Electrical connection bus

A connecting bus includes an electrically conductive bar comprising two electrical connector assemblies. At least one of the two electrical connector assemblies includes a female connector having at least one electrically conductive spring tongue. For each of the electrical connection assemblies included in the connecting bus, the electrically conductive bar includes a corresponding non-isolated zone surrounding the electrical connection assembly. The electrically conductive bar further includes an outside electrically insulating layer surrounding the whole electrically conductive bar apart from the non-isolated zone.

TECHNICAL FIELD OF THE INVENTION

The invention relates to a connecting bus and to a connector assembly including a connecting bus. For example the connecting bus of the present invention can be applied in vehicle electrical power equipment.

BACKGROUND OF THE INVENTION

Traditionally, electrical terminals of adjacent battery modules were electrically connected by a connecting bus having two holes adapted to these terminals. The mechanical and the electrical connection were provided by the pressure of a screw/bolt system. The reliability of the electrical connection was depending on the tightening torque of the screw. In a vehicle, vibration may affect the reliability of the screwed connecting bar.

In recent hybrid vehicles, the amount of electrical power equipment is increasing. The reliability of the electrical power connection comes to be a critical issue.

Traditional vehicle electrical power connectors were used to interconnect electrical devices suitable for high current intensity. Such a device could be a flexible electrical cable of a large cross-section or a rigid connecting bar which provides a similar large cross section. When such a connector was used with a rigid connecting bus, the electrical power contact of the connector was screwed on the connecting bus. This requires a very precise connector implementation on the power equipment. Therefore, there is a need for a vehicle connector assembly transmitting electrical power to a connecting bus which is compatible with the vibration environment of a vehicle and which is simple to implement in power equipment.

The invention provides a connecting bus and a connector assembly including a connecting bus, for vehicle power equipment which remedies to at least one of the above drawbacks.

A goal of the invention is to improve the reliability of the electrical connection provided by a connecting bus and to simplify the implementation into vehicle power equipment.

BRIEF SUMMARY OF THE INVENTION

According to one embodiment, the invention provides a connecting bus for a vehicle electrical power equipment, comprising an electrical conductive bar including two electrical connection means. At least one of the two electrical connection means comprises a female connector including one or several electrically conductive spring tongues.

According to one embodiment, the invention provides a connector assembly for vehicle electrical power equipment, comprising at least one electrical connector for vehicle power equipment, and at least one connecting bus, electrically connected to the connector by an electrical connection means. The electrical connection means comprises a female connector including one or several spring tongues.

The spring tongues of the connection means provide a safer connection than a screw/bolt system because there is no unscrew or drift risk. The electrical connection is prevented from being discontinued and is simple to install.

In some other embodiments, one might also use one or more of the features as defined in dependent claims.

DETAILED DESCRIPTION OF THE INVENTION

As illustrated inFIG. 1, the connecting bus1comprises an electrically conductive bar2and two female connectors3. The electrically conductive bar2is substantially flat and extends along a middle line22having a U-shape within a plane of the electrically conductive bar2. The cross-section of the electrically conductive bar2, perpendicularly to the middle line22, is rectangular. The electrically conductive bar2has a width, parallel to the bar plan and a thickness perpendicularly to the bar plane. The thickness is bigger than a tenth of the width, so the bar is rather rigid.

As illustrated inFIG. 2, the female connector3comprises a socket4and an insulating housing5surrounding the socket4. The socket4comprises a rigid tubular part6from which a plurality of cantilevered spring tongues7, separated by gaps or slots, extend. The cantilevered spring tongues7taper inwardly towards the interior of the socket4so as to define a tubular contact region, and then flare outwardly to provide a guiding end portion. The socket4is adapted to receive a pin contact8following an insertion axis9.

The socket4can be made of a cut and rolled sheet. The tubular part6is press-fitted into annular opening, formed in of the electrically conductive bar2, and is delimited by annular edges10. The insulating housing5comprises fixation means12adapted to be tightly fixed to the electrically conductive bar2. The fixation means12may include a centering shape and/or crimping hooks or the like. The insulating housing5comprises a guiding aperture11, concentric with the insertion axis9. The diameter of the guiding aperture11is such that the major radial impact during the insertion of the pin contact8into the female connector3is transmitted to the insulating housing5and directly to the electrically conductive bar2without damaging the soft spring tongues7.

The connecting bus1further comprises an insulating layer13covering nearly all the exposed surfaces of the electrically conductive bar2. Only some unprotected zones14are prevented from being covered by the insulating layer13. The unprotected zones14include the inside cylindrical surface of the annular edge10, so the press-fitting of the tubular part6into the unprotected surface provides the electrical connection. Therefore, the electrical connection extends from the pin contact8to the spring tongues7, and then to the electrically conductive bar2. The insulating layers13covers the electrically conductive bar2all around each of the female connector3and extends from one female connector3to the other.

The electrically conductive bar2could be made of a solid copper alloy or the like. The insulating layer13could be made by an insulating paint or by a polymer sheath or the like.

The cross-section of the pin contact8is similar to the sum of the cross-section of each individual spring tongue7. The cross-section of the electrically conductive bar2is similar or larger than the cross-section of the pin contact8. So, the resistivity of the electrical connection is rather constant from the pin contact8to the electrically conductive bar2. Preferably, the electrically conductive bar2has a substantially constant cross-section all along the middle line22. This avoids hot points due to joule effect.

As illustrated inFIG. 3or4, electrical equipment15, used for example in a vehicle electrical power system, comprises a connector assembly20including two electrical power connectors16. Each of the power connectors16comprises two power contacts17a,17b. One power contact17ais connected to the positive pole of a vehicle battery (not illustrated); the other power contact17bof the power connector16is connected to the negative pole of the battery. Each power contact17a,17bcomprises a back pin21similar to the pin contact8previously described.

The two positive power contacts17aof each power connector16are electrically interconnected by a first connecting bus1as previously described. The two negative power contacts17bare interconnected by a second connecting bus1a, similar to the first connecting bus1, apart from the fact that the global shape is not a “U”, but a “Y”. Two extremities of the “Y” shape comprise each a female connector3and the third extremity of the “Y” shape comprises a traditional electrical connection means18, made of a simple hole19surrounded by an unprotected zone14.

The electrical connection means18further hold the whole connecting bus1a, and stops the connecting bus1.

The power contact17a,17bare adapted for a vehicle power system. The electrical current passing through these power contacts could be as high as160A. The voltage between the positive and the negative poles could be 400 V. The two connecting buses1,1amay touch each other. The insulating layer13is suitable for such voltage isolation.

The electrically conductive bars2are substantially flat, with a width between five and ten times the bar thickness. This provides a large cross-section for the electrically conductive bar2with a relatively small thickness and a rather rigid connecting bar. The axial insertion tolerance for a safe connection between the back pin21and the female connector3is much larger than the thickness of the electrically conductive bar2plus the insulating layer13. The first connecting bus1is pushed on the back pin21, up to an abutting position. The second connecting bus1ais pushed up into abutment with the first connecting bus1.

As illustrated inFIG. 5, a connector assembly30comprises an electrical power connector31, similar to the power connector16previously described and a connecting bus32which include one female connector3as described inFIG. 2and traditional connection means33.

The electrical power connector31comprises a power contact34which includes a front pin35, adapted to electrically mate with a power socket of a connector (not illustrated) complementary to the connector31. The power contact further includes a back pin36. Both front pin35and back pin36have an extremity with an ogive shape, suitable for repeated mating with the complementary connector or with the female connector3. The back pin36may have a cross section larger than 35 square millimeters (mm2). Any smooth longitudinal profile can be used, like a hemispheric profile.

The traditional connection means33may consist in a simple hole37, surrounded by a non-isolated zone38. Electrical power equipment39comprises an electrical terminal40against which the hole37is screwed by a screw41.

The hole37and the non-isolated zone38provide an electrical connection as well as a mechanical fixation onto the electrical terminal40. As the connecting bus32is rather rigid, the whole connecting bus32is held. Therefore, the position of the female connector3is determined by the mechanical fixation with respect to the terminal40.

The traditional connecting bars comprise two holes at each extremity. When these traditional connecting bars had to connect a connector to an internal terminal, the dimensional tolerance requested between the connector and the electrical terminal had to be tightly controlled. Due to the spring tongue7of the present connector, the dimensional tolerance between the connector31and the electrical terminal40is less critical in particular in the axial direction of the back pin36.

In a variant, the connector assembly20or30may have a connecting bus comprising a connecting pin and the corresponding power contact17a,17bor34may have a female connector.

In another variant, the connecting bus1or1a, may comprise three or more female connectors3. Such a variant could be used to connect battery equipment50to several electrical engines as in some hybrid vehicles.

As illustrated inFIG. 6, a battery50comprises three stacks51a,51b, and51cof eight battery modules52. Each adjacent module52of the same stack is electrically connected by a shunt53having a U shape. Two adjacent stacks51a-51b, or51b-51care electrically connected by a connecting bus1as previously described inFIG. 1. The shunts53could also be provided as such buses. In such case, the shunts53could be all fixed to a common cover, for example of elastomeric material, so as to provide some play along the X and Y directions, to enable easy connection of a large number of battery modules.