Patent Application
20220234455
Priority is claimed to German Patent Application No. DE 10 2021 101 528.6, filed on Jan. 25, 2021, the entire disclosure of which is hereby incorporated by reference herein.
The invention relates to a module for a plug-in connector part, a plug-in connector part, and a method for producing such a plug-in connector part.
Particularly in the field of e-mobility, the highest demands with respect to the current-carrying capacity and the associated thermal loads exist for plug-in connector parts and associated cable assemblies. In addition to the cables, the plug-in connectors are regularly exposed to high charging currents—for example, of several hundred amperes. These high currents are supposed to be transmitted with the lowest possible power loss. Even higher currents are being considered for the future. Against this background, it is worth noting that the power loss rises as the square of the current. This regularly results in the problem of designing components which provide as good an electrical performance as possible with a manageable overall size. In the case of electromechanical connections, this typically means as small an electrical resistance as possible, with simultaneously controlled heating.
This has often been successfully achieved with actively-cooled plug connectors and charging cables. However, the technical effort that is usually required for this is reflected in the costs and the effort for the production of the actively-cooled components of the corresponding charging devices.
To date, there have been no suitable solutions—particularly in a charging current range in which active cooling is not yet economical, but a conventional construction with crimped contacts potentially heats up too quickly, e.g., in a range around 300 A.
DE 10 2016 107 409 A1 proposes a plug-in connector part with active cooling. DE 10 2016 105 308 A1 describes a vehicle charging socket with thermal capacity elements.
In an embodiment, the present invention provides a module for a plug-in connector part, comprising: a sleeve; at least two busbars, arranged in the sleeve, to each of which a plug contact and at least one load line are connectable or connected; and at least one heat capacity element mounted in or on the sleeve, wherein the module is mountable on the plug-in connector part.
Subject matter of the present disclosure will be described in even greater detail below based on the exemplary figures. All features described and/or illustrated herein can be used alone or combined in different combinations. The features and advantages of various embodiments will become apparent by reading the following detailed description with reference to the attached drawings, which illustrate the following:
In an embodiment, the present invention provides a plug-in connector part which allows the lowest possible power loss and is particularly easy to produce.
Accordingly, a module for a plug-in connector part is specified, having a sleeve, at least two busbars, arranged in the sleeve, to each of which a plug contact and at least one load line can be connected or are connected, and at least one heat capacity element mounted in or on the sleeve. The (in particular, pre-assembled) module can be mounted on—in particular, in—the plug-in connector part.
In this way, a module, e.g., a pre-mounted and pre-testable module, is provided which can be installed in a particularly easy manner in the plug-in connector part and thus considerably simplify the production. The busbars can be designed with a particularly large cross-section and can thus significantly reduce the power loss. The heat capacity element enables the temperature rise to be delayed. The combination of the busbars with the heat capacity element and the installation in the module make it possible, in a particularly simple and easily producible structure, to limit the temperature rise to sufficiently low values over a typical charging period for charging the battery of an electric vehicle. The heat capacity element or the heat capacity elements is/are configured to absorb heat from the busbars. The heat capacity element(s) has/have a large thermal capacity and is/are thermally connected to one or both busbars so that heat can be introduced from the busbar(s) into the respective heat capacity element and absorbed there. This is based upon the idea of providing an increased heat capacity on a plug-in connector part, on the basis of which the heating of the plug-in connector part can be slowed down.
The connector part may be a high-current and/or high-voltage connector part. The module is in particular a high-current module. For example, the plug-in connector part is designed to conduct electrical currents of approximately 300 A or at least 300 A and/or have a power of approximately 135 kW or more than 135 kW.
For example, the at least one heat capacity element is produced from a material having a high specific heat capacity—for example, a specific heat capacity greater than 0.5 kJ/(kg*K), and in particular greater than 1.0 kJ/(kg*K). Alternatively or additionally, the material has a high thermal conductivity—for example above 50 W/(m*K), and in particular above 100 W/(m*K). This allows the heat to be efficiently conducted away from the busbars.
Optionally, the at least one heat capacity element is mounted on one of the busbars by means of a housing part—for example, made of an insulation material. As a result, electrical insulation of both parts with respect to other components and a fastening to one another is simultaneously made possible.
For example, the at least one heat capacity element lies flat against one of the busbars. This enables good heat transfer. The at least one heat capacity element can be in contact with the busbar—alternatively, with the interposition of an—in particular, planar—insulator. For example, the busbars and/or the heat capacity element(s) have a rectangular cross-section, at least in sections. Plane surfaces of the at least one heat capacity element and of the busbar(s) that are parallel to one another can thereby rest against one another.
In one embodiment, at least two heat capacity elements are provided. Optionally, the at least two busbars are arranged between the two heat capacity elements. This enables a particularly efficient absorption of heat.
For example, the module comprises at least one interface for mounting the pre-assembled module on the plug-in connector part. The interface is formed, for example, by a mounting adapter which, in one embodiment, closes an opening of the sleeve and, optionally, has an opening for each of the plug contacts. The mounting adapter can thus be mounted on a part—for example, a housing part—of the plug-in connector.
The busbars are mounted, for example, on an insulating support arranged in the sleeve. This enables further simplified production, since the insulating support with electrical insulation of the busbars from one another and the holder thereof fulfills a dual function. The insulating support has, for example, at least in sections, an H-shaped cross-section.
It can be provided that each of the busbars have a larger cross-section than one of the load lines connected or connectable thereto, or a cross-section greater than the sum of the cross-sections of several connected or connectable load lines—in particular, at least a cross-section that is twice as large (as the load line or load lines).
The at least two busbars can each have two sections which are at an angle to one another. Thus, the busbars can extend through an ergonomically-shaped plug-in connector part—in particular, in the form of a charging plug.
The sleeve can form an interior space, wherein the interior space is sealed—in particular, against water and/or dust. It is thus made possible for the module to be secured in its own right at least in sections against environmental influences and/or with respect to other lines or other components of the plug-in connector part.
According to one aspect, a plug-in connector part is provided for connecting to a mating connector part. The plug-in connector part comprises a housing and at least one module, arranged in the housing, according to any embodiment described herein.
The plug-in connector part may in particular be designed as a charging plug-in connector part—in particular, as a vehicle charging plug.
According to one aspect, a method for producing a plug-in connector part for connecting to a mating connector part is provided—in particular, the plug-in connector part according to any embodiment described herein. The method comprises assembling at least two busbars and at least one heat capacity element to form a pre-assembled module; and mounting the module in a housing of the plug-in connector part.
The idea forming the basis of the invention shall be explained in more detail below on the basis of the exemplary embodiment shown in the figures. The following are shown:
As can be seen from the enlarged view in
The plug-in connector part 2 has a plurality of contact elements on its plug-in sections 22, 23. For example, two plug contacts 21A, 21B for transmitting the charging current in the form of a direct current can be arranged on the plug-in section 22, while, for example, three or five contact elements for providing load contacts are provided on the plug-in section 23 in order to transmit an (e.g., multi-phase) alternating current and/or to provide contacts for data transmission. In the specific exemplary embodiment shown in
As shown schematically in
The plug-in connector part 2 further comprises a housing 20, which forms a handle 202. A user can grip the plug-in connector part 2 on the handle 202 and attach said plug-in connector part to the mating connector part 4 or pull it off
Load lines 30, which serve for transmitting a charging current through the plug-in connector part 2, are guided in the cable 3 connected to the plug-in connector part 2, as can be seen, for example, from
In order to enable a rapid charging of the electric vehicle 5, e.g., in the context of a so-called rapid-charging process, the transmittable charging currents have a high amperage—for example, an amperage on the order of magnitude of 300 A or higher. Such high charging currents can generally lead to thermal losses on a plug-in connector part and, consequently, to a heating of the plug-in connector part.
The plug-in connector part 2 is not actively cooled. In particular, it has no channels for liquid cooling. In order to significantly slow down the heating of the plug-in connector part 2, the plug-in connector part 2 in the present case comprises a high-current module, which is referred to below as module 1 for short and will be described in detail below. The module 1 is a self-contained structural unit and can be installed pre-assembled in the housing 20 of the plug-in connector part 2. Before being installed in the housing 20 of the plug-in connector part 2, the module 1 can be pre-checked for correct function.
The module 1 comprises a first section 16 and a second section 17. The plug contacts 21A, 21B are mounted on the first section 16. The load lines 30 are connected to the second section 17. The first section 16 and the second section 17 run at an angle to one another. In the present case, the first section 16 is at an obtuse angle to the second section 17. In the assembled state of the plug-in connector part 2, the module 1 is arranged completely, or at least almost completely, in the interior of the housing 20.
The module 1 further comprises two busbars 11A, 11B and several (in the present case, four) heat capacity elements 12A-12D. The busbars 11A, 11B have a large cross-section—in particular, a substantially larger cross-section than the load line 30 connected in each case thereto—or, as in the example shown, in the case of several load lines 30 (in the present case, two) each connected to a busbar 11A, 11B, a larger or substantially larger cross-section than the sum of the cross-sections of the load lines 30 connected thereto. By using the busbars 11A, 11B, a particularly low electrical resistance can be achieved.
The busbars 11A, 11B each have a first section 110 and a second section 111. The first section 110 and the second section 111 are in each case extended longitudinally and, like the two sections 16, 17 of the module 1, are, as a whole, at an angle to each other. The first section 110 is adjoined by a mounting section 112 (at the end of the first section 110 facing away from the second section 111). A threaded bore is provided on the mounting section 112, on which one of the plug contacts 21A, 21B can be mounted in each case.
Receptacles 113 for the load lines 30 are formed on the second section 111 (in the present case, at the end of the second section 111 facing away from the first section 110); see, in particular,
The busbars 11A, 11B each have a rectangular cross-section. The busbars 11A, 11B are each formed in one piece—in particular, also of the same material. For example, the busbars 11A, 11B are made of copper. Optionally, the busbars 11A, 11B are punched and bent for production.
The heat capacity elements 12A-12D are produced, for example, from a material having a specific heat capacity of above 0.5 kJ/(kg*K), and in particular above 1.0 kJ/(kg*K). Furthermore, the material has a high thermal conductivity, e.g., above 50 W/(m*K), and in particular above 100 W/(m*K). The heat capacity elements 12A-12D are formed in a block shape. Each of the heat capacity elements 12A-12D is formed in one piece. In the assembled state (see, in particular,
In the assembled state, the busbars 11A, 11B are electrically insulated from one another by an insulating support 13. For this purpose, the insulating support 13 comprises a separating section 130, which is arranged between the two busbars 11A, 11B in the assembled state. As can be seen in particular with reference to
The insulating support 13 further comprises two transverse parts 131, 132. The transverse parts 131, 132 each protrude at right angles from the separating section 130. In cross-section, the transverse parts 131, 132 and the separating section 130 are arranged as an H-shape; see, for example,
During assembly, for example, the busbars 11A, 11B and the heat capacity elements 12A-12D are first mounted on the insulating support 13—in the present case, screwed thereto—by means of the housing parts 15A, 15B, forming a mounted assembly. The mounted assembly is shown in
In the pre-assembled module 1, the two busbars 11A, 11B and the heat capacity elements 12A-12D are thus arranged in the sleeve 10.
Furthermore, the module 1 comprises a mounting adapter 14; see, in particular,
While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive. It will be understood that changes and modifications may be made by those of ordinary skill within the scope of the following claims. In particular, the present invention covers further embodiments with any combination of features from different embodiments described above and below. Additionally, statements made herein characterizing the invention refer to an embodiment of the invention and not necessarily all embodiments.
The terms used in the claims should be construed to have the broadest reasonable interpretation consistent with the foregoing description. For example, the use of the article “a” or “the” in introducing an element should not be interpreted as being exclusive of a plurality of elements. Likewise, the recitation of “or” should be interpreted as being inclusive, such that the recitation of “A or B” is not exclusive of “A and B,” unless it is clear from the context or the foregoing description that only one of A and B is intended. Further, the recitation of “at least one of A, B and C” should be interpreted as one or more of a group of elements consisting of A, B and C, and should not be interpreted as requiring at least one of each of the listed elements A, B and C, regardless of whether A, B and C are related as categories or otherwise. Moreover, the recitation of “A, B and/or C” or “at least one of A, B or C” should be interpreted as including any singular entity from the listed elements, e.g., A, any subset from the listed elements, e.g., A and B, or the entire list of elements A, B and C.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2021 101 528.6 | Jan 2021 | DE | national |
