Power connector assembly for electric drive unit

Abstract

A power connector assembly having first and second connector assemblies, each having a mating housing member. The housing member of the first connector assembly includes a mounting flange having one or more openings configured to receive threaded fasteners for securing the first connector assembly to another structure. The housing member of the second connector assembly extends from the housing member and has one or more covering members that cover or cover the openings of the housing member of the first connector assembly, thereby restricting access to the fasteners, making it impossible to remove the fasteners while the first and second connector assemblies are connected to each other.

Description

Technical Field

[0001] The present disclosure relates to a power connector assembly for an electric drive unit.

Background Art

[0002] An electric drive unit typically includes a battery, an inverter, and a rotating electrical machine, and is used for propelling at least a part of a vehicle. The electric drive unit may use a power connector assembly to removably connect the battery to other parts of the electric drive unit.

Summary of the Invention

[0003] This section provides an overview of the present disclosure and does not disclose comprehensively its full scope or all of its features.

[0004] In one form, the present disclosure provides a power connector assembly having a first connector assembly and a second connector assembly. The first connector assembly has a first housing and a plurality of first terminals. The first housing includes a first housing member and a mounting flange disposed around the first housing member. The mounting flange defines a plurality of fastener openings. The first terminals are housed within the first housing. The second connector assembly has a second housing and a plurality of second terminals. The second housing includes a second housing member and one or more covering members. The second housing member is in mating engagement with the first housing member. The one or more covering members extend outwardly from the second housing member to cover the fastener openings. The second terminals are housed within the second housing member. Each of the second terminals is mechanically and electrically engaged with one of the corresponding first terminals.

[0005] Further applicable ranges will become apparent from the description in this specification. The descriptions and specific examples in this summary are for illustrative purposes only and are not intended to limit the scope of the present disclosure. [Brief explanation of the drawing]

[0006] The drawings described herein are for illustrative purposes only and do not illustrate all possible embodiments, nor are they intended to limit the scope of this disclosure.

[0007] [Figure 1] Figure 1 is a schematic diagram of a power connector assembly constructed in accordance with the teachings of this disclosure in an environment including a battery and an electric drive unit.

[0008] [Figure 2] Figure 2 is a perspective view of the power connector assembly shown in Figure 1 when mounted on the housing of the electric drive unit.

[0009] [Figure 3] Figure 3 is a cross-sectional view along line 3-3 in Figure 2.

[0010] Throughout the drawings, the corresponding reference numbers indicate the corresponding parts. [Modes for carrying out the invention]

[0011] Referring to Figure 1 in the drawings, a power connector assembly constructed in accordance with the teachings of this disclosure is schematically shown, schematically indicated by reference numeral 10. The power connector assembly 10 is shown in operative operation with a battery 12 and an electric drive unit 14. The electric drive unit 14 includes an inverter 18, an electric motor 20, and a transmission and differential 22. Power input to the inverter 18 is used to operate the electric motor 20. The rotational power output from the electric motor 20 is transmitted through the transmission (of the transmission and differential 22), thereby driving the differential (of the transmission and differential 22). The power connector assembly 10 is configured to quickly, efficiently, and securely couple the battery 12 to the inverter 18. The power connector assembly 10 includes a first connector assembly 30 and a second connector assembly 32. The first connector assembly 30 is configured to be mounted in a housing 34 in which the inverter 18 is located, and is electrically coupled to the inverter 18. The second connector assembly 32 is electrically coupled to the battery 12 and is matable and engageable with the first connector assembly 30 along the insertion shaft 36, thereby mechanically and electrically coupling the second connector assembly 32 to the first connector assembly 30.

[0012] Referring to Figures 2 and 3, the first connector assembly 30 may include a first housing 40 and a plurality of first terminals 42. The first housing 40 has a first housing member 46 and a mounting flange 48 positioned around it or extending from the first housing member 46. The first housing member 46 defines a plurality of first terminal cavities 50 positioned parallel to the insertion shaft 36. The mounting flange 48 may define a plurality of fastener openings 52, which are configured to receive a plurality of threaded fasteners 54, which secure the first housing 40 to the housing 34 of the electric drive unit 14 (Figure 1). Each of the first terminals 42 is housed in a corresponding first terminal cavity 50 and is mechanically coupled to the first housing member 46. The first terminal 42 can be electrically connected to a positive lead wire 56 and a ground lead wire 58, which are similarly electrically connected to the inverter 18 (Figure 1).

[0013] The second connector assembly 32 may comprise a second housing 60 and a plurality of second terminals 62. The second housing 60 may comprise a second housing member 66 and one or more covering members 68. The second housing member 66 is configured to be slidably engaged with the first housing member 46 along the insertion shaft 36, thereby enabling the second housing member 66 to be mated and engaged with the first housing member 46. The second housing member 66 may define a plurality of second terminal cavities 70 arranged parallel to the insertion shaft 36. One or more covering members 68 may extend outward from the second housing member 66 to a position that covers the fastener opening 52. More specifically, one or more covering members 68 extend outward from the first housing member 46 to a position that substantially covers each of the threaded fasteners 54 that secure the first housing 40 to the housing 34, and inside the housing 34 is the inverter 18 (Figure 1). One or more covering members 68 can be spaced apart from the threaded fasteners 54 along the insertion shaft 36, but close enough to prevent a tool (not shown) from engaging with the threaded fasteners 54, thereby making it impossible to remove the threaded fasteners 54 from the housing 34 while the second connector assembly 32 is engaged with the first connector assembly 30. In the particular example provided, the threaded fasteners 54 are hex socket cap screws, so a tool (e.g., an Allen wrench) for removing the threaded fasteners 54 is inserted into the axial end of each head of the threaded fastener 54. Therefore, in this particular example, it is sufficient that one or more covering members 68 extend beyond the axial end of each head of the threaded fastener 54, thereby preventing the tool from being inserted into the axial end of the head of the threaded fastener 54. It will be understood that the configuration of the one or more covering members 68 may differ from the configuration shown in this example if the threaded fastener 54 has a different configuration.For example, if the fastener is a hexagonal-headed bolt that can be fastened with a tool such as an open-end wrench, one or more covering members 68 may extend not only beyond the axial end of the head of the threaded fastener 54, but also around the side of the head of the threaded fastener 54, thereby preventing the tool from engaging with the side of the head of the threaded fastener 54.

[0014] Each of the second terminals 62 is housed in a corresponding second terminal cavity 70 and is fixedly coupled to a second housing member 66. Each of the second terminals 62 can be attached to the positive and ground battery leads 80 and 82, respectively, which are electrically coupled to a corresponding terminal in the battery 12. Each of the second terminals 62 is mechanically and electrically engageable with a corresponding first terminal 42, thereby electrically coupling the terminal of the battery 12 (Figure 1) to a corresponding terminal in the positive lead 56 and the ground lead 58.

[0015] It will be understood that any desired type of locking or latching mechanism may be employed to secure the second connector assembly 32 to the first connector assembly 30, and, if necessary, to assist in mounting the second connector assembly 32 to the first connector assembly 30. Depending on the physical size of the conductors used for the positive and negative battery leads 80 and 82, and the positive and ground leads 56 and 58, a conventionally known cam lever mechanism (not shown) may be employed to mount and lock the second connector assembly 32 to the first connector assembly 30.

[0016] The above-described embodiments are provided for illustrative and explanatory purposes only. They are not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally interchangeable and usable in selected embodiments, even if not specifically illustrated or described, and are not limited to that particular embodiment. Similar elements or features may be modified in various ways. Such modifications will not be considered deviations from the disclosure, and all such modifications are intended to be within the scope of the disclosure.

Claims

1. A first connector assembly having a first housing and a plurality of first terminals, wherein the first housing comprises a first housing member and a mounting flange disposed around the first housing member, the mounting flange defining a plurality of fastener openings, and the first terminals are housed within the first housing. A second connector assembly having a second housing and a plurality of second terminals, wherein the second housing comprises a second housing member and one or more covering members, the second housing member mating and engaging with the first housing member, the one or more covering members extending outward from the second housing member and covering the fastener opening, the second terminals housed within the second housing member, and each of the second terminals mechanically and electrically engaged with one of the corresponding first terminals, the second connector assembly and A power connector assembly equipped with the following features.

2. The power connector assembly according to claim 1, wherein the first connector assembly is configured to be mounted on a housing of an electric drive unit including an inverter.

3. The power connector assembly according to claim 1, further comprising a plurality of threaded fasteners passing through the plurality of fastener openings, each threaded fastener having a head.

4. The power connector assembly according to claim 3, wherein the diameter of one or more covering members is greater than the diameter of the head.

5. The power connector assembly according to claim 3, wherein the threaded fastener is a hex socket cap screw.

6. The power connector assembly according to claim 1, wherein the second connector assembly is configured to be electrically coupled to a battery.

7. The power connector assembly according to claim 1, wherein the second housing member engages with the first housing member along the insertion axis.

8. A first connector assembly comprising a first housing and a plurality of first terminals, wherein the first housing comprises a first housing member and a mounting flange disposed around the first housing member, the mounting flange defining at least one fastener opening configured to receive a threaded fastener, and the first terminals are housed within the first housing, A second connector assembly having a second housing and a plurality of second terminals, wherein the second housing comprises a second housing member and one or more covering members, the second housing member mating and engaging with the first housing member, the one or more covering members extending outward from the second housing member and covering the at least one fastener opening, the second terminals housed within the second housing member, each of the second terminals mechanically and electrically engaged with one of the corresponding first terminals, and the one or more covering members are configured to be sufficiently close to the threaded fasteners to prevent a tool from engaging with the threaded fasteners and removing them while the second connector assembly is engaged with the first connector assembly. A power connector assembly equipped with the following features.

9. The power connector assembly according to claim 8, wherein the first connector assembly is configured to be mounted on a housing of an electric drive unit including an inverter.

10. The power connector assembly according to claim 8, further comprising a plurality of threaded fasteners passing through the plurality of fastener openings, each threaded fastener having a head.

11. The power connector assembly according to claim 10, wherein the diameter of one or more covering members is greater than the diameter of the head.

12. The power connector assembly according to claim 8, wherein the second connector assembly is configured to be electrically coupled to a battery.

13. The power connector assembly according to claim 1, wherein the second housing member engages with the first housing member along the insertion axis.

14. A first connector assembly including a plurality of first terminals configured to be electrically coupled to an inverter, and a mounting flange defining a plurality of fastener openings, A second connector assembly comprising a plurality of second terminals configured to be electrically coupled to a battery, wherein the second connector assembly has one or more covering members, the second connector assembly mating and engaging with the first connector assembly, and the one or more covering members cover the fastener opening while each of the second terminals is electrically engaged with one of the corresponding first terminals. A power connector assembly equipped with the following features.

15. The power connector assembly according to claim 14, wherein the first connector assembly is configured to be mounted on the housing of an electric drive unit including the inverter.

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