COMPONENT FOR HIGH-VOLTAGE SYSTEM OF A VEHICLE

Abstract

A component for a high-voltage electric system of a vehicle includes a hollow body having a circular cross section; a first contact arranged circumferentially in the body and configured to be externally exposed and to reach an interior of the body; a second contact arranged circumferentially in the body and configured to be externally exposed and to reach an interior of the body, the second contact separated from the first contact in the axial direction of the body; an axially movable connector element arranged within the body; and an electromagnetic relay to control axial movement of the connector element. The relay is configured so that actuation of the relay results in an axial movement of the connector element to form an electrical connection between the first contact and the second contact.

Claims

1. A component for a high-voltage electric system of a vehicle, the component comprising: a hollow body having a circular cross section; a first contact arranged circumferentially in the body and configured to be externally exposed and to reach an interior of the body; a second contact arranged circumferentially in the body and configured to be externally exposed and to reach an interior of the body, the second contact being separated from the first contact in the axial direction of the body; an axially movable connector element arranged within the body; and an electromagnetic relay arranged to control axial movement of the connector element, wherein the relay is configured so that actuation of the relay results in an axial movement of the connector element to form an electrical connection between the first contact and the second contact.

2. The component according to claim 1, wherein the connector element comprises a rod, a first flange attached to the rod and arranged to form a connection with the first contact and a second flange attached to the rod and arranged to form a connection with the second contact upon actuation of the relay.

3. The component according to claim 1, wherein at least one of the first and second contact extends into the interior of the body.

4. The component according to claim 1, wherein at least one of the first and second contact comprises a central opening through which the connector element is arranged.

5. The component according to claim 2, wherein the rod comprises an insulating sheath.

6. The component according to claim 5, wherein the insulating sheath comprises at least one opening enabling an electrical connection to be formed to the rod.

7. The component according to claim 1, further comprising a third and a fourth contact, each contact being arranged circumferentially in the body and configured to be externally exposed and to reach an interior of the body.

8. The component according to claim 7, wherein the third and fourth contact are low-voltage terminals.

9. The component according to claim 8, wherein the third and fourth contacts are connected to the electromagnetic relay to control actuation of the electromagnetic relay.

10. The component according to claim 1, wherein electromagnetic relay is a multi-stage electromagnetic relay.

11. The component according to claim 1, wherein the multi-stage electromagnetic relay comprises a first spring so that a first stage actuation of the relay requires a first actuation force and a second spring so that a second stage actuation of the relay requires a second actuation force higher than the first actuation force.

12. The component according to claim 1, further comprising a pyro fuse configured to destructively break the connection element upon actuation of the pyro fuse.

13. The component according to claim 1, further comprising a fifth contact arranged circumferentially in the body and configured to be externally exposed and to reach an interior of the body.

14. The component according to claim 1, wherein the body has a substantially cylindrical shape.

15. The component according to claim 1, wherein the body is tapered in a direction away from the cap.

16. The component according to claim 1, wherein at least one of the first and second contact area is threaded and configured to be threaded into a receiving socket.

17. The component according to claim 1, wherein further comprising a cap comprising a seal ring configured to form a seal against a socket.

18. A vehicle comprising a component according to claim 1.

19. A socket configured to receive a component according to claim 1.

20. A connector assembly comprising a component according to claim 1 and a socket configured to receive the component.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] With reference to the appended drawings, below follows a more detailed description of aspects of the disclosure cited as examples.

[0026] FIG. 1 is a schematic illustration of an exemplary component according to one example of the inventive concept.

[0027] FIG. 2 is a schematic cross section view of an exemplary component according to one example of the inventive concept.

[0028] FIGS. 3A and 3B are a schematic cross section view of an exemplary component according to one example of the inventive concept.

[0029] FIG. 4 is a schematic cross section view of an exemplary component according to one example of the inventive concept.

[0030] FIG. 5 is a schematic illustration of an exemplary connector assembly according to one example of the inventive concept.

[0031] FIG. 6 is a schematic illustration of an exemplary vehicle according to one example of the inventive concept.

DETAILED DESCRIPTION

[0032] Aspects set forth below represent the necessary information to enable those skilled in the art to practice the disclosure.

[0033] Present solutions for replaceable components in high voltage systems for example include a removable service box which encapsulates previously stated components together with several additional components in one removable package. This drives significant cost and design complexity due to additional components required to secure ease of service while maintaining degree of safety and system integrity. Moreover, such solutions may also fail to meet increased serviceability requirements where it is desirable that certain components should be replaceable without having to visit a workshop or the like.

[0034] FIG. 1 is an exemplary component 100 for a high-voltage electric system of a vehicle and FIG. 2 is a cross section view of the component 100. The component comprises a hollow body 102 having a circular cross section. The body 102 is substantially cylindrical and the body 102 is made from an electrically insulating material. Moreover, the body 102 is preferably hermetically sealed and may also be gas filled, for example by an inert gas, in part to protect the elements within the body and also to reduce the risk of arcing or the like inside the component 100.

[0035] The component further comprises first and second electrically conductive contacts 106, 110 arranged circumferentially in the body 102 and configured to be externally exposed and to reach an interior of the body 102, wherein the second contact 110 is separated from the first contact 106 as seen in the axial direction of the body 102. Both the width and the separation distance of the first and second contacts 106, 110 can be selected to ensure that there is no arcing or currents between the first and second contacts 106, 110. The properties of the first and second contacts 106, 110 can thereby be based on the properties and requirements of a particular high-voltage electric system.

[0036] In the present description, the first and second contacts 106, 110 are illustrated to reach all the way around the component 100 to provide a circular contact area. However, the first and second contacts 106, 110 may equally well be sectioned and/or divided into separate area portions along the circumference of the component 100 while still providing the same technical effects and benefits as contacts reaching all the way around the component 100. The first and second contacts 106, 110 may for example be formed by metal rings, such as copper rings, to provide good electrical conductivity. Moreover, the first and second contacts 106, 110 are arranged to reach an interior of the body 102 to form an electrical connection from the outside of the component 100 to within the hollow body 102.

[0037] As illustrated in FIG. 2, the component 100 further comprises an axially movable connector element 200 arranged within the body 102, and an electromagnetic relay 202 arranged to control axial movement of the connector element 200. The relay 202 is configured so that actuation of the relay 202 results in an axial movement of the connector element 200 to form an electrical connection between the first contact 106 and the second contact 110 through the connector element 200.

[0038] As illustrated in FIG. 2, the connector element 200 comprises a rod 204, a first flange 206 attached to the rod 204 and arranged to form a connection with the first contact 106 and a second flange 208 attached to the rod 204 and arranged to form a connection with the second contact 110 upon actuation of the relay 202. In the illustrated example, the first and second flanges 206, 208 are tapered in a shape corresponding to a recess in the respective first and second contacts 106, 110 in order to ensure good mechanical and thereby electrical connection between the flange and the contact. At least the first contact 106 is thus open, i.e. ring-shaped, at a central portion of the contact and the rod 204 of the connector element 200 is arranged through the opening so that the rod 204 can move in an axial direction of the component 100. It should be noted that the exact shape of the contacts and the connector element 202 may be modified in many different ways while still providing the described functionality of the inventive concept.

[0039] Moreover, the rod 204 of the connector element 200 comprises an insulating sheath 210 which is arranged around the rod 204 to prevent an electrical contact between the rod 204 and the first contact 106 when the connector element is in a non-actuated position.

[0040] The electromagnetic relay 202 is here represented by a spring loaded connection element 202 arranged together with a solenoid 216. The spring 214 is arranged to maintain the component in a disconnected state when no voltage is applied to the solenoid. Once a sufficiently high voltage is applied to the solenoid 202, an electromagnetic force acts on the connector element 202 to overcome the spring force and to form an electric connection between the first contact 106 and the second contact 110 through the rod 204.

[0041] The illustrated component 100 further comprises a cap 114 attached to an end portion 118 of the body 102. The cap 114 is here is here represented by a circular plate at the end portion 118 of the body 102 and the cap 114 is further illustrated to comprise a seal 120 in the form of a rubber gasket or the like configured to form an environmental seal when the component 100 is arranged in a corresponding socket. In general, the seal 120 may comprise an O-ring or a washer. It should however be noted that both the end cap 114 and the seal 120 may be configured in many different ways while still providing the desired functionality.

[0042] In some examples, the component 100 further comprises third and fourth contacts 115, 116 each arranged circumferentially on the body, and configured to be externally exposed and to reach an interior of the body. The third and fourth contacts 115, 116 are for example low-voltage terminals and the third and fourth contacts 115, 116 can consequently be made smaller as illustrated in FIGS. 1-2 since they do not have to carry the same amount of current as the high-voltage contacts 106, 110. The low-voltage terminals 115, 116 may for example provide gnd and vcc terminals for control signals for actuation of the electromagnetic relay 202. The third and fourth contacts 115, 116 are thereby electrically connected to a device within the component. In the present context, a low voltage is typically in the range below 48V, such as nominal voltage values of 3.3 V, 5 V, 12 V or 24 V to be used for control signals. High-voltage in the present context refers to voltages above 48 V, and in a high-voltage electric system of a vehicle the high voltage may be the so called traction voltage with voltages in range between 500 V and 900 V. The skilled person readily realizes that the number of terminals for both high-voltage and low-voltage connections can be increased or decreased depending on the required functionality for a particular application.

[0043] FIGS. 3A-B schematically illustrate an example where the component further comprises a fifth contact 304 arranged circumferentially in the body 102 and configured to be externally exposed and to reach an interior of the body 102. The fifth contact 304 is here arranged between the first and second contacts 106, 110 as seen in an axial direction of the cylindrical body 102 of the component 300. Moreover, the insulating sheath 210 of the rod 204 comprises an opening 212 enabling an electrical connection to be formed between the rod 204 and the fifth contact 304.

[0044] In example illustrated in FIGS. 3A-B, the electromagnetic relay is a multi-stage electromagnetic relay meaning that the relay can be controlled to actuate the connector element 200 in several distinct stages. The multi-stage electromagnetic relay 202 comprises a first spring 214 so that a first stage actuation of the relay requires a first actuation force and a second spring 302 so that a second stage actuation of the relay requires a second actuation force higher than the first actuation force.

[0045] FIG. 3A illustrates the first stage of actuation where the connector element 200 is moved in an axial direction away from the cap 114 but without forming a connection between the first and second contacts 106, 110 since the flange 208 of the connector element 200 is not in contact with the corresponding contact 110 of the component. Instead, a connection is formed between the first contact 106 and the fifth contact 304 via the rod 204 and through the opening 212 in the insulating sheath 210. The fifth contact 304 can for example be used to connect a battery to an external pre-charge resistor in a first stage of connection. In some examples, the component may be connected to another component of similar configuration which comprises the pre-charge resistor.

[0046] FIG. 3B illustrates the second stage of actuation where the connector element is fully actuated and moved in a direction away from the cap 114 so that an electrical connection is formed between the first contact 106 and the second contact 110, for example to fully connect an energy storage system of a vehicle to power consumers such as traction motors. In particular, the first contact 106 is connected directly to the rod 204 and the second contact 110 forms a contact to a flange 208 of the connector element 200. However, electrical connection between the first contact and the connector element may also be formed using a flange as illustrated in FIG. 2, and other configurations of the connector element are possible to achieve the described two stage connection.

[0047] In an example illustrated in FIG. 4, the component 400 further comprises a pyro fuse 402 configured to destructively break the connection element 200 upon actuation of the pyro fuse.

[0048] The pyro fuse 402 could for example be controlled via the same PWM signal that controls the electromagnetic relay 202. For example, 100% duty cycle of PWM could be configured to blow the pyro fuse. It would also be possible to provide additional circumferentially arranged low-voltage contacts to provide a control signal for triggering the pyro fuse 402.

[0049] FIG. 5 schematically illustrate a socket 500 configured to receive a component 100. The socket 500 and component together form a connector assembly 502. In the illustrated example, the socket 500 comprises a first electrical spring contact 504 arranged to form a contact with the first contact 106 and a second electrical spring contact 506 arranged to form a contact with the second contact 110 of the connector. The first and second electrical spring contacts 504, 506 are configured to have an inner diameter which is smaller than an outer diameter of a respective contact 106, 110 such that the central portion 508 of the spring contact 504, 506 press against the respective contact area 106, 110 when the component 100 is inserted into the socket 500, thereby forming an electrical connection between the component and the socket 500.

[0050] The socket 500 may advantageously also be configured to prevent or at least reduce the risk of insertion of foreign objects into the socket when no component is installed therein. The socket may for example comprises a seal (not shown) which both prevent insertion of foreign objects, and which protects the interior of the socket from dirt, water and the like when no component is installed.

[0051] FIG. 6 is a schematic illustration of an exemplary vehicle 600 comprising a component 100 according to one example of the inventive concept. Here it is illustrated that the component is easily accessible for improved serviceability of the vehicle 600.

[0052] Example 1. A component (100) for a high-voltage electric system of a vehicle, the component comprising: [0053] a hollow body (102) having a circular cross section; [0054] a first contact (106) arranged circumferentially in the body and configured to be externally exposed and to reach an interior of the body; [0055] a second contact (110) arranged circumferentially in the body and configured to be externally exposed and to reach an interior of the body, the second contact being separated from the first contact in the axial direction of the body; [0056] an axially movable connector element (200) arranged within the body; and [0057] an electromagnetic relay (202) arranged to control axial movement of the connector element, wherein the relay is configured so that actuation of the relay results in an axial movement of the connector element to form an electrical connection between the first contact and the second contact.

[0058] Example 2. The component according to example 1, wherein the connector element comprises a rod (204), a first flange (206) attached to the rod and arranged to form a connection with the first contact and a second flange (208) attached to the rod and arranged to form a connection with the second contact upon actuation of the relay.

[0059] Example 3. The component according to example 1 or 2, wherein at least one of the first and second contact extends into the interior of the body.

[0060] Example 4. The component according to any one of the preceding examples, wherein at least one of the first and second contact comprises a central opening through which the connector element is arranged.

[0061] Example 5. The component according to any one of examples 2 to 4, wherein the rod comprises an insulating sheath (210).

[0062] Example 6. The component according to example 5, wherein the insulating sheath (210) comprises at least one opening (212) enabling an electrical connection to be formed to the rod.

[0063] Example 7. The component according to any one of the preceding examples, further comprising a third and a fourth contact (115, 116), each contact being arranged circumferentially in the body and configured to be externally exposed and to reach an interior of the body.

[0064] Example 8. The component according to example 7, wherein the third and fourth contact are low-voltage terminals.

[0065] Example 9. The component according to example 8, wherein the third and fourth contacts are connected to the electromagnetic relay to control actuation of the electromagnetic relay.

[0066] Example 10. The component according to any one of the preceding examples, wherein electromagnetic relay is a multi-stage electromagnetic relay.

[0067] Example 11. The component according to any one of the preceding examples, wherein the multi-stage electromagnetic relay comprises a first spring (214) so that a first stage actuation of the relay requires a first actuation force and a second spring (302) so that a second stage actuation of the relay requires a second actuation force higher than the first actuation force.

[0068] Example 12. The component according to any one of the preceding examples, further comprising a pyro fuse (402) configured to destructively break the connection element upon actuation of the pyro fuse.

[0069] Example 13. The component according to any one of the preceding examples, further comprising a fifth contact (304) arranged circumferentially in the body and configured to be externally exposed and to reach an interior of the body.

[0070] Example 14. The component according to any one of the preceding examples, wherein the body has a substantially cylindrical shape.

[0071] Example 15. The component according to any one of the preceding examples, wherein the body is tapered in a direction away from the cap.

[0072] Example 16. The component according to any one of the preceding examples, wherein at least one of the first and second contact area is threaded and configured to be threaded into a receiving socket.

[0073] Example 17. The component according to any one of the preceding examples, wherein further comprising a cap comprising a seal ring (120) configured to form a seal against a socket.

[0074] Example 18. A vehicle comprising a component according to any one of the preceding examples.

[0075] Example 19. A socket configured to receive a component according to any one of examples 1 to 17.

[0076] Example 20. A connector assembly comprising a component according to any one of examples 1 to 17 and a socket configured to receive the component.

[0077] The terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting of the disclosure. As used herein, the singular forms a, an, and the are intended to include the plural forms as well, unless the context clearly indicates otherwise. As used herein, the term and/or includes any and all combinations of one or more of the associated listed items. It will be further understood that the terms comprises, comprising, includes, and/or including when used herein specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

[0078] It will be understood that, although the terms first, second, etc., may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element without departing from the scope of the present disclosure.

[0079] Relative terms such as below or above or upper or lower or horizontal or vertical may be used herein to describe a relationship of one element to another element as illustrated in the Figures. It will be understood that these terms and those discussed above are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. It will be understood that when an element is referred to as being connected or coupled to another element, it can be directly connected or coupled to the other element, or intervening elements may be present. In contrast, when an element is referred to as being directly connected or directly coupled to another element, there are no intervening elements present.

[0080] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0081] It is to be understood that the present disclosure is not limited to the aspects described above and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the present disclosure and appended claims. In the drawings and specification, there have been disclosed aspects for purposes of illustration only and not for purposes of limitation, the scope of the inventive concepts being set forth in the following claims.