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(11) | EP 4 800 848 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | AN ELECTRICAL CONNECTOR FOR ELECTRICALLY CONNECTING A FIRST CONDUCTOR ELEMENT AND A SECOND CONDUCTOR ELEMENT |
| (57) An electrical connector for electrically connecting a first and a second conductor
element, the connector comprising a bolt having a threaded outer portion arranged
for insertion through an opening in the first conductor element; an adapter having
an elongated body extending along an axial direction between a first and a second
end portion and arranged for insertion into a cylindrical opening of the second conductor
element, the cylindrical opening forming an inner contacting surface. The adaptor
comprises, an engagement portion having a through hole with an internal thread for
engaging with the threaded portion of the bolt, and an expandable portion having a
cylindrical outer contacting surface and arranged to expand outward radially as the
bolt is rotated relative to the adaptor so the cylindrical outer contacting surface
is pressed against the inner contacting surface for electrical connection and to secure
the relative position in the axial direction.
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TECHNICAL FIELD
[0001] The disclosure relates generally to electrical connectors. In particular aspects, the disclosure relates to an electrical connector for electrically connecting a first conductor element and a second conductor element. The disclosure can be applied to heavy-duty vehicles, such as trucks, buses, and construction equipment, among other vehicle types. Although the disclosure may be described with respect to a particular vehicle, the disclosure is not restricted to any particular vehicle.
BACKGROUND
[0002] A busbar is a critical component in electrical power distribution systems, particularly in high voltage applications, for distributing power from one or more sources to multiple devices, terminals or loads. The busbar may be understood as a conductive strip or bar, typically made from high-conductivity materials such as metals, e.g. copper or aluminum, which are designed to handle high current loads, making them ideal for the demanding electrical systems. In vehicles, such as heavy-duty vehicles, busbars are used to connect various critical components, such as batteries, alternators, and power distribution units, ensuring consistent and efficient power flow to essential systems like the engine, lighting, and advanced electronic controls. The busbars may provide a centralized point for electrical connections, replacing, for example, bulky and complex wiring harnesses with a more streamlined and organized solution. The use of busbars not only saves space, but also enhances the overall reliability and safety of the vehicle's electrical systems. The robust design of the busbars makes them withstand the harsh conditions often encountered in heavy-duty applications, including vibrations, high temperatures, and exposure to moisture and corrosive elements. By minimizing power losses and reducing the risk of electrical failures, busbars contribute to safety and the overall performance and longevity of heavy-duty vehicles.
[0003] While busbars offer numerous advantages, they also present certain limitations and challenges. By way of example, connecting the busbar to other conductor element may be challenging. Heat dissipation is a significant concern, as busbars can generate substantial heat due to high current flow. Moreover, installing and electrically connecting to a busbar involves several limitations and challenges as the rigid structure of the busbars can make the installation difficult, especially in confined or complex spaces, requiring precise alignment and support structures.
[0004] There is therefore a need for further development of busbar-based solutions for electrical power distribution. There is in particular a need for improved buss-bar based solutions enabling a more efficient assembly and installation, while providing the robust high-voltage electrical connections required by applications in heavy-duty vehicles.
SUMMARY
[0005] According to a first aspect of the disclosure, there is provided an electrical connector for electrically connecting a first conductor element and a second conductor element, wherein the electrical connector comprises: a bolt having a threaded outer portion and being arranged for insertion through an opening in the first conductor element; an adapter having an elongated body extending along an axial direction between a first end portion and a second end portion thereof and is arranged for insertion into a cylindrical opening of the second conductor element, the cylindrical opening forming an inner contacting surface; wherein the adaptor comprises, at the first end portion, an engagement portion having a through hole with an internal thread for threadably engaging with the threaded portion of the bolt, and at the second end portion, an expandable portion having a cylindrical outer contacting surface; wherein the expandable portion is arranged to expand outward radially as the bolt is rotated relative to the adaptor whereby the cylindrical outer contacting surface is pressed against the inner contacting surface such that an electrical connection is formed therebetween and whereby a relative position between the first and the second conductor elements is secured in the axial direction. The first aspect of the disclosure may seek to mitigate problems associated with assembly and alignment of electrical conductor elements. A technical benefit may include providing an electrical connector which allows for a more controlled and simplified assembly. A further technical benefit is that a simplified alignment of electrical components of power systems may be achieved. A more robust electrical connection between two conductor elements may further be provided. An improved high-voltage electrical connection may be provided, in particular applications in for heavy-duty vehicles. An electrical connector having a small foot-print may further be provided.
[0006] Optionally in some examples, including in at least one preferred example, the inner contacting surface and/or the cylindrical outer contacting surface are non-treaded surfaces. A technical benefit may include a smoother adjustment of the relative position between the first and the second conductor elements. The non-treaded surfaces may allow for an efficient electrical contact. Problems pertaining to localized field enhancement and discharges may be mitigated. A lower contact resistance may, moreover, be provided. Readjustment of the relative position between the first and the second conductor elements may, moreover, be simplified.
[0007] Optionally in some examples, including in at least one preferred example, the expandable portion comprises an expandable sleeve having one or more slits. A technical benefit may include that less force is required to expand the expandable portion. A more well-defined geometrical expansion may be obtained. The radius of the adaptor may thereby be efficiently increased at the expandable portion. The expandable sleeve may be flexible. The expandable sleeve may, by way of example, bent outward from the axial center of the adaptor, i.e. in a radial direction.
[0008] Optionally in some examples, the one or more slits may extend along the axial direction of the adaptor. A more uniform expansion along the axial direction of the adaptor may be achieved. The slits may be formed by recesses in the adaptor material. The slits may form elongated through holes.
[0009] Optionally in some examples, the slits may be equidistantly arranged around the circumference of the adaptor. A radially more uniform expansion may be achieved.
[0010] Optionally in some examples, including in at least one preferred example, the cylindrical outer contacting surface comprises one or more guiding elements extending in the axial direction at least partially between the first and second end portions of the adaptor and wherein the cylindrical opening correspondingly comprises one or more recesses for receiving the one or more guiding elements whereby the adaptor is slidably movable in relation to the second conductor element. A technical benefit may include that the relative motion of the first and the second conductor elements may be controlled with improved accuracy. A radial rotation of the adaptor relative to the second conductor element may be mitigated. A simpler assembly of the electrical connector may be achieved. The installation of the electrical connector may be simplified.
[0011] Optionally in some examples, including in at least one preferred example, an interior surface of the expandable portion comprises a wedge portion arranged to engage with a tip portion of the bolt such that the expandable portion is expanded radially outward. A technical benefit may include that an efficient expansion is provided. A more controlled radial movement of the movement of the cylindrical outer contacting surface may be achieved. The wedge portion may extend along a circumference of the interior surface. One or more wedge portions may be arranged at the interior surface. A plurality of wedge portions may be arranged in equidistantly around the circumference of the interior surface.
[0012] Optionally in some examples, including in at least one preferred example, the first conductor element is a busbar. A technical benefit may include that efficient and reliable power distribution is provided to or from the busbar via the electrical connector.
[0013] Optionally in some examples, including in at least one preferred example, the second conductor element forms part of a header or a fuse arrangement. A technical benefit may include that efficient and reliable power distribution is provided, for example, between the busbar and the header or fuse arrangement.
[0014] The wording header may be understood to refer to a conductor configured to facilitate transfer of current and voltage between different components or systems. By way of example, headers are arranged to handle the demands of high-power applications, ensuring reliable and efficient electrical connections, e.g. in applications such as vehicles, heavy-duty vehicles, for instance, electric vehicles. The header may comprise electrical connectors such as power outlets.
[0015] Optionally in some examples, including in at least one preferred example, the adaptor comprises a stopper element arranged to engage with an inner surface of the opening of the first conductor element such that the adapter is prevented to rotate in a rotation plane being perpendicular to the axial direction. A technical benefit may include that a relative rotational movement of the adaptor relative to the first conductor element is mitigated. A simplified assembly and installation of the electrical connector may be provided.
[0016] Optionally in some examples, including in at least one preferred example, the adapter comprises a clamping element arranged to clamp the first conductor element such that the adapter is prevented to rotate in a rotation plane being perpendicular to the axial direction. A technical benefit may include that a rotational movement of the adaptor relative to the first conductor element is mitigated. A simplified assembly and installation of the electrical connector may be provided.
[0017] Optionally in some examples, including in at least one preferred example, the expandable portion comprises a channel for receiving the bolt, and wherein the channel has a diameter that is smaller than the diameter of the bolt. A technical benefit may include that an efficient and uniform expansion of the expandable portion may be achieved.
[0018] Optionally in some examples, the channel may be extending in the axial direction across the length of the expandable portion.
[0019] Optionally in some examples, including in at least one preferred example at least the expandable portion of the adaptor comprises a metal, preferably copper. A technical benefit may include that an efficient expansion of the expandable portion may be achieved. An improved electrical connection may be provided.
[0022] Optionally in some examples, including in at least one preferred example, the expandable portion is in the shape of a right circular cylinder. A technical benefit may include that a more symmetric expansion of the expandable portion. An improved centering of the adaptor may be achieved.
[0023] According to a second aspect of the disclosure, there is provided a conductor element comprising an adaptor, the adaptor being slidable movable within a cylindrical opening of the conductor element, the cylindrical opening forming an inner contacting surface; wherein the adapter has an elongated body inserted into the cylindrical opening, the elongated body extending along an axial direction between a first end portion and a second end portion thereof; wherein the adaptor comprises, at the first end portion, an engagement portion having a through hole with an internal thread for receiving and threadably engaging with a threaded portion of a bolt, and at the second end portion, an expandable portion having a cylindrical outer contacting surface; wherein the expandable portion is arranged to expand outward radially as the bolt is rotated relative to the adaptor whereby the cylindrical outer contacting surface is pressed against the inner contacting surface such that an electrical connection is formed therebetween and whereby a relative position between the adaptor within the conductor element is secured in the axial direction.
[0024] Effects and features of the second aspect are to a large extent analogous to those described above in connection with the first aspect. Examples mentioned in relation to the first aspect are largely compatible with the second aspect.
[0025] Optionally in some examples, including in at least one preferred example, the adaptor further comprises a first stopper element and a second stopper element, wherein the first stopper element is arranged at a first distal end of the adaptor, the first distal end protruding out from the cylindrical opening at a first side of the conductor element, and wherein the second stopper element is arranged at a second distal end, the second distal end protruding out from the cylindrical opening at a second side, the second side being opposite to the first side whereby the stopper elements are preventing disassembly of the adaptor and the conductor element. A technical benefit may include that the conductor element is simpler to handle and install. The conductor element may be translated along the axial direction between the first and the second stopper elements.
[0026] Optionally in some examples, including in at least one preferred example, a spring element is arranged in between the first stopper element and the first side of the of the conductor element. A technical benefit may include that the adaptor is simpler to position in the axial direction relative to the conductor element. An improved alignment of two conductor elements may be achieved.
[0027] Optionally in some examples, the adaptor may be referred to as an electrically conductive plug.
[0028] The disclosed aspects, examples (including any preferred examples), and/or accompanying claims may be suitably combined with each other as would be apparent to anyone of ordinary skill in the art. Additional features and advantages are disclosed in the following description, claims, and drawings, and in part will be readily apparent therefrom to those skilled in the art or recognized by practicing the disclosure as described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] Examples are described in more detail below with reference to the appended drawings.
FIGs. 1a and 1b are exemplary schematic drawing of a prior art solution for mounting a busbar to a header according to an example.
FIG. 2a and 2b are exemplary schematic drawings of an electrical connector for electrically connecting a first conductor element and a second conductor element in a loose state (FIG. 2a), and in a tightened state (FIG. 2b) according to an example.
FIG. 2c is an exemplary schematic cross-section of a portion of FIG. 2a.
FIG 2d is an exemplary schematic drawing illustrating that the second conductor element of FIGs. 2a and 2b may be a header.
FIGs. 3a and 3b are exemplary schematic drawings of an electrical connector for electrically connecting a first conductor element and a second conductor element in an unassembled state (FIG. 3a), and in an assembled and tightened state (FIG. 3b) according to an example.
FIGs. 4a and 4b are exemplary schematic drawings of an electrical connector for electrically connecting a first conductor element and a second conductor element in a loose state (FIG. 4a), and in a tightened state (FIG. 4b) according to another example.
FIGs. 5a to 5c are exemplary schematic drawings of an electrical connector for electrically connecting a first conductor element and a second conductor element according to yet another example.
FIGs. 6a to 6d are exemplary schematic drawings of a conductor element according to an example.
FIG. 7 is an exemplary schematic drawing of an electrical connector according to an example.
DETAILED DESCRIPTION
[0030] The detailed description set forth below provides information and examples of the disclosed technology with sufficient detail to enable those skilled in the art to practice the disclosure.
[0031] FIGs. 1a and 1b are exemplary schematic drawings of a prior art solution for mounting a busbar to a header according to an example. FIGs. 1a and 1b illustrates the problem of alignment when assembling and electrically connecting a solid busbar to a header for enabling high-voltage applications. Put differently, a general problem with the prior art solution is that it requires delicate and time-consuming alignment of the parts in order to prevent damage and/or damage to the parts. In more detail, FIG. 1a illustrates a busbar 10 and a header 12 to be electrically connected via a bolt 14.
[0032] FIG. 1a further illustrates a situation where a gap 16 between the busbar 10 and the header 12 is formed after assembly. As a result of the mismatch in the alignment, the header 12 may be deformed or bent 18 when the bolt 14 is tightened, see FIG. 1b. The bending of the header 12 is illustrated by the arrow 20. The possible misalignment of the prior art solutions may cause quality issues and damage. The additional alignment and/or connection of additional components with the header may further be problematic, see the dash-dotted line which illustrates a displacement and/or a bending angle relative to the centrally unperturbed axes, i.e. the dotted line.
[0033] As a result, existing solutions require careful alignment and realignment of parts reducing the flexibility to design components for electrical power distribution systems and increasing the labor for assembly.
[0034] With reference to FIGs. 2a to 2d an electrical connector is described. In more detail, FIG. 2a and 2b are exemplary schematic drawings of an electrical connector for electrically connecting a first conductor element and a second conductor element in a loose state (FIG 1a), and in a tightened state (FIG 1b) according to an example. FIG 2c is an exemplary schematic cross-section of a part FIG. 2a. FIG. 2d is an exemplary schematic drawing illustrating that the second conductor element of FIGs 2a and 2b may be a header 105. It is further illustrated in FIGs. 2a to 2c that the first conductor element 102 may be a busbar 103. For improved clarity, only a portion 107 of the header 105 is illustrated in FIGs 2a and 2b. See FIGs 2d for a more complete drawing of the header 105. The portion 107 of the header 105 may according to some examples be referred to a connection portion or a header cube of the header 105.
[0035] With further reference to FIGs. 2a to 2d it is illustrated that the electrical connector 100 is arranged to electrically connect a first conductor element 102, i.e. the busbar 103 and a second conductor element 104, i.e. the header 105. The electrical connector 100 comprises a bolt 106 having a threaded outer portion 108. The bolt 108 is arranged to be inserted through an opening 110 in the first conductor element 102.
[0036] The electrical connector 100 further comprises an adaptor 112. The adaptor 112 has an elongated body 114 extending along an axial direction 116 between a first end portion 118 and a second end portion 120 thereof. The elongated body 114 of the adaptor is arranged to be inserted into a cylindrical opening 122 of the second conductor element 104, compare FIGs. 2a and 2b. The cylindrical opening 122 in the second conductor element 104 forms an inner contacting surface 124. The inner contacting surface 124 is arranged to form an electrical contact with the adaptor 112.
[0037] In more detail, and with reference to FIGs. 2a to 2c, the adaptor 112 comprises, at the first end portion 118, an engagement portion 126 having a through hole 128 with an internal thread 130 for threadably engaging with the threaded outer portion 108 of the bolt 106. The adaptor 112 further comprises, at the second end portion 120, an expandable portion 132 having a cylindrical outer contacting surface 134. The expandable portion 132 is arranged to expand outward radially as the bolt 106 is rotated relative to the adaptor 112 whereby the cylindrical outer contacting surface 134 is pressed against the inner contacting surface 124. As a result, an electrical connection is formed therebetween. Put differently, an electrical connection is formed when the bolt is screwed into the adaptor. The relative position between the first and the second conductor elements 102,104 is moreover secured in the axial direction 116 by the friction caused in between the cylindrical outer contacting surface 134 and the inner contacting surface 124 as they are pressed against each other. The surfaces 124, 134 are clamped together.
[0038] The inner contacting surface 124 of the cylindrical opening 122 may be a non-treaded surface. The inner contacting surface 124 may be a polished surface. A smooth movement of the cylindrical outer contacting surface 134 relative to the inner contacting surface 124 may thereby be achieved. An improved alignment may be achieved.
[0039] Correspondingly, the cylindrical outer contacting surface 134 may be a non-treaded surface. The cylindrical outer contacting surface 134 may be a polished surface.
[0040] Thus, the inner contacting surface 124 and/or the cylindrical outer contacting surface 134 may non-treaded surfaces.
[0041] The expandable portion may be deformable whereby the radius of the adaptor is at least locally increased at the expandable portion.
[0042] The expandable portion 132 may comprise an expandable sleeve 136 having one or more slits 138, see e.g. FIGs. 2a and 2b. The one or more slits 138 may extend in the axial direction 116. The one or more slits 138 may be formed as recesses in the elongated body 114 of the adaptor 112. The one or more slits 138 may form through holes in the elongated body 114. The one or more slits 138 are here illustrated to extend along a portion of the elongated body 114. In other examples, the one or more slits 138 may extend the length of the elongated body 114. Segments formed in between the slits may be bent outward.
[0043] With reference to FIG. 2c, it is illustrated that an interior surface 144 of the expandable portion 130 may comprise a wedge portion 146. The wedge portion 146 is arranged to engage with a tip portion 148 of the bolt 106 such that the expandable portion 132 is expanded radially outward. Put differently, the wedge portion 146, arranged in or adjacent to the expandable portion 132, is arranged to induce an outward expansion as the bolt 106 is rotated relative to the adaptor 112, i.e. screwed into the adaptor 112. The radial expansion causes the cylindrical outer contacting surface 134 to be pressed against the inner contacting surface 124. The outward expansion is illustrated by the arrows 135 in FIG. 2c.
[0044] The expandable portion 132 may have the shape of a right circular cylinder. The expandable portion 132 may further comprise a channel 156 for receiving the bolt 106. The channel 106 may further have a diameter that is smaller than the diameter of the bolt 106, see FIG. 2c. As a result, the expandable portion 132 is forced outward as the bolt 106 is rotated relative to the adaptor 112, i.e. as the bolt is screwed into and propagates along the axial direction into the expandable portion. The cylindrical outer contacting surface 134 is thereby pushed outward radially to form an electrical contact with the inner contacting surface 124. The relative position of the surfaces 124, 134 are secured.
[0045] At least the expandable portion 132 of the adaptor 112 may be formed by a metal. The metal may be copper. The metal may be copper-tungsten alloy.
[0048] According to other example, the expandable portion and/or the whole adaptor may be made of a metallic material. By way of example, the metallic material may comprise silver, gold and/or nickel.
[0051] According to some examples, the bolt 106 may be made of an alloy of copper and zinc, e.g. brass. Brass may be used to improve conductivity and the resistance to corrosion.
[0052] According to some examples, the bolt 106 may be formed by stainless steel. Steel may be used for improving corrosion resistance and mechanical strength.
[0053] FIGs. 3a and 3b are exemplary schematic drawings of the installation of an electrical connector to electrically connect busbar to a header according to an example. In more detail, FIGs 3a and 3b illustrate that according to some examples, an electrical connector 100 arranged to electrically connect a first conductor element 102, i.e. the busbar 103, and the second conductor element 104, i.e. the header 105. The electrical connector 100 comprises a bolt 106 as described above, see also FIG. 3b. In FIG. 3a the electrical connector 100 is illustrated before the bolt is inserted into an opening 110 in the first conductor element 102. The opening 110 may be elongated in a direction along a transversal direction 111. The transversal direction 111 is perpendicular to an axial direction 116. A relative movement of the second conductor element 102 in the transversal direction may thereby be obtained. The assembly and alignment of the first and second conductor elements 102, 104 may thereby be simplified.
[0054] The electrical connector 100 further comprises an adapter 112. The adaptor 112 having an elongated body 114 extending along the axial direction 116. It is further illustrated that an elongated body 114 of the adaptor 112 has been inserted into the second conductor element 104.
[0055] The adaptor 112 may comprise a stopper element or a plurality of stopper elements 150. The stopper element or elements 150 are arranged to engage with an inner surface 152 of the opening 110 of the first conductor element 102. The adapter 112 may thereby be prevented from rotated in a rotation plane being perpendicular to the axial direction 116.
[0056] According to some examples the length of the opening 110 may be larger than the distance between the stopper elements in the transversal direction. A translation of the adaptor 112 within the opening 110 may thereby be achieved. The stopper elements 150 may be arranged to abut the inner surface 152 in a direction perpendicular to the transversal direction 111 and the axial direction 116.
[0057] In FIG. 3b it is illustrated when the bolt 106 have been inserted through the opening 110 in the first conductor element 102 and through a cylindrical opening 122 in the second conductor element 104. By use of the one or more stopper elements 150 the adapter 112 may be prevented from rotating during the fastening of the bolt 116 in the adaptor 112. A more efficient expansion of the expanding portion may, moreover, be obtained.
[0058] FIGs. 4a and 4b are exemplary schematic drawings of an electrical connector for electrically connecting a busbar and a header according to another example. In more detail, FIGs. 4a and 4b illustrate that according to some examples, an electrical connector 100 arranged to electrically connect a first conductor element 102, i.e. a busbar 103 and the second conductor element 104, i.e. a header 105. The electrical connector 100 comprises a bolt 106 as described above.
[0059] In FIG. 4a the electrical connector 100 is illustrated when a bolt 106 is inserted into an opening 110 in the first conductor element 102. The opening 110 is elongated in a direction along a transversal direction 111. The transversal direction 111 is perpendicular to the axial direction 116. A relative movement of the first conductor element 102 in the transversal 111 direction may thereby be obtained. The assembly and alignment of the first and second conductor elements 102, 104 may thereby be simplified.
[0060] The electrical connector 100 further comprises an adapter 112. The adaptor 112 having an elongated body 114 extending along the axial direction 116. It is further illustrated that an elongated body 114 of the adaptor 112 has been inserted into the second conductor element 104.
[0061] The adapter 112 comprises a clamping element or clamping elements 154. The one or more clamping elements 154 are arranged to clamp the first conductor element 102 such that the adapter 112 is prevented to rotate in a rotation plane being perpendicular to the axial direction 116. The one or more clamping elements 154 may be arranged to enable a transversal displacement of the fist conductor element 102 relative to the adaptor 112. This may be achieved by the clamping elements 154 protruding from the adaptor 112 and comprising a gripping portion arranged to grip around a transversal side portion 155 of the first conductor element 102.
[0062] In FIG. 4b it is illustrated when the bolt 106 have been fully fastened such that an electrical connection between the first and the second elements 102, 104 are formed. By use of the one or more clamping elements 154 the adapter 112 may be prevented from rotating during the fastening of the bolt 116. A more efficient expansion of the expanding portion may, moreover, be obtained.
[0064] The cylindrical outer contacting surface may comprise one or more guiding elements extending in the axial direction at least partially between the first and second end portions of the adaptor. The cylindrical opening may correspondingly comprise one or more recesses for receiving the one or more guiding elements whereby the adaptor is slidably movable in relation to the second conductor element.
[0065] FIGs. 5a to 5c are exemplary schematic drawings of an electrical connector comprising an adaptor for electrically connecting a first conductor element and a second conductor element according to an example. In more detail, FIG. 5a illustrates that the adaptor 112 is attached to the first conductor element 102. The adaptor 112 has an elongated body 114 extending along an axial direction 116 between a first end portion 118 and a second end portion 120 thereof. The adaptor 112 further comprises, at the first end portion 118, an engagement portion having a through hole with an internal thread for threadably engaging with the threaded outer portion of a bolt as described above. The adaptor 112 also comprises, at the second end portion 120, an expandable portion 132 having a cylindrical outer contacting surface 134.
[0066] It is exemplified in FIGs. 5a to 5c that the first conductor element 102 may be a busbar 103 and that the second conductor element 104 may be a header 105. The elongated body 114 of the adaptor is arranged to be inserted into a cylindrical opening 122 of the second conductor element 104, see FIG. 5b. The cylindrical opening 122 in the second conductor element 104 forms an inner contacting surface 124. With further reference to FIG. 5c, it is illustrated that that an electrical connection may be formed between the first and the second conductor elements 102, 104 by inserting the adaptor 112 inside the cylindrical opening 122 of the second conductor element 104. A bolt 106 having a threaded outer portion 108 is moreover inserted through an opening in the first conductor element 102 and inside the adaptor 112. By rotating and tightening the bolt 106 relative the adaptor 112, the expandable portion 132 is expanded an electrical contact is formed between the inner contacting surface 124 and the cylindrical outer contacting surface 134.
[0067] FIGs. 6a to 6d are exemplary schematic drawings of a conductor element according to an example. FIG. 6a shows the conductor element 104 comprising an adaptor 112. The adaptor 112 is slidable movable within a cylindrical opening 122 of the conductor element 104. The cylindrical opening 122 forms an inner contacting surface 124.
[0068] The adapter 112 has an elongated body 114 which is inserted into the cylindrical opening 122. The elongated body 114 is extending along an axial direction 116 between a first end portion 118 and a second end portion 120 thereof. The adaptor 112 comprises, at the first end portion 118, an engagement portion 126 having a through hole with an internal thread for receiving and threadably engaging with a threaded portion of a bolt. The bolt may according to some examples be referred to as a screw.
[0069] The adaptor 112 further comprises at the second end portion 120, an expandable portion 132 having a cylindrical outer contacting surface 134. The expandable portion 132 is arranged to expand outward radially, see the arrows 135 in FIG. 6b, as the bolt 106 is rotated relative to the adaptor 112. The cylindrical outer contacting surface 134 is thereby pressed against the inner contacting surface 124 such that an electrical connection is formed therebetween. To this end the relative position between the adaptor 116 within the conductor element 104 is secured in the axial direction 116. An electrical contact may thereby be formed between the two conductor elements 102, 104, see FIGs. 6b and 6c.
[0070] With further reference to FIGs. 6a to 6d, the cylindrical outer contacting surface 134 may comprise one or more guiding elements 140 extending in the axial direction 116 at least partially between the first and second end portions 118,120 of the adaptor 112. The cylindrical opening 122 correspondingly comprises one or more recesses 142 for receiving the one or more guiding elements 140. The adaptor 112 may thereby be slidably movable in relation to the second conductor element 104. A rotation of the adaptor 114 relative to the second conductor element 104 may thereby be mitigated. The extent of the elongated portion 114 of the adaptor 112 may be larger than the extension of the inner contacting surface in the axial direction.
[0071] The adaptor 112 may further comprises a first stopper element 160 and a second stopper element 162, see FIGs. 6b and 6d. The first stopper element 160 may be arranged at a first distal end 164 of the adaptor 112, the first distal end 164 protruding out from the cylindrical opening 122 at a first side 166 of the conductor element 104. The second stopper element 162 may be arranged at a second distal end 168 of the adaptor 112. The second distal end 168 is protruding out from the cylindrical opening 122 at a second side 170. The second side 170 is opposite to the first side 166. The stopper elements 160,162 are arranged to prevent disassembly of the adaptor 112 and the conductor element 104.
[0072] According to some examples, a spring element 172 is arranged in between the first stopper element 160 and the first side 166 of the of the conductor element 104, see FIG. 6b.
[0073] FIG. 7 is another view of FIG. 2a, according to an example. FIG. 7 illustrates schematically a cross-sectional view of an electrical connector 100 for electrically connecting a first conductor element 102 and a second conductor element 104, wherein the electrical connector 100 comprises: a bolt 106 having a threaded outer portion 108 and being arranged for insertion through an opening 110 in the first conductor element 102; an adapter 112 having an elongated body 114 extending along an axial direction 116 between a first end portion 118 and a second end portion 120 thereof and is arranged for insertion into a cylindrical opening 122 of the second conductor element 104, the cylindrical opening 122 forming an inner contacting surface 124;wherein the adaptor 112 comprises, at the first end portion 118, an engagement portion 126 having a through hole 128 with an internal thread 130 for threadably engaging with the threaded outer portion 108 of the bolt 106, and at the second end portion 120, an expandable portion 132 having a cylindrical outer contacting surface 134; wherein the expandable portion 132 is arranged to expand outward radially as the bolt 106 is rotated relative to the adaptor 112 whereby the cylindrical outer contacting surface 134 is pressed against the inner contacting surface 124 such that an electrical connection is formed therebetween and whereby a relative position between the first and the second conductor elements 102, 104 is secured in the axial direction 116.
[0074] Exemplary methods and systems are set out in the following items:
Example 1: An electrical connector 100 for electrically connecting a first conductor element 102 and a second conductor element 104, wherein the electrical connector 100 comprises:
a bolt 106 having a threaded outer portion 108 and being arranged for insertion through an opening 110 in the first conductor element 102;
an adapter 112 having an elongated body 114 extending along an axial direction 116 between a first end portion 118 and a second end portion 120 thereof and is arranged for insertion into a cylindrical opening 122 of the second conductor element 104, the cylindrical opening 122 forming an inner contacting surface 124;
wherein the adaptor 112 comprises, at the first end portion 118, an engagement portion 126 having a through hole 128 with an internal thread 130 for threadably engaging with the threaded portion 108 of the bolt 106, and at the second end portion 120, an expandable portion 132 having a cylindrical outer contacting surface 134;
wherein the expandable portion 132 is arranged to expand outward radially as the bolt 106 is rotated relative to the adaptor 112 whereby the cylindrical outer contacting surface 134 is pressed against the inner contacting surface 124 such that an electrical connection is formed therebetween and whereby a relative position between the first and the second conductor elements 102, 104 is secured in the axial direction 116.
Example 2: The electrical connector according to example 1, wherein the inner contacting surface 124 and/or the cylindrical outer contacting surface 134 are non-treaded surfaces.
Example 3: The electrical connector according to example 1 or 2, wherein the expandable portion 132 comprises an expandable sleeve 136 having one or more slits 138.
Example 4: The electrical connector according to any one of examples 1 to 3, wherein the cylindrical outer contacting surface 134 comprises one or more guiding elements 140 extending in the axial direction 116 at least partially between the first and second end portions 118,120 of the adaptor 112 and wherein the cylindrical opening 122 correspondingly comprises one or more recesses 142 for receiving the one or more guiding elements 140 whereby the adaptor 112 is slidably movable in relation to the second conductor element 104.
Example 5: The electrical connector according to any one of examples 1 to 4, wherein an interior surface 144 of the expandable portion 130 comprises a wedge portion 146 arranged to engage with a tip portion 148 of the bolt 106 such that the expandable portion 132 is expanded radially outward.
Example 6: The electrical connector according to any one of examples 1 to 5, wherein the first conductor element 102 is a busbar 103.
Example 7: The electrical connector according to any one of examples 1 to 6, wherein the second conductor element 104 forms part of a header 105 or a fuse arrangement.
Example 8: The electrical connector according to any one of examples 1 to 7, wherein the adaptor 112 comprises a stopper element 150 arranged to engage with an inner surface 152 of the opening 110 of the first conductor element 102 such that the adapter 112 is prevented to rotate in a rotation plane being perpendicular to the axial direction 116.
Example 9: The electrical connector according to any one of examples 1 to 8, wherein the adapter 112 comprises a clamping element 154 arranged to clamp the first conductor element 102 such that the adapter 112 is prevented to rotate in a rotation plane being perpendicular to the axial direction 116.
Example 10: The electrical connector according to any one of examples 1 to 9, wherein the expandable portion 132 comprises a channel 156 for receiving the bolt 106, and wherein the channel 106 has a diameter that is smaller than the diameter of the bolt 106.
Example 11: The electrical connector according to any one of examples 1 to 10, wherein at least the expandable portion 132 of the adaptor comprises a metal, preferably copper.
Example 12: The electrical connector according to any one of examples 1 to 11, wherein the expandable portion 132 is in the shape of a right circular cylinder.
Example 13: A conductor element comprising an adaptor, the adaptor 112 being slidable movable within a cylindrical opening 122 of the conductor element 104, the cylindrical opening 122 forming an inner contacting surface 124;
wherein the adapter 112 has an elongated body 114 inserted into the cylindrical opening 122, the elongated body 114 extending along an axial direction 116 between a first end portion 118 and a second end portion 120 thereof;
wherein the adaptor 112 comprises, at the first end portion 118, an engagement portion 126 having a through hole 128 with an internal thread 130 for receiving and threadably engaging with a threaded portion 108 of a bolt 106, and at the second end portion 120, an expandable portion 132 having a cylindrical outer contacting surface 134;
wherein the expandable portion 132 is arranged to expand outward radially as the bolt 106 is rotated relative to the adaptor 112 whereby the cylindrical outer contacting surface 134 is pressed against the inner contacting surface 124 such that an electrical connection is formed therebetween and whereby a relative position between the adaptor 116 within the conductor element 104 is secured in the axial direction 116.
Example 14: The conductor element of example 13, wherein the adaptor 112 further comprises a first stopper element 160 and a second stopper element 162, wherein the first stopper element 160 is arranged at a first distal end 164 of the adaptor 112, the first distal end 164 protruding out from the cylindrical opening 122 at a first side 166 of the conductor element 104, and wherein the second stopper element 162 is arranged at a second distal end 168, the second distal end 168 protruding out from the cylindrical opening 122 at a second side 170, the second side 170 being opposite to the first side 166 whereby the stopper elements 160, 162 are preventing disassembly of the adaptor 112 and the conductor element 104.
Example 15: The conductor element of example 14, wherein a spring element 172 is arranged in between the first stopper element 160 and the first side 166 of the of the conductor element 104.
[0075] 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, actions, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, actions, steps, operations, elements, components, and/or groups thereof.
[0076] 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.
[0077] 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.
[0078] 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.
[0079] 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 disclosure being set forth in the following claims.
a bolt (106) having a threaded outer portion (108) and being arranged for insertion through an opening (110) in the first conductor element (102);
an adapter (112) having an elongated body (114) extending along an axial direction (116) between a first end portion (118) and a second end portion (120) thereof and is arranged for insertion into a cylindrical opening (122) of the second conductor element (104), the cylindrical opening (122) forming an inner contacting surface (124);
wherein the adaptor (112) comprises, at the first end portion (118), an engagement portion (126) having a through hole (128) with an internal thread (130) for threadably engaging with the threaded portion (108) of the bolt (106), and at the second end portion (120), an expandable portion (132) having a cylindrical outer contacting surface (134);
wherein the expandable portion (132) is arranged to expand outward radially as the bolt (106) is rotated relative to the adaptor (112) whereby the cylindrical outer contacting surface (134) is pressed against the inner contacting surface (124) such that an electrical connection is formed therebetween and whereby a relative position between the first and the second conductor elements (102, 104) is secured in the axial direction (116).
wherein the adapter (112) has an elongated body (114) inserted into the cylindrical opening (122), the elongated body (114) extending along an axial direction (116) between a first end portion (118) and a second end portion (120) thereof;
wherein the adaptor (112) comprises, at the first end portion (118), an engagement portion (126) having a through hole (128) with an internal thread (130) for receiving and threadably engaging with a threaded portion (108) of a bolt (106), and at the second end portion (120), an expandable portion (132) having a cylindrical outer contacting surface (134);
wherein the expandable portion (132) is arranged to expand outward radially as the bolt (106) is rotated relative to the adaptor (112) whereby the cylindrical outer contacting surface (134) is pressed against the inner contacting surface (124) such that an electrical connection is formed therebetween and whereby a relative position between the adaptor (116) within the conductor element (104) is secured in the axial direction (116).