US-12628291-B2 - Component for high-voltage system of a vehicle

US12628291B2US 12628291 B2US12628291 B2US 12628291B2US-12628291-B2

Abstract

A component for a high-voltage electric system of a vehicle includes a body having a circular cross section; an electrical device encapsulated within the body; a first electrically conductive contact area arranged circumferentially on the body and configured to form a first electrical connection to the electrical device; a second electrically conductive contact area arranged circumferentially on the body and configured to form a second electrical connection to the electric device, the second electrically conductive contact area being separated from the first electrically conductive contact area in the axial direction of the body; a cap attached to an end portion of the body; and a fastening mechanism configured to secure the component in a socket.

Inventors

Ringolds JARGANS
Diego Santos Pereira Netto

Assignees

VOLVO TRUCK CORPORATION

Dates

Publication Date: 20260512
Application Date: 20231130
Priority Date: 20221219

Claims (20)

1 . A component for a high-voltage electric system of a vehicle, the component comprising: a body having a circular cross section; an electrical device encapsulated within the body; a first electrically conductive contact area arranged circumferentially on the body and configured to form a first electrical connection to the electrical device; a second electrically conductive contact area arranged circumferentially on the body and configured to form a second electrical connection to the electric device, the second electrically conductive contact area being separated from the first electrically conductive contact area in the axial direction of the body, each of the first and second electrically conductive contact area being located at an axial distance from and separate from a respective end portion of the body; a cap located at and attached to an end portion of the body; and a fastening mechanism configured to secure the component in a socket.
2 . The component according to claim 1 , wherein the body has a substantially cylindrical shape.
3 . The component according to claim 1 , wherein the body is tapered in a direction away from the cap.
4 . The component according to claim 1 , wherein the electrical device is a contactor, a fuse or a pre-charge resistor.
5 . The component according to claim 1 , wherein the first contact area and the second contact area are configured to form a first high-voltage terminal connected to a corresponding first terminal of the electric device, and a second high-voltage terminal connected to a corresponding second terminal of the electric device.
6 . 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.
7 . The component according to claim 1 , further comprising third and fourth contact areas each arranged circumferentially on the body.
8 . The component according to claim 7 , wherein the third and fourth contact areas are low-voltage terminals.
9 . The component according to claim 1 , wherein the cap comprises a seal configured to form a seal against a socket.
10 . The component according to claim 1 , wherein the fastening mechanism comprises a bayonet coupling, a threaded coupling, a snap coupling, or a push-lock coupling.
11 . The component according to claim 1 , wherein an outer portion of the cap comprises a protruding element configured to be engaged by a tool or by hand.
12 . The component according to claim 1 , wherein an outer portion of the cap comprises a recess configured to be engaged by a tool.
13 . The component according to claim 1 , wherein a diameter of the body is stepwise decreasing in a direction away from the cap.
14 . A vehicle comprising a component according to claim 1 .
15 . A socket configured to receive a component according to claim 1 .
16 . A connector assembly comprising a component according to claim 1 and a socket configured to receive the component.
17 . The connector assembly according to claim 15 , wherein the socket comprises a first electrical spring contact arranged to form a contact with the first contact area and a second electrical spring contact arranged to form a contact with the second contact area.
18 . The connector assembly according to claim 16 , wherein the socket comprises a receiving mechanism configured to engage the fastening mechanism of the component such that the component is secured in the socket.
19 . The connector assembly according to claim 16 , wherein the socket comprises a seal configured to form a seal against the cap of the connector.
20 . A vehicle comprising a connector assembly according to claim 15 .

Description

TECHNICAL FIELD The disclosure relates generally to a component for a high-voltage system in a vehicle. In particular aspects, the disclosure relates to a component comprising an electrical device arranged within the component. The disclosure can be applied in heavy-duty vehicles having a high-voltage system, such as trucks, buses, and construction equipment. Although the disclosure may be described with respect to a particular vehicle, the disclosure is not restricted to any particular vehicle. BACKGROUND With the increasing use of electric and hybrid propulsion systems in heavy vehicle, it also becomes increasingly important to provide high-voltage systems which are reliable and easily serviceable. In particular, components which are subjected to wear, and which may require replacement are advantageously easily replaceable in the vehicle. Preferably, it should be possible to remove and replace components in a high-voltage system such as contactors, fuses and pre-charge components within a matter of minutes and without having to take the vehicle to a workshop. Accordingly, it is desirable to provide improved components for high-voltage systems which facilitate fast and easy replacement. SUMMARY According to a first aspect of the disclosure, it is provided a component for a high-voltage electric system of a vehicle, the component comprising: a body having a circular cross section; an electrical device encapsulated within the body; a first electrically conductive contact area arranged circumferentially on the body and configured to form a first electrical connection to the electrical device; a second electrically conductive contact area arranged circumferentially on the body and configured to form a second electrical connection to the electric device, the second contact area being separated from the first contact area in the axial direction of the body; a cap attached to an end portion of the body; and a fastening mechanism configured to secure the component in a socket. The first aspect of the disclosure seeks to provide an improved high-voltage component for a vehicle which is both safe as well as fast and easy to replace when needed. A technical benefit may include that the described component provides a plug-n-play functionality where the component is ready to be used as soon as it is installed and that the component can easily be accessed from an outside of the high-voltage electric system. A further advantage of the described component is that no alignment is required which significantly reduces the risk of a faulty installation. It is also possible to configure the component so that it can be installed and removed without using tools. In some examples, the body has a substantially cylindrical shape. The body thus has a circular cross-section which has substantially the same diameter over the length of the component, with the exception of the cap which may have a larger diameter. A technical benefit may include that the component is easy to install and that the component does not require alignment when being installed. Moreover, a cylindrical shape enables the use of many commonly used fastening mechanisms. In some examples, the body is tapered in a direction away from the cap. The body thus has a circular cross-section which has a decreasing diameter over the length of the component in a direction away from the cap. A technical benefit may include that the component may more easily fit into a correspondingly conical socket. In some examples, the electrical device is a contactor, a fuse or a pre-charge resistor. A technical benefit may include that since the aforementioned devices are subject to wear during use of the vehicle, it is advantageous that they are easy to replace. The devices may thus be enclosed within the component. In some examples, the first contact area and the second contact area are configured to form a first high-voltage terminal connected to a corresponding first terminal of the electric device, and a second high-voltage terminal connected to a corresponding second terminal of the electric device. Each of the first and second contact area can thereby act as a respective high-voltage terminal to connect a two-terminal device to a high voltage system of the vehicle. Then number of high voltage terminals can be increased if required by the device or if multiple devices are arranged in the same component. In some examples, at least one of the first and second contact area is threaded and configured to be threaded into a receiving socket, thereby forming a fastening mechanism or part of a fastening mechanism of the component. A technical benefit may include that a good electrical and mechanical connection can be ensured by the threaded contact areas when the component is installed in a socket. Moreover, the threaded connection may be sufficient so that no further fastening mechanism is required, thereby simplifying the design of the component. In some examples, the component further com