FR3141005A1 - IMPROVED FIXATION OF A POWER TERMINAL IN AN ELECTRIC POWER CONVERTER - Google Patents

Abstract

The present subject matter relates to an electrical power converter (100) comprising a housing (102) and a connector (104). The housing (102) contains electronic components adapted to convert direct current (DC) into alternating current (AC) and/or vice versa. The connector (104) is electrically connected to the electronic components. The connector (104) is mounted on the housing by fasteners in a direction parallel to the X-X` axis (112), the X-X` axis defining a direction along which one of said fasteners (110) is fixed to achieve said mounting. The connector (104) comprises a conductive element (106) and a plug (202). One end of the conductive element (106) is overmolded in a body (108) of electrically insulating material and is electrically connected to the electronic components. The plug (202), integrally formed on the body (108), is inserted and locked into a socket (200) formed in the housing (102). Figure for the abbreviation:FIG. 2B

Description

IMPROVED FIXATION OF A POWER TERMINAL IN AN ELECTRIC POWER CONVERTER Field of the invention

The present subject generally concerns an electrical power converter, and more specifically an improved fixing of a module in an electrical power converter.

Context

An electrical power converter is a power electronic device or circuit that converts direct current (DC) to alternating current (AC), and/or vice versa. An electrical power converter includes electronic components, such as power semiconductors, capacitors, etc., configured to perform the aforementioned function. An electrical power converter also includes a connector for connecting the electronic components to an electrical machine, such as a rotating electrical machine, an electrical energy source/storage, an electronic control unit (ECU). Generally, there are three types of connectors in an electrical power converter. One of three types of connectors makes an electrical connection between the electronic components of the electric power converter and a winding of a rotating electrical machine. A second type of connectors establishes a signal/control connection with an electronic control unit (ECU) to control the electric power converter and/or a rotating electric machine. A third type of these connectors is a power terminal which establishes a connection between the electrical power converter and an electrical power source/storage.

Generally, a connector, of one of the aforementioned types, is mounted on a housing of the electrical energy converter. Mounting to the housing is generally carried out using screws. The aforementioned mounting is normally not well balanced because one side of the connector is secured to the housing by screws while the other side is cantilevered and suitable for connection to an electrical machine, such as a machine rotary electric, a calculator, a source of electrical energy and/or an accumulator of electrical energy. The screws secure the connector against any movement along an axis in which the screwing is carried out. Additionally, any movement in a lateral direction relative to this axis is also blocked. However, the connector is susceptible to unwanted rotation due to unbalanced mounting. For example, in the case where the connector is a power terminal, one side of the power terminal is mounted on the housing and the other side is cantilevered. The side of the cantilevered power terminal is subject to rotational movement relative to the side mounted on the housing. Exposure to vibration in an operational environment can therefore have a negative effect on the structural integrity of the power connector. In such scenarios, the electrical communication between the electric power converter and the electric machine may also be affected, further harming the operational integrity of the electric power converter and the electric machine. Typically, to combat unwanted rotation of conventional connectors, additional components can be introduced. For example, in known manner, an additional component, such as a stopper, is used to stop such a rotational movement. However, the introduction of additional components only increases the nomenclature and complexity of the electrical power converter.

Therefore, the technical solution sought by the present subject consists of optimizing the attachment of a connector to the housing of an electrical energy converter, thereby improving the structural and operational integrity of the electrical energy converter.

The present object aims to solve the aforementioned problem of conventional electric power converters. The present object relates to an electrical power converter comprising: a housing intended to receive electronic components adapted to the conversion of direct current (DC) into alternating current (AC) and/or vice versa; a connector, mounted on the housing by clips, in a direction parallel to the X-X` axis, and electrically connected to the electronic components, the X-X` axis defining a direction along which one of said clips is fixed to achieve said assembly, in which the connector comprises: a conductive element overmolded in a body of electrically insulating material, one end of the conductive element being electrically connected to the electronic components; and a plug, formed integrally on the body, the plug being inserted and locked into a socket formed in the housing. The clips prevent axial movement of the connector along the X-X` axis, or parallel to it, and along lateral directions relative to the X-X` axis. The plug, locked into the socket of the housing, provides a further improvement in that it prevents unwanted rotation of the connector around the fixing points. More precisely, unwanted rotation around an axis perpendicular to the X-X` axis is stopped. The structural and operational integrity of the connector and the housing is therefore ensured.

In one example, the plug is substantially L-shaped and comprises: a connection portion extending from the connector body and protruding in a direction substantially perpendicular to the X-X` axis; and a plug-in part protruding from the connection part in a direction substantially parallel to the X-X` axis, in which the plug-in part is inserted and locked in the socket. Thus, due to the plug and socket configuration, the connector is locked in place and does not move undesirably relative to the housing.

According to one aspect, the pluggable part has a shape defined by a trapezoidal or oblong cross section. More precisely, the cross section of the plug-in part is either trapezoidal or oblong, when observed in a direction perpendicular to the X-X` axis.

According to one aspect, the base of the housing is a cavity whose interior periphery is configured to complete the shape of the pluggable part inserted into said cavity. In other words, when the pluggable part has a trapezoidal cross section, and therefore a trapezoidal shape, the inner periphery of the cavity is configured to be trapezoidal in shape. Likewise, when the pluggable part has an oblong cross section, and therefore an oblong shape, the interior periphery of the cavity is configured to be oblong in shape. This means that the plug-in part can be easily inserted into the base.

According to one aspect, there is a free space between the interior periphery of the base and the exterior periphery of the pluggable part.

In one aspect, the plug-in part is locked in the cavity by means of a bonding material disposed in the space between the inner periphery of the base and the outer periphery of the plug-in part. Accordingly, the plug, in particular the plug-in part, is mounted and locked in the base of the housing.

In one example, there is an interference fit between the outer periphery of the plug-in portion and the inner periphery of the socket. Therefore, in this example, the application of glue is not necessary.

In one example, the housing is a heat sink suitable for dissipating heat generated by electronic components. The case therefore serves both as housing for the electronic components and as a heat sink to evacuate the heat generated by these components.

In another example, the connector is a power terminal adapted to electrically connect the electronic components to an electrical energy storage source and/or to an electrical energy source.

The present object also relates to an assembly comprising: a rotating electric machine comprising stator windings, an electric power converter, configured in accordance with the preceding description, electrically connected to the stator windings of the rotating electric machine.

According to one aspect, one end of the conductive element of the connector is electrically connected to the electronic components and another end of this element is electrically connected to an electrical energy storage and/or to an electrical energy source. The connector, configured in the aforementioned manner, provides rigid assembly to guarantee an uninterrupted connection between the electrical energy converter and the electrical energy storage and/or the electrical energy source.

The characteristics, aspects and advantages of the present invention will be better understood in light of the following description and the accompanying figures. The description refers to the attached drawings, in which:

There illustrates an exploded view of an electric power converter, specifically describing a housing and a connector of the electric power converter, in accordance with the present subject;

There illustrates an isometric view of the housing and the connector mounted on the housing, in accordance with the present subject;

There illustrates a sectional view of the connector mounted on the housing, in accordance with this subject;

There illustrates an enlarged perspective of the , showing the connector mounted on the housing, in accordance with this subject;

There illustrates an isometric view of the electrical power converter housing, configured in accordance with this subject;

There shows an enlarged view of the , showing up close a socket of the housing, configured in accordance with the present subject;

There illustrates an isometric view of the electrical power converter connector, configured in accordance with this subject;

There illustrates a bottom view of the electrical power converter connector, configured in accordance with this subject;

There is an enlarged view of the , illustrating a plug formed integrally on the connector body, configured in accordance with this subject;

There illustrates a bottom view of the electrical power converter shown in , configured in accordance with this subject;

There shows an enlarged view of the , configured in accordance with this subject;

There illustrates an isometric view of the electric power converter in conjunction with a rotating electric machine, configured according to one example; And

There illustrates a sectional view of the electric power converter and the rotary electric machine shown in , configured according to an example.

Figures are not necessarily to scale and the size of some parts may be exaggerated to more clearly illustrate the example shown. Further, the drawings provide examples and/or examples consistent with the description, but the description is not limited to the examples and/or examples provided in the drawings.

detailed description

The present object therefore aims to solve the aforementioned problem in conventional electrical energy converters. More specifically, the present topic solves the problem of unreliable mounting of a connector in an electrical power converter. The connector may be any connector designed to provide an electrical connection between the electrical power converter and an electrical machine, such as a rotating electrical machine, an electrical power source, an electrical energy storage, a unit electronic control unit (ECU), or a combination thereof. However, for the sake of simplicity, the connector mentioned in the description and shown in the figures is a power terminal making it possible to electrically connect the electrical power converter to a source of electrical energy and/or to an electrical energy accumulator .

In the following description, reference is made to the accompanying drawings, which form an integral part of the invention, and in which a specific implementation of the invention is illustrated. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is understood that the embodiments may be combined, or that other embodiments may be used, and that structural modifications and logic can be provided without departing from the scope of the present invention. The following detailed description should therefore not be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.

There illustrates an exploded view of an electrical power converter 100, in accordance with the present subject. The electrical power converter 100 includes a housing 102 and a connector 104 mounted on the housing 102. The housing 102 accommodates electronic components (not shown) essential for the conversion of electrical energy from direct current (DC) to alternating current ( AC) and/or vice versa. As explained previously, these electronic components can include power semiconductors, capacitors, etc. which, in tandem, carry out the aforementioned electrical energy conversion. The connector 104 is adapted to electrically connect the electrical components of the electrical energy converter 100 to a source of electrical energy and/or to an electrical energy accumulator (not shown). The connector 104 is mounted, or assembled, in one direction along an axis XX` 112, or parallel thereto, by means of fasteners. Axis XX` 112 shown on the specifically defines a direction along which one of the clips 110 is inserted into the connector 104. For the sake of simplicity, any axis parallel to axis XX` 112 can also be called here "fixing axis". During assembly, connector holes 114 formed in connector 104 are aligned with housing holes 116 formed in housing 102. The holes, namely connector holes 114 and housing holes 116 , are aligned so as to be exposed for insertion with the fastener 110 in one direction along the fastening axis. The fixing element 110, in particular the screws in the illustrated examples, is inserted through the holes 114, 116 and then fixed. Consequently, the connector 104 is mounted on the housing 102. The connector 104 comprises a conductive element 106, overmolded in a body 108 of electrically insulating material, to establish an electrical connection between the electrical energy converter 100 and a source of electrical energy and/or electrical energy storage. One end of the conductive element 106, formed of pins 107, is electrically connected to the electronic components; and the other end of the conductive element 106, formed of a conductor of cylindrical shape, is configured to allow the mounting of a conductive cable coming from an electrical energy storage source and/or a source of electrical energy. The end of connector 104 facing housing 102 is the side of housing 212; and the side of the connector 104, configured to connect to the electrical energy storage and/or the electrical energy source (or "battery") is the side of the battery 214. For clarity, consider a plan (not shown) formed by the axes along which the fasteners are inserted during assembly, the side of the plane where the pins 107 are formed is the side of the housing; and the side of the plane where the cylindrical shaped conductor is formed is the battery side. The conductive element 106, in particular the pins 107, is connected to one of the electronic components of the housing 102, in a direction perpendicular to the axis XX` 112, to establish the electrical connection. Connector 104 further includes a plug formed integrally on body 108 of connector 104. The plug is inserted into a socket formed in the housing and then locked in place. Thus, the connector 104 is not only prevented from moving in any direction, it is also blocked from rotation. The plug and receptacle configuration, as described above, adds to the structural stability of the connector 104 and housing 102 assembly, thereby ensuring the operational integrity of the electrical power converter 100.

There illustrates an assembled view of the electrical power converter 100, configured in accordance with the present subject. There illustrates a cross-sectional view of the electrical power converter shown in . Furthermore, the illustrates an enlarged view of the cross section of the , describing a configuration of the electrical power converter 100 to obtain optimized attachment of the connector 104 to the housing 102. For the sake of brevity, due to the similarities between the illustrations of FIGS. 2A, 2B & 2C, the description of the aforementioned figures is provided here in tandem.

There shows a socket 200 formed in the housing 102, into which a plug 202 is inserted (shown in the and 2C) of connector 104. In a non-limiting manner, the plug 202 is substantially L-shaped. In the examples illustrated, the plug 202 is formed on the side of the housing 212. The plug 202 comprises a connection part 204 and a plugging part 206. connection part 204 extends from the body 108 of the connector 104. The connection part 204 is configured to protrude in a direction substantially perpendicular to the axis XX`. Further, the plug-in part 206 is configured to be inserted into the socket 200, and protrudes from the connection part 204 of the plug 202. The plug-in part 206 protrudes from the connection part 204 in one direction parallel to axis XX` 112, and is therefore inserted in the aforementioned direction.

According to one aspect, the base 200 is a cavity whose interior periphery 208 completes the shape of the plug-in part 206. During assembly, the plug 202, more precisely the plug-in part 206, is inserted into the base 200. In the examples illustrated , there is clearance between the inner periphery 208 of the base 200 and the outer periphery 206 of the plug-in part. In this example, the free space in the base 200, or cavity, is filled with a bonding material 210. The bonding material 210 essentially glues the plug-in portion 206 of the plug 202 into the base 200, thereby ensuring that 'unintentional slipping of the pluggable part of the base 200 does not occur.

There illustrates the box 102 configured in accordance with the present subject; and the illustrates a cross-sectional view of the , specifically describing the socket 200. The inner periphery 208 of the socket 200, as previously described, is configured to complement and allow insertion of the plug 202, particularly the pluggable portion 206. In the aspects illustrated in the figures, the base 200, after having been inserted with the plug-in part 206, is filled with connecting material 210. In a non-limiting example, not shown in the figures, the outer periphery of the plug-in part 206 can be configured to obtain a tight fit with the inner periphery 208 of the base 200. In the aforementioned example, the interference fit can be achieved by pressing the plug 202, in particular the pluggable part 206, into the socket 200. Consequently, the connector 104 is locked in place and prevented from rotating undesirably. In this example, because connector 104 is mounted and locked by means of an interference fit, bonding material is not necessary. Furthermore, the operational integrity of the connector 104, mounted on the housing 102 and electrically connected to the electrical components, is ensured.

In one example, the housing 102 functions as a heat sink to improve the dissipation of the heat generated inside the electrical energy converter 100. In this example, the housing 102 has a dual function: it accommodates electronic components and serves as a heat sink to carry heat away from these components. The housing 200, as explained in the description above, accommodates electronic components suitable for converting direct current into alternating current and/or vice versa. For example, cavities 300, formed in housing 102, are configured to accommodate capacitors. Additionally, power modules are also housed in the housing 102. Additionally, the housing 102 may also be equipped with a liquid cooling system 302, as illustrated in the example figures (e.g., ), in order to further improve the dissipation of heat generated by electronic components. Therefore, the connector 104, configured in accordance with the present subject matter, is reliably mounted and secured to the housing 102, such that the structural and operational integrity of the housing 102 is not affected.

There illustrates an isometric view of connector 104, configured in accordance with the present subject. There illustrates another perspective view of connector 104, configured in accordance with the present subject. There shows an enlarged view of the , representing the cap 202, configured in accordance with this subject.

The aforementioned figures show the conductive element 106 and a body 108 covering said element 106. The conductive element 106 is formed, on the side of the housing 212, of pins 107 adapted for electrical connection with the electronic components. The battery side 214 of the conductive element 106 is formed of a conductor 201 of cylindrical shape, each being adapted to receive a terminal of a cable connected to an electrical energy accumulator and/or to a source of electrical energy . When mounting the connector 104 on the housing 102, the plug (represented by a hatched/dark part in the figures), in particular the pluggable part 206, is inserted into the socket 200 formed in the housing 102. The plug 202 is formed on the body 108 of the connector 104 such that it is located between two connector holes 116, the connector holes 116 being formed such that they are parallel to the axis XX`. The aforementioned positioning of the plug 202 between the connection holes 116 provides structural rigidity to the connector 104 mounted on the housing 102. The pluggable portion 206 of the plug 202 is configured to have a trapezoidal cross section when viewed in the perspective illustrated in 4B, that is to say when it is seen in a direction perpendicular to the axis XX`. The views represented on the and 4C show the plug-in part 206 with a trapezoidal shape defined by the aforementioned trapezoidal cross section. Accordingly, the socket 200, in particular the inner periphery 208, is configured to complete the trapezoidal shape of the plug-in part 206.

In another example, the pluggable part 206 has an oblong shape (not shown) defined by an oblong cross section when seen in the perspective shown in 4B, that is to say when seen in one direction perpendicular to the X-X` axis. Therefore, in this example, the base 200 is shaped to complement the oblong shape of the plug-in part 206.

There illustrates a perspective view of the housing 102 and the connector 104 mounted on the housing 102. The shows in particular a cross section along a plane intersecting the pluggable part 206 and the socket 200. The is an enlarged view of the , illustrating the aforementioned sectional view of the plug-in part 206 inserted in the base 200. In the examples illustrated, the plug-in part 206 has a trapezoidal section. The base 200, or cavity, whose interior periphery 208 is configured to match the shape of the plug-in part 206, is inserted with the plug-in part 206. Furthermore, in the example of the , there is a free space 500 between the outer periphery 502 of the plug-in part 206 and the inner periphery 208 of the base 200. Furthermore, the cavity, in particular the free space 500, is filled with the bonding material 210. The bonding material 210 may be a glue that holds the pluggable portion 206 in place and prevents it from moving, thereby blocking the movement of the connector 104.

The present subject also relates to an assembly 600 which includes an electric power converter 100, configured in accordance with the description above, and an electric machine 602. illustrates an isometric view of an assembly 600 configured as indicated above. There illustrates a sectional view of the assembly 600 represented on the . The electric power converter 100, in accordance with the present subject, may operate in conjunction with an electric machine, such as a rotating electric machine, an electric power source, an electric energy storage, an electronic control unit (ECU ), or a combination of these. In the example illustrated in the figures, the electric power converter 100 is in electrical communication with a rotary electric machine 602, the rotary electric machine 602 being able to be controlled to operate as a motor (in motor mode) or a generator (in motor mode). generator). It can also be said that the electric power converter 100 functions as a voltage converter which functions as a rectifier bridge in generator mode and/or as an inverter in motor mode of the rotary electric machine 602. Consequently, the rotary electric machine 602 , an electromechanical device, preferably polyphase, can convert electrical energy into mechanical energy, or vice versa.

In addition, the electrical energy converter 100 is connected to an electrical energy accumulator (not shown) and/or to a source of electrical energy (not shown) by cables 606. The cables 606 have lugs 608 which adapt to the conductive element 106 on the side of the battery 214. More precisely, the battery side 214 of the conductive element 106 is the conductor 201 of cylindrical shape configured to allow the mounting of the lugs 608. In addition, the conductive element 106 on the side of the housing 212 is formed of pins 107 adapted for electrical connection with the electronic components. The connector 104, configured in accordance with the description above, therefore guarantees the maintenance of the structural integrity of the assembly 600 and the operational integrity with the storage of electrical energy and/or the source of electrical energy .

In one aspect, the rotary electric machine 602, although typically used to drive motor vehicles, can have many applications, such as lawn mowers, drones, pumps, turbines, etc. In a scenario where the rotary electric machine 602 operates as a motor to drive a motor vehicle, the electric power converter 100 receives direct current from an electric power source, converts the direct current to alternating current and supplies it to a stator 612 of the rotary electric machine 602 which then interacts with a rotor 614. In a scenario where the rotary electric machine 602 operates as a generator, for example when the motor vehicle is driven by an internal combustion engine, the rotor 614 of the rotating electric machine 602 is driven, thereby interacting with the stator 612 to generate alternating current. The alternating current can then be converted into direct current by the electrical energy converter 100, to be stored in an electrical energy accumulator. The source of electrical energy and the storage of electrical energy, mentioned in the above scenarios, can be the same.

In the illustrated examples, the electrical power converter 100 is included or integrated into the rotating electrical machine 602. However, in another example, the electrical power converter 100, operating in the manner described above, may not be integrated to the rotary electric machine 602. In other words, it can exist as a separate component of the rotary electric machine 602, while remaining in electrical connection with said machine to perform the operations described in the example above. The present invention applies to the two examples of electrical power converters 100.

Various modifications of the disclosed embodiments, as well as other embodiments of the object, will become apparent to those skilled in the art by reference to the description of the object. It is therefore envisaged to make such modifications without departing from the scope of this subject.

Claims (11)

Electric power converter (100) comprising:
a housing (102) intended to accommodate electronic components capable of converting direct current (DC) into alternating current (AC) and/or vice versa;
a connector (104), mounted on the housing (102) by fixings (110), in a direction parallel to the XX` axis (112), and electrically connected to the electronic components, the XX` axis (112) defining a direction along which one of said fixings (110) is fixed to achieve said assembly, in which the connector (104) comprises:
a conductive element (106) molded into a body (108) of electrically insulating material, one end of the conductive element (106) being electrically connected to the electronic components; And
a plug (202), integrally formed on the body (108), is inserted and locked into a socket (200) formed in the housing (102). Electrical power converter (100) according to claim 1, in which the plug (202) is substantially L-shaped and comprises:
a connection part (204) extending from the body (108) of the connector (104) and protruding in a direction substantially perpendicular to the axis XX`; And
a plug-in part (206) protruding from the connection part (204) in a direction substantially parallel to the axis XX`, in which the plug-in part (206) is inserted and locked into the socket (200). An electric power converter (100) according to claim 2, wherein the plug-in portion (206) has a shape defined by a trapezoidal or oblong cross section. An electrical power converter (100) according to any one of claims 1 to 3, wherein the socket (200) of the housing (102) is a cavity whose inner periphery (208) is configured to complement the shape of the plug-in portion (206) inserted into said cavity. Electric power converter (100) according to one of claims 1 to 4, in which there is a clearance (500) between the inner periphery (208) of the socket (200) and the outer periphery (502) of the plug-in part (206). Electric power converter (100) according to one of Claims 1 to 5, in which the plug-in part (206) is blocked in the cavity by means of a bonding material (210) arranged in the free space (500). . Electric power converter (100) according to one of claims 1 to 3, wherein there is a tight fit between the outer periphery (502) of the plug-in part (206) and the inner periphery (208) of the base (208). Electrical power converter (100) according to one of claims 1 to 7, in which the housing (102) is a heat sink adapted to the dissipation of the heat generated by the electronic components. Electrical power converter (100) according to one of claims 1 to 8, in which the connector (104) is a power supply terminal adapted to electrically connect the electronic components to a source of storage of electrical energy and/or 'electric energy. Assembly (600) comprising
a rotating electric machine (602) comprising stator windings,
an electric power converter (100), configured according to any one of the preceding claims, electrically connected to the stator windings of the rotating electric machine (602). Assembly (600) according to claim 10, wherein one end of the conductive element (106) of the connector (104) is electrically connected to the electronic components and another end of this element (106) is electrically connected to a storage source of electrical energy and/or to a source of electrical energy.