Bus bar element

Abstract

The present invention relates to a busbar element (10) for use in automotive applications and in charging stations. The busbar element (10) comprises a first terminal body (1) which extends along a first axis (X) and has a first surface (5) and a second surface (4) defining a thickness along a third axis (Z). The first terminal body (1) is configured to be electrically coupled to an electrical interface. A main body (3) extends from the first terminal body (1). Said first terminal body (1) has an opening (8) which is configured to receive a fixing element, a first thickness (T1) of the opening (8) of the first terminal body (1) extending along the first axis (X) towards the main body (3) being greater than a second thickness (T2) of at least a portion of the first terminal body (1) extending towards an axial end Figure for abstract: [Figure 1B]

Description

Title of the invention: Bus bar element

[0001] The present invention relates to a busbar element, a busbar system intended in particular for the electrical coupling of a plurality of electrically conductive elements of an electrical device, preferably for automotive applications and in charging stations.

[0002] In recent years, automobiles are using energy from more than one source; these are commonly referred to as hybrid vehicles. For example, a type of hybrid vehicle that uses an engine and an electric motor for propulsion is known as a hybrid electric vehicle (HEV). In a non-limiting example, the electric motor alone propels the vehicle and a battery powers the electric motor. This type of vehicle is known as a battery-powered electric vehicle (BEV). Automobiles typically include a plurality of electrical components such as a cell, a battery, an inverter, electrical energy converters, a battery module, on-board chargers, etc. In general, in an automobile, for its operation, it is essential to electrically couple a plurality of electrical and electronic components to each other and to other components.In the case of a battery module that comprises a plurality of cells, it is mandatory to connect the individual cells using an interconnect or terminal connector or cell connector or bus bar element to obtain the power output required for the operation of the automobile.

[0003] As is known, the volume of such a bus bar is not considered in relation to the current density. Therefore, it is necessary to solve the technical problem associated with the typical bus bar element explained above.

[0004] The present arrangement therefore aims to provide a bus bar element, to overcome the above-mentioned drawbacks and other drawbacks of known arrangements.

[0005] The present arrangement relates to a bus bar element for an electrical connection comprising: a first terminal body extending along a first axis having a first surface and a second surface defining a thickness configured to be electrically coupled to an electrical interface; a main body extending from the first terminal body, said first terminal body having an opening configured to receive a fastening element; a first thickness of the opening of the first terminal body extending along the first axis towards the main body being greater than a second thickness of at least a portion of the first terminal body extending towards an axial end. Therefore, thanks to the shape, the busbar element is improved with different volumes with respect to different current densities throughout the busbar element and the busbar element with improved material utilization results in material reduction.

[0006] According to one aspect of the arrangement, a first boundary of the opening along the first axis toward the main body has the first thickness along a third axis and a second boundary of the opening along the first axis toward the axial end has the second thickness along the third axis. By having different thicknesses on either side of the opening, the volume of the busbar element is reduced, and the associated CO2 and production cost are thus reduced.

[0007] According to one aspect of the arrangement, the first terminal body is inclined downwardly away from the main body and along the first axis. Therefore, the material is avoided from having an inclined portion of the first terminal body, since the current density is low in this area, the bus bar element is thus improved with a different volume with respect to a different current density.

[0008] According to another aspect of the arrangement, the bus bar element is made of a sheet material and defines a width along a second axis and a length along the first axis, said first axis and said second axis being perpendicular to each other. Accordingly, material removed from the sheet material can be recycled.

[0009] According to yet another aspect of the arrangement, a first width of the main body is greater than a cross-sectional width of the first terminal body at least along a plane perpendicular to the first axis.

[0010] According to an example of the arrangement, the first terminal body has a curved shape with a third width.

[0011] According to an example of the arrangement, the first terminal body has a circular axial end of first diameter.

[0012] According to an example of the arrangement, the opening is a circular profile of second diameter.

[0013] According to an example of the arrangement, the first width of the main body extending in the second axis is at least greater than the first diameter.

[0014] According to an example of the arrangement, the first terminal body having the opening extends along the first axis and to the axial end.

[0015] According to yet another aspect of the arrangement, the bus bar element comprises a second terminal body extending from the main body. An advantage of using the first terminal body and the second terminal body is to interconnect two terminals for an electrical connection.

[0016] According to yet another aspect, the present invention relates to a bus bar connector assembly comprising a first bus bar element in accordance with present arrangement and a second busbar element in accordance with the present arrangement, the first surface of the first terminal body of the first busbar element being configured to abut a first surface of a first terminal body of the second busbar element for electrical coupling. Whereby the clearance required to accommodate the overlap of busbar elements within a housing is reduced, since the overlap of busbar elements lies well within the thickness of the main body.

[0017] According to yet another aspect, the present invention relates to a bus bar connector assembly in which a central axis of the opening of the first terminal body of the first bus bar member coincides with a central axis of an opening of the first terminal body of the second bus bar member to receive the fastening member for electrical coupling. Whereby a progressive current transfer takes place.

[0018] Therefore, the bus bar element is thus held in place and provides mechanical stability, particularly in applications where vibration or movement is a problem.

[0019] The current density of a bus bar element is more in the first terminal body and / or the second terminal body, at the opening adjacent to the main body. Accordingly, the volume of the bus bar element is improved by having more volume in high current density regions that are in the first terminal body and / or the second terminal body, at the opening adjacent to the main body and avoiding volume in low current density regions that are in the first terminal body and / or the second terminal body, at the opening toward the axial end along the first X-axis.

[0020] The features, aspects and advantages of the present arrangement may be better understood by referring to the following description and figures. The components in the figures are not necessarily to scale, the emphasis being rather on illustrating the principles of the arrangement. In addition, in the figures, like reference numerals designate corresponding parts. In the drawings:

[0021] [Fig. 1 A] illustrates a side view of one embodiment of a bus bar element configured in accordance with the present invention;

[0022] [Fig. 1B] illustrates a side view of another embodiment of a bus bar element configured in accordance with the present invention;

[0023] [Fig.2] illustrates a top view of one embodiment of a bus bar element configured in accordance with the present invention;

[0024] [Fig. 3] illustrates a side view of a bus bar connector assembly configured in accordance with an arrangement of the present invention;

[0025] [Fig.4], [Fig.5], [Fig.6], [Fig.7], [Fig.8], [Fig.9] and [Fig.10] illustrate a top view of various embodiments of a bus bar element configured in accordance with the present invention.

[0026] The figures are not necessarily to scale and the size of certain parts may be exaggerated to more clearly illustrate the example shown. In addition, the drawings provide examples and / or examples in accordance with the description; however, the description is not limited to the examples and / or examples provided in the drawings.

[0027] In the following description, reference is made to the accompanying drawings, which are part thereof, and in which there are illustrated in an illustrative manner specific embodiments in which the invention may be applied. These embodiments are described in sufficient detail to enable a person skilled in the art to practice the invention, and it will be understood that the embodiments may be combined or other embodiments may be used and that structural and logical modifications may be made without departing from the scope of the present invention. The following detailed description should therefore not be construed as limiting and the scope of the present invention is defined by the appended claims and their equivalents.

[0028] Identical, similar or analogous elements retain the same reference from one figure to another. Ordinal numbers are used to differentiate characteristics. They do not define a position of a characteristic. Therefore, for example, a third characteristic of a product does not mean that the product has a first and / or a second characteristic.

[0029] [Fig. 1 A] illustrates a side view of one embodiment of a bar element bus bar 10 configured in accordance with the present invention. [Fig.lB] illustrates a side view of another embodiment of a bus bar element configured in accordance with the present invention. This description relates to [Fig.lA] and [Fig.lB] in tandem for brevity.

[0030] The bus bar element 10 is for an electrical connection that comprises a first terminal body 1 extending along a first axis X having a first surface 5 and a second surface 4 defining a thickness along a third axis Z. In other words, the thickness of the first terminal body 1 is defined by the distance between the first surface 5 of the first terminal body 1 and the second surface 4 of the first terminal body 1. The thickness of the first terminal body 1 is not uniform. In other words, the distance between the first surface 5 of the first terminal body 1 and the second surface 4 of the first terminal body 1 is not uniform. The first terminal body 1 is configured to be electrically coupled to an interface electrical. A main body 3 extends from the first terminal body 1. The first terminal body 1 has an opening 8. Said first terminal body 1 having the opening 8 is configured to receive a fixing element 20 (illustrated in [Fig.3]), a first thickness T1 of the opening 8 of the first terminal body 1 extending along the first axis X towards the main body 3 being greater than a second thickness T2 of at least a portion of the first terminal body 1 extending towards an axial end.

[0031] [Fig.lA] illustrates an example where the first terminal body 1 extends from the first portion 11 of the main body 3. But it is also possible to have a second terminal body 2 extending from the second portion 12 of the main body 3. [Fig.lB] illustrates such an example, in which the busbar element 10 comprises a second terminal body 2 extending from the second portion 12 of the main body 3. Therefore, the first terminal body 1 and the second terminal body 2 facilitate mounting of the busbar element 10 on an electrical interface, and both the first terminal body 1 and the second terminal body 2 operate to distribute electrical power to establish an electrical connection.

[0032] In an example illustrated in [Fig.lB], the main body 3 is arranged between the first terminal body 1 and the second terminal body 2. Said main body 3 has a first surface denoted 5' and a second surface denoted 4'. The distance between the first surface 5' of the main body 3 and the second surface 4' of the main body 3 defines a thickness T4 of the main body 3. The thickness T4 of the main body 3 is for example uniform and between 1 mm and 10 mm. Preferably, the thickness T4 is between 2 mm and 5 mm. According to one aspect, the thickness T4 of the main body 3 is greater than the first thickness T1 of the opening 8 of the first terminal body 1.

[0033] According to [Fig.lA] and [Fig.lB], the first terminal body 1 of the bus bar element 10 has a first surface 5 and a second surface 4 defining a thickness along a third axis Z. The first terminal body 1 is inclined downwardly away from the main body 3 along the first axis X. The thickness of the first terminal body 1 is not uniform. In other words, the distance between the first surface 5 of the first terminal body 1 and the second surface 4 of the first terminal body 1 is not uniform. The first surface 5 of the first terminal body 1 and the second surface 4 of the first terminal body 1 are inclined or beveled at an angle α to each other. In one aspect, the angle α is between the first surface 5 of the first terminal body 1 and the first axis X.The second surface 4 of the first terminal body 1 is parallel to the first axis X and the first surface 5 of the first terminal body 1 is inclined towards the axial end along the . first axis X at an angle α relative to the first axis X. Similarly, the second terminal body 2 has a first surface denoted 5" and a second surface denoted 4" defining a thickness along the Z axis. Said first surface 5" of the second terminal body 2 and the second surface 4" of the second terminal body 2 are inclined at an angle α as described above. Preferably, the angle α takes the value between 3° and 15°. The thickness T3 of the first terminal body 1 at the axial end along the first axis X away from the main body 3 is between 0.5 mm and 5 mm.

[0034] In yet another embodiment, the second terminal body 2 extends from the main body 3 according to the above description such that the main body is disposed between the first terminal body 1 and the second terminal body 2.

[0035] In one embodiment, the first thickness T1 of the bus bar element 10 from the first terminal body 1 towards the main body 3 is greater than the second thickness T2 of the first terminal body 1 towards the free end.

[0036] In an exemplary embodiment, as shown in [Fig.lA] and [Fig.lB], the first terminal body 1 has the opening 8. The opening 8 has a central axis C. The opening 8 extends axially between the first surface 5 of the first terminal body 1 and the second surface 4 of the first terminal body 1. In other words, the opening 8 extends along the central axis C as a through opening 8 in the first terminal body 1.

[0037] In yet another embodiment, the second terminal body 2 has an opening 8 according to the description above.

[0038] In one example, the opening 8 is a complementary circular profile for receiving a fixing element 20 as illustrated in [Fig.lA] and [Fig.lB]. Said opening 8 of the first terminal body 1 having a first limit 8a along the first axis X towards the main body 3 has the first thickness T1 along a third axis Z and the second limit 8b of the opening 8 along the first axis X towards the axial end of the first terminal body 1 has the second thickness T2 along the third axis Z.

[0039] In one embodiment, the first thickness T1 of the boundary 8a of the opening 8 along the first axis X toward the main body 3 is greater than the second thickness T2 of the second boundary 8b of the opening 8 along the first axis X toward the axial end of the first terminal body 1. The thickness of the opening 8 involves the distance or depth through which the opening 8 extends between the first surface 5 of the first terminal body 1 and the second surface 4 of the first terminal body 1. In other words, the first thickness T1 of the opening 8 is the distance or depth of the opening 8 with the first boundary 8a in the first axis X toward the main body 3. The second thickness T2 of the opening 8 is the distance or depth of the opening 8 with the second limit 8b along the first axis X towards the axial end of the first terminal body 1.

[0040] In one embodiment, the opening 8 has a rounded, elliptical, or elongated profile. In one embodiment (not shown), the opening 8 is a circular profile and has internal threads. A threaded fastener is intended to cooperate with the internal threads of the opening 8 for fastening.

[0041] In an exemplary embodiment, illustrated in [Fig.8], the opening 8 extends along the first axis X toward the main body 3 to meet the first boundary 8a and toward the axial end of the first terminal body 1 as an elongated opening to meet the second boundary 8b.

[0042] In one embodiment, the opening 8 extends along the first axis X toward the main body 3 to meet the first boundary 8a and toward the axial end of the first terminal body 1 is open without the second boundary 8b, in other words, there is no second boundary 8b as illustrated in [Fig.4], [Fig.7] and [Fig.9].

[0043] In one example, the second limit 8b is introduced (not shown) in the embodiments shown in [Fig.4], [Fig.7] and [Fig.9] by welding to accommodate the tightening torque of the fastener 20.

[0044] In one embodiment, the fastening element 20 is a bolt and nut with washer (not shown) as illustrated in [Fig. 3]. The washer (not shown) is used to provide better gripping to hold the flat surface of the nut and bolt flange on the inclined surface of the first terminal body 1 and the second terminal body 2 of the bus bar element 10.

[0045] In a non-limiting manner, the opening 8 of the bus bar element 10 is configured to be fixed with the various electrical or electronic equipment or another bus bar element as indicated in the remainder of the description below by means of the fixing element 20 introduced through the opening 8. A mounting comprises a direct mounting either by bolting or by welding as non-limiting examples.

[0046] [Fig.2] illustrates a top view of one embodiment of a bus bar element 10 configured in accordance with the present invention.

[0047] In one embodiment, the bus bar member 10 is made of a sheet material and defines a width along a second Y axis and a length along the first X axis. The first X axis and the second Y axis are perpendicular to each other.

[0048] In an embodiment illustrated in [Fig.2], the main body 3 has two distal ends opposite each other along the first axis X. The main body 3 has a first part 11 and a second part 12 at the distal ends of the main body 3. The first terminal body 1 and / or the second terminal body terminal 2 have a curved shape with a third cross-sectional width W3. The third cross-sectional width W3 is measured between the axial end of the first terminal body 2 and the first part 11 of the main body 3. The third cross-sectional width W3 is also measured between the axial end of the second terminal body 3 and the second part 12 of the main body 3. Said first part 11 and second part 12 form in one piece the main body 3 extending from the first terminal body 1 and / or the second terminal body 2. The first part 11 and the second part 12 converge along each side of the first axis X. The width of the boundary between the first terminal body 1 or the second terminal body 2 and the main body 3 is a second width W2. The main body 3 extends along the second axis Y having a first width W1 along the second axis Y.The first width Wl of the main body 3 is greater than the third width W3 of cross-section of the first terminal body 1 and / or the second terminal body 2 at least along a plane perpendicular to the first axis X.

[0049] In an exemplary embodiment illustrated in [Fig.2], the first terminal body 1 and the second terminal body 2 have circular axial ends of a first diameter D2. Furthermore, the first terminal body 1 and the second terminal body 2 have the opening 8. The opening 8 is a circular opening of second diameter DI. The diameter range DI is between 4 mm and 12 mm, preferably between 6 mm and 10 mm. The first diameter D2 is given by the expression D2 = D1 + (2*T4). Preferably, the range of the first diameter D2 is between 6 mm and 32 mm. The second diameter DI of the opening 8 is complementary to the bolt diameter of the fastener 20. Preferably, the first diameter D2 is greater than the second width W2 but not greater than the first width W1.

[0050] Said first width W1 is greater than the second width W2 and the third width W3. The first width W1 of the main body 3 extending along the second axis Y is at least greater than the first diameter D2. Preferably, the range of the first width W1 is between 10 mm and 34 mm. Preferably, the range of the second width W2 is between 6 mm and 16 mm.

[0051] In one embodiment, the main body 3 has a non-uniform thickness with a maximum thickness extending along the third axis Z and reducing towards the first part 11 and / or the second part 12 of the main body 3 along the first axis X.

[0052] [Fig. 3] illustrates a side view of a bus bar connector assembly 11 configured in accordance with an arrangement of the present invention. A bus bar connector assembly 11 includes a first bus bar member 10 configured in accordance with the present invention as described above and a second bus bar element 10a configured in accordance with the present invention as described above. The first surface 5 of the first terminal body 1 of the first bus bar element 10 abuts against a first surface 5a of a first terminal body 1a of the second bus bar element 10a for electrical coupling.

[0053] By way of non-limiting example, a central axis C of the opening 8 of the first terminal body 1 of the first bus bar element 10 substantially coincides with a central axis C1 of an opening 8 of the first terminal body 1a of the second bus bar element 10a.

[0054] The first bus bar element 10 and the second bus bar element 10a are coupled together by a fixing element 20 for electrical coupling, as illustrated in [Fig.3].

[0055] In one example, the first terminal body 1 of the bus bar element 10 is configured to mechanically and electrically couple to a conductive element or to electrical or electronic equipment. For example, the conductive element may be a second bus bar element 10a whose corresponding terminal body 1a is configured in accordance with the present invention, as illustrated in [Fig. 3]. Also, in a non-limiting manner, a greater number of bus bar elements in accordance with the present invention are coupled in an example described above.

[0056] [Fig.4], [Fig.5], [Fig.6], [Fig.7], [Fig.8], [Fig.9] and [Fig.10] illustrate a top view of various embodiments of a bus bar element configured in accordance with the present invention; the description herein refers to [Fig.4], [Fig.5], [Fig.6], [Fig.7], [Fig.8], [Fig.9] and [Fig.10] in tandem for brevity.

[0057] According to one aspect of the present invention, the main body 3 comprises a first portion 11 and a second portion 12 at the distal ends of the main body 3. Said first portion 11 and the second portion 12 form the main body 3 in one piece. The first portion 11 and the second portion 12 converge along each side of the first axis X having a second width W2 at the distal ends of the main body 3 from which the first terminal body 1 and the second terminal body 2 extend on either side of the main body 3 along the first axis X. The main body 3 extends along the second axis Y having a first width W1 along the second axis Y. The first width W1 of the main body 3 is greater than a cross-sectional width of the first terminal body 1 and the second terminal body 2 at least along a plane perpendicular to the first axis X.

[0058] The busbar element 10 can be used for the distribution of electrical energy and for electrically coupling a plurality of electrical or electronic equipment such as inverters, electrical power converters, battery modules, on-board chargers, etc. to each other and to other components of an automobile. The bus bar element 10 serves as a primary component for interconnecting various battery cells in a battery module to obtain a required power output from the battery module. By way of non-limiting example, the above-mentioned equipment may further be used in association with rotating electrical machines such as alternators, starter-alternators, or even reversible machines or electric motors.A reversible machine is a rotating electric machine that can operate reversibly, on the one hand as an electric generator in alternator function, and on the other hand as an electric motor, for example, to start a thermal engine of a motor vehicle. Such rotating electric machines can also be applied as a traction motor for hybrid or electric vehicles.

[0059] The present invention relates to the application of the bus bar element 10 in automotive applications, but it can be understood that the application can extend to various other industries, such as aerospace, mining, electrical distribution, energy and power generation, etc.

[0060] Various modifications to the disclosed embodiments, as well as alternative embodiments of the invention, will become apparent to those skilled in the art upon reading the description of the invention. It may therefore be considered that such modifications may be made without departing from the scope of the present invention.

Claims

Claims

1. A busbar element (10) for an electrical connection comprising: a first terminal body (1) extending along a first axis (X) having a first surface (5) and a second surface (4) defining a thickness along a third axis (Z) configured to electrically couple to an electrical interface; a main body (3) extending from the first terminal body (1); said first terminal body (1) having an opening (8) configured to receive a fastening element (20); a first thickness (T1) of the opening (8) of the first terminal body (1) extending along the first axis (X) towards the main body (3) being greater than a second thickness (T2) of at least a portion of the first terminal body (1) extending towards an axial end.

2. A busbar element (10) according to claim 1, a first boundary (8a) of the opening (8) along the first axis (X) towards the main body (3) having the first thickness (T1) along a third axis (Z) and a second boundary (8b) of the opening (8) along the first axis (X) towards the axial end having the second thickness (T2) along the third axis (Z)

3. A bus bar element (10) according to any one of claims 1 to 2, the first terminal body (1) being inclined downwardly away from the main body (3).

4. A bus bar element (10) according to any one of claims 1 to 3, the bus bar element (10) being made of a sheet material defining a width along a second axis (Y) and a length along the first axis (X), said first axis (X) and said second axis (Y) being perpendicular to each other.

5. A busbar element (10) according to any one of claims 1 to 4, a first width (Wl) of the main body (3) being greater than a cross-sectional width of the first terminal body (1) at least along a plane perpendicular to the first axis (X).

6. A busbar element (10) according to any one of claims 1 to 5, the first terminal body (1) having a curved shape with a third width (W3).

7. A busbar element (10) according to claim 6, the first terminal body (1) having a circular axial end with a first diameter (D2).

8. A busbar element (10) according to any one of claims 1 to 7, the opening (8) being a circular profile with a second diameter (Dl).

9. Busbar element (10) according to claim 7 in combination with claims 4 and 5, the first width (Wl) of the main body (3) extending in the second axis (Y) being at least greater than the first diameter (D2).

10. A busbar element (10) according to any one of claims 1 to 9, the first terminal body (1) having the opening (8) extending along the first axis (X) and towards the axial end.

11. A busbar element (10) according to any one of claims 1 to 10, the busbar element (10) comprising a second terminal body (2) extending from the main body (11).

12. A bus bar connector assembly (11) comprising a first bus bar member (10) according to any one of claims 1 to 11 and a second bus bar member (10a) according to any one of claims 1 to 11, the first surface (5) of the first terminal body (1) of the first bus bar member (10) being configured to abut against a first surface (5a) of a first terminal body (1a) of the second bus bar member (10a) for electrical coupling.

13. A bus bar connector assembly (11) according to claim 12, a central axis (C) of the opening (8) of the first terminal body (1) of the first bus bar member (10) substantially coinciding with a central axis (Cl) of an opening (8i) of the first terminal body (la) of the second bus bar member (10a) for receiving the fastening element (20) for electrical coupling.

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