0062] The inclined portion 40 of the deflection member has an inclination of between 30° and 60° relative to a plane perpendicular to the first positive connector 21 and to the second negative connector 22 of said power filtering module 2. Such an inclination makes it possible to promote the routing of the coating substance along the inclined portion 40, by gravity.

[0063] With reference to [Fig. 3], the inclined portion 40 has a proximal end near the first positive connector 21 and a distal end at a distance from and opposite the first positive terminal 31 of the voltage converter 3.

[0064] The distal end of the inclined portion 40 extends at a distance of between 1.5 mm and 4 mm from the first positive terminal 31 of the voltage converter 3.

[0065] The deflection member 4 may further comprise a retaining portion 41. The retaining portion 41 projects from the inclined portion 40, in particular from the distal end of the inclined portion 40. This retaining portion 41 has a bowl shape configured to receive a surplus of coating substance.

[0066] By surplus coating substance is meant the coating substance not used for coating the first positive terminal 31 and the first positive connector 21 but which would still have been placed in the electrical assembly 1.

[0067] Thus, the coating substance is arranged on the first positive connector 21 and first positive terminal 31 of the electrical assembly 1. The coating substance initially covers the latter, then by gravity, the coating substance is conveyed towards the deflection member 4 and in particular towards the inclined portion 40 of said deflection member 4. This inclined portion 40 guides the coating substance towards an area not covered by the substance of the first positive connector 21 and first positive terminal 31. Thus, by this inclined portion 40, the coating substance is pushed towards the first positive connector 21 and first positive terminal 31 allowing them to be completely coated.

[0068] In the case of a surplus of coating substance, the surplus is conveyed, by gravity, into the retention portion 4L

[0069] The invention also relates to a method of coating the first positive connector 21 of the power filtering module 2 and the first positive terminal 31 of the voltage converter 3 to form the electrical assembly 1.

[0070] The method comprises at least the steps of connecting the first positive connector 21 of the power filtering module 2 and the first positive terminal 31 of the voltage converter 3, then connecting the second negative connector 22 of the power filtering module 2 and the second negative terminal 32 of the voltage converter 3, finally coating the first positive connector 21 of the power filtering module 2 and the first positive terminal 31 of the voltage converter 3 by applying the coating substance to said first positive connector 21 of the power filtering module 2 and to said first positive terminal 31 of the voltage converter 3. The deflection member 4 of the coating substance receives a portion of said coating substance and guides it between the deflection member 4 and the first positive terminal 31 of the voltage converter 3.

[0071] In particular, the first positive connector 21 of the power filtering module 2 and the first positive terminal 31 of the voltage converter 3 are connected by welding, in particular by laser welding. The same applies to the second negative connector 22 of the power filtering module 2 and the second negative terminal 32 of the voltage converter 3.

[0072] Due to these welds, it is not possible to put a coating on the first positive connector 21, first positive terminal 31, second negative connector 22 and second negative terminal 32. The latter are therefore left exposed to the surrounding environment and therefore to environmental constraints such as salt spray, causing their total or partial corrosion.

[0073] With the coating method which is the subject of the invention, the coating substance, such as resin or glue, is placed on the first positive connector 21, first positive terminal 31 at least, then by the effect of gravity, the coating substance will flow around the latter before reaching the deflection member 4. In particular, the coating substance is first conveyed towards the inclined portion 40, which will allow, by its inclination, the placement of substance on the lower part of the first positive connector 21 and first positive terminal 31, thus allowing the complete coating of the latter.

[0074] In the case of a surplus of coating substance, the surplus flows, by gravity, into the retaining portion 41.

[0075] Thus, the retaining portion 41 makes it possible to maintain the coating substance in the same place, that is to say to channel it only in the area where it is desired to apply it.

[0076] In addition, such a method allows the complete coating of the first positive connector 21 and the first positive terminal 31 in a single manufacturing operation. Thus, the coating is carried out while maintaining the production cycle of the electrical assembly 1, as well as its production time and therefore its production cost.

[0077] It will also be noted 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 embodiment described above, in light of the teaching which has just been disclosed to them.

[0078] In the detailed presentation of the invention which is made above, the terms used must not be interpreted as limiting the invention to the embodiment set out in the present description, but must be interpreted to include all equivalents whose prediction is within the reach of a person skilled in the art by applying his general knowledge to the implementation of the teaching which has just been disclosed to him.

Claims

1.

2.

3.

4.

5. Claims Electrical assembly (1) comprising a power filtering module (2) and a voltage converter (3) connected to each other, • the power filtering module (2) comprising at least one capacitor, a first positive connector (21) and a second negative connector (22), said connectors being rigid; • the voltage converter (3) comprising a first positive terminal (31) and a second negative terminal (32), said terminals being rigid; the first positive connector (21) of the filter module (2) being fixed to the first positive terminal (31) of the voltage converter (3), and the second negative connector (22) of the filter module (2) being fixed to the second negative terminal (32) of the voltage converter (3); at least said first positive connector (21) and said first positive terminal (31) being covered by a coating substance; said assembly further comprising a deflection member (4) for deflecting said coating substance, said deflection member (4) projecting from the filtering module (2) or from the voltage converter (3) and extending at a distance from and opposite at least the first positive terminal (31) of the voltage converter (3), so as to receive a portion of the coating substance, said deflection member (4) being configured to guide the coating substance between the deflection member (4) and the first positive terminal (31) of the voltage converter (3). Electrical assembly (1) according to claim 1, in which the deflection member (4) is made of plastic. Electrical assembly (1) according to one of claims 1 and / or 2, in which the deflection member (4) and said filtering module (2) are integral. Electrical assembly (1) according to any one of claims 1 to 3, in which the deflection member (4) is made of a single material with said filtering module (2). Electrical assembly (1) according to any one of claims 1 to 4, wherein the deflection member (4) comprises at least one inclined portion (40) configured to guide and push the coating substance under the first positive terminal (31) of the voltage converter (3).

6. Electrical assembly (1) according to claim 5, wherein the inclined portion (40) of the deflection member (4) has an inclination of between 30° and 60° relative to a plane perpendicular to the first positive connector (21) and to the second negative connector (22) of said power filtering module (2).

7. Electrical assembly (1) according to any one of claims 5 and / or 6, in which the inclined portion (40) of the deflection member (4) comprises a proximal end located near the first positive connector (21) and a distal end located at a distance from and opposite the first positive terminal (31) of the voltage converter (3), said distal end extending at a distance of between 1.5 mm and 4 mm from the first positive terminal (31) of the voltage converter (3).

8. Electrical assembly (1) according to any one of claims 5 to 7, wherein the deflection member (4) further comprises a retaining portion (41), projecting from the inclined portion (40) and having a bowl shape configured to receive a surplus of coating substance.

9. Electrical assembly (1) according to any one of claims 1 to 8, wherein the voltage converter (3) comprises a main module and a terminal module (30), the main module comprising at least a first positive terminal and a second negative terminal, the terminal module (30) being assembled to the main module and comprising at least: • a first positive terminal (31) forming the first positive terminal (31) of the voltage converter (3); and • a second negative terminal (32) forming the second negative terminal (32) of the voltage converter (3); the first positive terminal of the main module and the first positive terminal (31) of the terminal module (30) being at the same high potential, the second negative terminal of the main module and the second negative terminal (32) of the terminal module (30) being at the same low potential;the first positive terminal (31) of the terminal block module (30) being fixed to the first positive connector (21) of the power filter module (2) and the second negative terminal (32) of the terminal block module (30) being fixed to the; second negative connector (22) of the power filter module (2).

10. Method for coating the first positive connector (21) of the power filtering module (2) and the first positive terminal (31) of the voltage converter (3) of the electrical assembly (1) according to one of claims 1 to 9, comprising the following steps: • connect the first positive connector (21) of the power filter module (2) and the first positive terminal (31) of the voltage converter (3); • connect the second negative connector (22) of the power filter module (2) and the second negative terminal (32) of the voltage converter (3); and • coating the first positive connector (21) of the power filtering module (2) and the first positive terminal (31) of the voltage converter (3) by applying the coating substance to said first positive connector (21) of the power filtering module (2) and to said first positive terminal (31) of the voltage converter (3), the deflection member (4) of the coating substance receiving a portion of said coating substance and guiding it between the deflection member (4) and the first positive terminal (31) of the voltage converter (3).

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