Power electrical interconnector

Abstract

The invention relates to a power electrical interconnector (10) of an interlocking system (11), for an electronic device such as an on-board vehicle charger (2), in particular of the single-phase or three-phase type, the power electrical interconnector (10) comprising: a body (14) made of insulating material, in particular of a plastic material, one or more power electrical contact elements (15), in particular of the male or female type, disposed in said body (14) and configured to transmit power, this or these power electrical contact elements (15) being in particular configured to be soldered onto an electronic board (16), at least one interlocking contact element (17) disposed in said body (14) and configured to be connected to a complementary interlocking contact element (18) on an external power connector (19),in order to allow detection of a connection interruption on the power electrical contact element(s) (15), this interlocking contact element (17) being specifically configured to be soldered onto an electronic board (16). Figure for the abbreviation: Fig. 2,

Description

Title of the invention: Power electrical interconnector

[0001] The invention relates in particular to a power electrical interconnector for an electronic device, configured to participate in an interlock function.

[0002] In known electronic devices, there is an interlock function that acts like a circuit breaker and triggers an alert in the event of a disconnection between power connection parts (such as an external connector or customer connector) or a deterioration of a power connection (high voltage). The interlock system relies on a continuous low-voltage loop that monitors all the connectors and high-voltage components of the vehicle. If this low-voltage signal is interrupted, it indicates a potential problem in the high-voltage system. Disconnection of the customer connector can lead to a risk of arcing (the appearance of sparks or electrical arcs) or overheating due to a degradation of contact resistance. These events can lead to a fire. The interlock function is therefore a safety function.In general, an interlock system is configured to prevent the operation of one or more components under its control when predefined conditions are not met. For example, an interlock system includes an interlock loop with a master component that generates a voltage transmitted via a power line connecting various components. The non-master components, called slave components, depend on the master for their operation.

[0003] Generally, the interlock function is managed by a wired connection (for example, in the form of two cables to be connected) between the customer connector and the electronic board. The interlock function is controlled by a microcontroller located on a control electronic board, which may be in an on-board charger (OBC) or in another device in the vehicle. This type of cable-based solution requires manual operation to clip the cables to an interconnector on the printed circuit board (PCB). This proves complex, generates additional labor / operation costs, and makes it difficult to detect incorrect assembly.

[0004] The invention aims in particular to address these problems.

[0005] The invention thus relates to a power electrical interconnector for an interlocking system, for an electronic device such as an on-board vehicle charger, in particular of the single-phase or three-phase type, the power electrical interconnector comprising: - a body made of insulating material, particularly plastic, - one or more power electrical contact elements, in particular male or female type, arranged in said body and configured to transmit power, this or these power electrical contact elements being specifically configured to be soldered onto an electronic board, - at least one interlocking contact element disposed in said body and configured to be connected to a complementary interlocking contact element on an external power connector, so as to allow detection of a connection interruption on the electrical power contact element(s), this interlocking contact element being configured in particular to be soldered onto an electronic board.

[0006] The interlock contact element(s) are advantageously configured to detect an accidental disengagement of the external power connector of the interconnector, for example caused by vibrations or movements during use of the vehicle or handling by an operator, or during a vehicle maintenance operation.

[0007] The electrical power contact elements and the interlocking elements are advantageously arranged in the same insulating body.

[0008] The invention reduces the number of operations required by directly integrating the power and signal contacts (interlocking contact element) into a single interconnector, thus eliminating the need for dedicated cables and connection operations between the external (client) connector and the electronic board. This simplification decreases complexity, reduces costs, and improves reliability by minimizing the risk of incorrect assembly.

[0009] According to one aspect of the invention, the interlocking contact element(s) are of the female type.

[0010] According to one aspect of the invention, the interlocking contact element comprises two opposite arms for the insertion of the complementary male-type interlocking contact element.

[0011] According to one aspect of the invention, the interlocking contact element(s), particularly of the female type, are configured to be held in the body of the power electrical interconnector by mechanical insertion, particularly by clipping, into the body of the power electrical interconnector. According to one aspect of the invention, the interlocking contact element(s) are configured to be held in the body of the power electrical interconnector by an elastic clipping tab formed to retract when the interlocking contact element is inserted into a cavity in the body, then to resume a deployed form after passing through a shoulder of the cavity, so as to immobilize the interlocking contact element in said cavity.

[0012] According to another aspect of the invention, the interlocking contact element is overmolded in the insulating material of the interconnector body.

[0013] According to one aspect of the invention, the interlocking contact element, in particular metallic, comprises: - a first section, for example in the form of a tab, configured to be fixed to an electronic board and in particular in contact with a signal trace of said electronic board, - a second section provided with opposite branches for the insertion of the additional male type interlocking contact element.

[0014] According to one aspect of the invention, the first and second sections form a bend at their junction, in particular a right-angle bend. This is particularly appropriate when the electronic board is parallel to a base of the external power connector. If the electronic board is perpendicular to a base of the external power connector, the interlocking contact element can be straight, without a bend. In this case, the first and second sections are aligned.

[0015] According to one aspect of the invention, the first section is fixed perpendicularly to the electronic board.

[0016] According to one aspect of the invention, the power electrical contact element is configured to be used with a single-phase network or a three-phase network.

[0017] According to one aspect of the invention, there are four power electrical contact elements and two interlocking contact elements. This is appropriate for a three-phase system. For a single-phase system, only two power electrical contact elements are required.

[0018] According to one aspect of the invention, the interconnector comprises two interlocking contact elements configured to establish a continuous loop enabling the detection of a connection interruption. According to one aspect of the invention, one of the interlocking contact elements is configured to ensure current flow in the forward direction and another interlocking contact element is configured to ensure current flow in the reverse direction, thus defining a loop that is closed when the connections are correctly made.

[0019] According to one aspect of the invention, the interlocking contact elements are configured to be connected, in particular by conductive tracks, to a microcontroller on an electronic control board of the electronic device.

[0020] According to one aspect of the invention, the electrical power contact elements are of the female type.

[0021] According to one aspect of the invention, the interlocking contact elements are configured to transmit a low voltage signal in a closed loop, in normal operation (excluding accidental disengagement).

[0022] The invention also relates to an electronic device, in particular an on-board vehicle charger, comprising: - an electronic card, - an electrical interconnector as mentioned above, fixed to said electronic board.

[0023] According to one aspect of the invention, the electronic device comprises a metal case and a cover configured to close the case.

[0024] According to one aspect of the invention, the electronic device is of the high-voltage type or of the low-voltage type, comprising an interconnector according to the invention

[0025] The invention further relates to an external power connector configured to cooperate with an electrical interconnector as mentioned above, the external power connector comprising a complementary interlocking contact element configured to be connected to an interlocking contact element of the electrical interconnector, in addition to one or more electrical power contact elements.

[0026] According to one aspect of the invention, the complementary interlocking contact element is of the male type, for example in the form of a pin.

[0027] According to one aspect of the invention, the complementary interlocking contact elements, in particular of the male type, are overmolded into a base of the external power connector. These complementary interlocking contact elements are, for example, of the "Lead frames" type.

[0028] According to one aspect of the invention, the power electrical contact element(s) are of the male type, for example in the form of a pin.

[0029] The invention also relates to an interlocking system, in particular for an on-board vehicle charger, comprising: - an electrical interconnector as described above, - an external power connector configured to cooperate with said electrical interconnector, the external power connector having a complementary interlocking contact element configured to be connected to an interlocking contact element of the electrical interconnector, in addition to one or more electrical power contact elements.

[0030] The interlocking system is configured to detect an accidental disengagement of the external power connector of said interconnector.

[0031] According to one aspect of the invention, the interlock system is configured to trigger an alert in the event of a disconnection between parts of the power connection, or to cut off the power connection.

[0032] Other features, details and advantages of the invention will become clearer upon reading the following description on the one hand, and several exemplary embodiments given by way of illustration and not limitation with reference to the accompanying schematic drawings on the other hand, in which:

[0033] [Fig-1] Fig.1 schematically represents, in perspective, a set electronics including an on-board charger, according to an example of an embodiment of the invention;

[0034] [Fig.2] Fig.2 schematically represents, in perspective, a system interlock of the on-board charger of the [Fig.1], seen from one side;

[0035] [Fig.3] Fig.3 schematically represents, in perspective, the system interlocking of [Fig.2], seen from an opposite side with respect to [Fig.2];

[0036] [Fig.4] Fig.4 shows, alone, an interlocking contact element of the system interlock of the [Fig.2];

[0037] [Fig. 5] Fig. 5 shows, by itself, an external power connector of the system interlock of the [Fig.2];

[0038] [Fig.6] Fig.6 shows the electronic board which carries the electrical interconnector of the on-board charger of the [Fig.1].

[0039] The features, variants, and different embodiments of the invention can be combined in various ways, provided they are not incompatible or mutually exclusive. In particular, variants of the invention may be conceived comprising only a selection of features, described hereafter in isolation from the other described features, if this selection of features is sufficient to confer a technical advantage and / or to differentiate the invention from the prior art.

[0040] Figure 1 shows an electronic assembly 1 comprising an on-board charger 2 (which defines an electronic device within the meaning of the invention) suitable for assembly with an external module (not shown) which is here a power distribution unit (or "Power Distribution Unit" in English for PDU).

[0041] The on-board charger 2 is configured to convert the alternating current available on the electrical network into direct current capable of charging the vehicle's battery.

[0042] The on-board charger 2 comprises a main housing 5, which is here a cast part, and a plurality of electronic boards housed in the main housing 5.

[0043] The on-board charger 2 further includes a cover 7, which is here a cast part, configured to close the main housing 5.

[0044] The cover 7, generally in the form of a plate with reinforcing ribs on its inner face, is configured to receive, on its outer face 9, an external module.

[0045] As can be seen in Figures 2 to 6, the electronic device, here the on-board charger 2, comprises: - an electronic card 16, - an electrical interconnector 10 fixed to said electronic card 16.

[0046] An external power connector 19, configured to cooperate with the electrical interconnector 10, is fixed to the main housing 5, on its lateral periphery 30. This fixing is done using screws 31 for example.

[0047] The external power connector 19 has two complementary interlocking contact elements 18, each configured to be connected to an interlocking contact element 17 (only one is shown in [Fig.2]) of the electrical interconnector 10, in addition to several electrical power contact elements 15.

[0048] The additional interlocking contact element 18 is of the male type, for example in the form of a metal pin.

[0049] The additional interlocking contact elements 18, of male type, are for example overmolded into a base 29 (see [Fig.5]) of the external power connector 19.

[0050] The power electrical contact elements 15 are of the male type, for example each in the form of a pin overmolded in the base 29. These power electrical contact elements 15 are used to transmit electrical power.

[0051] An interlocking system 11 thus comprises: - the electrical interconnector 10, - the external power connector 19 configured to cooperate with said electrical interconnector 10, the external power connector 19 having two complementary interlocking contact elements 18 configured to be connected to interlocking contact elements 17 of the electrical interconnector 10.

[0052] The interlocking system 11 is configured to detect an accidental disengagement of the external power connector 19 from said interconnector 10.

[0053] The interlock system 11 is configured to trigger an alert in the event of a disconnection between parts of the power connection, or to cut off the power connection.

[0054] The power electrical interconnector 10 comprises: - a body 14 made of insulating material, here a plastic material, - several female-type power electrical contact elements 12 (see [Fig.3]), arranged in said body 14 and configured to transmit power, these power electrical contact elements 12 being configured to be soldered onto the electronic board 16, - two interlocking contact elements 17 arranged in said body 14 and configured to be connected to a complementary interlocking contact element 18 on the external power connector 19, so as to allow detection of a connection interruption on the electrical power contact elements 12, these interlocking contact elements 17 being soldered onto an electronic board 16.

[0055] The interlock contact element(s) 17 are advantageously configured to detect an accidental disengagement of the external power connector 19 from the interconnector 10, for example caused by vibrations or movements during use of the vehicle or handling by an operator, or during a maintenance operation of the vehicle 20.

[0056] The electrical power contact elements 12 and the interlocking elements 17 are advantageously arranged in the same insulating body 14.

[0057] The invention makes it possible to reduce the number of operations required by directly integrating the power contacts 12 and signal contacts 17 (interlocking contact element 17) into a single interconnector 10, thus eliminating the need for dedicated cables and connection operations between the external connector 19 (customer) and the electronic board 16. This simplification reduces complexity, lowers costs and improves reliability by minimizing the risks of incorrect assembly.

[0058] The interlocking contact elements 17 are of the female type.

[0059] Each interlocking contact element 17 comprises two opposite elastic arms 21 for the insertion of the complementary male-type interlocking contact element 18, as illustrated in [Fig.4].

[0060] The interlocking contact elements 17 are configured to be held in the body 14 of the power electrical interconnector 10 by mechanical insertion, in particular by clipping, into the body 14 of the power electrical interconnector 10.

[0061] In the example described, each metallic interlocking contact element 17 comprises: - a first section 25, in the form of a tab, configured to be fixed to an electronic card 16 and in contact with a signal track 26 of said electronic card 16, - a second section 27 provided with the opposite branches 21 for the insertion of the additional male type interlocking contact element 18.

[0062] The first section 25 and the second section 27 form a bend 28 at their junction, here a right-angle bend. This is particularly appropriate when the electronic board 16 is parallel to the base 29 of the external power connector 19. If the electronic board 16 is perpendicular to a base 29 of the external power connector 19, the interlocking contact element 17 can be straight, without a bend. In this case, the first section 25 and the second section 27 are aligned.

[0063] The first section 25 is fixed perpendicularly to the electronic card 16.

[0064] The power electrical contact element 15 can be configured for use with a single-phase or three-phase network.

[0065] There are four power electrical contact elements 15 and two interlocking contact elements 17. This is appropriate for a three-phase system. For a single-phase system, only two power electrical contact elements 15 are required.

[0066] The two interlocking contact elements 17 are configured to establish a continuous loop enabling the detection of a connection interruption. One of the interlocking contact elements 17 is configured to ensure current flow in the forward direction and the other interlocking contact element 17 is configured to ensure current flow in the reverse direction, thus defining a loop that is closed when the connections are made correctly.

[0067] The interlocking contact elements 17 are configured to be connected, in particular by conductive tracks 26, to a microcontroller on an electronic control board of the electronic device 2.

[0068] The interlocking contact elements 17 are configured to transmit a low voltage signal 34 in a closed loop, in normal operation (excluding accidental disengagement).

Claims

Demands

1. Power electrical interconnector (10) of an interlocking system (11), for an electronic device such as an on-board vehicle charger (2), in particular of the single-phase or three-phase type, the power electrical interconnector (10) comprising: - a body (14) made of insulating material, in particular of a plastic material, - one or more power electrical contact elements (15), in particular of the male or female type, disposed in said body (14) and configured to transmit power, said or these power electrical contact elements (15) being in particular configured to be soldered onto an electronic board (16), - at least one interlocking contact element (17) disposed in said body (14) and configured to be connected to a complementary interlocking contact element (18) on an external power connector (19),in order to enable the detection of a connection interruption on the power electrical contact element(s) (15), this interlocking contact element (17) being specifically configured to be soldered onto an electronic board (16).

2. Electrical interconnector according to the preceding claim, wherein the interlocking contact element(s) (17) are of the female type, and the interlocking contact element (17) comprises two facing arms (21) for the insertion of the complementary interlocking contact element (18) of the male type.

3. Electrical interconnector according to any one of the preceding claims, wherein the interlocking contact element(s) (17) are configured to be retained in the body (14) of the power electrical interconnector (10) by mechanical insertion, in particular by clipping, into the body (14) of the power electrical interconnector (10).

4. Electrical interconnector according to any one of the preceding claims, wherein the interlocking contact element (17), in particular metallic, comprises: - a first section (25), for example in the form of a tab, configured to be fixed on an electronic card (16) and in particular in contact with a signal track (26) of said electronic card (16), - a second section (27) provided with opposite branches (21) for the insertion of the complementary interlocking contact element (18) of male type.

5. Electrical interconnector according to the preceding claim, wherein the first section (25) is fixed perpendicularly to the electronic board (16) and in particular the first section (25) and the second section (27) form a bend (28) at their junction, in particular a right-angle bend.

6. Electrical interconnector according to any one of the preceding claims, wherein the interconnector (10) comprises two interlocking contact elements (17) configured to establish a continuous loop enabling the detection of a connection interruption.

7. Electronic device (2), in particular an on-board vehicle charger, comprising: - an electronic card (16), - an electrical interconnector (10) according to any one of the preceding claims fixed on said electronic card (16).

8. External power connector (19) configured to cooperate with an electrical interconnector (10) according to any one of the preceding claims, the external power connector (19) comprising a complementary interlocking contact element (18) configured to be connected to an interlocking contact element (17) of the electrical interconnector (10), in addition to one or more electrical power contact elements (15).

9. External connector according to the preceding claim, wherein the complementary interlocking contact elements (18), in particular of the male type, are overmolded into a base (29) of the external power connector (19).

10. Interlocking system (11), in particular for an on-board charger (2) for a vehicle, comprising:

11. - an electrical interconnector (10) according to any one of claims 1 to 6, - an external power connector (19) configured to cooperate with said electrical interconnector (10), the external power connector (19) having a complementary interlocking contact element (18) configured to be connected to an interlocking contact element (17) of the electrical interconnector (10), in addition to one or more electrical power contact elements (15). Interlocking system (11) according to the preceding claim, wherein the interlocking contact elements (17) are configured to be connected, in particular by conductive tracks, to a microcontroller on an electronic control board of the electronic device (2).