FR2932023A1 - Connector for energy storage device in motor vehicle, has armature partially drowned in plastic material of support, and electric power terminal mounted on armature, where armature is realized from steel sheet - Google Patents

Abstract

The connector (40) has a support (41) made of plastic material, and an armature partially drowned in the plastic material. Electric power terminal (42) is mounted on the armature, where the armature is realized from a steel sheet. The armature includes a rectangular shaped frame and a fixation portion of the terminal extending inside the frame. The fixation portion of the terminal is connected to the frame by branches. A power trace is placed close to the terminal. The trace includes a metallic lug and is arranged for connected to an energy storage battery.

Description

Connector, especially for energy storage device

The invention relates to a connector, in particular for a device for storing energy, in particular for equipping a motor vehicle. In a known manner, in a motor vehicle, an energy storage device may be provided to be loaded during a regenerative braking phase and discharged during vehicle start-up and acceleration phases.

The energy storage device may comprise a chain of energy storage cells connected in series, these cells each comprising for example a super-capacitor. Differences in charge voltage may occur between the cells due in particular to: - differences between the capacitance values inherent to the manufacture of the cells, - the existence of leakage currents of different intensities. The persistence of these deviations over time can cause accelerated aging or even destruction of cells that support the highest load voltages. It is known to provide an electronic unit provided with a balancing circuit to correct these imbalances. For example, reference can be made to US patent application 2003/0214267. It is further necessary to provide a connection unit having a plurality of signal exchange paths for connecting the electronic unit to one or more external devices. These and other elements, useful for the operation of the energy storage device are to be mounted on this device without compromising its sealing.

One of the aims of the invention is to meet this requirement.

Furthermore, the energy storage device must be connected for example to a battery of the motor vehicle via an electrical power terminal. Another object of the invention is to provide a new connector comprising such an electrical power terminal. The invention thus has, according to one of its aspects, a connector, in particular for a device for storing energy, the connector comprising: an electronic unit, in particular arranged for at least one controlling the storage device of energy and generate information representative of the state of the energy storage device, for example in order to perform a diagnosis of the energy storage device, - an electrical connection unit, on the one hand, connected to the electronic unit and, on the other hand, arranged to be connected to a complementary connection element, this connection unit having in particular a plurality of signal exchange channels, - a support made in one piece, in particular by molding of a plastic material, the electronic unit and the connection unit being carried by this support. Thanks to the invention, because several elements, namely for example the electronic unit and the connection unit, are mounted on the same support so as to form an assembly that can be set up at a single location, in particular on a wall of the energy storage device, it is possible to more easily obtain a satisfactory seal between the inside and the outside of the energy storage device, compared for example in the case where these different elements would be arranged in several openings of the wall of the energy storage device. In addition, when the carrier carrying the electronic unit is made of plastic material, it is easier to avoid short circuit problems which, if necessary, could arise when the electronic unit is attached directly to a metal part of the energy storage device. The support, when made of plastic, can, if desired, exhibit excellent flatness characteristics, which can be advantageous when using a seal which is then compressed properly for ensure a better seal. The support may carry, if necessary, other elements useful for the energy storage device. For example, the connector may comprise a ventilation unit carried by the support. In an exemplary implementation of the invention, the aeration unit comprises an air permeable membrane. This membrane is for example of the type marketed under the trademark Gore-tex. The support may comprise an orifice and the aeration unit may be arranged in this orifice. The support may comprise a substantially flat wall and the electronic unit may be arranged at least partially facing this substantially flat wall. If desired, the ventilation unit is disposed opposite the electronic unit, on this substantially flat wall. In an exemplary implementation of the invention, the connector comprises an electrical power terminal carried by the support. Advantageously, the electronic unit comprises an electronic card fixed on the support, in particular by crimping, snapping or screwing.

Preferably, the support is made of plastic, and the connection unit comprises at least one electrical contact element partially embedded in the plastic material of the support. The subject of the invention is also an assembly, in particular designed to be mounted on a motor vehicle, comprising: an energy storage device, in particular comprising a plurality of energy storage cells, comprising a tank, in particular in which are arranged the energy storage cells, - a connector as defined above, fixed on the tank of the energy storage device. Advantageously, the tank of the energy storage device comprises an opening, in particular on a side wall of the tank, arranged to partially receive the connector.

In an exemplary implementation of the invention, the energy storage cells are partially embedded in a resin deposited inside the tank, and the tank comprises a wall arranged to separate the resin from a receiving compartment. the connector. If desired, the electronic unit of the connector is arranged to allow balancing of the electrical charge between the energy storage cells. The invention also relates, independently or in combination with the foregoing, to a connector, in particular for a device for storing energy, the connector comprising: a support made of plastic material, an armature, in particular a metal frame, at least one partially embedded in the plastic material of the support, - an electrical power terminal mounted on the armature. Thanks to the invention, the armature makes it possible to reinforce the mechanical strength of the power terminal at a tightening torque exerted on it. Advantageously, the reinforcement comprises a metal, in particular being made from a sheet such as a steel sheet. In an exemplary implementation of the invention, the armature comprises a frame, in particular of substantially rectangular shape, and this frame 30 comprises a fixing portion of the electrical power terminal extending inside the frame. The power terminal is for example welded to the armature. If desired, the fixing portion of the electrical terminal can be connected to the frame via two branches of the frame.

Preferably, the connector comprises at least one trace of power disposed near the electrical power terminal, this trace comprising a metal lug and in particular being arranged to be connected to an energy storage battery. In an exemplary implementation of the invention, the connector comprises three electrical traces arranged around the electrical power terminal, these three traces forming in particular three sectors evenly distributed around the power terminal. The connector may for example comprise an insulating ring on which the power traces extend, this insulating ring being arranged so that the traces extend in a plane raised with respect to a plane of the support. This ring can further electrically isolate the traces vis-à-vis the terminal and between them. In an exemplary implementation of the invention, the connector comprises an electronic unit and an electrical connection unit connected to this electronic unit, the electrical connection unit comprising in particular a plurality of signal exchange channels. The support may comprise a wall, in particular a substantially flat wall, and an aeration unit comprising an air-permeable membrane directly fixed on the wall of the support.

Said wall of the support may comprise a grid portion substantially facing the membrane of the aeration unit. The invention also relates to an assembly, in particular arranged to be mounted on a motor vehicle, comprising a connector comprising a substantially flat wall and an aeration unit provided with an air permeable membrane and waterproof. , the membrane being fixed on the wall of the connector, covering an orifice formed thereon. The subject of the invention is also an assembly, in particular arranged to be mounted on a motor vehicle, comprising: an energy storage device, in particular comprising a plurality of energy storage cells, comprising a tank, in particular in which the energy storage cells are arranged, a connector as defined above, mounted on the tank.

The subject of the invention is also, independently or in combination with the foregoing, an assembly, in particular arranged to be mounted on a motor vehicle, comprising: a device for storing energy, in particular comprising a plurality of storage cells; energy, comprising a tank, in particular in which the energy storage cells are arranged, the tank comprising upper and lower half-shells assembled together, the tank comprising a bottom formed on the lower half-shell and a compartment opening at the outside on the bottom of the tank, - a connector comprising an electronic unit and a support carrying the electronic unit, the electronic unit being introduced at least partially into said compartment of the tank. The half-shells may have different shapes and / or sizes from one half-shell to another, or alternatively be symmetrical.

Thanks to the invention, because the electronic unit is introduced into the compartment through the bottom of the tank, the interface between the two half-shells can be completely free for the establishment of a seal, for example a seal. In an exemplary implementation of the invention, the bottom of the vessel extends substantially parallel to a plane, and the support of the connector has a face inclined with respect to said plane. The compartment of the tank opens preferably on the bottom by an inclined face against which the inclined face of the connector support. Advantageously a seal is disposed between the respective inclined faces of the connector support and the compartment of the tank. The invention makes it possible to ensure a satisfactory seal between the inside and the outside of the tank, at the level of the connector. The interface between the tank and the connector along an inclined plane is very advantageous in terms of management of the seal, with respect for example to an interface on two perpendicular planes. In an exemplary implementation of the invention, the bottom of the tank extends substantially parallel to a plane, and the electronic unit comprises an electronic card, the electronic card extending in the compartment of the tank perpendicular to the plan of the bottom of the tank.

If desired, the tank comprises at least one holding lug and the electronic card is maintained with the aid of this holding lug at one end of the card remote from the bottom of the tank. This can be useful when the device is vibrating. Advantageously, the electronic card is secured to the holding tab by at least one fastening element, in particular a clip, disposed between the electronic card and the holding tab. In an exemplary implementation of the invention, the support of the electronic unit comprises an electrical connection unit, on the one hand connected to the electronic unit and on the other hand arranged to be connected to an element of complementary connection from outside the tank. If desired, the electrical connection unit extends substantially perpendicular to a side wall of the vessel. The electronic unit may comprise an electronic card, and the electronic card may be disposed on the support only substantially along an edge of this card, which comprises at least one other edge remote from the support. The connector may for example be fixed to the tank removably, in particular using at least one screw.

In an exemplary implementation of the invention, the assembly may comprise at least one electrical power terminal mounted on the tank at a location separate from that of the connector. Advantageously, a resin is deposited in the tank, and the compartment of the tank for receiving the electronic unit comprises a wall separating the resin from the electronic unit. If necessary, the electronic unit has a height greater than that of the lower half-shell of the tank when the electronic unit is introduced into the compartment of the tank. The energy storage cell comprises for example at least one supercapacitor. As a variant, the energy storage cell may comprise, for example, a Li-On (Lithium-Ion), Ni-Mh (nickel-metal hydride) or lead battery. Preferably, the electronic unit comprises a circuit for balancing the energy storage cells. Alternatively, other types of electronic cards may be provided. The invention will be better understood on reading the following detailed description of examples of non-limiting embodiments of the invention, and on examining the appended drawing, in which: FIG. schematically and partially, an energy storage device equipped with a connector according to an exemplary implementation of the invention, - Figures 2 to 6 show, schematically and partially, different views of the connector of Figure 1 at various stages of assembly, FIG. 7 illustrates, diagrammatically and partially, in perspective, an energy storage device with a connector according to another example of implementation of the invention, FIG. a detail view, schematic and partial, in perspective, of the energy storage device and the connector of FIG. 7; FIG. 9 is an isolated, schematic and partial view of the connector of FIGS. 7 and 8; f FIGS. 10 and 11 show, schematically and partially, the connector of FIG. 9 at different assembly stages; FIG. 12 shows, schematically and partially, in perspective, a device for storing energy in accordance with another example of placing FIG. 13 represents, diagrammatically and partially, in perspective, the device of FIG. 12, without the upper half-shell of the tank, FIG. 14 schematically and partially showing various elements of the device. FIG. 13, FIG. 15 is a diagrammatic and partial sectional representation of the device of FIG. 13, and FIG. 16 is a diagrammatic and partial sectional view of a connector according to another example. implementation of the invention. FIG. 1 shows an energy storage device 1 for a micro-hybrid device with alternator-starter for a motor vehicle. Where appropriate, the micro-hybrid device comprises a regenerative braking system.

The device 1 comprises a plurality of energy storage cells 2 arranged in a tank 3, and partially embedded in a resin deposited in the bottom of the tank 3. Each cell 2 comprises a supercapacitor or EDLC in English (double electrochemical layer capacitator).

Alternatively, the cells 2 may comprise a Li-On battery (Lithium-Ion), Ni-Mh (nickel-metal hydride) or lead. The tank 3 comprises a half-shell 4 forming the bottom of this tank 3 and having a side wall 5.

This side wall 5 has an opening 7, in the described example of substantially rectangular shape, arranged to receive a connector 10. The tank 3 further comprises a wall 8 arranged to separate the resin in the tank 3 of a compartment 9 receiving the connector 10. This connector 10 is for example screwed on the side wall 5.

As can be seen in FIGS. 2 to 6, the connector 10 comprises: an electronic unit 12 arranged to control and balance the energy storage cells 2 and to generate information representative of the state of the storage device; energy 1, for example in order to perform a diagnosis of the cells 2, - an electrical connection unit 14, on the one hand, connected to the electronic unit 12 and, on the other hand, arranged to be connected to an element complementary connection circuit not shown, this connection unit 14 having a plurality of signal exchange paths, for example eight in the present example, - a support 15 made in one piece, by molding a material thermoplastic such PBT (polybutylene terephthalate) charged, the electronic unit 12 and the connection unit 14 being carried by this support 15.

The support 15 carries other elements useful for the energy storage device 1. The connector 10 comprises a ventilation unit 16 carried by the support 15. The ventilation unit 16 comprises an air permeable membrane. This membrane is for example of the type marketed under the trademark Gore-tex.

The support 15 comprises an orifice 17, visible in FIGS. 4 and 6, and the aeration unit 16 is disposed in this orifice 17. For example, reference can be made to US Pat. No. 7,166,024, which describes such a ventilation unit.

The support 15 has a substantially flat wall 19 and the electronic unit 12 is disposed facing this substantially flat wall 19. The ventilation unit 16 is arranged facing the electronic unit 16 on this substantially flat wall 19. The electronic unit 12 comprises an electronic card 20 fixed on an annular rim 18 of the support 15 via pads 21 of this support 15, as can be seen in FIG. 4. These pads 21 are deformed to hold the electronic card 20. Alternatively, the pads 21 may be arranged to allow to screw or latch the electronic card 20 on the support.

The connection unit 14 comprises a plurality of electrical contact elements, comprising rods 23 partially embedded in the plastic material of the support 15. The connection unit 14 has a tubular wall 25 surrounding the connection elements 23.

In the example just described, the connector 10 is devoid of electric power terminal. Of course, it is not beyond the scope of the present invention when the connector comprises other elements useful for the operation of the energy storage device, among which at least one electrical power terminal.

FIG. 7 shows an assembly 30 comprising a energy storage device 1 and a connector 40. As previously described, the device 1 comprises a cover 31 for closing the tank 3. The connector 40 comprises a support 41 made of plastic material and carrying an electric power terminal 42.

Lugs 33 associated with this terminal 42 are provided inside the tank 3 to electrically connect the cells 2 to each other, as shown in FIG. 8. The connector 40 comprises a metal reinforcement 44 (see FIG. 10) embedded in the plastic material of the support 40 during molding thereof. The armature 44 reinforces the strength of the power terminal 42 to a torque exerted on it. In the example described, the frame 44 is made from a sheet such as a steel sheet, and comprises a frame 45 of substantially rectangular shape. This armature 44 further comprises an attachment portion 46 of the electrical power terminal 42, inside the frame 45. The power terminal 42 is for example welded to the frame 44. The fixing portion 46 of the terminal electrical 42 is connected to the frame 45 through two branches 48. If desired, more branches 48 may be provided. The connector 40 has three power traces 50 arranged near the power terminal 42, these traces 50 having a metal lug 51 and being arranged to be connected to a battery of the vehicle. The three electrical traces 50 arranged around the power terminal 42 form three sectors regularly distributed around the power terminal 42 (see in particular Figure 9). The connector 40 comprises an insulating ring 55 on which the power traces 50 extend, this ring 55 being arranged in such a way that the traces 50 extend in a plane raised with respect to a parallel plane of the support 41. traces 50 are electrically isolated from the power terminal 42. These traces 50 are also electrically insulated from each other.

After overmolding the armature 44 by the plastic material of the support 41, the power terminal 42 is surrounded by three radial ribs 56 (see FIG. 9) and the lugs 51 are embedded in the plastics material except for their ends.

Two of the three lugs 51 are interconnected to be at the same electrical potential. Like the connector 10 described above, the connector 40 comprises an electronic unit 12 provided with a printed circuit board 20, and an electrical connection unit 14 connected to this electronic unit 12, the electrical connection unit 14 comprising a plurality of signal exchange paths, as illustrated in FIG. 11. A substantially rectangular seal 58 is provided between the connector 40 and the vessel 3. Alternatively, a bead of adhesive may be used at the place of the joint.

The connector 40 is fixed on the tank 3, in the example described, using screws 59 (see Figure 9). In the examples which have just been described, the electronic card 20 is arranged parallel to the associated support. Alternatively, as will now be described, the electronic card can be arranged cantilevered on the support. FIGS. 12 and 13 show an assembly 60 comprising: an energy storage device 61 comprising a plurality of energy storage cells 2 and comprising a tank 62 in which the energy storage cells 2 are arranged , the tank 62 comprising lower and upper half-shells 63 assembled together, the tank 62 comprising a bottom 65 formed on the lower half-shell 63 and a compartment 67 opening outwards on the bottom 65 of the tank 62, a connector 70 comprising an electronic unit 12 and a support 71 carrying the electronic unit 12, the electronic unit 12 being introduced into said compartment 67 of the tank.

The bottom 65 of the tank 62 extends substantially parallel to a plane P, and the support 71 of the connector 70 has an inclined face 72 with respect to the plane P, as can be seen in particular in FIGS. 14 and 15. angle of inclination A is for example between 10 ° and 45 °. The compartment 67 of the tank 62 opens on the bottom 65 by an inclined face 75 against which the inclined face 72 of the support 71 of the connector 70 engages. A seal 77, of substantially rectangular shape in the example described, is arranged between the inclined faces 72 and 75. Alternatively, a bead of adhesive can be used to seal.

The invention makes it possible to ensure a satisfactory seal between the inside and the outside of the tank 62, at the level of the connector. The electronic unit 12 comprises an electronic card 20 extending in the compartment 67 of the tank 62 perpendicular to the plane P of the bottom 65 of the tank 62.

As illustrated in FIGS. 14 and 15, the lower half-shell 63 has two retaining tabs 80 and the electronic card 20 is held by means of these retaining tabs 80 at one end 81 of the card 20 away from the bottom 65 of the tank 62, via staples 83, arranged between the electronic card 20 and the retaining tabs 80.

The support 71 of the electronic unit 20 comprises an electrical connection unit 14, on the one hand connected to the electronic unit 20 and on the other hand arranged to be connected to a complementary connection element, not shown, since outside the tank.

The electrical connection unit 14 extends substantially perpendicular to the electronic card 20 and to the side wall 79 of the tank 62. The electronic card 20 is disposed on the support 71 only substantially along a straight edge of this card 20, which comprises another rectilinear edge 84 remote from the support 71. The connector 70 is fixed on the tank 62 by screws 86. The assembly 60 comprises two electrical power terminals 42 mounted on the tank 62 at different locations from that connector 70.

A resin 78 is deposited in the bottom of the tank, and the compartment 67 of the tank for receiving the electronic unit 12 comprises a wall 88 separating the resin from the electronic unit. In the example considered, the electronic unit 12 has a height greater than that of the half-shell 63 of the tank 62 when the electronic unit 12 is introduced into the compartment 67 of the tank. In other words, as illustrated in FIG. 15, the electronic card 20 projects outside the half-shell 63. Of course, the invention is not limited to the implementation examples which have just been described.

For example, the support 15 described with reference to FIGS. 2 to 6 may comprise a substantially flat wall 19, and the ventilation unit comprises an air permeable membrane 90 directly fixed on the wall 19 of the support, as illustrated on FIG. Figure 16. This wall 19 of the support 15 may comprise a grid portion 91 disposed substantially facing the membrane 90 of the aeration unit. When the wall 19 is vertical, a liquid outlet channel 95 may be provided in this wall 19, between the grid 91 and the membrane 90. Preferably, this evacuation channel 95 is inclined with respect to the wall 19 of the support 15.30

Claims (12)

Revendications1. Connector (40), in particular for energy storage device (1), the connector comprising: a support (41) made of plastic material, an armature (44) at least partially embedded in the plastic material of the support, an electrical terminal power unit (42) mounted on the armature. 2. Connector according to the preceding claim, characterized in that the armature (44) comprises a metal, being in particular made from a sheet such as a steel sheet. 3. Connector according to one of the preceding claims, characterized in that the armature (44) comprises a frame (45), in particular of substantially rectangular shape, and in that the armature comprises a fixing portion (46). electrical power terminal extending inside the frame. 4. Connector according to the preceding claim, characterized in that the fixing portion (46) of the electrical terminal is connected to the frame via two branches (48). 5. Connector according to any one of the preceding claims, characterized in that it comprises at least one power trace (50) disposed near the power terminal (42), the trace having a metal lug and being in particular arranged to be connected to an energy storage battery. 6. Connector according to the preceding claim, characterized in that it comprises three electrical traces (50) arranged around the electrical power terminal, these three traces forming in particular three regularly distributed sectors 5 around the power terminal. 7. Connector according to one of the two preceding claims, characterized in that it comprises an insulating ring (55) on which the traces of power extend, this ring being arranged so that the traces 10 ' extend in an elevated plane with respect to a support plane. 8. Connector according to any one of the preceding claims, characterized in that it comprises an electronic unit (12) and an electrical connection unit (14) connected to this electronic unit, the electrical connection unit comprising in particular a plurality of signal exchange paths. 9. Connector according to any one of the preceding claims, the support having a substantially flat wall, characterized in that it comprises a ventilation unit (16) comprising an air permeable membrane directly fixed to the wall of the support. 10.Connector according to the preceding claim, characterized in that said wall of the support comprises a grid portion (91) disposed substantially opposite the membrane (90) of the aeration unit. 11. An assembly, in particular arranged to be mounted on a motor vehicle, comprising a connector according to any one of claims 1 to 10 comprising a substantially flat wall and an aeration unit provided with an air permeable membrane and impermeable to water, the membrane (90) being fixed on the wall of the connector, covering an orifice formed thereon. 12. A set, in particular arranged to be mounted on a motor vehicle, comprising: an energy storage device (1), in particular comprising a plurality of energy storage cells, comprising a tank, in particular in which are disposed the energy storage cells, a connector (40) according to any one of claims 1 to 10 mounted on the vessel.