DE102021112300A1 - CONTACT EQUIPMENT FOR A DOUBLE CURRENT RAIL, COUNTERPART TO THE CONTACT DEVICE AND CONTACT SYSTEM FOR TWO DOUBLE CURRENT RAILS - Google Patents

Abstract

The present invention relates to a contact device (104) for a double busbar (102), the double busbar (102) having a first busbar (108) and a second busbar (110), which are separated from one another by insulation (112) and are stacked one on top of the other to form a stack, the contact device (104) having an outer contact socket (114) and an inner contact socket (116) arranged coaxially in the outer contact socket (114), an outer laminar strip ( 122) for contacting a mating socket (120) of a counterpart (106) to the contact device (104) and on an inside of the inner contact socket (116) an inner laminar strip (124) for contacting a contact pin (120) of the counterpart (106) is arranged, wherein the outer contact socket (114) is arranged on a flat side of the first busbar (108) and with the first busbar ( 108) is electrically conductively connected, the inner contact socket (116) being electrically conductively connected to the second busbar (110) and penetrating the first busbar (108).

Description

technical field

The present invention relates to a contact device for a double busbar, a counterpart to the contact device and a contact system for two double busbars.

State of the art

The present invention is described below mainly in connection with vehicle on-board networks. However, the invention can be used in any application in which electrical loads, in particular large electrical loads with significant outputs of, for example, more than 10 kW or with significant voltages of, for example, more than 100V, are transmitted.

In a low-voltage electrical system of a vehicle, electrically conductive sheet metal of a body can be used as ground, which means that separate return lines can be dispensed with. In this way, approximately half of all cables in the vehicle can be dispensed with.

Motor vehicle high voltage with, for example, more than 300V or even more than 700V can be used to transmit large electrical loads. Busbars made of solid metal material can be used for high-voltage motor vehicles. If busbars are used, separate plus and minus busbars may be required for safety reasons. The plus and minus rails can be designed as a double rail.

Description of the invention

It is therefore an object of the invention to provide an improved contact device for a double busbar, an improved counterpart to the contact device and an improved contact system for two double busbars using means that are as simple as possible in terms of construction. An improvement here can relate, for example, to an improved emission characteristic, in particular a reduced emission of electromagnetic fields.

The object is solved by the subject matter of the independent claims. Advantageous developments of the invention are specified in the dependent claims, the description and the accompanying figures.

In an electrically driven vehicle, large electrical current flows are required, even with high-voltage vehicle voltage, in order to transmit drive power or braking or recuperation power. Electromagnetic fields are generated around current-carrying conductors of the vehicle by the current flows. The conductors can be shielded to reduce or even prevent the fields from being radiated. Alternatively or additionally, the conductors for the outgoing line and the return line can be arranged as parallel and close together as possible, since the electromagnetic fields caused by the opposing current flows cancel each other out.

Even with busbars, the busbar for the forward line and the busbar for the return line can be arranged very close together by stacking the two busbars congruently one on top of the other. The stacked busbars are individually electrically insulated. This arrangement can be referred to as a double busbar.

In order to maintain the cancellation effect at contact points as well, the approach presented here proposes a double socket with contact lamella, which also enables the current flows to be routed coaxially at the contact point.

A contact device for a double busbar is proposed, the double busbar having a first busbar and a second busbar, which are separated from one another by insulation and are stacked one on top of the other, the contact device having an outer contact socket and an inner one arranged coaxially in the outer contact socket Has a contact socket, with an outer lamellar strip for contacting a mating socket of a counterpart to the contact device being arranged on an inside of the outer contact socket, and an inner lamellar strip for contacting a contact pin of the counterpart being arranged on an inside of the inner contact socket, with the outer contact socket on a flat side the first busbar is arranged and is electrically conductively connected to the first busbar, the inner contact socket being electrically conductively connected to the second busbar and the first Stromsc hiene penetrates.

Furthermore, a counterpart to the contact device according to the approach presented here is proposed, the counterpart having a counter-socket for contacting the outer lamellar strip of the contact device and a contact pin arranged coaxially in the counter-socket for contacting the inner lamellar strip of the contact device.

Furthermore, a contact system for two double busbars is proposed, with the double busbars each having two busbars, which are each separated from one another by insulation and stacked one on top of the other, with a first of the double busbars having a contact device according to the approach presented here, and a second of double busbars has a counterpart according to the approach presented here, the outer mating socket being arranged on a flat side of a first busbar of the second double busbar and being electrically conductively connected to the first busbar, the contact pin being electrically conductively connected to a second busbar of the second double busbar and the first conductor rail penetrates, the outer contact socket being electrically conductively connected to the outer mating socket via the outer laminar strip, and the inner contact socket being electrically conductive via the inner laminar strip d is connected to the contact pin.

A busbar can be understood as a solid strip of sheet metal. The bus bar can be made of an aluminum material or a copper material, for example. Aluminum or aluminum alloys have good electrical conductivity with low weight and low material costs. Copper or copper alloys can have a higher electrical conductivity than aluminum or aluminum alloys. In addition, copper or a copper alloy can be resistant to oxidation and have a low contact resistance. The conductor rail can have a rectangular line cross section. In this case, the conductor rail can be elongate and have a length of, for example, more than 0.5 m, preferably more than 1 m, and a width of, for example, between 0.5 cm and 10 cm, preferably between 1 cm and 5 cm. The conductor rail can also have a thickness of between 1 mm and 10 mm, for example. The conductor rail can have insulation on all sides, i.e. it can be surrounded by insulation. The insulation can be made of a plastic material, for example. The plastic material can be a thermoplastic. The busbar can be overmoulded with the thermoplastic. The insulation can have properties that are designed for high-voltage motor vehicles of up to 1000 volts direct current. In particular, a material thickness of the insulation can ensure dielectric strength against the motor vehicle high voltage.

A double busbar can consist of two busbars with the same dimensions. The two busbars can be stacked on top of each other on flat sides. The busbars can also be at a small distance from one another. The busbars can be arranged congruently. The double busbar can be covered with a plastic material. Alternatively or additionally, the double busbar can be covered with a fabric material. The fabric material can, for example, be wound around the double busbar as a fabric tape. The double busbar can also be additionally shielded against the emission of electromagnetic fields by an electrically conductive jacket.

When installed, one busbar of the double busbar can be connected to a positive potential of the high-voltage motor vehicle. The other busbar of the double busbar can be connected to a negative potential of the high-voltage motor vehicle. Current flows through the two busbars thus flow in opposite directions and are of equal magnitude. Due to the spatial proximity of the busbars in the double busbar, the resulting electromagnetic fields compensate each other essentially completely.

A contact socket can be made of a copper material. The contact socket can be rotationally symmetrical. The contact socket can essentially be a hollow cylinder. The contact socket can have a connection geometry for electrically conductive connection to the respective busbar. The contact sockets can be connected to the busbars by friction welding.

A laminar strip can encircle an inner diameter of the outer or inner contact socket. The laminar strip can be electrically conductive and be electrically conductively connected to the inside of the respective contact socket. The slat band can have resilient slats. The laminar strip can have a smaller inner diameter than the respective contact socket. The lamellae can be aligned essentially axially with respect to the respective contact socket. The lamellae can be elastically deformed when they come into contact with the counterpart and press against the counterpart with a resulting restoring force. An axial offset and/or an angular offset between the contact device and the counterpart can be compensated for by the elasticity of the lamellae.

A mating socket can essentially correspond to a contact socket. An outer diameter of the mating socket can be smaller than the inner diameter of the outer contact socket in the area of the outer lamellar strip. The outside passage diameter of the mating bush can be larger than the inside diameter of the outer laminar band. The mating bush can be designed without a lamellar strip.

A contact pin can be a solid electrical conductor. The contact pin can be made of a copper material. The contact pin can be rotationally symmetrical. An outer diameter of the contact pin can be smaller than the inner diameter of the inner contact socket in the area of the inner lamellar strip. The outer diameter of the contact pin can be larger than the inner diameter of the inner laminar band. The contact pin can have a connection geometry for electrically conductive connection to the second busbar. The contact pin can be connected to the busbar by friction welding.

The contact sockets are electrically isolated from each other. An insulating bush can be arranged between the inner contact bush and the outer contact bush.

Likewise, the mating socket and the contact pin are electrically insulated from one another. An insulating bush can also be arranged between the mating bush and the contact pin. The insulating bush can be rotationally symmetrical. The insulating bush can be essentially hollow-cylindrical.

The outer contact socket can have a circumferential groove on the inside, i.e. an annular groove, for the outer laminated strip. Alternatively or additionally, the inner contact socket can have a circumferential groove for the inner lamellar strip on the inside. At least partial areas or an entirety of the laminated strip assigned to the respective contact socket can be accommodated in such grooves. The laminated strip can be fixed axially in the respective contact socket by a groove. The lamellae of the lamellar strip can protrude from the groove into an interior of the respective contact socket. The lamella strip can be inserted into the groove as a round strip with a length corresponding to the circumference of the groove. The lamella band can be pressed against a base of the groove by a restoring force.

In the area of the outer laminar strip, an annular gap for the mating socket can be arranged between the outer contact socket and the inner contact socket. The gap can be wider than the mating bushing. The gap can be limited on its inside by the insulation. The gap can be formed by a shoulder of the outer and/or inner contact socket. The mating socket can be inserted between the outer contact socket and the inner contact socket through the gap. The contact system can thus have a low overall height.

The insulator arranged between the outer contact socket and the inner contact socket can cover an end face of the inner contact socket. The insulator can have a hole for the contact pin. The contact pin can center itself on the hole.

Lamellae of the outer lamellar band and/or the inner lamellar band can be elongate, extend essentially parallel to an axial direction of the outer and inner contact socket and protrude radially inwards at least in regions beyond an inner surface of the associated contact socket.

Lamellae of the outer lamellar strip and/or the inner lamellar strip can protrude radially inwards over an inner surface of the associated contact socket in an elastically resilient manner.

The sipe bands may each have an upper girdle, a lower girdle, and a plurality of sipes arranged transversely between the upper girdle and the lower girdle. The lamella bands can be stamped and bent parts. The lamella bands can have slits between the lamellas. The slat strips can be easily bent through the slots. The belts can connect the individual slats to one another like a ladder at both ends. The slats can be pre-bent in an arc shape.

The mating socket and the contact pin can be centered in the contact device via the preferably arcuate lamellae which project radially inwards. When inserting the mating socket and the contact pin into the contact sockets, the lamellae can be elastically bent back against the pre-bending and thus build up the restoring force as a contact force.

character list

• 1 eine Schnittdarstellung eines Kontaktsystems gemäß einem Ausführungsbeispiel.
• 2 eine perspektivische Darstellung auf eine Doppelstromschiene mit einer Kontakteinrichtung gemäß einem Ausführungsbeispiel.

An advantageous exemplary embodiment of the invention is explained below with reference to the accompanying figures. Show it:

• 1 a sectional view of a contact system according to an embodiment.
• 2 a perspective view of a double busbar with a contact device according to an embodiment.

The figures are only schematic representations and only serve to explain the invention. are the same or have the same effect consistently provided with the same reference numerals.

Detailed description

1 shows a sectional view of a contact system 100 according to an embodiment. 2 shows a perspective view of a double busbar 102 with a contact device 104.

The contact system 100 electrically connects two double busbars 102 here. The contact system can also connect a double busbar 102 to another electrical component. The contact system 100 consists of a contact device 104 and a counterpart 106 to the contact device 104.

The double busbars 102 each consist of two parallel running busbars 108, 110. The busbars 108, 110 each have electrical insulation 112. The contact device 104 and the counterpart 106 are arranged at the end regions of the double current busbars 102 . In this case, the contact device 104 and the counterpart 106 are aligned transversely to a main extension direction of the double busbars 102 and are each arranged on a flat side of the respective double busbar 102 .

The contact device 104 has two coaxially arranged contact sockets 114, 116. The contact sockets 114, 116 are essentially hollow-cylindrical. An outer contact socket 114 encloses an inner contact socket 116. Between the contact sockets 114, 116 an insulation 112 is also arranged. The outer contact socket 114 is electrically conductively connected to the first busbar 108 of the first double busbar 102 . The inner contact socket 116 is electrically conductively connected to the second busbar 110 of the first double busbar 102 . The inner contact socket 116 runs in an electrically insulated manner through the first busbar 108 in order to reach the second busbar 110 arranged behind it.

The counterpart 106 has a counter socket 118 and a contact pin 120 . The mating sleeve 118 is essentially hollow-cylindrical. The mating socket 118 encloses the contact pin 120. Between the mating socket 118 and the contact pin 120 an insulation 112 is arranged. The mating socket 118 is electrically conductively connected to the first busbar 108 of the second double busbar 102 . The contact pin 120 is electrically conductively connected to the second busbar 110 of the second double busbar 102 . The contact pin 120 runs in an electrically insulated manner through the first busbar 108 in order to reach the second busbar 110 arranged behind it.

In one embodiment, contact pin 120 leads mating socket 118 . The contact pin 120 thus contacts the inner contact socket 116 before the mating socket 18 contacts the outer contact socket. The contact pin 120 can have an insertion bevel at its end. The contact device 104 and the counterpart 106 can be aligned with one another and axially plugged together via the insertion bevel.

In the contacted state of the contact system 100, the mating socket 118 is arranged in the outer contact socket 114. An outer laminar strip 122 of the contact device 104 is arranged between the outer contact socket 114 and the mating socket 118 . The outer laminated strip 122 is clamped into the outer contact socket 114 when the mating socket 118 is inserted and connects the outer contact socket 114 and the mating socket 118 in an electrically conductive manner.

In the contacted state of the contact system 100, the contact pin 120 is arranged inside the inner contact socket 116. An inner laminar strip 124 of the contact device 104 is arranged between the inner contact socket 116 and the contact pin 120 . When the contact pin 120 is inserted, the inner laminar strip 124 is clamped into the inner contact socket 116 and electrically conductively connects the inner contact socket 116 and the contact pin 120 .

In one embodiment, the laminar strips 122, 124 each consist of a ladder-shaped strip of sheet metal. The slat bands 122, 124 have an upper chord 126, a lower chord 128 and the slats 130 formed between the slits by a plurality of parallel slits cut or stamped in the strip. The slats 130 are arcuately bent about a longitudinal axis of the strip. For insertion into the contact sockets 114, 116, the strips are cut to length and spirally wound. Within the contact sockets 114, 116 the winding is released and the strips rest against the inner sides of the contact sockets 114, 116 in a ring shape by a restoring force of the upper and lower straps 126,128.

In one embodiment, bus bars 108, 110 are aluminum material while contact sockets 114, 116, mating socket 118 and contact pin 120 are copper material. The contact sockets 114, 116, the mating socket 118 and the contact pin 120 are connected to the busbars 108, 110 through Friction welding connected to get a secure electrically conductive connection.

In one exemplary embodiment, the laminar strips 122, 124 are arranged in a ring shape on the insides around the grooves 132 running around the contact sockets 114, 116. The laminar strips 122, 124 are fixed axially by the grooves 132 and cannot be displaced axially when the mating bushing 118 is pushed into the outer contact bushing 114 or when the contact pin 120 is pushed into the inner contact bushing 116.

In one embodiment, mating sleeve 118 is disposed in an annular gap 134 between outer contact sleeve 114 and insulation 112 . The inner contact socket 116 has a circumferential recess by a material thickness of the mating socket 118 in order to provide space for the gap 134 . The contact device 104 and the counterpart 106 are nested through the gap 134 and have a reduced overall height.

In one embodiment, the insulator 112 covers an end face of the inner contact socket 116. Electrical contact between the mating socket 118 and the inner contact socket 116 can thus be reliably avoided.

In one exemplary embodiment, the contact device 104 and the counterpart 106 each have an electrically insulating housing 136 . The housing 136 also encloses the end regions of the double busbars 102. The two housings 136 are sealed from one another by a seal surrounding the outer contact socket 114.

In other words, a double socket with a contact lamella is presented as a contact system for a double-bar power transmission system.

In addition to classic round conductor and single rail systems in the field of e-mobility, double rail systems can also be used to transmit electrical energy, as they have advantages in terms of lower electromagnetic field radiation due to field cancellation. The field cancellation results from a geometric arrangement of congruent rectangular rails one on top of the other at the smallest possible distance from one another. Interfaces with a contacting system are required to connect these double rail systems to components such as charging sockets, switch boxes or batteries.

The present approach presents a contacting system that consists geometrically of two concentric socket contacts that are electrically insulated from one another. The laminar strips used as contact surfaces on the inner surfaces of the bushings are characteristic. These can be pre-punched as an endless strip, cut to length and inserted into an annular groove provided for this purpose in the bush. The necessary contact force is applied via the external screw connection of the housing. The contact system retains a degree of freedom in the plug-in direction, with further prestressing of the inner socket elements by means of e.g. B. a wave spring for tolerance compensation between the contact pairs of the plus and the minus side of the contact is not required. The contact system can be screwed or locked on the housing side. Possible areas of application are the interface to the charging socket, the interface to the switch box or battery, and use as a flying separation point for a segmented double rail in difficult installation spaces where the entire length does not seem manageable.

In the context of the increasing electrical performance requirements in the context of e-mobility, the aspect of occupant protection against electromagnetic pollution (ICNIRP) is increasingly coming into focus. High-voltage (HV) double rail systems can transport high amounts of energy with low electromagnetic field emissions at the same time. The rail system requires suitable interfaces suitable for outdoor use. Thanks to the contact system presented, the double rail can be used in the installation space as an interface to the switch box or battery. The contact system can also be used as an interface to the charging socket, as an interface to the switch box or battery, and as a flying separation point for a segmented double rail in difficult installation spaces where the entire length does not seem manageable.

The contact is not made via the end faces of the socket geometries, but via an embedded contact lamella on the inside of the sockets. The contact system retains a degree of freedom in the plug-in direction, preloading one of the pairs of contact sockets via a spring element is not necessary.

The figure shows the sectional view through the double socket contact system with flanged busbars. The case illustration is conceptual only. In the finished construction, the header and connector housing are screwed or locked together. The inner contact pin, which makes contact with the contact lamella of the inner socket, is clearly visible in section. The outer contact system is represented by a socket in the header (around the pin), which makes contact with the contact lamella of the upper outer contact socket. The contact system can be found on Sei the header can be used as a floating separation point if the double rail system cannot be installed in one piece (e.g. for assembly reasons). The contact system can also be used as an interface to the charging socket. There are options here for screwing directly into one of the DC pins or connecting to contacts (screwed, plugged) of the charging socket via rail sections.

To ensure protection against accidental contact and the isolation of the potentials, the two sockets are covered by plastic geometries that are pushed back during the plugging process.

Since the devices described in detail above are exemplary embodiments, they can be modified to a large extent in the usual way by a person skilled in the art without departing from the scope of the invention. In particular, the mechanical arrangements and the size ratios of the individual elements to one another are merely exemplary.

Reference List

100

contact system

102

double track

104

contact facility

106

counterpart

108

first power rail

110

second power rail

112

insulation

114

outer contact socket

116

inner contact socket

118

mating bush

120

contact pin

122

outer slat band

124

inner slat band

126

top strap

128

lower strap

130

lamella

132

groove

134

gap

136

Housing

Claims (9)

Contact device (104) for a double busbar (102), the double busbar (102) having a first busbar (108) and a second busbar (110), which are separated from one another by insulation (112) and are stacked on top of one another to form a stack, wherein the contact device (104) has an outer contact socket (114) and an inner contact socket (116) arranged coaxially in the outer contact socket (114), with an outer laminar strip (122) for contacting a mating socket ( 120) of a counterpart (106) to the contact device (104) and an inner laminar strip (124) for contacting a contact pin (120) of the counterpart (106) is arranged on an inside of the inner contact socket (116), the outer contact socket (114) is arranged on a flat side of the first busbar (108) and is electrically conductively connected to the first busbar (108), the inner contact socket (116) is electrically conductively connected to the second busbar (110) and penetrates the first busbar (108). Contact device (104) according to claim 1 , in which the outer contact socket (114) has a circumferential groove (132) on the inside and the outer laminated strip (122) is accommodated in the groove (132) at least in some areas, and/or in which the inner contact socket (116) is on the Inside has a circumferential groove (132), and the inner lamellar strip (122) is accommodated at least in regions in the groove (132). Contact device (104) according to one of the preceding claims, in which an annular gap (134) for accommodating the mating bushing (118) is arranged between the outer contact bushing (114) and the inner contact bushing (116) in the region of the outer laminar strip (122). Contact device (104) according to one of the preceding claims, in which insulation (112) arranged between the outer contact socket (114) and the inner contact socket (116) covers an end face of the inner contact socket (116). The contactor (104) of any preceding claim, wherein said outer lamina band (122) includes an upper chord (126), a lower chord (128) and a plurality of transversely between said upper chord (126) and lower chord (128) arranged slats (130) and / or the inner slat band (124) has an upper chord (126), a lower chord (128) and a plurality of transversely between the upper chord (126) and the lower chord (128) arranged slats ( 130). Contact device (104) according to one of the preceding claims, in which the lamellae (130) of the outer lamellar strip (122) and/or the inner lamellar strip (124) are elongate, extending essentially parallel to an axial direction of the outer and inner contact socket (114, 116) and protrude radially inwards, at least in some areas, beyond an inner surface of the associated contact socket (114, 116). Contact device (104) according to one of the preceding claims, in which the lamellae (130) of the outer lamellar strip (122) and/or the inner lamellar strip (124) protrude radially inwards in an elastically resilient manner beyond an inner surface of the associated contact socket (114, 116). Counterpart (106) to a contact device (104) according to one of Claims 1 until 7 , wherein the counterpart (106) has a counter-bushing (118) for contacting the outer laminar strip (122) of the contact device (110) and a contact pin (120) arranged coaxially in the counter-bushing (118) for contacting the inner lamellar strip (124) of the contact device ( 104). Contact system (100) for two double busbars (102), the double busbars (102) each having two busbars (108, 110), which are each separated from one another by insulation (112) and are stacked one on top of the other to form a stack, with a first of the double busbars (102) a contact device (104) according to one of Claims 1 until 7 having, and a second of the double busbars (102) has a counterpart (106) according to claim 8 has, wherein the mating socket (118) is arranged on a flat side of a first busbar (108) of the second double busbar (102) and is electrically conductively connected to the first busbar (108), the contact pin (120) being connected to a second busbar (110 ) is electrically conductively connected to the second double busbar (102) and penetrates the first busbar (108), the outer contact socket (114) being electrically conductively connected to the outer mating socket (118) via the outer laminar strip (122) and the inner contact socket ( 116) is electrically conductively connected to the contact pin (120) via the inner laminar strip (124).

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