Electrical assembly having electrical connectors
The electrical assembly addresses the issue of metallic particles by using a containment chamber to prevent short circuits and reduce costs, ensuring reliable electrical connections.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- VALEO EAUTOMOTIVE GERMANY GMBH
- Filing Date
- 2025-11-17
- Publication Date
- 2026-05-21
AI Technical Summary
Existing electrical assemblies face issues with metallic particles generated during screwing operations, which can cause short circuits and require larger isolation distances and additional costs with the use of cap nuts.
An electrical assembly design featuring a first and second electrical connector with a nut and screw assembly, enclosed by an insulating piece forming a containment chamber that prevents metallic particles larger than 200 μm from escaping, using crimped nuts and a plastic housing to maintain electrical contact and prevent disturbances.
The design effectively confines metallic particles, preventing short circuits and reducing assembly costs while maintaining electrical connectivity.
Smart Images
Figure EP2025083217_21052026_PF_FP_ABST
Abstract
Description
[0001] DESCRIPTION
[0002] Title: Electrical assembly comprising electrical connectors. Field of the invention
[0003] [1] The field of the invention is that of electrical assemblies.
[0004] State of the art
[0005] [2] We know of electrical assemblies in which the electrical connectors are assembled by screwing.
[0006] [3] However, the screwing operation can create burrs on the assembled metal parts, chips, or more generally metal particles.
[0007] [4] These metallic particles may damage the electrical assembly, in particular they may create short circuits within the electrical assembly.
[0008] [5] Electrical assemblies are also known in which the electrical connectors are assembled using cap nuts. Cap nuts then advantageously contain the metallic particles generated during tightening.
[0009] [6] However, cap nuts are larger than conventional nuts, and in particular, longer. Furthermore, cap nuts are made of conductive metallic materials.
[0010] [7] The use of blind nuts requires the use of large isolation distances to avoid any disruption to the operation of the electrical assembly.
[0011] [8] Moreover, the use of blind nuts presents additional costs for the production of the electrical assembly.
[0012] [9] The invention aims to overcome at least some of these drawbacks.
[0013] Description of the invention
[0014]
[0010] The invention relates to an electrical assembly comprising:
[0015] a first electrical connector having at least one mounting hole, a second electrical connector placed against the first electrical connector and having at least one mounting hole,
[0016] at least one electrical connection element arranged to maintain contact, particularly electrical contact, between the first electrical connector and the second electrical connector, this electrical connection element comprising:
[0017] • at least one nut fixed to the second electrical connector, • at least one screw extending through the mounting hole of the first electrical connector and the mounting hole of the second electrical connector, and screwed into the nut so as to form a screw-nut assembly with the nut
[0018] at least one insulating piece comprising at least one cavity, fixed in relation to the second electrical connector,
[0019] the cavity being arranged to enclose at least a portion of the electrical connection element so as to form with the second electrical connector a containment chamber.
[0020]
[0011] The containment chamber is arranged to prevent metallic particles with a characteristic diameter D greater than 200 pm from escaping the containment chamber.
[0021]
[0012] For example, the containment chamber is arranged so that the distance between one end of said chamber opposite the second electrical connector and said second electrical connector is at most equal to 200pm.
[0022]
[0013] For example, the cavity is formed of a base and at least one side wall extending from the base. Again, for example, the side wall comprises a first end in contact with the base and a second end opposite said first end and being, at least partially, facing the second electrical connector.
[0023]
[0014] According to one aspect of the invention, the electrical connection element creates an electrical link between the first electrical connector and the second electrical connector.
[0024]
[0015] According to one aspect of the invention, the cavity is arranged to enclose at least the nut and a portion of the screw of at least one electrical connection element so as to form with the second electrical connector the containment chamber.
[0025]
[0016] According to one aspect of the invention, the first electrical connector comprises at least one fixing zone, each fixing zone comprising at least one fixing hole for the first electrical connector.
[0026]
[0017] According to one aspect of the invention, the second electrical connector comprises at least one fixing zone, each fixing zone comprising at least one fixing hole for the second electrical connector.
[0027]
[0018] According to one aspect of the invention, the fixing areas of the first electrical connector and the second electrical connector are substantially flat areas.
[0028]
[0019] According to one aspect of the invention, the second electrical connector is placed in contact with the first electrical connector such that each fixing area of the first electrical connector is in contact with a fixing area of the second electrical connector, defining at least one contact area of the electrical connectors, and such that at least one fixing hole of the first electrical connector and at least one fixing hole of the second electrical connector are placed opposite each other.
[0029]
[0020] At the level of at least one contact zone of the electrical connectors, an upper surface of the first electrical connector, an lower surface of the first electrical connector, an upper surface of the second electrical connector and an lower surface of the second electrical connector are defined.
[0030]
[0021] According to one aspect of the invention, the lower surface of the first electrical connector is placed in contact with the upper surface of the second electrical connector.
[0031]
[0022] According to one aspect of the invention, the first electrical connector and the second electrical connector are made of conductive material.
[0032]
[0023] According to one aspect of the invention, the screw-nut assembly is arranged to allow an electrical connection between the first electrical connector and the second electrical connector.
[0033]
[0024] According to one aspect of the invention, the lower surface of the first electrical connector, the upper surface of the first electrical connector, the lower surface of the second electrical connector, and the upper surface of the second electrical connector are flat and substantially parallel to each other.
[0034]
[0025] According to one aspect of the invention, the nut is placed on the underside of the second electrical connector.
[0035]
[0026] According to one aspect of the invention, the nut is crimped onto the second electrical connector.
[0036]
[0027] In particular, the nut is crimped onto the underside of the second electrical connector.
[0037]
[0028] According to one aspect of the invention, the nut is crimped inside the fixing hole of the second electrical connector.
[0038]
[0029] Alternatively, the nut is placed on the underside of the second electrical connector without being inserted into the fixing hole of the second electrical connector.
[0039]
[0030] According to one aspect of the invention, the electrical assembly comprises a housing, in particular a plastic housing, in which the second electrical connector is placed, in particular in which the first electrical connector and the second electrical connector are placed.
[0040]
[0031] According to one aspect of the invention, the insulating piece is the housing in which the second electrical connector is placed.
[0041]
[0032] According to one aspect of the invention, the insulating part is formed from insulating material, for example from plastic.
[0042]
[0033] According to one aspect of the invention, the containment chamber is formed by the cavity and the lower face of the second electrical connector.
[0043]
[0034] According to one aspect of the invention, the containment chamber formed by the cavity and the lower face of the second electrical connector has dimensions chosen to prevent the passage of metallic chips / particles with a characteristic diameter greater than D.
[0044]
[0035] In particular, the containment chamber formed by the cavity and the underside of the second electrical connector has no gap larger than D.
[0036] According to one aspect of the invention, the electrical assembly has a gap between the cavity and the underside of the second electrical connector. In particular, the gap extends from the end of the cavity's side wall opposite the second electrical connector to said second electrical connector.
[0045]
[0037] According to one aspect of the invention, the gap formed between the cavity and the lower face of the second electrical connector makes it easier to assemble the second electrical connector onto the insulating piece.
[0046]
[0038] According to one aspect of the invention, the gap has a thickness E strictly less than D, so that a metallic particle of characteristic diameter D cannot escape from the containment chamber through the gap.
[0047]
[0039] According to one aspect of the invention, the lower face of the second electrical connector and the electrical connection element are in electrical contact and are therefore at the same electrical potential V1, this potential also being the potential of the first electrical connector. This will be referred to hereafter as the potential of the electrical connection element.
[0048]
[0040] According to one aspect of the invention, the containment chamber is arranged so that all the metal parts enclosed by the containment chamber are placed at the same electrical potential.
[0049]
[0041] Advantageously, the invention makes it possible to avoid the creation of electrical disturbances by metallic particles inside the containment chamber.
[0050]
[0042] According to one aspect of the invention, the electrical assembly comprises a plurality of electrical connectors, in particular at least three electrical connectors described above, such as:
[0051] Each electrical connector has at least one mounting hole, and each electrical connector is electrically connected to at least one other electrical connector by an electrical connecting element as described.
[0052]
[0043] In other words, in this example, the electrical assembly comprises at least two connection groups, each of the groups comprising at least two electrical connectors and an electrical connection element arranged to maintain said two associated electrical connectors in contact.
[0053]
[0044] According to one aspect of the invention, the electrical assembly comprises a plurality of cavities arranged to enclose each at least a portion of an electrical connection element so as to form with an electrical connector a containment chamber, this containment chamber being arranged to prevent metallic particles of a characteristic diameter D from exiting the containment chamber.
[0054]
[0045] According to one aspect of the invention, at least one containment chamber encloses a portion of a plurality of electrical connection elements placed at the same electrical potential.
[0046] According to one aspect of the invention, each containment chamber encloses only electrical connection elements placed at the same electrical potential.
[0055]
[0047] According to one aspect of the invention, an insulating part of the electrical assembly comprises a plurality of cavities, each forming, with separate electrical connectors, separate containment chambers.
[0056]
[0048] According to one aspect of the invention, the containment chambers enclose electrical connection elements placed at the same electrical potential.
[0057]
[0049] According to another embodiment of the invention, the containment chambers enclose electrical connection elements placed at distinct electrical potentials.
[0058]
[0050] According to one aspect of the invention, a single insulating piece forms all of the cavities forming the different containment chambers of the electrical assembly.
[0059]
[0051] Alternatively, each containment chamber of the electrical assembly is formed by a separate insulating piece.
[0060]
[0052] According to one aspect of the invention, the electrical assembly is configured to be able to be integrated into an inverter, a DC / DC converter or an on-board OBC charger, in particular for a motor vehicle.
[0061]
[0053] The invention also relates to a method for assembling an electrical assembly according to the invention, comprising the following steps:
[0062] a step of securing the nut to the second electrical connector, including a step of crimping the nut onto the underside of the second electrical connector,
[0063] a step of attaching the second electrical connector to the insulating piece, a step of placing the first electrical connector in contact with the second electrical connector,
[0064] a step of making electrical contact of the first electrical connector on the second electrical connector, comprising a step of screwing the screw onto the nut through the fixing hole of the first electrical connector and the fixing hole of the second electrical connector.
[0065] List of figures
[0066]
[0054] Other features, details and advantages of the invention will become clearer upon reading the following description on the one hand, and several illustrative and non-limiting examples of embodiments given with reference to the accompanying schematic drawings on the other hand, in which:
[0067]
[0055] [Fig. 1] Figure 1 is a cross-sectional view of an electrical assembly according to the invention,
[0056] [Fig. 2] Figure 2 is a cross-sectional view of an electrical assembly according to the invention in which a containment chamber encloses a portion of a plurality of electrical connection elements placed at the same electrical potential,
[0068]
[0057] [Fig. 3] Figure 3 is a representation of an electrical assembly according to the invention.
[0069]
[0058] 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.
[0070] Detailed description
[0071]
[0059] Figure 1 shows a cross-sectional view of an electrical assembly 100 comprising a first electrical connector 1 having a fixing hole 3 and a second electrical connector 2 placed against the first electrical connector 1 and having a fixing hole 4.
[0072]
[0060] The electrical assembly 100 comprises two electrical connection elements 5 arranged to maintain in contact, in particular in electrical contact, the first electrical connector 1 and the second electrical connector 2.
[0073]
[0061] Each electrical connection element has a nut 6 fixed to the second electrical connector 2.
[0074]
[0062] Each electrical connection element 5 has a screw 7 extending through the fixing holes 3 of the first electrical connector 1 and the fixing holes 4 of the second electrical connector 2, the screws being screwed onto the nuts 6 so as to form with the nuts two screw-nut assemblies 8.
[0075]
[0063] The electrical connection element 5 includes an insulating piece 9 having at least one cavity 10, fixedly positioned relative to the second electrical connector 2.
[0076]
[0064] The cavity 10 is arranged to enclose at least a portion of the electrical connection element 5 so as to form with the second electrical connector 2 a containment chamber 11, this containment chamber being arranged to prevent metallic particles 12 of a characteristic diameter D greater than 200 pm from exiting the containment chamber.
[0077]
[0065] The electrical connection element 5 creates an electrical link between the first electrical connector 1 and the second electrical connector 2.
[0066] The cavity 10 is arranged to enclose at least the nuts 6 and a portion of the screws 7 so as to form with the second electrical connector the containment chamber 11.
[0078]
[0067] The containment chamber 11 allows all particles 12 with a diameter greater than 200 pm to be confined.
[0079]
[0068] The first electrical connector 1 has at least one mounting area 20, here one mounting area 20, each mounting area having a mounting hole 3 for the first electrical connector 1.
[0080]
[0069] The second electrical connector 2 has at least one mounting area 21, here one mounting area 21, each mounting area 21 having at least one mounting hole 4 of the second electrical connector 2.
[0081]
[0070] The fixing areas 20 of the first electrical connector 1 and the fixing areas 21 of the second electrical connector 2 are substantially flat areas.
[0082]
[0071] The second electrical connector 2 is placed in contact with the first electrical connector 1 so that each fixing area 20 of the first electrical connector is in contact with a fixing area 21 of the second electrical connector, defining contact areas 22 of the electrical connectors, and so that the fixing hole 3 of the first electrical connector 1 and the fixing hole 4 of the second electrical connector 2 are placed opposite each other.
[0083]
[0072] At the level of the contact area 22 of the electrical connectors, an upper surface of the first electrical connector 23, an lower surface of the first electrical connector 24, an upper surface of the second electrical connector 25 and an lower surface of the second electrical connector 26 are defined.
[0084]
[0073] The lower surface of the first electrical connector 24 is placed in contact with the upper surface of the second electrical connector 25.
[0085]
[0074] The first electrical connector 1 and the second electrical connector 2 are made of conductive material.
[0086]
[0075] The screw-nut assembly 8 is arranged to allow an electrical connection between the first electrical connector 1 and the second electrical connector 2.
[0087]
[0076] The lower surface of the first electrical connector 24, the upper surface of the first electrical connector 23, the lower surface of the second electrical connector 26, the upper surface of the second electrical connector 25 are flat and substantially parallel to each other.
[0088]
[0077] The nuts 6 are placed on the underside of the second electrical connector 26.
[0089]
[0078] The nuts 6 are crimped onto the second electrical connector 2.
[0090]
[0079] In particular, the nuts 6 are crimped onto the underside of the second electrical connector 26.
[0080] According to an embodiment not shown, at least one nut 6 is crimped inside the mounting hole 4 of the second electrical connector 2, so that a portion of the nut 6 fits into the mounting hole 4.
[0091]
[0081] Alternatively, the nuts 6 are placed on the underside of the second electrical connector 26 without being inserted into the fixing holes 4 of the second electrical connector 2.
[0092]
[0082] The insulating piece 9 is a plastic housing in which the second electrical connector 2 is placed, in particular a housing in which the first electrical connector 1 and the second electrical connector 2 are placed.
[0093]
[0083] The insulating part 9 is formed from insulating material, for example from plastic.
[0094]
[0084] The containment chamber 11 is formed by the cavity and the lower face of the second electrical connector.
[0095]
[0085] The containment chamber formed by the cavity 10 and the lower face of the second electrical connector 26 has dimensions chosen to prevent the passage of chips and / or metallic particles 12 of a characteristic diameter greater than D.
[0096]
[0086] In particular, the containment chamber 11 formed by the cavity 10 and the lower face of the second electrical connector 26 does not have any spacing of size greater than D.
[0097]
[0087] The electrical assembly 100 has a gap 30 between the cavity 10 and the lower face of the second electrical connector 26.
[0098]
[0088] The gap 30 formed between the cavity 10 and the lower face of the second electrical connector 26 makes it easier to assemble the second electrical connector 2 onto the insulating piece 9.
[0099]
[0089] The gap 30 has a thickness E strictly less than D, so that a metallic particle 12 of characteristic diameter D cannot exit the confinement chamber 11 through the gap 30.
[0100]
[0090] The lower face of the second electrical connector 26 and the electrical connection element 5 are in electrical contact, and are therefore placed at the same electrical potential V1, this potential also being the potential of the first electrical connector 1. We will refer to the potential of the electrical connection element 26 in the following.
[0101]
[0091] The containment chamber 11 is arranged so that all the metal parts enclosed by the containment chamber 11 are placed at the same electrical potential.
[0102]
[0092] Advantageously, the invention makes it possible to avoid the creation of electrical disturbances by metallic particles 12 inside the containment chamber 11.
[0093] The electrical assembly 100 comprises a plurality of electrical connectors, in particular at least three electrical connectors as described, here four electrical connectors 7, 2, 31, 32 such as:
[0103] Each electrical connector 7, 2, 31, 32 has at least one mounting hole 3, 4, 33, 34,
[0104] Each electrical connector is electrically connected to at least one other electrical connector by an electrical connection element 5.35 as described.
[0105]
[0094] The electrical assembly 100 comprises a plurality of cavities, here two cavities 70,40 arranged to each enclose at least a portion of an electrical connection element 5,35 as described so as to form with an electrical connector 2 a containment chamber 77,41, this containment chamber 77,41 being arranged to prevent metallic particles 12 of a characteristic diameter D from exiting the containment chamber 77,41.
[0106]
[0095] Each containment chamber 77.41 encloses only electrical connection elements 5.35 placed at the same electrical potential.
[0107]
[0096] Figure 2 shows a cross-sectional view of an electrical assembly 100 in which a containment chamber 11 encloses a portion of a plurality of electrical connection elements 5,35 placed at the same electrical potential.
[0108]
[0097] Figure 3 shows an electrical assembly 100 according to the invention, in which an insulating part 9 of the electrical assembly 100 has a plurality of cavities 10 each forming with separate electrical connectors 5 separate containment chambers 11.
[0109]
[0098] The electrical assembly 100 comprises a plurality of electrical connectors 40, in particular at least three electrical connectors as described, here eight electrical connectors 40 such as:
[0110] each electrical connector has at least one fixing hole 41, each electrical connector is electrically connected to at least one other electrical connector 40 by an electrical connection element 5 as described.
[0111]
[0099] The electrical assembly 100 comprises a plurality of cavities 10 arranged to each enclose at least a portion of an electrical connection element 5 as described so as to form with an electrical connector 2 a containment chamber 77, this containment chamber being arranged to prevent metallic particles 12 of a characteristic diameter D from exiting the containment chamber 11.
[0112]
[0100] Each containment chamber 11 encloses only electrical connection elements 5 placed at the same electrical potential.
[0101] A single insulating piece 9 forms all the cavities 10 forming the different containment chambers 11 of the electrical assembly 100.
[0113]
[0102] According to an embodiment of the invention not shown, each containment chamber 11 of the electrical assembly 100 is formed by a separate insulating piece 9.
[0114]
[0103] For readability, only two electrical connection elements are shown in this figure.
Claims
DEMANDS
1. Electrical assembly (100) comprising: a first electrical connector (1) having at least one fixing hole (3), a second electrical connector (2) placed against the first electrical connector (1) and having at least one fixing hole, - At least one electrical connection element (5) arranged to maintain in contact, particularly in electrical contact, the first electrical connector (1) and the second electrical connector (2), this electrical connection element (5) comprising: o at least one nut (6) fixed to the second electrical connector (2), o at least one screw (7) extending through the fixing hole (3) of the first electrical connector (1) and the fixing hole (4) of the second electrical connector (2), and being screwed onto the nut (6) so as to form with the nut (6) a screw-nut assembly (8) at least one insulating piece (9) comprising at least one cavity (10), fixed in relation to the second electrical connector (2), the cavity (10) being arranged to enclose at least a portion of the electrical connection element (5) so as to form with the second electrical connector (2) a containment chamber (11), this containment chamber being arranged to prevent metallic particles (20) of a characteristic diameter D greater than 200 pm from exiting the containment chamber (11).
2. Electrical assembly (100) according to claim 1, wherein the cavity (10) is arranged to enclose at least the nut (6) and a portion of the screw (7) of at least one electrical connection element (5) so as to form with the second electrical connector (2) the containment chamber (11).
3. Electrical assembly (100) according to any one of the preceding claims, wherein the screw-nut assembly (8) is arranged to permit an electrical connection between the first electrical connector (1) and the second electrical connector (2).
4. Electrical assembly (100) according to any one of the preceding claims, wherein the nut (6) is crimped onto the second electrical connector (2), in particular is crimped onto the underside of the second electrical connector (2).
5. Electrical assembly (100) according to any one of the preceding claims, wherein the insulating piece (9) is a housing in which the second electrical connector (2) is placed.
6. Electrical assembly (100) according to any one of the preceding claims, comprising a gap (30) between the cavity (10) and the underside of the second electrical connector (26).
7. Electrical assembly (100) according to the preceding claim, wherein the gap (30) has a thickness E strictly less than D, so that a metallic particle (12) of characteristic diameter D cannot exit the containment chamber (11) through the gap (30).
8. Electrical assembly (100) according to any one of the preceding claims, wherein the containment chamber (11) is arranged so that all the metal parts enclosed by the containment chamber (11) are placed at the same electrical potential.
9. An electrical assembly (100) according to any one of the preceding claims, comprising a plurality of electrical connectors (1, 2, 31, 32, 40), in particular at least three electrical connectors, such as: each electrical connector has at least one mounting hole (3,4,33,34,41), each electrical connector (1,2,31,32,40) is electrically connected to at least one other electrical connector by an electrical connection element (5).
10. Electrical assembly (100) according to the preceding claim, in which at least one containment chamber (11) encloses a portion of a plurality of electrical connection elements (5) placed at the same electrical potential.
11. Electrical assembly (100) according to any one of claims 9 or 10, wherein an insulating part (9) of the electrical assembly (100) comprises a plurality of cavities (10) each forming with separate electrical connectors (2, 32, 40) separate containment chambers (11).
12. A method for assembling an electrical assembly (100) according to any one of the preceding claims, comprising the steps: a step of fixing the nut (6) onto the second electrical connector (2), in particular a step of crimping the nut (6) onto the underside of the second electrical connector (2), a step of fixing the second electrical connector (2) onto the insulating piece (9), a step of placing the first electrical connector (1) in contact with the second electrical connector (2), a step of making electrical contact of the first electrical connector (1) on the second electrical connector (2), comprising a step of screwing the screw (7) onto the nut (6) through the fixing hole (41) of the first electrical connector and the fixing hole (42) of the second electrical connector (2).