Electrical connection device for battery system

Abstract

This electrical connection device comprises: - an electrical conductor (6) including a terminal portion (16) generally in the form of a rigid strip having a first cavity (20), this first cavity (20) defining a first receiving location configured to receive a fastening means (11), and - a protective ferrule (8) connected to the electrical conductor (6) and having a second cavity, this second cavity defining a second receiving location intended to receive the terminal portion (16), the protective ferrule (8) having a main access opening from the terminal portion (16) to the second receiving location, the protective ferrule having a first orifice, called the measuring orifice (30), extending opposite the terminal portion (16), the measuring orifice (30) being sized to comply with the IP2X criterion or the IPXXB criterion of standard EN IEC 60529 in the version in force on 1 September 2024. Figure 2

Description

Title of the invention: Electrical connection device for battery system

[0001] The invention relates to the field of battery systems. More particularly, the invention relates to an electrical connection device, a motor vehicle battery system comprising such an electrical connection device, and a motor vehicle comprising such a battery system.

[0002] A battery system, particularly for motor vehicles, generally comprises several battery cells configured to produce electrical energy and supply it to the vehicle to perform various functions, such as propulsion. These cells are connected to each other and to a control unit, which manages the cells, by means of an electrical conductor, often referred to by the English term "busbar." During the manufacture of the battery system, the busbar, which forms the electrical conductor, is connected to and fixed to the cells, and then these components are rigidly fixed inside a battery system casing.

[0003] During the battery system's lifetime, it may require maintenance or inspection operations, for example, to verify that it continues to function correctly or to extend its lifespan. Some of these operations require measuring the current flowing through the electrical conductor or measuring the voltage at a point on the electrical conductor. Because the electrical conductor and cells are fixed within the casing, and due to the overall compactness inside the battery system, this measurement can be difficult to perform.

[0004] Furthermore, since an electric current necessarily flows through the electrical conductor during the measurement, it is necessary to ensure the safety of the operator performing the measurement and to protect them from electrocution or electric shock. It is known to include in the battery system a protective cap, made of an insulating material, connected to and encasing the electrical conductor. The presence of such a protective cap reduces the risk of electrical contact between the electrical conductor and the operator. However, the presence of the protective cap further complicates the operator's task of measuring the current or voltage.

[0005] The invention aims in particular to remedy these problems by facilitating the measurement of electrical intensity or electrical voltage on the electrical conductor, while ensuring the safety of an operator carrying out such a measurement.

[0006] To this end, the invention relates to an electrical connection device which comprises:

[0007] - an electrical conductor comprising a terminal portion in the general shape of a rigid strip having a first cavity, this first cavity defining a first receiving location configured to receive a fastening means, and

[0008] - a protective end cap connected to the electrical conductor and having a second cavity, this second cavity defining a second receiving location intended to receive the terminal portion, the protective tip having a main access opening from the terminal portion to the second receiving location, the protective tip having a first orifice, called the measuring orifice, extending opposite the terminal portion,

[0009] the measuring orifice being dimensioned so as to comply with the IP2X criterion or the IPXXB criterion of the EN IEC 60529 standard in the version in force on September 1, 2024.

[0010] Thus, the presence of the measuring orifice allows an operator to easily access the electrical conductor in order to perform a current or voltage measurement. They can pass a probe or electrode of a measuring device through the measuring orifice so that it comes into contact with the electrical conductor, even if the electrical conductor is fitted with a protective cap. Furthermore, because the measuring orifice is sized to meet the IP2X or IPXXB criterion of standard EN IEC 60529, it is ensured that an operator cannot accidentally pass a finger through the measuring orifice and touch the electrical conductor. This guarantees their safety during the current or voltage measurement.

[0011] Advantageously, the electrical connection device further includes a fastening means housed in the first and second cavities.

[0012] The electrical connection device thus includes means which allow it to be easily fixed in a battery system.

[0013] Advantageously, the protective tip has a wall through which a second orifice, called the access orifice, extends opposite the first receiving location and is intended to provide access to the fastening means through the protective tip.

[0014] Thus, the protective tip does not completely obstruct the fastening means, so that the fastening means can be easily accessed to fix the electrical connection device in a battery system or to release the electrical connection device from it.

[0015] Preferably, the access opening is sized to comply with the IP2X criterion or the IPXXB criterion of the EN IEC 60529 standard in the version in force on September 1, 2024.

[0016] This ensures that the presence of the access opening does not create a risk of electrocution or electric shock for an operator.

[0017] According to a first embodiment of the invention, the fastening means comprises a screw, and the protective tip has an additional access opening for the fastening means to the first receiving location.

[0018] The fastening means is thus made with simple and easy-to-use means.

[0019] Preferably, the screw comprises a screw head housed in the second cavity, between the terminal portion and the wall of the protective cap through which the access opening passes.

[0020] In this way, the fastening means is held in the second cavity.

[0021] Preferably, the protective tip includes at least one elastic retaining tab for the fastening means in the second cavity, this at least one elastic tab extending inside the additional opening of the protective tip.

[0022] This ensures that the fastening means does not escape from the second cavity and that it remains firmly attached to the electrical conductor via the protective tip.

[0023] According to a second embodiment of the invention, the fastening means comprises a nut and an insulating button fixed to the nut and made of an electrically insulating material.

[0024] The fastening means is thus achieved with simple and easy-to-use features. Furthermore, since a nut is generally made of electrically conductive metal, the presence of the button protects an operator from any contact between a finger and the nut.

[0025] Preferably, the access port has a circular crown shape whose center is defined by the insulating button.

[0026] The dimensioning of the access opening so as to comply with the IP2X criterion or the IPXXB criterion of the EN IEC 60529 standard is thus facilitated by the presence of the insulating button thanks to which the access opening has the shape of a circular ring whose center is formed by the insulating button.

[0027] Advantageously, the first cavity extends between two branches of the terminal portion of the electrical conductor, the two branches being spaced apart by a distance greater than or equal to a diameter of the fastening means.

[0028] Thus, the electrical conductor has a housing facilitating the integration of the fastening means into the electrical connection device.

[0029] Preferably, the two branches join on either side of the first cavity.

[0030] The shape of the electrical conductor thus allows the fastening means to be retained in the electrical connection device, which contributes to the good cohesion of the elements constituting the electrical connection device.

[0031] Advantageously, the electrical conductor has at least one shoulder in its terminal portion, and the protective end cap includes at least one retaining clip for the electrical conductor that snaps into place with at least one shoulder of the electrical conductor.

[0032] This ensures that the protective tip is reliably fixed to the electrical conductor, which contributes to the good cohesion of the elements constituting the electrical connection device.

[0033] Advantageously, the protective tip includes several ribs extending inside the main opening towards the second cavity.

[0034] This ensures that the electrical conductor is properly guided in the protective end cap and is correctly positioned in relation to the measurement and access ports.

[0035] Preferably, the ribs extend over the lower and upper faces of the protective tip and the distance separating the ribs on the lower face from the ribs on the upper face is slightly less than the thickness of the terminal portion of the electrical conductor.

[0036] The protective tip is mounted slightly forcibly on the terminal portion of the electrical conductor, thus allowing the protective tip to be held in position by means of friction forces.

[0037] The invention also provides for a battery system for a motor vehicle, comprising at least one electrical connection device as defined above.

[0038] The invention also provides for a motor vehicle comprising a motor vehicle battery system as defined above. Brief description of the figures

[0039] The invention will be better understood upon reading the following description, given solely by way of example and made with reference to the accompanying drawings in which:

[0040] [Fig-1] is a schematic view of a motor vehicle, according to the invention, including a battery system according to the invention,

[0041] [Fig.2] is a perspective view of an electrical connection device according to a first embodiment of the invention intended to equip the vehicle and the battery system of the [Fig.1],

[0042] [Fig.3] is a perspective view of an electrical conductor of the electrical connection device of [Fig.2],

[0043] [Fig.4] is a perspective view of a protective end cap of the device electrical connection of the [Fig.2],

[0044] [Fig. 5] is a perspective view from a different angle of the protective tip of the [Fig.4],

[0045] [Fig.6] is a perspective view illustrating the arrangement of a fastening means in the electrical connection device of [Fig.2],

[0046] [Fig.7] is a perspective view of an electrical connection device according to a second embodiment of the invention intended to equip the vehicle and battery system of the [Fig. 1], and

[0047] [Fig.8] is a perspective view illustrating the arrangement of a fastening means in the electrical connection device of [Fig.7]. Detailed description

[0048] A vehicle 1 according to the invention is shown in [Fig. 1]. The vehicle 1 comprises a battery system 2 according to the invention, which is intended to supply electrical energy to the vehicle, for example for the propulsion of the vehicle.

[0049] An electrical connection device 4, according to a first embodiment of the invention, intended to equip the battery system 2 and the vehicle 1 of [Fig. 1], is shown in [Fig. 2]. The electrical connection device 4 is configured to make an electrical connection between different components of the battery system 2, for example between battery cells (not shown) and a control element (not shown) for these battery cells.

[0050] The electrical connection device 4 comprises an electrical conductor 6 to which a protective ferrule 8 is attached, the latter being made of an insulating material. The protective ferrule 8 serves to protect an electrical connection between the electrical conductor 6 and an electrical component 10, the nature of which may vary from one battery system to another. The electrical connection device 4 further comprises a fastening means 11, including a screw 12 in this first embodiment, for fastening the electrical conductor 6, fitted with its protective ferrule 8, to the electrical component 10.

[0051] The electrical conductor 6 is shown in more detail in [Fig. 3]. The electrical conductor 6 comprises a core 13 made of an electrically conductive material, for example, a metal. The core 13 of the electrical conductor 6 has a terminal portion 16 in the general shape of a rigid strip with a rectangular cross-section, defining a principal axis 18 of the electrical connection device 4. On a portion of the electrical conductor 6 adjacent to the terminal portion 16, the core 13 is enclosed in a sheath 14 made of an insulating material.

[0052] The terminal portion 16 of the electrical conductor 6 has a first cavity 20 extending along the main axis 18. This first cavity 20 defines a first receiving location, the function of which will be described later. The first cavity 20 extends between two branches 22, which are symmetrical to each other with respect to the main axis 18, of the terminal portion 16 of the electrical conductor 6. Thus, the first cavity 20 has a generally elongated and straight shape. The terminal portion 16 of the electrical conductor 6 also has two shoulders 24, symmetrical to each other with respect to the main axis 18, extending along the edge of the core 13. The function of these shoulders 24 will be described later.

[0053] The protective end cap 8 is shown in more detail in [Fig. 4]. The protective end cap 8 has a second cavity 26 which defines a second receiving location for receiving the terminal portion 16 of the electrical conductor 6. The protective end cap 8 has a main opening 28 allowing access of the terminal portion 16 of the electrical conductor 6 to the second receiving location in the second cavity 26.

[0054] The protective end cap 8 has a first orifice, called the measuring orifice 30, configured to extend opposite the terminal portion 16 of the electrical conductor 6, as illustrated in [Fig.2], when it extends into the second receiving location formed by the second cavity 26. The measuring orifice 30 is dimensioned to comply with the IP2X or IPXXB criterion of standard EN IEC 60529 in the version in force on 1 September 2024, to prevent an operator working on the electrical connection device from risking electrocution or electric shock by coming into contact with a live conductive element, while allowing the passage of a probe or electrode of a measuring device for measurement or maintenance operations.

[0055] The protective end cap 8 comprises at least two clips 32 for retaining the electrical conductor 6, each of which snaps into place with one of the two shoulders 24 of the electrical conductor 6, as illustrated in [Fig. 2]. These two clips 32 are formed on the edges of the protective end cap 8 and are symmetrical to each other with respect to the main axis 18. Each of these clips 32 has a general rod shape with a tooth sized to extend into one of the shoulders 24 and is formed from the rest of the protective end cap 8.

[0056] The protective cap 8 has a wall through which passes a second opening, called the access opening 34, extending opposite the first receiving location formed in the first cavity 20 and intended to provide access to the fastening means 11 through the protective cap 8. In this first embodiment of the invention, as previously indicated, the fastening means 11 comprises the screw 12 which extends into the protective cap 8, inside the second cavity 26, and into the electrical conductor 6, inside the first cavity 20. In the illustrated example, the screw 12 has a screw head housed in the second cavity 26, between the end portion 16 and the wall of the protective cap 8 through which the access hole 34 passes. The fastening means 11 is thus housed in both the first cavity 20 and the second cavity 26. Thanks to the access hole 34, it is possible to screw or unscrew the screw 12 from the fastening means 11 when it is housed in the first and second cavities 20, 26 to alternately fix the electrical conductor 6 with its protective cap 8 to the electrical component 10 or release the electrical conductor 6 with its protective cap 8 from the electrical component 10.The access opening 34 is also sized to comply with the IP2X or IPXXB criterion of the EN IEC 60529 standard in the version in force on September 1, 2024, to prevent an operator working on the battery system 2 from risking electrocution or electric shock by coming into contact with a live conductive element, while allowing the screwing and unscrewing of the fastening means 11.

[0057] The protective cap 8 has an additional opening 36 for accessing the fastening means 11 at the first receiving position. This additional opening 36 allows the fastening means 11 to be inserted into the protective cap 8 by simply sliding it into the protective cap 8. The protective cap 8 further includes two elastic tabs 38 for retaining the fastening means 11 in the second cavity 26. The elastic tabs 38 extend inside the additional opening 36 of the protective cap 8. They are arranged on both sides of the additional opening 36 and are symmetrical to each other with respect to the main axis 18. Each elastic tab 38 is shaped like a curved tooth with a convex face extending opposite the additional opening 36 and a concave face extending opposite the second cavity 26.

[0058] Figure 5 illustrates the protective end cap 8 from a different angle than the previous figure. The protective end cap 8 comprises several ribs 40 extending inside the main opening 28 towards the second cavity 26 and parallel to the main axis 18, on the lower and upper faces of the protective end cap 8. These ribs 40 allow the terminal portion 16 of the electrical conductor 6 to assume a fixed and determined position inside the protective end cap 8. For this purpose, the distance between the ribs 40 on the lower face and the ribs 40 on the upper face can be slightly less than the thickness of the terminal portion 16 of the electrical conductor 6. In this way, the protective end cap 8 is slightly press-fitted onto the terminal portion 16 of the electrical conductor 6 and held in position by friction forces.

[0059] We will now describe a method for assembling the electrical connection device 4 with reference to [Fig.6].

[0060] The procedure begins by inserting the end portion 16 of the electrical conductor 6 into the protective sleeve 8 through the main opening 28. As it does so, the end portion 16 slides along the ribs 40. Furthermore, the clips 32 of the protective sleeve 8 deform elastically as the end portion 16 of the electrical conductor 6 passes through them until they reach the shoulders 24. At this point, the clips 32 return to their original shape to extend into the shoulders 24, thus ensuring that the electrical conductor 6 is held securely in the protective sleeve 8. Once the electrical conductor 6 is fully inserted into the protective sleeve 8, the end portion 16 extends opposite the measuring orifice 30, and the first cavity 20 extends opposite the access orifice 34.

[0061] Next, the fastening means 11 is inserted into the protective cap 8 via the additional opening 36 until it reaches the first cavity 20. During this insertion, the fastening means 11 elastically deforms the elastic tabs 38, easily due to the orientation of the domed face of the elastic tabs 38. Once the fastening means 11 has passed the elastic tabs 38, the latter return to their initial shape, and a force applied by the fastening means 11 on the tabs 38 to remove it from the protective cap 8 does not deform the elastic tabs 38 in any significant way, due to the orientation of the concave face of the elastic tabs 38. Therefore, the elastic tabs 38 retain the fastening means 11 in the protective cap 8, in the second cavity 26.At this point, the fastening means 11 extends in relation to the access hole 34, so that it is possible to screw in the screw 12 to fix the electrical conductor 6, fitted with its protective end cap 8, to the electrical component 10. The access hole 34 has dimensions smaller than the dimensions of the fastening means 11 in order to prevent the fastening means 11 from escaping through the access hole 34. The screw 12 is intended to engage in a tapped hole provided in the electrical component 10 so as to make the electrical connection between the electrical conductor 6 and the electrical component 10.

[0062] Figure 7 shows an electrical connection device 4' according to a second embodiment of the invention. The elements of this electrical connection device 4' that are identical to those of the previous embodiment bear identical reference numerals. In what follows, only the elements of this electrical connection device 4' that distinguish it from that of the previous embodiment will be described.

[0063] Instead of comprising a screw, the fastening means 11 of the electrical connection device 4' according to the second embodiment of the invention comprises a nut 42 is intended to cooperate with a threaded rod formed on the electrical component 10. The fastening means 11 further includes an insulating button 44 made of an electrically insulating material, such that the insulating button 44 is positioned opposite the access hole 34. Due to the presence of this insulating button 44, the access hole 34 has the shape of a circular ring whose center is defined by the insulating button 44, since contact with this insulating button 44 does not generate any electrical conduction. In other words, this circular ring is defined by an outer circle formed by the contour of the access hole 34, and by an inner circle formed by the contour of the insulating button 44.

[0064] Since the nut 42 is less bulky than the screw of the first embodiment, it can be foreseen that the two arms 22 of the terminal portion 16 of the electrical conductor 6 will meet on either side of the first cavity 20 as illustrated by the dotted lines 46 in [Fig. 3]. In this way, the first cavity 20 is surrounded by a completely closed contour.

[0065] As illustrated in [Fig. 8], the assembly method for the electrical connection device according to the second embodiment is similar to that of the previous embodiment. The main difference lies in the insertion of the nut into the second cavity. The nut is inserted into the protective end cap 8 through the access hole 34, the diameter of which is larger than the dimensions of the nut 42.

[0066] The invention is not limited to the embodiments shown and other embodiments will be obvious to a person skilled in the art. List of references

[0067] 1: vehicle 2: Battery system 4: Electrical connection device 6: electrical conductor 8: Protective tip 10: electrical component 11: means of attachment 12: screw 13: soul 14: sheath 16: terminal portion 18: main axis 20: first cavity 22: branch 24: shoulder 26: second cavity 28: Main opening 30: measuring orifice 32: clip 34: access port 36: additional opening 38: elastic tab 40: ribs 42: nut 44: Insulating button 46: dotted line

Claims

Demands

1. Electrical connection device (4;4'), characterized in that it comprises: - an electrical conductor (6) including a terminal portion (16) generally in the form of a rigid strip having a first cavity (20), this first cavity (20) defining a first receiving location configured to receive a fastening means (11), and - a protective end cap (8) connected to the electrical conductor (6) and having a second cavity (26), this second cavity (26) defining a second receiving location intended to receive the terminal portion (16), the protective end cap (8) having a main opening (28) for access from the terminal portion (16) to the second receiving location, the protective end cap (8) having a first orifice, called the measuring orifice (30), extending opposite the terminal portion (16), the measuring orifice (30) being dimensioned so as to comply with the IP2X criterion or the IPXXB criterion of standard EN IEC 60529 in the version in force on 1 September 2024.;

2. Electrical connection device (4; 4') according to the preceding claim, further comprising a fastening means (11) housed in the first and second cavities (20, 26).

3. Electrical connection device (4; 4') according to the preceding claim, wherein the protective end cap (8) has a wall through which a second orifice, called the access orifice (34), passes, extending opposite the first receiving location and intended to provide access to the fastening means (11) through the protective end cap (8).

4. Electrical connection device (4; 4') according to the preceding claim, wherein the access port (34) is dimensioned to comply with the IP2X criterion or the IPXXB criterion of standard EN IEC 60529 in the version in force on 1 September 2024.

5. Electrical connection device (4) according to any one of claims 2 to 4, wherein the fastening means (11) comprises a screw (12), and wherein the protective end cap (8) has an additional opening (36) for accessing the fastening means (11) to the first receiving location.

6. Electrical connection device (4) according to claim 5, wherein the protective end cap (8) comprises at least one elastic tab (38) for retaining the fastening means (11) in the second cavity (26), this at least one elastic tab (38) extending inside the additional opening (36) of the protective end cap (8).

7. Electrical connection device (4') according to any one of claims 2 to 4, wherein the fastening means (11) comprises a nut (42) and an insulating button (44) fixed to the nut (42) and made of an electrically insulating material.

8. Electrical connection device (4') according to claim 7 taken in combination with claim 3 or 4, wherein the access port (34) has a circular crown shape whose center is defined by the insulating button (44).

9. Electrical connection device (4; 4') according to any one of the preceding claims, wherein the first cavity (20) extends between two branches (22) of the terminal portion (16) of the electrical conductor (6), the two branches (22) being spaced apart by a distance greater than or equal to a diameter of the fastening means (11).

10. Electrical connection device (4') according to claim 9 taken in combination with claim 7 or 8, wherein the two branches (22) join on either side of the first cavity (20).

11. Electrical connection device (4; 4') according to any one of the preceding claims, wherein the electrical conductor (6) has at least one shoulder (24) in its terminal portion (16), and the protective end cap (8) includes at least one clip (32) for retaining the electrical conductor (6) which snaps into at least one shoulder (24) of the electrical conductor (6).

12. Electrical connection device (4; 4') according to any one of the preceding claims, wherein the protective end cap (8) comprises several ribs (40) extending inside the main opening (28) towards the second cavity (26).

13. Battery system (2) for motor vehicle, comprising at least one electrical connection device (4; 4') according to any one of the preceding claims.

14. Motor vehicle (1), comprising a battery system (2) for motor vehicle according to the preceding claim.

Images