Patent Publication Number: US-2022231436-A1

Title: Module Connector With At Least One Displaceable Contact Assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of the filing date under 35 U.S.C. § 119(a)-(d) of German Patent Application No. 102021100997.9, filed on Jan. 19, 2021. 
    
    
     FIELD OF THE INVENTION 
     The invention relates to a module connector for electrically connecting two electric modules and, more particularly, to a module connector for connecting two battery modules. 
     BACKGROUND 
     The distance between the two electric modules connected to a module connector can deviate from a predetermined reference distance, even if the electric modules are arranged in a grid dimension. Known module connectors are not able to compensate for such positional deviations. 
     SUMMARY 
     A module connector for electrically connecting a pair of electric modules includes a pair of contact assemblies spaced from one another and fastening the module connector to the electric modules, a conductor assembly electrically connecting the contact assemblies and, with the contact assemblies, forming an electrical connection between the electric modules, and a housing formed of an electrically insulating material. The contact assemblies and the conductor assembly are accommodated in the housing. At least one of the contact assemblies is fastened to the conductor assembly in a manner displaceable relative to the conductor assembly in a direction of displacement directed towards and/or away from the other of the contact assemblies. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will now be described by way of example with reference to the accompanying FIGURES, of which: 
         FIG. 1  is a sectional side view of a module connector according to an embodiment; 
         FIG. 2  is an exploded perspective view of the module connector; and 
         FIG. 3  is a sectional side view of a module connector according to another embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENT(S) 
     The invention shall be explained hereafter by way of example on the basis of different, merely exemplary configurations with reference to the drawings. The individual configurations merely reproduce a possible combination of features. Individual features of a configuration can be omitted in accordance with the explanations herein if the technical effect associated with the respective feature is not crucial for a particular application. Conversely, a feature can be added to a configuration described if the technical effect associated with this feature is crucial for a particular application of the configuration. In the drawings, the same reference characters are used for features which correspond to one another with regard to function and/or structure. 
     Shown in  FIGS. 1 and 2  is a module connector  1  which connects two electric modules  2 , for example, two battery modules, in particular battery modules  2  of an electric vehicle, to one another in an electrically conductive manner. Module connector  1  comprises two contact assemblies  4  spaced from one another which serve to establish electrical contact with electric modules  2  and to fasten module connector  1  to electric modules  2 . 
     For the electrical and mechanical connection to a contact assembly  4 , an electric module  2  is provided with a contact and fastening point  6  which is configured to be complementary to contact assembly  4 , as shown in  FIG. 1 . A distance  8  between contact and fastening points  6  of the electric modules  2  to be connected is typically predetermined, but can deviate from a predetermined reference distance. 
     Module connector  1  comprises a conductor assembly  10 , shown in  FIGS. 1 and 2 , which electrically connects both contact assemblies  4 . Conductor assembly  10  can be a power rail  12  extending end-to-end between both contact assemblies  4 . Power rail  12  can have an arch  14 , in particular a U-shaped arch, in an embodiment between both contact assemblies  4 , in order to compensate for changes in length of conductor assembly  10  due to temperature fluctuations. Power rail  12 , in an embodiment, has a rectangular conductive cross section, flat sides  16  of which point in the direction towards and away from electric modules  2 . Other conductive cross sections, for example, square, polygonal, circular, oval, or U-shaped, are also possible. 
     At least one contact assembly  4   a  is displaceable in a direction of displacement  18  shown in  FIGS. 1 and 2  relative to conductor assembly  10  in the direction toward the other contact assembly  4   b  or away therefrom. This makes it possible to compensate for deviations from predetermined distance  8 , changing the distance between the contact assemblies  4   a ,  4   b ; the one displaceable contact assembly  4  must simply be moved relative to the conductor assembly  10 . In contrast to the curved and flexible conductor assemblies, which have to be bent open elastically to compensate for different distances between the modules, the solution according to the invention enables a force-free change in the distance  8  during installation. For length compensation, it is sufficient if only one displaceable contact assembly  4   a  is provided. In an embodiment, however, contact assemblies  4  of a module connector  1  are configured to be identical, so that both contact assemblies  4   a ,  4   b  are displaceable. 
     Module connector  1 , as shown in  FIG. 1 , comprises a housing  20  in which conductor assembly  10  and contact assemblies  4  are accommodated. The housing  20  is fabricated from electrically insulating material and, at least in the region of contact assemblies  4 , is part of a finger and touch protection that conforms in particular to standards and prevents contact with live parts. 
     In order to compensate for different distances  8 , displaceable contact assembly  4   a  can be arranged to be displaceable in housing  20 . In an embodiment, however, displaceable contact assembly  4   a  is coupled rigidly to housing  20  with respect to direction of displacement  18 . Displaceable contact assembly  4   a  can be displaced together with housing  20  in direction of displacement  18 , and in an embodiment in a plane  22  parallel to direction of displacement  18 . 
     Plane  22 , shown in  FIG. 1 , extends perpendicularly about a pivot axis  24 , about which one contact assembly, for example, displaceable contact assembly  4   a , can be pivoted about other contact assembly  4  or  4   b , respectively. Pivot axis  24  extends through one contact assembly  4  and runs perpendicular to the connecting line between both contact assemblies  4  or the same elements of both contact assemblies  4 , respectively. The remainder of module connector  1  can be pivoted about contact assembly  4  through which pivot axis  24  passes, so that the former can be aligned accordingly during assembly. A pivot axis  24  can extend through each of both contact assemblies  4 ,  4   a ,  4   b  so that (remaining) module connector  1  can be pivoted about each contact assembly  4 ,  4   a ,  4   b . This makes it possible to align the module connector  1  correctly for connecting the two electric modules  2 . The contact assembly  4 , about which the remainder of the module connector  1  is pivotable, can be displaceable or fixed with respect to the conductor assembly  10 . 
     Housing  20  can comprise two housing parts  26 ,  28 , shown in  FIGS. 1 and 2 , which are displaceable relative to one another in direction of displacement  18 . Housing parts  26 ,  28  can form a guide  29  which limits the movability of both housing parts  26 ,  28  to a displaceability in direction of displacement  18 . For example, housing  20  can be configured to be telescopic to follow the change in the distance  8  without gaps arising through which contact with a current-carrying element could be established. For this purpose, one housing part  26  can be inserted into the other housing part  28 . Two telescopic housing parts  26 ,  28  can overlap in particular in the middle between both contact assemblies  4 . If arch  14  is arranged at this point, then the inner clear width of both housing parts  26  can be increased accordingly in order to be able to accommodate arch  14  during the telescopic motion. The inner clear width of housing parts  26  can decrease towards contact assemblies  4 . 
     In other embodiments, more than two telescopic housing parts  26 ,  28  can also be present. For example, a third housing part can be arranged centrally between two outer housing parts. The two outer housing parts can be inserted to be displaceable into the central housing part or the central housing part can be inserted to be displaceable into the two outer housing parts. 
     In each of the housing parts  26 ,  28 , one of two contact assemblies  4  is retained to be immovable relative to the respective housing part  26 ,  28  at least in direction of displacement  18 , an in an embodiment in plane  22  containing direction of displacement  18 . 
     One or each housing part  26 ,  28  can be formed by two or more housing shells  26   a ,  26   b ,  28   a ,  28   b  shown in  FIG. 2 . Housing shells  26   a ,  26   b  or  28   a ,  28   b  can be assembled, for example, clipped together, in an embodiment perpendicular to plane  22  or in an assembly direction  30  pointing towards electric modules  2  or in an assembly direction  30  pointing along pivot axis  24 , respectively. In this way, a contact assembly  4  and a section of conductor assembly  10  can be placed into a housing part  26 ,  28 , whereupon two housing shells  26   a ,  26   b  or  28   a ,  28   b , respectively, are closed around the respective contact assembly  4  and the respective section of conductor assembly  10 . In this way, conductor assembly  10  and contact assembly  4  are retained in a captive manner in housing  20  or in respective housing part  26 ,  28 , respectively. Which housing part  26 ,  28  is inserted into other housing part  28 ,  26  is irrelevant. 
     The compensation of a change in distance  8  between the contact assemblies  4   a ,  4   b  in such a configuration takes place exclusively by way of the relative motion of the housing parts  26 ,  28  to one another and not by way of a motion of a contact assembly  4  in the housing  20  or in the housing part  26 ,  28  accommodating the contact assembly  4 . This makes it easier to provide finger and/or touch protection conforming to standards. The housing parts  26 ,  28  that are displaceable relative to one another also overlap even when the greatest possible distance  8  between the two contact assemblies  4   a ,  4   b  has been assumed. In one configuration, the two housing parts  26 ,  28  overlap in the middle between the two contact assemblies  4   a ,  4   b.    
     A contact assembly  4 , as shown in  FIGS. 1 and 2 , can comprise a fastening element  32 , for example, in the form of a screw  34 . A screw shank  36  can be provided with a finger and/or touch protection  40  at its end  38 . Fastening element  32  can be coated and/or covered with a finger and/or touch protection  40 , at least at the points at which it is not in contact with power rail  20  or an electric module. The screw  34  can be fabricated from material having good electrical conductivity and can be part of a current path through the module connector  1  along which current flows from one to the other of the two electric modules  2 . The screw  34  does not necessarily have to comprise a thread; instead of a thread, one or more latching elements or a bayonet lock can also be present. 
     Finger and/or touch protection  40  of screw head  42  can comprise one or more radially projecting ribs  44 , shown in  FIGS. 1 and 2 , which extend in the radial direction to a collar  46 , that is formed by housing  20  and that projects away from conductor assembly  10 , against which they can abut. The inner contour of collar  46  is circular in an embodiment, but can also be polygonal. Rib  44  is circumferential in an embodiment and has an outer contour that is complementary to the inner contour of collar  46 , so that finger and/or touch protection  40  of the screw head  42  closes the interior of collar  46  as a kind of cover and prevents direct access to conductor assembly  10 . Collar  46  is part of the finger and/or touch protection  40  formed by housing  20 . 
     With such a configuration, housing  20 , in particular its collar  46 , and screw head  42  at the same time can together form a guide or bearing point  47  for contact assembly  4   a . Due to bearing point  47 , fastening element  32  can be rotated about an axis of rotation  48 , shown in  FIG. 1 , and is guided along axis of rotation  48  so as to be displaceable with respect to housing  20  and conductor assembly  10 , but is fixated in other directions of motion. Such fixation ensures that no gaps arise that could allow for live parts to be touched. 
     With regard to conductor assembly  10  disposed opposite screw head  42 , contact assembly  4  comprises a contact ring  50  which, as shown in  FIGS. 1 and 2 , can also be configured in a sleeve-shaped manner. Contact ring  50  is fabricated from material that conducts electricity very well, for example, a material made of or containing copper and/or aluminum. Fastening element  32  extends through contact ring  50 . The contact ring  50  is part of the current path. 
     Contact ring  50 , as shown in  FIG. 1 , can comprise a shoulder  52  which projects in the radial direction and which is received in a seat  56  of housing  20  or a housing part  26 ,  28  that is formed to be complementary. Shoulder  52  is therefore disposed between conductor assembly  10  and housing  20 . The contact ring  50  can have a circular or polygonal base area or outer contour. 
     Contact ring  50  comprises a passage opening  58 , shown in  FIG. 2 , which in an embodiment forms a further bearing point  60  for fastening element  32 . Like at bearing point  47 , fastening element  32  can be rotated by contact ring  50  at bearing point  60  about axis of rotation  48  and is guided in a displaceable manner along axis of rotation  48 , but is otherwise fixated. Two bearing points  47 ,  60  are disposed opposite one another with respect to conductor assembly  20  and thereby prevent fastening element  32  from canting or becoming wedged in housing  20 . A motion perpendicular to the axis of rotation  48  is blocked by the bearing points  47 ,  60 . 
     Contact ring  50  is, in an embodiment, coupled rigidly with respect to direction of displacement  18  or a motion in plane  22 , respectively, to fastening element  32 . Contact ring  40  consequently moves along with fastening element  32  when fastening element  32  is displaced with respect to conductor assembly  10 . In particular, the contact ring  40  can be combined in a manner displaceable in one piece with the remainder of the contact assembly  4 . The direction of displacement can be predetermined, for example, by the direction of the oblong hole  64  described in detail below. 
     Contact ring  50  can be retained immovably in housing  20  or in a housing part  26 ,  28 , so that it transfers the displacement of fastening element  32  of displaceable contact assembly  4   a  with respect to other contact assembly  4   b  to housing  20  or housing part  28 . Bearing points  47 ,  60  therefore not only serve to guide fastening element  32 , but also to transfer displacement  18  of displaceable contact assembly  4   a  to housing part  28  or a telescopic motion of housing  20  to contact assembly  4   a , respectively. 
     The contact ring  50  touches the conductor assembly  10  at least in a state of the module connector  1  in which the latter is attached to the two electric modules  2 . This enables the current flow via the contact ring  50 . Additionally or alternatively, the fastening device  32  can also establish a conductive connection between the conductor assembly  10  and the electric module  2 . 
     Housing  20  or a housing part  28 , respectively, in an embodiment forms a collar  62  shown in  FIG. 1  which is disposed opposite collar  46 , projects toward electric module  2  or along axis of rotation  48  and projects beyond contact ring  50 . Collar  62  is also part of the finger and touch protection provided by housing  20 . 
     To enable the displaceability of contact assembly  4  in direction of displacement  18 , conductor assembly  10  can be provided with a hole  63  shown in  FIG. 2 , in particular an oblong hole  64 , through which contact assembly  4  or, if present, fastening element  32  extends. Contact assembly  4  is displaceable in hole  63  in direction of displacement  18 . The displaceable contact assembly  4  is displaceable until it is completely fastened to the respective electric module  2 . 
     Longitudinal direction  66  of oblong hole  64  in an embodiment corresponds to direction of displacement  18 . Direction of displacement  18  or longitudinal direction  66 , respectively, is directed towards the other contact assembly  4 . It in an embodiment intersects pivot axis  24 . Fastening element  32  is accordingly displaceable in oblong hole  64  while distance  8  changes. The displaceability of the fastening element  32  makes it possible to compensate for different distances between the battery modules  2  in a simple manner. Oblong hole  64 , in an embodiment, is disposed in plane  22 . The oblong hole  64  has a length  70  in the direction of displacement  18 . 
     In order to always obtain the same or at least very little changing electrical transition resistance between electric modules  2 , regardless of distance  8  between contact assemblies  4 , the surface area of an in particular planar contact zone  68 , in which conductor assembly  10  and contact ring  50  touch at least with module connector  1  attached to electric modules  2 , is the same regardless of the relative position of contact ring  50  or contact assembly  4 , respectively, and conductor assembly  10 . Smaller changes in the surface area of contact zone  68  in the range of ±15% are still considered to be the same surface area. This configuration ensures that the transition resistance of the module connector  1  is independent of the displacement position of the contact assembly  4 . Even large currents can then be transmitted regardless of the relative position of the contact assembly  4  and the conductor assembly  10 . 
     One way of ensuring a constant surface area of contact zone  68  is that a length  10  of oblong hole  60  is less than or equal to the sum of half of diameter  72  of passage opening  58  of contact ring  50  and half of outer diameter  74  of contact ring  50  in plane  76  of contact zone  68 . Moreover, a distance  78  between oblong hole  64  and end  80  of conductor assembly  10  closest to oblong hole  64  should be greater than or equal to half the difference between outer diameter  74  of the contact ring and diameter  72  of the passage opening in plane  76 . 
     As already explained above, it is sufficient to have only one of two contact assemblies  4  be displaceable, i.e. extend, for example, through an oblong hole  64 . Instead of an oblong hole  64 , a hole which fixates non-displaceable contact assembly  4  in direction of displacement  18  or in plane  22  in a non-displaceable manner with respect to conductor assembly  10  can be present on non-displaceable contact assembly  4 . However, in order to be able to compensate for larger changes in distance, it is also possible for both contact assemblies  4   a ,  4   b  to be of identical configuration and to be fastened to the conductor assembly  10  in a manner displaceable with respect to the conductor assembly  10 . For example, both contact assemblies  4   a ,  4   b  can extend through holes  63 , in particular oblong holes  64 , of the conductor assembly  10  and can be displaceable in the holes  62 . 
     In the configuration of  FIGS. 1 and 2 , conductor assembly  10  comprises a power rail  12  that is disposed end-to-end between contact assemblies  4 , or conductor assembly  10  consists of an end-to-end power rail  12 , respectively. 
     However, in another embodiment, it is sufficient to have a power rail be present only at displaceable contact assembly  4   a  or at both contact assemblies  4 , as shown in  FIG. 3 . Conductor assembly  10  can comprise a flexible conductor  82  between these power rails  12   a ,  12   b , for example, in the form of a woven fabric, knitted fabric, cable, or wire mesh. In the region of flexible conductor  82 , the conductor assembly can have an arch  14 , as in the case with end-to-end power rail  12 . Otherwise, the configuration in  FIG. 3  is identical to the configuration of  FIGS. 1 and 2 . The adaptation of the distance  8  between the contact assemblies  4   a ,  4   b  should be effected exclusively by displacement of the at least one displaceable contact assembly  4   a  relative to the conductor assembly  10  and without elastic deformation of the flexible conductor  82 . This is the only way to keep the connection between the module connector  1  and the electric modules  2  free of force.