DE102019117649A1 - Actively cooled charging connector part - Google Patents

Abstract

A connector part (1) for connection to a mating connector part (3) comprises at least one bridge element (10A, 10B) with a cooling line receptacle (103) for thermally conductive contact with a coolant line (22) of a cable (2), one on the bridge element (10A, 10B) ) provided and with an electrical line (21) of the cable (2) electrically connectable plug contact (11) and a heat sink (12) which is in heat-conducting connection with the bridge element (10A, 10B) and which forms a coolant channel (120), to which the coolant line (22) can be connected.

Description

The invention relates to a connector part for electrical connection with a mating connector part according to claim 1, a connector arrangement and a bridge element.

Particularly in the field of e-mobility, there are particularly high requirements for connector parts and associated charging cables with regard to their functional performance, stability and safety. With high direct current charging currents, e.g. around 500 A, considerable electrical heat is regularly released in all components of the guide path.

In particular through standards, narrow limits are set with regard to the permissible heating of the components in the wiring harness, e.g. with a temperature limit of 90 ° C. In addition, the dimensions of plug-in connections are regularly limited, so that in terms of design the challenge arises to conduct the highest possible electrical power, in particular in the sense of high charging currents, over existing geometries and at the same time to keep the heating within the specified limits.

For this purpose, charging connectors and charging cables are liquid-cooled, see DE 10 2016 105 311 A1 and DE 10 2016 107 409 A1 .

In addition to being exposed to high currents, contacts in charging connectors are also regularly operated at voltages of up to 1500 V DC. This can mean that any type of cooling on live components which are to be thermally well coupled must also be sufficiently well insulated electrically in order to avoid insulation faults in power contacts to the coolant circuit. In the case of water-based cooling liquids, in particular, the coolant circuit is generally at ground potential in its entirety. As part of an insulation coordination, it is usually ensured that specified air and creepage distances are maintained and that insulating components have at least a specified dielectric strength.

A good thermal connection with good electrical insulation at the same time poses a particular challenge.

The object of the present invention is to enable a plug connector part that can be cooled as effectively as possible with a limited installation space.

This object is achieved by an object having the features of claim 1.

Thereafter, a plug connector part for electrical connection to a mating connector part is provided, which comprises at least one bridge element, at least one plug contact and a heat sink. The bridge element is optionally designed for the electrical connection of an electrical line of a cable and has a cooling line receptacle for the heat-conducting system with a coolant line of the cable. The plug contact is provided on the bridge element (e.g. adjoins it) and can (e.g. via the bridge element) be electrically connected (and optionally connected) to an electrical line of the cable. The heat sink is in a thermally conductive connection with the bridge element and forms a coolant channel to which the coolant line of the cable is or can be connected.

In this way, a connector part is provided in which the parts carrying the load current (e.g. the bridge element) can be cooled both by the cooling line and by the heat sink. This enables particularly efficient cooling in a particularly small space. The bridge element and the heat sink are separate components from one another.

The connector part can be a high-current and / or high-voltage connector part. For example, the bridge element is designed to conduct electrical currents with a power of 10 kW or more, in particular of 50 kW or more, 135 kW or more, or 350 kW or more. For example, the bridge element is designed to conduct electrical currents with currents of 100 A or more, 200 A or more, 300 A or more, in particular 500 A or more.

Optionally, the bridge element is connected to the plug contact in an electrically conductive and / or thermally conductive manner. The bridge element can thus fulfill several functions at the same time, namely, in particular, conduction of heat and conduction of electrical current.

The bridge element can be made in one piece, e.g. from copper, which enables particularly good electrical and thermal conduction. The bridge element and the plug-in contact can be constructed in several parts and can be in contact with one another, for example fastened to one another. Alternatively, the bridge element and the plug contact are formed integrally with one another. Optionally, the bridge element and the plug contact are firmly connected to one another, e.g. welded and / or soldered.

The cooling line receptacle of the bridge element can be concave and / or elongated. For example, the Cooling line receptacle designed in the form of a recess. This enables particularly good heat conduction over a large contact surface. The cooling line receptacle is optionally designed in the form of a groove.

The cooling line receptacle can be aligned perpendicular to the plug contact. This enables a small installation depth, as is often necessary, for example, for installation in a vehicle.

The bridge element optionally has a base body and a thermal bridge protruding from the base body. The thermal bridge protrudes from the base body, for example, in a direction that runs parallel or essentially parallel to the longitudinal extension of the cooling line receptacle.

An electrically insulating heat-conducting element can be arranged on the bridge element. The heat-conducting element can be designed in such a way that it receives the heat bridge of the bridge element. The heat conducting element is optionally in flat contact with the heat sink. Such a heat-conducting element can achieve particularly reliable electrical insulation of the bridge element from the heat sink. An electrically insulating plastic or an electrically insulating ceramic with high thermal conductivity can be used as the material for the heat-conducting element.

The connector part can (precisely) comprise two bridge elements, in particular two bridge elements as described above. Both bridge elements are in a thermally conductive connection with the heat sink. One of the bridge elements can serve as the positive conductor of a direct current connection, the other as the negative conductor.

The heat sink has, for example, (precisely) one inlet and (precisely) one outlet, with coolant introduced through the inlet in an inlet direction flowing out of the outlet in an outlet direction. It can be provided that the inlet direction and the outlet direction are opposite. The heat sink can thus fulfill a double function, namely contribute to cooling the bridge element (s) and deflect the coolant flow by 180 °. The coolant channel extends from the inlet to the outlet.

The connector part is designed, for example, as a vehicle charging socket, in particular for high-current charging using direct current.

According to one aspect, a plug connector arrangement is provided which comprises a plug connector part according to any configuration described herein, and a cable which comprises an electrical line and a coolant line. The electrical line is electrically connected to the connection surface of the bridge element. The coolant line is in contact with the cooling line receptacle of the bridge element and is connected to the coolant channel of the heat sink (in particular with another, e.g. adjacent section).

The bridge element can be cooled on the cooling line receptacle and over the thermal bridge by means of coolant flowing through the coolant line.

The electrical line and the coolant line can be coaxial. No separate lines are necessary. For example, the electrical line surrounds the coolant line. The electrical line comprises, for example, a layer of litz wires, in particular copper litz wires. This enables particularly efficient cooling of the electrical line, which can be used at the same time to cool the bridge element.

The electrical line can be connected to the connection surface via a welded connection. This enables a particularly secure connection with a low transition resistance.

Optionally, the connector part comprises two bridge elements of the type described. Both bridge elements are in a thermally conductive connection with the heat sink, the cable or cables comprising two electrical lines and two coolant lines. The electrical lines are each electrically connected to the connection surface of one of the bridge elements. The coolant lines are each in contact with the cooling line receptacle of one of the bridge elements and are connected to the coolant channel of the heat sink. In this way, both conductors of a direct current connection can be cooled particularly well.

According to one aspect, a bridge element is provided, in particular for the plug connector part according to any configuration described herein. The bridge element comprises a base body which has a connection surface for the electrical connection of an electrical line of a cable and a cooling line receptacle for thermally conductive receiving of a coolant line of the cable. Furthermore, the bridge element comprises a connecting section (e.g. in the form of a plug contact connection), via which a plug contact for pluggable connection with a mating plug contact is or can be electrically connected to the connection surface, and a thermal bridge protruding from the base body, for example.

Such a bridge element enables heat to be dissipated both via the cooling line receptacle and via the thermal bridge, which is a enables particularly efficient dissipation of heat.

• 1 eine Ansicht eines Fahrzeugs mit einer Ladebuchse und einer Ladestation mit einem daran angeordneten Kabel;
• 2A und 2B Ansichten des Steckverbinderteils gemäß 1 mit daran angeschlossenen Leitungen;
• 3A und 3B Teile des Steckverbinderteils gemäß 2A und 2B mit mehreren Leitungen in einer perspektivischen Ansicht (3A) und in einer Explosionsansicht (3B);
• 4A und 4B ein Brückenelement des Steckverbinderteils mit einem Steckkontakt, sowie Leitungen gemäß 2A und 2B in einer perspektivischen Ansicht (4A) und in einer Explosionsansicht (4B);
• 5 ein Brückenelement des Steckverbinderteils gemäß 2A und 2B, Leitungen und einen Steckkontakt;
• 6A und 6B aufgeschnittene Ansichten des Brückenelements gemäß 5;
• 7A bis 8B Ansichten des Brückenelement des Steckverbinderteils gemäß 2A und 2B; und
• 9A bis 9E Ansichten eines Kühlkörpers des Steckverbinderteils gemäß 2A und 2B mit daran montierten Wärmeleitelementen.

The idea on which the invention is based is to be explained in more detail below with reference to the exemplary embodiments shown in the figures. Show it:

• 1 a view of a vehicle with a charging socket and a charging station with a cable arranged thereon;
• 2A and 2 B Views of the connector part according to 1 with lines connected to it;
• 3A and 3B Parts of the connector part according to 2A and 2 B with several lines in a perspective view ( 3A) and in an exploded view ( 3B) ;
• 4A and 4B a bridge element of the connector part with a plug contact, and lines according to 2A and 2 B in a perspective view ( 4A) and in an exploded view ( 4B) ;
• 5 a bridge element of the connector part according to 2A and 2 B , Cables and a plug contact;
• 6A and 6B cut-away views of the bridge element according to FIG 5 ;
• 7A to 8B Views of the bridge element of the connector part according to 2A and 2 B ; and
• 9A to 9E Views of a heat sink of the connector part according to FIG 2A and 2 B with heat conducting elements mounted on it.

1 shows an electrically powered vehicle 4th , also referred to as an electric vehicle, with a connector part 1 , here in the form of a charging socket, for a detachable electrical connection with a mating connector part 3 . Together form the connector part 1 and the mating connector part 3 a connector. Also shows 1 a charging station 5 used to charge the vehicle 4th serves. The charging station 5 is designed to provide a charging current in the form of a direct current (alternatively or additionally an alternating current) and has a cable that connects at one end to the charging station 5 and at the other end to the mating connector part 3 is connected in the form of a charging plug. The mating connector part 3 is in the example shown as a manually operated charging plug for the electric vehicle 4th educated.

2A and 2 B show the connector part 1 . The connector part 1 is available for mounting on the electric vehicle 4th designed, specifically as a vehicle inlet, e.g. according to the CCS (Combined Charging System) type 2 .

The connector part 1 is designed to transmit a charging current in the form of a direct current and / or in the form of an alternating current. It represents an actively cooled charging connector part. The connector part is here 1 to a coolant circuit 40 of the vehicle 4th and to a direct current network 41 of the vehicle 4th connected.

The connector part 1 includes a housing 16 . The case 16 forms a connection area for the mating connector part 3 . Two plug contacts are used for this 11 to build a DC circuit. The plug contacts 11 are high-current load contacts. The plug contacts 11 are e.g. turned parts. You can conduct currents of 50 A or more, in particular 100 A or more, during, in particular for the duration of a charging process or discharging process. Additional plug contacts serve, for example, as protective conductors (PE) and as AC or three-phase current contacts or as data connections.

For connection to the direct current network 41 are cables 2 to the connector part 1 connected. One of two cables each 2 serves to connect the positive and negative pole of a direct current connection. Together with the cables 2 forms the connector part 1 a connector assembly. The cables 2 are in one direction on the connector part 1 connected, which is approximately perpendicular to an insertion direction of the mating connector part 3 to the connector part 1 is aligned. Some of the cables, especially the two cables, are optional 2 for direct current transmission in a common cable or in a cable bundle, as in 2A illustrated by dashed lines.

3A and 3B show parts of the connector part 1 , which in themselves already serve as a connector part, and cables connected to them 2 .

The connector part 1 generally comprises at least one, here two bridge elements 10A , 10B for connecting an electrical line 21st of the respective cable 2 and with a cooling line holder 103 to the thermally conductive system with a coolant line 22nd of the cable 2 the one with the bridge element 10A , 10B electrically connected plug contact 11 and a heat sink 12th , the one with the bridge element 10A , 10B is in a thermally conductive connection and one coolant channel 120 (see in particular 9C to 9E) forms to which the coolant line 22nd connectable and connected. The bridge element (s) 10A , 10B is / are electrical from the heat sink 12th isolated. Every bridge element 10A , 10B provides an electrical connection between the respective plug contact 11 and the respective electrical line 21st here.

The cooling line intake 103 is perpendicular to the plug contact 11 aligned. In the cooling line intake 103 is the cooling line 22nd insertable, specifically so that along the circumference of the cooling line 22nd part of the cooling line 22nd of the cooling line intake 103 is facing and part of the cooling line 22nd of the cooling line intake 103 is turned away.

The cables 2 each include the coolant line 22nd by the electric line 21st is surrounded. The coolant line 22nd is designed as a hose, for example. For example, water can be used as a coolant. The electrical line 21st is, for example, a layer of copper strands that form the coolant line 22nd surrounds along its length. The electrical line 21st from each of the cables 2 is electrical to one connector end 23A , 23B connected.

For electrical connection of each of the two cables 2 on one of the two bridge elements 10A , 10B is the respective connection end 23A , 23B electrically with the corresponding bridge element 10A , 10B connected, for example welded thereto, for example by means of ultrasonic welding. Furthermore, the (exposed) coolant line is located 22nd each of the cables 2 flat on the respective bridge element 10A , 10B at. One of the two also in 2A visible DC plug contacts 11 is on one of the two bridge elements 10A , 10B attached and electrically connected to it.

Each of the bridge elements 10A , 10B establishes an electrical connection between an electrical conductor 21st from one of the cables 2 with one of the plug contacts 11 here. Furthermore, each of the bridge elements is standing 10A , 10B with the respective coolant line 22nd in two-dimensional system. The bridge elements 10A , 10B can thus be cooled by the coolant flowing in the coolant lines. One of the coolant lines is used here 22nd as the inlet, the other for the coolant line 22nd as a process.

Further details of the bridge elements 10A , 10B are described below in connection with the 7A to 8B explained.

3A and 3B also show a heat sink 12th on which both coolant lines 22nd are connected. Furthermore, the bridge elements 10A , 10B in each of a receptacle of the heat sink 12th plugged in. More details of the heat sink 12th are described below in connection with the 9A to 9E explained.

4A and 4B show one of the two bridge elements 10A , 10B with the assigned cable 2 . It can be seen that the coolant line 22nd of the cable 2 on the bridge element 10A is attached, in the present case by means of two clamps 14th each with one screw 15th to the bridge element 10A are screwed. This causes the coolant line 22nd safe on the bridge element 10A held and also pressed against it, which ensures particularly good heat conduction between the coolant lines 22nd and the bridge elements 10A , 10B enables.

5 shows the other of the two bridge elements 10A , 10B . Especially when compared to 4A and 4B it becomes clear that the in 4A and 4B shown bridge element 10A the connection end 23A and the coolant line 22nd on opposite sides of the bridge element 10A on the bridge element 10A issue. At the in 5 other bridge element shown 10B of the connector part 1 are the connection end 23B and the coolant line 22nd on the same side of the bridge element 10B on the bridge element 10B at.

6A and 6B show using the example of the in 5 bridge element shown 10B such as the coolant line 22nd , in the example shown specifically using a clamp 14th and screw 15th , on the bridge element 10B is attached. The bridge elements 10A , 10B have a cooling line receptacle for this purpose 103 which has substantially the same radius as the coolant line 22nd .

7A and 7B show one of the bridge elements 10A , 10B . In particular in the views of the 7A and 7B it can be seen that the bridge elements 10A a base body 101 has on which a flat connection surface 102 for connecting the electrical line 21st of the corresponding cable 2 is trained. The corresponding connection end is concrete 23A (eg made of copper) can be welded to it, it being alternatively conceivable instead of a flat surface as a connection surface 102 to provide a mounted socket for a crimp connection. Opposite the connection surface 102 forms the main body 101 the cooling line intake 103 out. The cooling line intake 103 is designed as a concave, groove-like elongated recess which has the cross section of a segment of a circle. The radius of the cooling line intake 103 is based on the diameter of the coolant line 22nd Voted. An optional remaining gap between the coolant line 22nd and the bridge element 10A can additionally be or be filled with a thermally conductive medium, for example a thermally conductive adhesive. This serves to ensure a particularly efficient heat transfer for cooling between the bridge element 10A and the coolant line 22nd to realize.

In the basic body 101 there are also several, here two screw holes 104 for mounting the clamps 14th educated. From the basic body 101 there is a plug contact connection 105 ab, in the present case in a direction perpendicular to the main plane of the main body 101 . At the plug contact connection 105 is a through hole, here in the form of a bore 106 educated. At the hole 106 is the corresponding plug contact 11 mountable, eg weldable or screwable with it.

Furthermore stands from the base body 101 a thermal bridge at an obtuse angle 100A from. The thermal bridge 100A is rod-shaped.

8A and 8B show the other of the bridge elements 10A , 10B . This bridge element 10B is similar to the bridge element 10A according to 7A and 7B educated. The difference is the connection surface 102 of the bridge element 10B however, formed on the same side as the cooling line receptacle 103 . The thermal bridge also extends 100B in the same plane as the main body 101 . The plug contact connection 105 of the bridge element 10B according to 8A and 8B is adjacent to the thermal bridge 100B and at a distance from the cooling line receptacle 103 arranged. The plug contact connection 105 of the bridge element 10A according to 7A and 7B is at a distance from the thermal bridge 100A and adjacent to the cooling line receptacle 103 arranged.

The bridge elements 10A , 10B are massive, flat parts made of thermally and electrically good conductive material, e.g. copper. The bridge elements 10A , 10B have a cross-section that allows the conduction of high currents. For example, the bridge elements have a cross section perpendicular to the direction of longitudinal extension at at least one point with a width and height whose ratio is not greater than 3: 1 or 4: 1.

9A to 9E show the heat sink 12th as well as two heat conducting elements 13th .

The heat sink 12th comprises a base body 122 , the recordings for connection with one hose connection each 121 having. The receptacles are in fluid connection with a channel, which in the closed state together with a cover 123 the coolant duct 120 trains. To the hose connections 121 are the two coolant lines 22nd can be connected so that they can be connected via the coolant duct 120 are in fluid communication with each other. A seal 124 seals the lid 123 compared to the base body 122 from. Screws 126 or other fasteners secure the lid 123 on the main body 122 .

The basic body 122 and the lid 123 each have two mutually parallel plane surfaces 127 on. Each of the planar surfaces 127 stands in flat contact with a heat conducting element 13th . A mounting bracket 125 clamps the heat conducting elements 13th against the main body 122 and the lid 123 .

In the heat conducting elements 13th is a thermal bridge 100A , 100B from one of the two bridge elements 10A , 10B recorded. Specifically, the heat conducting elements each have a shaft section for this purpose 130 on, which is closed at the end. The heat conducting elements 13th are each made of a heat conductor, which is also an electrical insulator, e.g. made of aluminum nitride ceramic. Thus the bridge elements 10A , 10B from the heat sink 12th electrically isolated.

Furthermore, the heat conducting elements 13th each a surface section 131 which extends in a plane which is perpendicular to the direction of longitudinal extension of the respective shaft section 130 runs. In this way, particularly reliable electrical insulation can be achieved. The heat conducting elements 13th cause a galvanic separation of the bridge elements 10A , 10B from the heat sink 12th .

Here are the heat conducting elements 13th each in the form of a cap or a hat. The surface sections 131 are designed in the form of a brim.

The bridge elements 10A , 10B are thus in two places through coolant, which through the coolant lines 22nd flows, coolable, namely both via the cooling line receptacles 103 as well as over the thermal bridges 100A , 100B , which enables particularly effective cooling in a small space. The entire part of the bridge elements 10A , 10B , which is between the plug contact 11 and connection surface 102 is located, is penetrated by the load current during operation and heated accordingly. The massive and therefore highly thermally conductive cross-section of the bridge elements 10A , 10B conducts the resulting heat well to these heat transfers.

List of reference symbols

1

Connector part

10A, 10B

Bridge element

100A, 100B

Thermal bridge

101

Base body

102

Connection surface

103

Cooling line intake

104

Screw hole

105

Plug contact connection (connecting section)

106

drilling

11

Plug contact

12

Heat sink

120

Coolant duct

121

Hose connection

122

Base body

123

cover

124

poetry

125

Mounting bracket

126

screw

127

Flat surface

13

Heat conducting element

130

Shaft section

131

Area segment

14th

clamp

15th

screw

16

casing

2

electric wire

21st

electrical line

22nd

Coolant line

23A, 23B

Connection end

3

Mating connector part

4th

vehicle

40

Coolant circuit

41

DC network

5

Charging station

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• DE 102016105311 A1 [0004]
• DE 102016107409 A1 [0004]

Claims (17)

Connector part (1) for connection to a mating connector part (3) with - At least one bridge element (10A, 10B) with a cooling line receptacle (103) for the heat-conducting system with a coolant line (22) of a cable (2), - A plug contact (11) provided on the bridge element (10A, 10B) and electrically connectable to an electrical line (21) of the cable (2) and - A heat sink (12) which is in a thermally conductive connection with the bridge element (10A, 10B) and which forms a coolant channel (120) to which the coolant line (22) can be connected. Connector part (1) Claim 1 , characterized in that the bridge element (10A, 10B) is designed to conduct electrical currents of 200 A or more. Connector part (1) Claim 1 or 2 , characterized in that the bridge element (10A, 10B) is electrically connected to the plug contact (11). Plug connector part (1) according to one of the preceding claims, characterized in that the bridge element (10A, 10B) is formed in one piece. Plug connector part (1) according to one of the preceding claims, characterized in that the cooling line receptacle (103) of the bridge element (10A, 10B) is designed as a concave, elongated recess. Connector part (1) Claim 5 , characterized in that the cooling line receptacle (103) is aligned perpendicular to the plug contact (11). Plug connector part (1) according to one of the preceding claims, characterized in that the bridge element (10A, 10B) has a base body (101) and a thermal bridge (100A, 100B) protruding from the base body (101). Connector part (1) Claim 7 , characterized by an electrically insulating heat conducting element (13) which receives the heat bridge (100A, 100B) of the bridge element (10A, 10B) and which is in flat contact with the heat sink (12). Plug connector part (1) according to one of the preceding claims, characterized by two bridge elements (10A, 10B), both bridge elements (10A, 10B) being in a thermally conductive connection with the cooling body (12). Plug connector part (1) according to one of the preceding claims, characterized in that the cooling body (12) has an inlet and an outlet, wherein coolant introduced through the inlet in an inlet direction flows out of the outlet in an outlet direction which is directed opposite to the inlet direction. Plug connector part (1) according to one of the preceding claims, characterized in that the plug connector part (1) is designed as a vehicle charging socket for high-performance DC charging. Connector arrangement with a connector part (1) according to one of the preceding claims and a cable (2) which comprises an electrical line (21) and a coolant line (22), the electrical line (21) electrically connected to a connection surface (102) of the bridge element (10A, 10B) is connected and the coolant line (22) is in contact with the cooling line receptacle (103) of the bridge element (10A, 10B) and is connected to the coolant channel (120) of the heat sink (12). Connector arrangement according to Claim 12 , characterized in that the bridge element (10A, 10B) can be cooled on the cooling line receptacle (103) and over the heat bridge (100A, 100B) by means of coolant flowing through the coolant line (22). Connector arrangement according to Claim 12 or 13th , characterized in that the electrical line (21) surrounds the coolant line (22). Connector arrangement according to one of the Claims 12 to 14th , characterized in that the electrical line (21) is connected to the connection surface (102) via a welded connection. Connector arrangement according to one of the Claims 12 to 15th , characterized in that the connector part (1) comprises two bridge elements (10A, 10B), both bridge elements (10A, 10B) being in a thermally conductive connection with the heat sink (12), with two electrical lines (21) and two coolant lines (22 ) are provided and the electrical lines (21) are each electrically connected to the connection surface (102) of one of the bridge elements (10A, 10B) and the coolant lines (22) are each in contact with the cooling line receptacle (103) of one of the bridge elements ( 10A, 10B) and are connected to the coolant channel (120) of the heat sink (12). Bridge element (10A; 10B) for the connector part (1) according to one of the Claims 1 to 11 , With - a base body (101) which has a connection surface (102) for connecting an electrical line (21) of a cable (2) and a cooling line receptacle (103) for receiving a coolant line (22) of the cable (2) in a thermally conductive manner, - a connecting section ( 105), via which the connection surface (102) and a plug contact (11) are electrically connected to one another, and - a thermal bridge (101; 100B) protruding from the base body (101).

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