Connector for coupling an electric motor to a power source

• US 8,523,576 B2
• Filed: 10/24/2011
• Issued: 09/03/2013
• Est. Priority Date: 10/24/2011
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations LLC (General Motors Company)
• Inventors: Heien, Stephen G., Chang, Jimmy M.
• Primary Examiner(s): Gilman, Alexander
• Application Number:
  US13/280,082
• Publication Number:
  US 20130099562A1
• Time in Patent Office: 680 Days
• Field of Search: 439/34, 439/125, 439/890, 439/320, 310/71, 903/904, 903/915, 431/258
• US Class Current: 439/34
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 3/0069 relating to the isolation, e.g. ground fault or leak current
• CPC Class Codes: B60L 3/04 Cutting off the power supply under fault conditions protective devices and circuit arrangements in general H01H; H02H
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: H01R 13/5202 Sealing means between parts of housing or between housing part and a wall, e.g. sealing rings
• CPC Class Codes: H01R 13/743 integral with the housing
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

A connector is provided for coupling an electric motor of a vehicle to a power source. The connector comprises electrode and a connector housing receiving at least a portion of the electrode. The connector housing is configured to snap-fit into a powertrain housing of the vehicle via compliant flanges. In this way, the connector may be coupled to the vehicle powertrain housing without other fasteners.

Claims

1. A connector, comprising:

an electrode having a first end configured with a flattened portion having a hole formed therein for fastening to a terminal block within a vehicle powertrain housing and a second end configured to receive a mating end of a cable coupled to an inverter; and

a connector housing receiving at least a portion of the electrode and configured to snap-fit into a one of a plurality of connector openings in a connector block of a vehicle powertrain housing via compliant flanges positioned on the connector housing;

wherein, the connector may be coupled to the vehicle powertrain housing without other fasteners and wherein the inverter is coupled to the terminal block within the vehicle powertrain housing.

2. The connector of claim 1, wherein the electrode comprises aluminum or an aluminum alloy with nickel plating.

3. The connector of claim 1, wherein the mating end of the cable includes a housing having a hole formed therein for receiving a fastener to electrically couple the housing to the connector block of the vehicle powertrain housing providing electromagnetic interference protection to the interface between the connector and the mating end of the cable.

4. The connector of claim 1, wherein the electrode comprises copper or a copper alloy.

5. The connector of claim 1, wherein the connector housing comprises a polyphenylene sulfide plastic.

6. The connector of claim 1, wherein the connector housing includes a groove configured to receive an o-ring.

7. A connector, comprising:

an electrode having a first end configured to receive a mating end of a cable from an inverter and a second end configured with a flattened portion having a hole formed therein for fastening for electrically connecting to a terminal block of a vehicle powertrain; and

a connector housing receiving at least a portion of the electrode and having compliant flanges positioned on the connector housing and configured to deform slightly when pressed into one of a plurality of connector openings in a connector block of a vehicle powertrain housing and snap back to form a snap-fit connection with the connector block of the powertrain housing;

wherein, the connector may be coupled to the vehicle powertrain housing without other fasteners and wherein the inverter is coupled to the terminal block within the vehicle powertrain housing.

8. The connector of claim 7, wherein the electrode comprises aluminum or an aluminum alloy with nickel plating.

9. The connector of claim 7, wherein the electrode comprises copper or a copper alloy.

10. The connector of claim 7, wherein the connector housing comprises a polyphenylene sulfide plastic.

11. The connector of claim 7, wherein the connector housing includes a groove configured to receive an o-ring.

12. The connector of claim 7, wherein the mating end of the cable includes a housing having a hole formed therein for receiving a fastener to electrically couple the housing to the connector block of the vehicle powertrain housing providing electromagnetic interference protection to the interface between the connector and the mating end of the cable.

13. The connector of claim 7, wherein the flattened portion of the second end of the electrode has a hole formed therein for fastening to a the terminal block within the vehicle powertrain housing.

14. A connector, comprising:

an electrode having a first end configured to receive a mating end of a cable from an inverter and a second end having a flattened portion with a hole formed therein for fastening to a terminal block within a vehicle powertrain housing thereby forming an electrically connection to the terminal block the electrode also having a groove configured to receive an o-ring for forming a seal between the electrode and connector housing; and

a the connector housing being configured to receive at least a portion of the electrode and having compliant flanges positioned on the connector housing and configured to deform slightly when pressed into one of a plurality of connector openings in a connector block of the vehicle powertrain housing and snap back to form a snap-fit connection with the connector block of powertrain housing, the connector housing also having a groove configured to receive an o-ring for forming a seal between the connector and the powertrain housing;

wherein, the connector may be coupled to the vehicle powertrain housing without other fasteners and wherein the inverter is coupled to the terminal block within the vehicle powertrain housing.

15. The connector of claim 14, wherein the mating end of the cable includes a housing having a hole formed therein for receiving a fastener to electrically couple the housing to the connector block of the vehicle powertrain housing providing electromagnetic interference protection to the interface between the connector and the mating end of the cable.