Connector assembly for battery modules in electric vehicles

Abstract

To provide a functional connector assembly while ensuring reliability.SOLUTION: A connector assembly 1 for battery modules M of an electric vehicle comprises: a connector element 2 and a counterpart 3 arranged to be mutually connected in an electrically conductive manner, the connector element comprising a protective casing 4 having an outer collar configured for coupling with the counterpart; an electrical connection unit 5 having opposite ends suitable for electrically connecting two connector assemblies; a fastening unit comprising a connection screw axially placed within the outer collar and engaged with the counterpart; an integrated sealing system to prevent water infiltration into the connector element or the counterpart; and a locking ring to lock in place the screw inserted inside the outer collar even when not fixed to the counterpart, where the locking ring comprises at least one locking flange cooperating with a locking shoulder formed along the inner surface of the outer collar.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a connector assembly for a battery module of an electric vehicle, the connector assembly comprising: A connector element and a counterpart arranged to be conductively connected to each other along a connection direction, the connector element includes a protective casing having an outer collar configured to be electrically insulated and to mate with a receiving portion of the mating component; and an electrical connection unit having opposite ends adapted to electrically connect two connector assemblies disposed on corresponding battery modules, wherein for each end, the electrical connection unit comprises a connection end connected to a connector element; a fastening unit axially disposed within the outer collar and having a connecting screw that engages with a mating part; Equipped with. [Background technology]

[0002] Connectors of the above type are made to electrically connect a plurality of battery modules that form a battery pack installed in an electric drive vehicle.

[0003] Document DE 10 2021 117 336 describes a connector assembly for such applications, which comprises two connector parts that are connected to one another by means of a connecting screw.

[0004] In general, in the field of electrical connectors for battery modules, the need to simplify and increase the reliability of the electrical connections between the various components is now a major concern for manufacturers. With this in mind, the solutions described in the above documents can be further refined to overcome some of the drawbacks. Summary of the Invention [Problem to be solved by the invention]

[0005] SUMMARY OF THE INVENTION It is an object of the present invention to provide a connector assembly of the above type which is extremely simple and functional whilst ensuring overall reliability in use.

[0006] It is a further object of the present invention to provide a method for assembling such a connector assembly that makes the assembly process highly intuitive. [Means for solving the problem]

[0007] To achieve one or more of the above objects, the present invention relates to a connector assembly for a battery module of an electric vehicle, the connector assembly comprising: A connector element and a mating part arranged to be conductively connected to each other along a connection direction, the connector element includes a protective casing having an outer collar configured to be electrically insulated and to mate with a receiving portion of the mating component; and an electrical connection unit having opposite ends adapted to electrically connect two connector assemblies disposed on corresponding battery modules, wherein for each end, the electrical connection unit comprises a connection end connected to a connector element; a protective casing made of a single piece including the outer collar and a receiving portion for engaging one end of the electrical connection unit; A fastening unit having a connecting screw axially disposed in an outer collar and engaging with a mating part, the connecting screw further comprises a fastening unit that engages with the connecting end to electrically connect the connector element, the mating part, and an electrical connection unit that is connected to another connector assembly; an integrated sealing system to prevent water from entering the connector element or the mating part; A locking ring for locking a screw inserted into an outer collar in place when not fastened to a mating part, said locking ring comprising at least one locking flange cooperating with a locking shoulder formed along an inner surface of the outer collar. Equipped with.

[0008] In one or more embodiments, the sealing system includes a first sealing element configured as an annular gasket disposed within a receiving seat formed along a lower portion of the outer collar that engages with the cup portion of the mating component.

[0009] In one or more embodiments, the sealing system includes a second sealing element configured as an annular gasket that radially overlaps the end of the electrical connection unit and that, in the final assembled configuration, is disposed within a receptacle of the protective casing.

[0010] In one or more embodiments, the sealing system includes a third sealing element configured as an annular gasket secured within a joint of the cover that engages the upper edge of the outer collar.

[0011] In one or more embodiments, the locking ring includes a pair of locking flanges that cooperate with a pair of locking shoulders, respectively, such that during assembly: the locking ring is axially inserted into the upper cap of the screw with the flange oriented in an offset position relative to the shoulder to allow axial insertion of the ring along the collar to the base of the cap; The locking ring rotates about the axis of the screw so that the shoulder vertically overlaps the flange.

[0012] In one or more embodiments, each flange includes a respective flexible locking tab carrying a contact tooth adapted to interengage with a side edge of the locking shoulder.

[0013] The present invention is also directed to an assembly method as set forth in the accompanying claims.

[0014] Further features and advantages of the invention will emerge from the following description taken in conjunction with the accompanying drawings, given purely as non-limiting examples, in which: [Brief explanation of the drawings]

[0015] [Figure 1] 1 is a perspective view of a preferred embodiment of a connector assembly according to the present invention in a connected configuration; [Figure 2] FIG. 2 is an exploded perspective view of the connector element shown in the previous figure. [Figure 3] FIG. 2 is a perspective view of a top cover that is part of the connector element shown in the previous figure. [Figure 4] 3 is a further perspective view of the protective casing already shown in FIG. 2; [Figure 5] 3 is a further perspective view of the locking ring already shown in FIG. 2. FIG. [Figure 6] 1A-1C illustrate steps of a method for assembling a connector assembly. [Figure 7] 1A-1C illustrate steps of a method for assembling a connector assembly. [Figure 8] 8 is a cross-sectional view of the connector assembly taken along plane VIII-VIII shown in FIG. 1. [Figure 9] FIG. 10 is a further cross-sectional view of the connector assembly in its final assembled configuration. DETAILED DESCRIPTION OF THE INVENTION

[0016] The following description sets forth various specific details for a thorough understanding of one or more example embodiments. The embodiments may be practiced without one or more of those specific details, or with other methods, components, materials, etc. In other cases, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring various aspects of the embodiments. The use of the phrase "one embodiment" in this description is intended to indicate that a particular configuration, structure, or feature described in connection with that embodiment is included in at least one embodiment. Thus, in some cases, phrases such as "in one embodiment" appearing in various places in this description do not necessarily refer to the same embodiment. In addition, particular configurations, structures, or features may be combined and / or associated with one or more embodiments as appropriate in ways other than as shown herein; thus, for example, a feature illustrated in this specification in connection with one figure may be applied to one or more embodiments illustrated in a different figure.

[0017] The references provided herein are merely for convenience and therefore do not limit the scope or breadth of protection of the embodiments.

[0018] It should also be noted that only those elements useful for understanding the invention are described in the following description, provided that, for example, a connector assembly may include additional basic elements known per se that are necessary for its operation.

[0019] In the accompanying drawings, reference numeral 1 indicates a preferred embodiment of an overall connector assembly according to the present invention, made for electrically connecting a plurality of battery modules M forming a battery pack to be installed in an electric vehicle.

[0020] 1 shows a preferred embodiment of a connector assembly 1 in a connected state. The connector assembly 1 comprises a connector element 2 configured to mate with a mating component 3 already mounted on a corresponding battery module M, thereby simultaneously achieving electrical and mechanical coupling along a connection direction.

[0021] FIG. 2 is an exploded perspective view showing the components that form connector element 2. As shown in FIG.

[0022] The connector element 2 comprises a protective casing 4 which is electrically insulated and has an outer collar 4' configured to mate with a mating part 3. The mating part 3 comprises an electrically insulated tactile protection which defines a receiving part suitable for receiving a lower part of the outer collar 4 along the connection direction.

[0023] Reference number 5 denotes an electrical connection unit, partially shown in Figures 1, 2 and 8, suitable for electrically connecting two connector assemblies 1 to be arranged in respective modules M of a battery assembly of a vehicle. The electrical connection unit 5 may be configured as a bundle of connecting cables housed axially along a tubular casing, with both ends configured to connect to the respective connector assemblies 1 in the assembled configuration.

[0024] In one or more embodiments, the protective casing 4 of the connector element 2 is made as a single piece, comprising said outer collar 4' and a receiving portion 6 for engaging an end of the electrical connection unit 5. For the illustrated embodiment, the receiving portion 6 forms an additional outer collar oriented perpendicular to the outer collar 4' for mating with the mating part 3. Indeed, for the configuration shown in FIG. 1 , the outer collar 4' mates with the mating part 3 along a vertical direction, and the end of the electrical connection unit 5 engages with the receiving portion 6 along a horizontal direction. It will thus be understood that in the configuration shown in FIG. 1 , the tubular casing of the electrical connection unit 5 extends along said horizontal direction, perpendicular to the direction of connection between the connector element 2 and the mating part 3.

[0025] The connector assembly 1 comprises a fastening unit 7 configured to fasten the connector element 2 to a mating part 3. With reference to Figures 2 and 8, the fastening unit 7 comprises a connection screw 8 axially disposed within the outer collar 4' that mates with a nut element 9 disposed within the collar of the mating part 3, thereby establishing the connection between the connector element 2 and the mating part 3. According to a further feature, in the final connected configuration the connection screw 8 also mates with a connection end 10 of the electrical connection unit 5 through a fastening hole 11 cut in the connection end 10, thereby establishing the electrical connection between the connector element 2, the mating part 3 and the electrical connection unit 5 that is to be connected to another connector assembly 1. It will now be seen that in the final assembled configuration, the end of the connection unit 5 is spaced apart within the receiving portion 6 of the casing 4 so that the fastening holes 11 axially engage with the screws 8 which connect the connector element 2 with the mating part 3. The screws 8 also engage a contact ring 21 which is disposed within the collar 4' and has two faces which contact the connection end 10 of the connection unit 5 and corresponding faces 21' formed in the collar 4', respectively.

[0026] Preferably, the electrical connection unit 5 comprises a coupling flange 12 suitable for engaging with respective ribs 13 cut along the outer surface of the receiving portion 6 (FIGS. 1, 2, 8).

[0027] To establish an electrical connection, the fastening unit 7 is made from an electrically conductive material and the nut element 9 is also mounted so as to contact a portion of the electrical contact portion 9' which is centrally located within the contact protection portion of the counter part 3.

[0028] According to a further feature, the connector assembly 1 comprises an electrically insulating upper cover 14 arranged above the heads 15 of the connecting screws 8, i.e., opposite the mating component 3, to close the connector element 2. Thus, when observing the assembled configuration of Fig. 1, it should be noted that the connection direction, in which the lower part of the connector element 2 mates with the mating component 3 mounted on the upper surface of the battery module M, extends along a substantially vertical axis. At this time, the cover 14 engages with the open upper end of the protective casing 4 of the connector element 2.

[0029] According to an additional preferred feature, the cover 14 comprises an elastic retaining element 16, such as a retaining rope, having two ends connected to the cover wall of the cover 14 and to the protective casing 4 of the connector element 2, respectively.

[0030] 3 and 8, the cover 14 is provided with corresponding elements 17 that protrude from the inner surface of the upper end plate (projecting towards the screw heads in the final assembled configuration), the protruding elements 17 being positioned to contact the screw heads 15 if the screws 8 are not properly secured in their mating parts 3, thereby providing a warning to the assembler.

[0031] According to a further feature of the present invention, the connector assembly 1 comprises an integrated sealing system to prevent water from entering the connector element 2 or the mating component 3 .

[0032] In one or more embodiments, the sealing system includes a first sealing element 18 configured as an annular gasket disposed within a receiving seat formed along the lower portion of the outer collar 4′. The receiving seat is sized to accommodate the first sealing element 18 and form a lock with the cup portion 3′ of the mating component 3, thereby disposing the annular gasket between the mating component 3 and the lower portion of the casing 4 of the connector component 2.

[0033] In one or more embodiments, the sealing system comprises a second sealing element 19 configured in the form of an annular gasket that engages an end of the electrical connection unit 5. More particularly, the second sealing element 19 is disposed between the connection end 10 that connects with the connection screw 8 and the mating flange 12, such that in the final assembled configuration, the annular gasket engages within the receiving portion 6 of the protective casing 4 of the connector element 2.

[0034] In one or more embodiments, the sealing system includes a third sealing element 20 configured as an annular gasket secured within a mating portion 14' of the cover 14 that engages the upper edge of the outer collar 4'. Thus, when observing Figure 9, it should be noted that the mating portion 14' is formed by the outer wall of the cover 14 and the inner wall onto which the annular gasket is mounted.

[0035] According to a further feature of the present invention, the connector assembly 1 includes a screw locking ring 22 secured within the protective casing 4 of the connector element 2 and cooperating with at least one locking element formed within the outer collar 4' for the purpose of keeping the screw 8 in place when not attached to the mating part 3. The fixing screw 8 includes an electrically insulating upper cap 8' disposed over the head 15 of the screw. The locking ring 22 is sized to fit radially onto the base 8'' of the upper cap 8'. According to a preferred embodiment shown in Figures 4-7, the locking ring 22 includes two locking flanges 23 cooperating with respective locking shoulders 24 formed along the inner surface of the cylindrical wall of the outer collar 4'.

[0036] During assembly, after the locking screw 8 is inserted into the outer collar 4', the bore 11 of the connecting end 10, and the contact ring 21, the locking ring 22 is placed around the screw cap 8' with its flange 23 oriented in an offset position relative to the shoulder 24 (FIG. 6), allowing the ring 21 to be inserted axially along the collar 4', thereby overcoming the volume of the locking shoulder 24. Once the locking ring 22 is placed on the bottom edge of the cap 8' on the screw head, the ring 22 can be rotated so that the flange 23 is vertically aligned with the shoulder 24 (FIG. 7). In an actual exemplary embodiment, the rotation of the locking ring 22 is performed through an angle of 90°. In one or more embodiments, rotation of the locking ring 22 is accomplished using an assembly tool having an operating head adapted to cooperate with the ring 22 and the outer collar 4 ′ having the shoulder 24 .

[0037] 6 and 7, each flange 23 carries a respective flexible locking tab 25 carrying contact teeth 26 suitable for interengagement with a side edge of the locking shoulder 24. During rotation of the locking ring 22, the flexible tabs 25 carrying the teeth 26 pass under the respective shoulder 24, thereby rotating together with the ring 22, until in the final configuration the end of each tab 25 rises, thereby achieving contact between the teeth 26 and the side edge of the shoulder 24.

[0038] In accordance with the aforementioned structure, the present invention is also directed to a method for assembling a connector assembly 1 having the above-mentioned characteristics, the method comprising: Inserting the contact ring 21 into the connector element 2 so that it abuts against the corresponding surface 21'; placing an end of the electrical connection unit 5 into the receiving portion 6 of the connector element 2; Inserting the connecting screws 8 into the outer collar 4' by engaging them in the contact ring 21 and the fastening holes 11 at the ends of the electrical connection unit 5; Assembling the lock ring 22 by inserting the lock ring 22 axially along the screw cap 8' and then rotating it; Connecting the connector element 2 with the mating component 3 Includes:

[0039] As can be seen in the final assembled configuration shown in FIGS. 8 and 9, the head of the screw contacts the connection end 10 of the connection unit 5 which contacts the contact ring 21 .

[0040] Of course, given the principles of the present invention, the details of the construction and the embodiments may differ significantly from those described and shown merely by way of example, without departing from the scope of protection of the present invention. [Explanation of symbols]

[0041] 1 Connector Assembly 2 Connector Elements 3 Mating parts 3' Cup section M Battery Module 4 Protective casing 4' outer collar 6 Receiving section 13 Ribs 5 Electrical Connection Unit 10 Connection end 11 Fastening hole 12 Connecting flange 7 Fastening Unit 8 Connecting screws 8' Top Cap 8'' base 15 head 9 Nut Elements 9' Electrical contact part 21 Contact Ring 21' Contact surface 14 Top cover 14' joint 16 Elastic Retaining Element 17 Protruding elements 18 First sealing element 19 Second sealing element 20 Third sealing element 22 Lock ring 23 Lock flange 25 flexible tab 26 Tooth 24 Lock shoulder

Claims

1. A connector assembly (1) for a battery module (M) of an electric vehicle, comprising: - the connector assembly (1) comprises a connector element (2) and a mating part (3) arranged to be electrically conductively connected to each other along a connection direction; - said connector element (2) comprises a protective casing (4) having an outer collar (4'); the outer collar (4') is electrically insulated and configured to couple with a receiving portion of the mating part (3); - the connector assembly (1) comprises an electrical connection unit (5) having two ends for electrically connecting two connector assemblies (1) arranged in corresponding battery modules (M); For each end, the electrical connection unit (5) has a connection end (10) that is connected to the connector element (2), - said protective casing (4) is made in one piece with said outer collar (4') and a receiving portion (6) for engaging with one end of said electrical connection unit (5); - the connector assembly (1) comprises a fastening unit (7) having a connecting thread (8), the connecting thread (8) being axially disposed within the outer collar (4') and configured to engage with the mating part (3); - the connecting screw (8) is further configured to engage with the connecting end (10) to electrically connect the connector element (2), the counter part (3) and the electrical connection unit (5); - said connector assembly (1) comprises an integrated sealing system to prevent water from entering said connector element (2) or said mating part (3); - the connector assembly (1) comprises a locking ring (22) for locking the connecting screw (8) inserted in the outer collar (4') in position even when not fastened to the mating part (3), The locking ring (22) comprises at least one locking flange (23) which cooperates with a locking shoulder (24) formed along the inner surface of the outer collar (4'). Connector assembly (1).

2. The sealing system comprises a first sealing element (18) configured as an annular gasket; The first sealing element (18) is disposed in a receiving seat formed along the lower part of the outer collar (4') which engages with the cup portion (3') of the mating part (3). A connector assembly (1) according to claim 1.

3. the sealing system comprises a second sealing element (19) configured as an annular gasket (19) radially overlapping the end of the electrical connection unit (5), the second sealing element (19) is arranged in the receiving portion (6) of the protective casing (4) in the final assembled configuration; A connector assembly (1) according to claim 1 or 2.

4. the receiving portion (6) forms a further outer collar oriented along a direction substantially perpendicular to the connecting direction for connecting the connector element (2) and the mating part (3); A connector assembly (1) according to claim 1 or 2.

5. The connector assembly (1) comprises an electrically insulating upper cover (14) above the head (15) of the connecting screw (8) and coupled with the open upper end of the protective casing (4). A connector assembly (1) according to claim 1 or 2.

6. The sealing system comprises a third sealing element (20) configured as an annular gasket; a third sealing element (20) fixed in a joint (14') of the top cover (14) that engages with the upper edge of the outer collar (4'); A connector assembly (1) according to claim 5.

7. The upper cover (14) comprises a protruding element (17) protruding from the inner surface of the upper closing surface; the protruding element (17) is arranged to come into contact with the head (15) when the connecting screw (8) is not properly fastened to the mating part (3); A connector assembly (1) according to claim 5.

8. said connecting screw (8) is provided with an electrically insulating upper cap (8'); The locking ring (22) is sized to fit into the base (8'') of the top cap (8'). A connector assembly (1) according to claim 1 or 2.

9. The locking ring (22) comprises a pair of locking flanges (23) each cooperating with a pair of locking shoulders (24); During assembly, - the locking ring (22) is axially inserted into the upper cap (8') with the pair of locking flanges (23) oriented in an offset position relative to the pair of locking shoulders (24) to allow axial insertion of the locking ring (22) along the outer collar (4') up to the base (8''); - the locking ring (22) rotates around the axis of the connecting screw (8) so that the pair of locking shoulders (24) vertically overlap the pair of locking flanges (23); A connector assembly (1) according to claim 8.

10. Each of the pair of locking flanges (23) comprises a respective flexible locking tab (25) carrying a contact tooth portion (26) configured to mutually engage with a side edge portion of a locking shoulder (24). A connector assembly (1) according to claim 9.

11. A method for assembling a connector assembly (1) according to claim 1, comprising the steps of: - inserting one end of the electrical connection unit (5) into the receiving portion (6) of the connector element (2); - inserting the connecting screw (8) into the outer collar (4') and engaging it with the fastening hole (11) of the connecting end (10); - assembling said locking ring (22) by axial insertion along the upper cap (8') of said connecting screw (8) and subsequent rotation; - connecting said connector element (2) with said mating part (3); Including, method.

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