PASSIVE DETECTION OF OVERHEATING IN A POWER CONNECTOR

Abstract

Electrical connector comprising a detection device for detecting potential overheating, which comprises an electrically conductive element and an electrically insulating element inserted between the electrically conductive element and a low-voltage line. The electrically conductive element exerts an elastic force on the insulating element. For example, the electrically conductive element is a spring. In the event of overheating, the insulating element deforms under the pressure of the electrically conductive element and enables an electrical connection between two low-voltage lines. The overheating is detected as a consequence of the electrical design of this connection between the low-voltage lines.

Claims

1. Electrical connector comprising: a housing that houses at least one first conductive component configured so as to be integrated in a first low-voltage electrical line and at least one second conductive component configured so as to be integrated in a second low-voltage electrical line, at least one first material forming the housing, at least one electrically insulating element and at least one electrically conductive element, inserted between the first conductive component and the second conductive component, wherein the electrically insulating element consisting of a second material having a melting temperature less than or equal to the melting temperature of the at least one first material, and wherein the electrically conductive element exerting an elastic force on the electrically insulating element that is suitable for deforming the electrically insulating element, when the electrically insulating element has a temperature greater than or equal to its melting temperature and establishing an electrical connection between the first conductive component and the second conductive component.

2. Electrical connector according to claim 1, wherein the first conductive component is configured so as to be connected to an interlock control circuit of a high-voltage circuit by way of the first low-voltage electrical line.

3. Electrical connector according to claim 1, wherein the second conductive component is a shielding element attached to the housing.

4. Electrical connector according to claim 3, wherein the electrically insulating element is inserted between the electrically conductive element and the shielding element.

5. Electrical connector according to claim 1, wherein the electrically insulating element and the electrically conductive element are integrated together in a passive detection device installed in a recess in the housing.

6. Electrical connector according to claim 1, wherein the electrically conductive element exerts a force of between 1 and 50 newtons on the electrically insulating element.

7. Electrical connector according to claim 1, wherein the electrically conductive element is a helical spring compressed between the electrically insulating element and at least one of the first and second conductive components.

8. Connection assembly comprising a connector according to claim 1, and a mating connector comprising a housing that houses signal contacts that are configured so as to be integrated in the first low-voltage electrical line, these signal contacts being connected to the first conductive component when the connector and the mating connector are coupled.

9. Method for detecting overheating in a connection assembly, wherein the deformation of an electrically insulating element made of plastic, under stress from an electrically conductive element, is used to modify an electrical circuit.

10. Method according to claim 9, comprising an operation of collecting a signal by taking a series of electrical measurements on a first low-voltage line, furthermore comprising an operation of monitoring, over time, whether the signal collected in the course of the series of electrical measurements taken on the first low-voltage line undergoes a variation following a connection of the first low-voltage line to a second low-voltage line, this connection being the consequence of the deformation of the electrically insulating element.

11. Method according to claim 10, comprising an operation in which a first conductive component is connected to an interlock control circuit of a high-voltage circuit and the variation of the signal occurs following a connection of the first conductive component to a shielding element of the connector, by way of the electrically conductive element.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Other features and advantages of the invention will become apparent on reading the following detailed description, and from the appended drawings. In these drawings:

[0029] FIG. 1 schematically shows one exemplary embodiment of a connection assembly comprising a connector and a mating connector, before the connector and the mating connector are coupled;

[0030] FIG. 2 schematically shows the connection assembly shown in FIG. 1 after the connector and the mating connector have been coupled;

[0031] FIG. 3 schematically shows the connection assembly shown in FIG. 1 after the connector and the mating connector have been coupled and after deformation of a passive detection device for detecting overheating;

[0032] FIG. 4 schematically shows, from an electrical viewpoint, the state of the passive detection device for passively detecting overheating, before overheating;

[0033] FIG. 5 schematically shows, from an electrical viewpoint, the state of the passive detection device for passively detecting overheating, after overheating;

[0034] FIG. 6 schematically shows, in perspective, an example of one embodiment of a connector equipped with a passive detection device for detecting overheating;

[0035] FIG. 7 schematically shows a sectional view of the connector from FIG. 6;

[0036] FIG. 8 schematically shows, in perspective, one exemplary embodiment of a passive detection device for detecting overheating, as may be installed in a connector such as the one from FIG. 6;

[0037] FIG. 9 schematically shows, in elevation from its front face or coupling face, a detail of the connector from FIG. 6.

DETAILED DESCRIPTION

[0038] One example of a connection assembly 1 is shown schematically in FIG. 1. This connection assembly comprises a connector 100 configured so as to be coupled to a mating connector 200, parallel to a coupling direction A.

[0039] The connector 100 is a cable connector. The mating connector 200 is a receptacle configured so as to be installed on a wall 300 through which it passes. According to this example, the connector 100 is a female connector and the mating connector 200 is a male connector.

[0040] The connector 100 comprises in particular a housing 102, power contacts 104, a conductive component 106, a shielding element such as a shielding cage 108 and a passive detection device 110 for passively detecting potential overheating.

[0041] The housing 102 of the connector 100 is formed of one or more elements made of insulating plastic. The power contacts 104 are housed in chambers formed in the housing 102. These are female power contacts that are each respectively electrically connected to a cable 112. In this example, the conductive component 106 is an electrical contact blade with two flexible contact tabs 114 that are electrically connected to one another so as to form a shunt. The shielding cage 108 consists of one or more metal sheets made of electrically conductive material. The shielding cage 108 is configured so as to at least partially screen the electromagnetic waves generated by the flow of high currents through the connection assembly 1. The shielding cage 108 is in electrical contact with the individual shielding braids of the cables 112 (and/or with a shielding sheath common to multiple cables 112, this configuration not being shown).

[0042] The mating connector 200 comprises in particular a housing 202, power contacts 204, signal contacts 206 and a shielding element such as a shielding cage 208.

[0043] The housing 202 of the mating connector 200 is formed of one or more elements made of insulating plastic. The power contacts 204 are housed in chambers formed in the housing 202. These are male power contacts that are each respectively electrically connected to a cable 212. The signal contacts 206, of which there are two, are each respectively connected to an interlock control circuit 210 by electrical wires 214. The signal contacts 206 and the electrical wires 214 are therefore integrated in a first low-voltage electrical line. The interlock control circuit 210 controls the opening and the closure of the high-voltage circuit comprising the power contacts 204 of the mating connector 200.

[0044] The shielding cage 208 consists of one or more metal sheets made of electrically conductive material. The shielding cage 208 is configured so as to at least partially screen the electromagnetic waves generated by the flow of high currents through the connection assembly 1. The shielding cage is in electrical contact with the individual shielding braids of the cables 212 (and/or with a shielding sheath common to multiple cables 112, this configuration not being shown). The shielding cage 208 is also in electrical contact with the wall 300, which is itself connected to the ground of the vehicle.

[0045] The shielding cages 108, 208 are therefore intended to participate in a second low-voltage electrical line connected to the ground of the vehicle. As an alternative, the shielding cages 108, 208 are integrated in a low-voltage electrical line that is not connected to the ground of the vehicle.

[0046] When the connector 100 and mating connector 200 are coupled, the male power contacts 204 and female power contacts 104 are connected in pairs, the signal contacts 206 are connected to the conductive component 106, thereby closing the loop of the interlock control circuit 210, and the respective shielding cages 108, 208 of the connector 100 and mating connector 200 are in electrical contact with one another (thereby also potentially making it possible to connect the cage of the connector to the ground of the vehicle).

[0047] When the connector 100 and mating connector 200 are coupled, the interlock control circuit 210 controls and triggers the supply of power to the power contacts 204 (FIG. 2). Without overheating, the detection device 110 electrically insulates the conductive component 106 from the shielding cage 108 of the connector 100. The first and second low-voltage electrical lines are isolated from one another.

[0048] In the event of overheating of the connector 100 and/or the mating connector 200, the detection device 110 deforms and connects the conductive component 106 to the shielding cage 108 of the connector 100 (FIG. 3). The interlock control circuit 210 detects a variation in the signal measured on the loop of the interlock control circuit 210. For example, before overheating, the interlock control circuit 210 continuously measures a voltage that corresponds to a resistance R, representing the resistance of the electrical wires 214, of the signal contacts 206 and of the conductive component 106, and the contact resistances between these various elements. After overheating, the interlock control circuit 210 measures a voltage that corresponds to a resistance R′, representing the resistance of one of the electrical wires 214, of one of the signal contacts 206, of part of the conductive component 106 and of the detection device 110, and the contact resistances between these various elements. The variation between R and R′ is enough to signal a change of configuration in the detection device 110, this change resulting from overheating in the connection assembly 1. As an alternative, grounding the interlock control circuit renders it inoperative, thereby possibly causing the disconnection of the supply of power to the power contacts 104, 204.

[0049] The change of configuration of the detection device 110 is shown schematically in FIGS. 4 and 5. In FIG. 4, before overheating, there is no connection (practically infinite resistance in the detection device 110) between the second low-voltage electrical line 216 of the interlock control circuit 210 and the line 116 incorporating the shielding cage 108 (the first low-voltage electrical line 116 and second low-voltage electrical line 216 are isolated from one another). In FIG. 5, after overheating, the detection device 110 connects the second low-voltage electrical line 216 of the interlock control circuit 210 and the line 116 incorporating the shielding cage 108 (the first low-voltage electrical line 116 and second low-voltage electrical line 216 are connected to one another).

[0050] One particular exemplary embodiment of a connector 100 is described with reference to FIGS. 6 to 9 (FIG. 1).

[0051] According to this example, the connector 100 comprises an internal housing element 120, an external housing element 130, two shielding metal sheets 141, 142 forming the shielding cage 108, a conductive component 106, a detection device 110, and a coupling assistance device 150.

[0052] The shielding metal sheets 141, 142 are inserted between the internal housing element 120 and external housing element 130.

[0053] The detection device 110 comprises an electrically conductive element 160 and an electrically insulating element 170 (FIG. 8). The electrically conductive element 160 is a helical spring. The axial force Fx supplied by the electrically conductive element 160 is for example between 1 and 50 newtons. The electrically conductive element 160 is installed in a support 180. In the exemplary embodiment shown in FIG. 8, the support 180 is integral with the electrically insulating element 170, and consists of a material having a melting temperature of between 125° C. and 200° C. For example, said melting temperature is equal to or close to 180° C. For example, this polymer material is a polypropylene, a polyethylene or an epoxy.

[0054] The support 180 and the electrically insulating element 170 form one part having a U-shaped cross section. One of the branches of the U comprises an opening 182 for the passage of the electrically conductive element 160 (see FIG. 7). The other branch of the U corresponds to the insulating element 170 on which the electrically conductive element 160 bears and exerts a pressure corresponding to the axial force Fx.

[0055] When the detection device 110 is installed in the connector 100, the support 180 is surrounded in a recess formed in the internal housing element 120 of the connector 100, such that the electrically conductive element 160 is in electrical contact, via one of its axial ends, with the conductive component 106 (and more particularly one of its flexible tabs 114) and is insulated, at the other axial end, from the shielding metal sheet 141 by the insulating element 170 (FIG. 9).

[0056] The electrically insulating element 170 is therefore inserted between the electrically conductive element 160 and the shielding metal sheet 141. The thickness E of the electrically insulating element 170 thus inserted is for example between 0.5 millimetres and 2 millimetres. For example, this thickness E is equal to or close to 0.8 millimetres.

[0057] Thus, in the event of overheating, that is to say if the temperature in the connector becomes for example greater than or equal to 180° C., the insulating element softens and, under the effect of the pressure exerted by the electrically conductive element 160 on the electrically insulating element 170, the electrically conductive element 160 passes through the electrically insulating element 170 and establishes electrical contact with the shielding metal sheet 141.

[0058] It is possible to conceive of other variants of the detection device 110 described above. For example, an electrically insulating element 170 similar to the one described above may be inserted between the electrically conductive element 160 and the conductive component 106. As an alternative, the electrically insulating element 170 is inserted between the electrically conductive element 160 on one side and between the electrically conductive element 160 and the shielding cage 108 on another side.

[0059] Likewise, the shielding element may be formed of something other than a metal sheet (for example a housing element on which a conductive layer is deposited).

[0060] Likewise, the electrically conductive element may be other than a spring (for example a component that expands under the effect of heat).

[0061] The detection device may be installed in the mating connector 200, rather than in the connector 100, or else in the connector 100 and the mating connector 200.

[0062] Rather than a connection device 1 that makes it possible to connect two power cables 112, 212 in pairs, the connection device 1 may be designed to connect a single cable or more than two cables.

[0063] The connector and mating connector do not necessarily have shielding and/or are not necessarily connected to an interlock control circuit. In this case, the low-voltage lines may be dedicated lines or lines configured so as to transmit a signal.

[0064] Although the different examples have specific components shown in the illustrations, embodiments of this invention are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples.

[0065] Although an example embodiment has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of the claims. For that reason, the following claims should be studied to determine their true scope and content.