Description of the invention

As demonstrated previously, there is a real need to provide a solution in response to the technical problem of improving the insulation of the flat conductors constituting the laminated connectors (in particular at the edges) and of the application of the chosen insulating material, while keeping manufacturing cost reasonable and increasing productivity.

The invention described in the present application responds to this need, by proposing an economically attractive solution and increased performance for connectors produced according to the prescribed method, which in all or part does not require the use of films.

To do this, the invention relates first of all to a method of manufacturing a connector device capable, among other things, of making an inter or intra static converter (s) connection of electrical energy (power module circuits, capacitors , filters, connectors,...), said device comprising at least two flat conductors and at least one insulating material disposed between the aforementioned two conductors, said method is characterized in that:

• the flat conductors possibly prepared in a tank are positioned in a geometric position such that the conductors are kept parallel and spaced apart by a value at least equal to the thickness of the desired insulation, said conductors having a preferential orientation,

• said prepared flat conductors are impregnated with at least one impregnation resin introduced into the tank, said impregnation resin having physicochemical characteristics allowing it to be maintained in the form of a coating layer on all of the accessible faces said flat conductors prepared after at least the latter have been extracted from said tank,

• the device is extracted from said tank, and

• the crosslinking of said impregnation resin is carried out.

Advantageously, the conductors are placed in a positioning device that does not generate spatial constraints at the level of the external dimensions of said device before introduction of the resin.

The term “positioning device which does not generate spatial constraints at the level of the external dimensions of said device” is understood to mean a positioning device which has no influence, during the manufacture of the device and / or at the level of the device. finalized, on the external dimensions of said device.

By way of non-limiting example, and unlike the positioning device provided by the invention, a mold (for example: for casting or injection) generates spatial constraints at the level of the external dimensions of a connector device designed for help from it.

Indeed, the particular external conformation of the manufactured connector device is complementary to that of the mold used. The mold constrains (retains) spatially (in space, in volume) the material cast or injected into it. According to the invention, the combination of the gap between the conductors and the specific features of the liquid resin which, during the extraction, allow the liquid resin to be held in place without the need for a mold.

According to the invention, the preparation step advantageously comprises at least one step of placing at least one savings. These savings are for example preferably chosen from the group comprising: stoppers (for example: in elastic material resistant to heat, and / or waterproof, and / or mechanically fixed, and / or in non-adherent material), adhesives (for example : peelable adhesives). The savings can all be of the same nature or be mixed. They can be reusable or single use. Nevertheless, a person skilled in the art knows how to choose the nature of the savings, and their number according to the needs of the device to be manufactured. The savings are intended to protect the conductive surfaces on which the components are fixed, these surfaces not having to be covered with insulation.

Also, the method comprises a step consisting in placing said prepared flat conductors in an initial geometric position in said positioning device.

Preferably, said initial geometric position corresponds to a manufacturing position, and even more preferably to a position E x apart if the positioning device can be actuated. The initial position corresponds to the clamped end position S if the positioning device cannot be actuated. Moreover, according to the invention, the method comprises the installation of spacers of given thickness to maintain a chosen spacing between the conductors. More preferably, the assembly is carried out by the resin "through" the positioning device, that is to say it is not possible to distinguish an inlet and / or an outlet defined for said device. positioning (unlike for example a mold,

Depending on the variant of the method chosen, the step of collecting the connector device may, among other things, require:

• to separate the positioning device (and therefore the frame, and / or any other element which constitutes it, when said positioning device has one), and / or

• to separate savings if they exist.

The invention also relates to any connector device which can be obtained by implementing the method described above. Said connector device is, among other things, able to make an inter or intra static converter (s) connection of electrical energy, that is to say that it is suitable and capable of being used in order to make a connection. :

• Intra-converter, ie for example:

o between at least two power modules (as defined above) belonging to the same converter, or o inside a power module, for example: between at least two semiconductor chips, or between a semi-conductor chip - conductor and an external connection, or

• Inter-converters, ie between at least two converters, for example.

Thus, the invention relates in particular to a connector device obtained via the proposed manufacturing method, said device being remarkable in that it comprises at least two flat conductors and at least one insulating material such as a resin acting as an insulator and / or assembly means.

As previously described, multilayer connector devices are generally made of a complex of flat conductors and insulating material (s).

According to the invention, the flat conductors are preferably made of copper or aluminum. Advantageously (but not necessarily) the conductors are protected by a surface treatment, such as among others: tinning, nickel plating, silver plating. Preferably, the conductors have a thickness of between 1 and 4 millimeters.

The conductor manufacturing process (for example: punching, bending, injection, casting) is irrelevant, and a person skilled in the art knows how to choose the process best suited to the intended application.

Finally, the invention can be used for various purposes (laminated busbars of static electric energy converters, internal laminated busbars of power semiconductor modules, etc.), and the Applicant notably claims the use of any connector device proposed. , obtained by the implementation of the method presented, as connector inter or intra static converter (s) of electrical energy.

Description of the drawings

The invention will be clearly understood with the aid of the following description (by way of non-limiting example) of the drawings illustrating the interconnection device and the associated manufacturing process, where:

FIG. 1 shows a manufacturing positioning device of a connector device with the flat conductors associated with it in its initial manufacturing position and of any intermediate position (s).

FIG. 2 represents the same positioning device with the connector device in the final manufacturing position. A detail of the different layers of varnish or resins and conductors is shown. FIGS. 3 to 5 represent different stages of the manufacturing cycle of the connector device placed in an impregnation tank.

Description of general embodiments of the invention

According to Figures 1 to 3, the method according to the invention allows the manufacture of a connector device 1. This device 1 (and its steps / manufacturing principle) shown in Figures 1 and 2, in its geometric positioning device 40, thus comprises at least two flat conductors 2 and at least one insulating material 30.

Preferably, said device 1 is in multi-layered form, that is to say that it is possible to distinguish all of the various layers of materials which constitute it.

Advantageously, the insulating material 30 is one of: the resin (s) 31, the spacer (s) 32.

When the insulating material 30 is a spacer 32, the latter is preferably in at least partial contact with the conductors 2. However, in complex variants of the device, it is for example possible to combine the positions of the resins and of the spacers; the spacer can for example be placed between conductors 2 coated with enameling resin, so as to guarantee a predefined spacing which will subsequently be filled by at least one impregnating resin.

The term “spacer” 32 is understood to mean an element separating at least two consecutive conductors 2. Optionally, several spacers (32) can also come into contact with each other when the arrangement of the device 1 requires it. Advantageously, said spacer 32 consists of at least one material that is not or only slightly compressible. Preferably, said spacer 32 is made of at least one electrically insulating material 30. Most preferably, the outer surface of said spacer 32 is made of an insulating material 30.

Said spacer 32 may be solid. However, in preferred variants of the invention, said spacer 32 is porous. In advanced variants of the invention, the device 1 comprises both: solid spacer (s) 33, porous spacer (s) 34. A person skilled in the art knows how to choose the most appropriate characteristics for the spacer 32, according to the specific needs of the intended application. Advantageously, when the spacer 32 is full, said spacer 32 is a film of insulating material. Preferably, said spacer 32 is a rigid film, for example a mica film 33.

Preferably, in the variants where said spacer 32 is porous, the latter is for example a felt block 34. The porosity allows the retention of the resin (s) by capillarity.

The operations of assembling the flat conductors 2 with insulators 32 also aim to geometrically stabilize the components between them throughout the manufacturing cycle and to simplify the arrangement of the connector device 1 in the positioning device 40.

When the insulating material 30 is a resin 31, the latter at least partially coats the conductor (s) 2. In certain preferred variants of the invention, when the insulating material 30 is a resin 31, the latter completely coats the conductor (s) 2, that is to say that the conductor 2 is in contact exclusively with said resin 31.

Preferably, each conductor 2 is individually coated with at least one layer of enamel varnish 35 before assembling the conductors 2.

By enamelling varnish 35 is meant a resin which exhibits particular aptitudes of adhesion to the electrical conductor 2, of electrical resistance, of thermal stability and of adhesion with respect to other possible insulators, such as for example an impregnation resin.

Quite preferably, the enamel varnish 35 comprises at least one filler in the form of inorganic particles of size preferably less than 150 μηι such as for example: silica (SiO2), alumina (A12O3), magnesia (MgO). Thanks to this inorganic filler, the resin exhibits less deterioration of its electrical characteristics under partial discharge stresses.

The term “impregnation resin 36” is understood to mean a resin in liquid form initially which has the ability to mechanical, chemical and electrical resistance, and optionally good retention by thixotropic effect. Quite preferably, the impregnation resin (36) comprises at least one filler in the form of inorganic particles of size preferably less than 150 μιη such as for example: silica (SiO2), alumina (A12O3), magnesia (MgO).

Advantageously, the impregnation resin (36) is chosen from resins with a thermal class greater than (or equal to) 180 ° C., such as for example: Elmotherm VF970® resin, Aquanel VF 111®.

Any combination of resin 35, 36 with or without a bulking agent in the form of inorganic particles can be envisaged, and a person skilled in the art knows how to choose the most suitable combination for the intended application.

Advantageously, the characteristic parameters of the enamelling varnish 35 are chosen from:

- dynamic viscosity: 100 to 4000 mPa.s, and / or

- temperature class: 120 ° C to 240 ° C (120/140/155: 180/200/220/240 ° C), according to standard IEC 60085: 2007, and / or

- dielectric strength greater than or equal to 30 kV / mm, and / or

- more preferably the chemical nature is chosen from: polyurethane (PUR), thermoplastic elastomer (TPE).

By way of example, the enamelling resin (35) can be chosen from the VOLTATEX WIRE® range (Dupont).

The enamelling resin (varnish) can be crosslinked by the action of heat or by the action of Ultra Violet rays. For the latter, we can retain by way of example the resins of the company Green Isolight International:

- GII 206 which has a class of 280 ° C and which is based on polyester acrylate;

- GII 200 which has a class of 120 ° C and which is polyalcohol modified acrylate.

Advantageously, the characteristic parameters of the impregnation resin 36 are chosen from:

- dynamic viscosity: 100 to 1000 mPa.s, and / or

- temperature class: 120 ° C to 240 ° C (120/140/155: 180/200/220/240 ° C), according to standard IEC 60085: 2007, and / or

- dielectric strength greater than or equal to 30 kV / mm

- Thixotropic aptitude,

- more preferably the chemical nature is chosen from: epoxy, polyester, polyester-imide.

By way of example, the impregnation resin 36 can be chosen from the ranges: VOLTATEX® (Dupont), DAMISOL® (VonRoll).

A device 1 as described above is manufactured using the method provided according to the invention, which implements at least one positioning device 40 of said conductors 2, said positioning device 40 preferably comprising, among other things, a positioning frame 50.

During manufacture, the step of preparing the conductors 2 comprises at least one step of laying savings 60 in any zone of the conductors 2 which must remain free of any insulation.

In advanced variants, the positioning device 40 further comprises a mechanical clamping means 70 for the conductor, preferentially associated with the frame 50.

Advantageously, the step of arranging said prepared flat conductors (2) in said positioning device 40 comprises a step of positioning at least one spacer 32, said spacer 32 connecting at least two flat conductors 2 together.

Most preferably, the device 1 comprises at least one porous spacer 34. Such a characteristic makes it possible to ensure:

- good impregnation of the resin 31 by capillarity, in the variants of the process where the assembly of the device 1 is carried out by impregnation of resin 31,

- Safety in the absence of electrical contact between two consecutive conductors 2 by establishing a spacing distance corresponding to the thickness of the spacer 32.

- A retention effect of the resin 31 in the case where P inter-conductor spacing 2 is substantial. Preferably, it is considered that there is a substantial spacing between the conductors 2 when the difference is between 1 and 5 mm.

Preferably, in order to ensure optimal maintenance (during manufacture) of the constituent elements of the device 1 such as the conductors 2 and the spacers 32, said frame 50 comprises at least one protuberance 75 at the end of which is positioned a stopper (for example: mechanical stopper) 76.

Advantageously, said stop 76 acts as a geometric reference zone in space for, inter alia, at least one element from: flat conductor (s) 2, spacer 32.

Advantageously, said protuberances 75 are in sufficient number to ensure:

• a geometric positioning of each flat conductor 2, and / or spacer 32 in the dedicated variants, relative to said chassis 50, and / or,

• maintenance without displacement of the conductors 2, and / or of the spacer (s) 32 in the dedicated variants:

o between them (conductor 2 / conductor 2, and / or conductor 2 / spacer

32, and / or spacer 33 / spacer 34, and / or

o with said frame 50.

After extraction of the connector, and removal of the mist 76, the resin flows so that it covers the bearing zone of the stop 76. The stop 76 can also rely on a saving.

Regarding the mechanical clamping, this can for example consist of a head screw 77 and a support washer 78 passing through the slots made in the conductor 2, the whole screwed onto a rod 79 geometrically secured to the frame 50.

Advantageously, according to an advanced variant of the positioning device according to the invention, the latter is also able to generate spatial constraints at the level of the internal dimensions of said connector device 1, by bringing the flat conductors 2 together. This approximation is preferably effected by the use of an actuatable positioning device 40.

Preferably, said positioning device is capable of adopting several positions, that is to say that said positioning device is capable of maintaining the flat conductors of the busbar in at least one manufacturing position with a preferential orientation:

• one or more position (s) apart Εχ (including an initial position),

• a tight position S (corresponding to the end position)

The “separated” position (s) E x correspond to an arrangement in which the different conductors are more distant from each other during manufacture (compared to their desired position in the finished product). The position for which the spacing is the greatest between the conductors advantageously corresponds to the initial position I of manufacture.

The "tight" position S corresponds to the arrangement of the conductors desired in the finished product.

In the case where the positioning device is not movable, the separated position (or positions) and the clamped position are the same (in particular the initial position and the final position are identical).

Thus, advantageously according to the method, the positioning device 40 can be mobilized between: at least one manufacturing position called "spread position" Εχ, and a manufacturing position called "tight position" S. On the other hand, the method is remarkable. in that it comprises at least one displacement step D consisting in causing said positioning device to pass from said separated position to said clamped position.

Thus, in preferred variants of the positioning device 40, the latter comprises, inter alia, at least one mobilization means 80, allowing the actuation of said positioning device 40, such as for example: a motor, a mechanical articulation, a jack pneumatic.

When the method implements an actuatable positioning device 40, the method can comprise at least one tightening step R corresponding to the passage from a separated position E x (several separated positions can be provided) to the clamped position S.

Preferably, according to the method, a single clamped position is provided, corresponding to the final position of the elements of the device 1.

A person skilled in the art knows how to choose the number and the order of arrangement of the tightening steps, between themselves and with respect to the other manufacturing steps, according to the characteristics of the device 1 to be manufactured and of the application. aimed.

Also, the method advantageously further comprises a step consisting in placing at least the flat conductors 2 (optionally prepared) in a tank 90, as shown in FIG. 3, capable of receiving at least one impregnation resin 36 (step of placing in the tank, separate from the disposal step in the positioning device). Furthermore, the step of assembling said device

1 further comprises an impregnation step consisting in impregnating at least said flat conductors 2 with at least one impregnation resin 36. The method also advantageously comprises a step of extracting X of the device 1 from said tank 90. ​​Said resin d 'impregnation 36 has physicochemical characteristics allowing it to be maintained in the form of a coating layer on all of the accessible faces of said flat conductors

2 after extraction (extraction step X) of the latter from said tank 90 (preferably after extraction of all the constituent elements of the device and / or of the manufacturing means such as among others: the positioning device 40).

Advantageously, in advanced variants of the process, the extraction step X follows a step of emptying V of the tank 90, said emptying is preferably carried out towards a drain buffer tank (possibly identical to the reserve buffer tank of resin 91 bringing the resin to the impregnation tank 90, which facilitates for example the recycling of the material).

Preferably, the device 1 is assembled by resin impregnation 36, said impregnation resin 36 is introduced into the tank 90 (for example from the bottom (the bottom) or laterally to the device 1, for example from a buffer reserve tank of resin 91), as presented successively in Figures 3 to 5 where we see the level of impregnation resin 36 gradually rising in the tank 90, so that the impregnation is not carried out by sprinkling (covering of the device 1 " from top to bottom ”) but by raising the impregnation resin 36, that is to say by raising between the constituent elements of the device 1 (conductor 2, spacers 32, etc.) and / or between the means of manufacture implemented in the method, such as among others: positioning device 40, clamping means 70,etc ..

More preferably, the impregnation is carried out by raising into contact, at least in part, with said flat conductors 2. Even more preferably, by raising around said flat conductors 2 (complete coating, for example when there is no 'savings).

Advantageously, the speed of the impregnation is controlled by the regulation of the pressure inside the tank 90.

Preferably, the tank 90 is a closed tank (directly closed or able to be closed).

According to variants of the method, the rise of the impregnation resin 36 takes place at ambient pressure, by capillary action. In these variants, the tank 90 may or may not be closed.

Other variants of the method use a closed tank 90. In this case, sub-variants are provided, depending on the chosen combination of steps detailed below. Thus, in addition to the operations of placing the connector device 1 in the tank and its removal, opening and closing the tank 90, the process with closed tank 90 comprises, among other things, at least one step among the following:

• step of depressurizing the tank 90, preferably at a value less than or equal to 1 bar: this depression is used, among other things, for the introduction of the resin by pressure difference from a buffer tank,

• a partial vacuum step (carried out at least once during the manufacturing process), preferably bringing the tank 90 to a pressure between 0.1 and 0.3 bars and / or preferably taking place during a time span between 1 and 3 minutes. This step makes it possible to extract the air bubbles trapped in the connector device 1,

• A step of pressurizing said tank 90 (carried out at least once during the manufacturing process), preferably bringing the tank 90 to a pressure of between 2 to 3 bars and / or preferably carried out for a period of time between 2 to 5 minutes (this overpressure is practiced in an obvious manner, possibly after the depressurization step, and in all cases after the introduction of the resin 36 into the tank 90, it makes it possible to route the resin in all cavities of the device 1).

A person skilled in the art knows how to choose the order, the presence or the absence, the nature and number of repetitions that are most suitable for the stages of depressurizing and regulating the internal pressure of the tank 90, placing under partial vacuum. , pressurized, entering the manufacturing process of the device 1.

Advantageously, in some advanced variants of the method implementing a tank 90 (open or closed), where the positioning device (40) can be actuated, the method is remarkable in that:

• the positioning device 40 is placed in the tank 90 (tank setting step) in a separated position E x , as shown in Figures 3 and 4, and

• l'étape de déplacement D, consistant à resserrer le dispositif de positionnement 40 pour rapprocher les conducteurs 2 les uns des autres jusqu'à la position finale serrée S visualisable sur la figure 5, est effectuée une fois que la résine d'imprégnation 36 a complètement imprégné le dispositif 1 (le niveau de résine 36 dans la cuve 90 permet de recouvrir complètement le dispositif 1), avant l'étape de vidange V si celle-ci existe ou sinon avant l'étape d'extraction X.

Advantageously, in some advanced variants of the method implementing a tank 90 (open or closed), where the device 1 is assembled by resin impregnation 36, the manufacturing process further comprises a step of crosslinking F of the (or) impregnation resin 36, carried out after the extraction step X. The crosslinking of the impregnation resin 36 can be carried out for example: spontaneously at room temperature, or in an oven, or under the action of UV radiation.

Advantageously, in some advanced variants of the method implementing a tank 90 (open or closed), the step of placing at least one element among others: positioning device 40, flat conductors 2, spacer (s) 32, is to arrange in said tank 90 said elements so that all the conductors are inclined, that is to say that the normal to the plane corresponding to the largest surface of the flat conductors 2 is inclined with respect to vertically at a typical angle between 45 ° and 85 °.

Or, advantageously, in other advanced variants of the method implementing a tank 90 (open or closed), the step of placing at least one element among others: positioning device 40, flat conductors 2 , spacer 32, consists in placing said elements in said tank 90 in a preferential orientation so that the normal to the plane corresponding to the largest surface (in terms of finished product) of the device (busbar) is inclined with respect to the vertical with a typical angle between 45 ° and 85 °. This inclination makes it possible to limit the trapping of air bubbles under a horizontal flat surface and / or in the recesses during the rise of the impregnation resin.

Advantageously, the conductors 2 are positioned in a spaced position (E x ) such that the difference is greater than the thickness of the desired resin in order then to bring the conductors 2 together before the emptying step if this exists or otherwise before the step of extracting the tank 90. ​​The bringing together of the conductors 2 makes it possible, among other things, to expel any air bubbles. The use of a spaced position E x during the impregnation avoids the possible future trapping of air bubbles between the conductors 2 once they are in the tight position S.

Advantageously, the method according to the invention is remarkable in that in advanced variants of the step for preparing the flat conductors 2, the latter further comprises at least one iteration of the following cycle of steps:

• first deposit a layer of enamel varnish 35 of thickness A, preferably by dipping followed by draining (nevertheless, any other suitable method - depending on the resin chosen - can be implemented, such as '' deposition by spraying or with a varnish in aerosol form or by centrifugal coating),

• then crosslink the enamelling varnish 35.

Those skilled in the art know how to choose the number of iterations of the step cycle presented previously, so as to obtain a final desired thickness B of enamelling resin 35, coating said flat conductors 2 (the coating can be carried out for each conductor individually, or for all conductors in one

past). Among other things, the number of iterations (and therefore the final thickness B) is chosen as a function of the voltage that the device must withstand.

Preferably, said thickness B is between 30 and 200 microns, in order to allow the device to operate at a voltage of between 300 and 1250 volts. Preferably, said thickness A is between 3 and 15 microns. A first advantage of these different stages A of deposition of enameling resin (varnish) 35 is to avoid the creation of micro-cavities in the thickness of the insulation (any micro-cavity being liable to become the site of discharges. partial prejudicial to the durability of the electrical performance of the insulation and / or insulation).

A second advantage is to reduce the risk of an accidental localized lack of varnish because the layers are deposited independently of one another.

A third advantage will be to take advantage of characteristics specific to each type of varnish, for example a first layer with a high adhesion capacity on the conductive surfaces, a following layer (different resin) with higher mechanical performance.

The crosslinking of the enamelling varnish 35 can for example be carried out spontaneously at room temperature or in an oven, or under the action of UV radiation.

Advantageously, the method according to the invention is remarkable in that in advanced variants of the step for preparing flat conductors 2, the latter further comprises at least one step for preparing (treating) the surfaces, chosen for example between others among: degreasing, dust removal.

Examples of preferred embodiments

Below are briefly presented two particularly preferred embodiments of the invention. Reference will be made to the general description for details concerning the steps mentioned. However, the realization of any variant provided according to the general description presented above is of course possible.

1) busbar produced using “raw” conductors assembled by tank impregnation

The method of manufacturing such a busbar comprises in particular the following steps:

• place the prepared conductors 2 (for example: degreased) in the positioning device 40, in a spaced initial position (position I and position Ex identical),

• arrange the assembly consisting of the positioning device 40 and the conductors 2 in the tank 90 so that the normal to the plane corresponding to the largest surface of the device 1 (as a finished product) is inclined relative to to the vertical axis at an angle between 45 ° and 85 °,

• carry out a step of depressurizing the tank 90,

• assemble the constituent elements of device 1 by:

o resin impregnation 36, by rising between the constituent elements of the device 1 and the manufacturing means, and o carrying out a displacement step D consisting in tightening the positioning device 40 to bring the conductors 2 closer to each other until to the tight final position S, and o carrying out a step of partially evacuating the tank 90, and o carrying out a step of putting the tank 90 under pressure,

• carrying out a step of emptying the tank 90,

• carrying out a step of extracting the device 1 from the tank 90,

• carrying out a step of crosslinking the impregnation resin 36,

• collect device 1 as a finished product.

2) busbar produced using enamelled conductors assembled by tank impregnation

The method of manufacturing such a busbar comprises in particular the following steps:

• preparing the flat conductors 2 by depositing enamel varnish 35 (followed by a step of crosslinking said varnish 35, and possibly reiteration to obtain several layers of varnish 35),

• arrange the conductors 2 prepared in the positioning device 40,

• arrange the assembly consisting of the positioning device 40 and the conductors 2 in the tank 90 so that the normal to the plane corresponding to the largest surface of the device 1 (as a finished product) is inclined relative to to the vertical axis at an angle between 45 ° and 85 °,

• carry out a step of depressurizing the tank 90,

• assemble the constituent elements of device 1 by:

o resin impregnation 36 by rising between the constituent elements of the device 1 and the manufacturing means, and

o carrying out a step of partial vacuuming of the tank 90, and o carrying out a step of pressurizing the tank 90,

• carrying out a step of emptying the tank 90,

• carrying out a step of extracting the device 1 from the tank 90,

• carrying out a step of crosslinking the impregnation resin 36,

• collect device 1 as a finished product.

Interest of industrial implementation

All of the technical characteristics set out above clearly demonstrate the utility and the potential for industrial application of the device and of the manufacturing process proposed.

The depositor thus recalls among other things that:

• the elimination of polymer films and / or adhesives (glue), which have limited temperature characteristics, makes it possible to switch to a much higher thermal class:

o at a minimum, the thermal class of the most common resins is 180 ° C, whereas current laminated busbars are designed to work at a temperature below 130 ° C,

o the use of the device according to the invention at an even higher temperature up to 240 ° C. is achievable by the use of more sophisticated resins, available on the market and which meet the desired standards.

• The use of more efficient films (PEN, PEEK, POLY-EVflDE type) is no longer a relevant approach, because these are very expensive compared to a resin of the same temperature class, moreover, if the availability of such films does not pose a problem, the existence of adhesives with high temperature resistance suitable for the film of laminated “busbars” is not yet an obvious industrial reality.

• the economic gain expected for a multilayer connector according to the invention can reach 10 to 50% taking into account the high cost of films at high temperature

• the manufacturing process lends itself to mass production of “busbars”, by the use of large capacity tanks in which several different “busbar” conformations and a large number of “busbars” can be processed simultaneously. Thus, the Applicant considers that the production capacity of “busbars” is likely to be

multiplied by at least a factor of 5, by the use of the proposed process, for a similar amount of industrial investment.

The manufacturing process also lends itself to mass production of busbars from conductors with complex geometries (multiple folds, non-planar shapes,...),

the resin impregnation manufacturing process makes it possible to achieve significant energy savings, by eliminating the use of heating presses (with an estimated ratio of at least 3 in favor of the proposed process).

The proposed process presents the possibility of using varnishes loaded with inorganic particles, which degrade less under the constraints of partial discharges. This technical possibility makes it possible to obtain a controlled lifetime in the presence of partial discharges, unlike current technology which requires the absence of partial discharges.

The proposed process makes it easier to envision a global ecological approach, by offering the possibility of using aqueous solvents instead of organic solvents in the resins.
CLAIMS

1. A method of manufacturing a multilayer connector device (1) capable of making an inter or intra static converter (s) connection of electrical energy, said device (1) comprising at least two flat conductors (2) and at least one insulating material (30, 31, 32, 33, 34, 35, 36) disposed between the aforementioned two conductors (2), said method being characterized in that:

• the flat conductors (2), optionally prepared (2), are positioned in a tank (90) in a geometric position such that the conductors (2) are kept parallel and spaced apart by a value at least equal to the thickness of the desired electrical insulation, said conductors (2) having a preferential orientation,

• said prepared flat conductors (2) are impregnated with at least one impregnation resin (36) introduced into the tank (90), said impregnation resin (36) having physicochemical characteristics allowing, after extraction from the tank, its maintenance in the form of a coating layer on all of the accessible faces of said flat conductors (2),

• the device (1) is extracted from said tank (90),

• the crosslinking of said impregnation resin (36) is carried out to assemble the flat conductors.

2. A method of manufacturing a connector device (1) according to claim 1, characterized in that the conductors (2) are placed in a positioning device (40) which does not generate spatial constraints at the level of the external dimensions. of said device (1) before introduction of the impregnation resin (36).

3. A method of manufacturing a connector device (1) according to claim 1 or 2, characterized in that spares (60) are placed to preserve the conductive surfaces of the flat conductors (2) from a covering by the resin and / or spacers (32) are placed to keep the flat conductors (2) apart.

4. A method of manufacturing a connector device (1) according to any one of claims 1 to 3, characterized in that the impregnation is carried out by raising the impregnation resin (36) between the constituent elements of the device (1).

5. A method of manufacturing a connector device (1) according to one of claims 1 to 4, characterized in that a closed vessel (90) is used and the method comprises at least one step from: a placing step under vacuum of the vessel (90), a step of partially evacuating the vessel (90), a step of pressurizing the vessel (90), each step being carried out at least once.

6. A method of manufacturing a connector device (1) according to any one of the preceding claims, characterized in that one proceeds to the emptying of the tank (90) before extracting the connector device (1).

7. A method of manufacturing a connector device (1) according to claim 1 to 6, characterized in that the conductors (2) are positioned in a separated position (Εχ) such that the difference is greater than l 'thickness of impregnation resin (36) desired to then bring the conductors (2) together before the emptying step if this exists or otherwise before the step of extracting the tank (90).

8. A method of manufacturing a connector device (1) according to one of claims 1 to 7, characterized in that said flat conductors (2) are disposed inclined in the tank (90), normal to the corresponding plane. with the largest surface of the device (1), as a finished product, being inclined with respect to the vertical by an angle of between 45 ° and 85 °.

9. A method of manufacturing a connector device (1) according to one of claims 1 to 8, characterized in that to prepare the flat conductors (2) is deposited at least one layer of enamel resin (35) d 'thickness A on said conductors (2), to then crosslink said enamel resin (35).

10. A method of manufacturing a connector device (1) according to one of claims 1 to 9, characterized in that the flat conductors (2) are prepared by at least one surface treatment step.

11. Connector device (1) obtained via the manufacturing method according to one of claims 1 to 10, characterized in that it comprises at least two flat conductors (2) and at least one insulating material (30) also having a function. assembly.

12. Connector device (1) according to the preceding claim, characterized in that at least one resin (31, 35, 36) comprises at least one bulking agent in the form of inorganic particles.

13. Means for implementing the method according to any one of claims 1 to 10, characterized in that the means comprise a tank (90) and a geometric positioning device (40) of the

flat conductors (2) such that the conductors are kept parallel and spaced apart by an amount at least equal to the thickness of the desired insulation, which positioning device (40) does not generate spatial constraints on the external dimensions of said connector device (1) and the conductors 2 are positioned so that the normal to the plane corresponding to the largest surface of the device 1 (as a finished product) is inclined relative to the vertical axis of a angle between 45 ° and 85 °.

14. Use of the connector device (1) according to any one of claims 11 to 12 as inter connector or intra converter (s) static (s) of electrical energy.