DE102021112300B4 - CONTACT DEVICE FOR A DOUBLE POWER RAIL, MATCH TO THE CONTACT DEVICE AND CONTACT SYSTEM FOR TWO DOUBLE POWER RAILS - Google Patents

Abstract

First double busbar (102) with a contact device (104), the first double busbar (102) having a first busbar (108) and a second busbar (110), which are separated from each other by insulation (112) and stacked one on top of the other 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), wherein on an inside of the outer contact socket (114) there is an outer lamellar strip (122) for contacting a Counter socket (120) of a counterpart (106) to the contact device (104) is arranged and on an inside of the inner contact socket (116) an inner lamellar strip (124) for contacting a contact pin (120) of the counterpart (106) is arranged, 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) being electrically conductively connected to the second busbar (110) and the first Busbar (108) penetrates.

Description

Technical area

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 electrical systems. However, the invention can be used in any application in which electrical loads, in particular large electrical loads with significant powers of, for example, more than 10kW or with significant voltages of, for example, more than 100V, are transmitted.

In a vehicle's low-voltage electrical system, electrically conductive sheet metal from a body can be used as ground, which means there is no need for separate return lines. This means that approximately half of all cables in the vehicle can be eliminated.

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

The publication WO 2019/037 357 A1 describes a connector. The connector includes a plug head and a socket head used to connect to the plug head in an inserted manner. The connector head includes a connector head base and a connector set provided on the connector head base. The socket head includes a socket head base, a socket set provided on the socket head base and enabling insertion of the plug set, and a crown spring set fixedly provided in the socket set and used to be in elastic contact with the plug set. The crown spring set is provided in the socket set and after the plug set is inserted into the socket set, the crown spring set is elastically deformed according to the shape of the plug set and is firmly connected to the plug set all the time, so that the plug head and the socket head are in good contact , after they are connected together, facilitating the transmission of a large current.

The publication DE 10 2007 059 521 A1 relates to a high-current coaxial connection with two plug-in elements that can be connected to one another, a first and a second union nut being provided on a plug-in element, the first union nut being screwed with a first thread onto a plug-in contact to be fixed on the plug-in element, while the second union nut overlapping the first union nut is screwed with a second thread onto a mating thread section on the other plug-in element. Both union nuts are secured against rotation relative to each other and the first and second threads are different.

The publication DE 10 2007 007 541 A1 describes a high-current coaxial connection with two plug-in elements that can be connected to one another, the high-current coaxial connection having two spring contact elements arranged coaxially to one another for producing electrical contact between the two plug-in elements.

From the publication DE 10 2013 201 125 A1 a connector is known. The connector has an inner conductor which is arranged in an electrically insulating housing, the inner conductor comprising a line-side first inner conductor part for connecting to a line, and a plug-side second inner conductor part for connecting to a plug. The first inner conductor part and the second inner conductor part are connected to one another via a press fit and riveted together.

The publication CN 2 11 556 357 U relates to a coaxial connector connection contact piece comprising a male terminal and a female terminal that mates with the male terminal.

Description of the invention

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

The task is solved by the subjects of the independent claims. Advantageous developments of the invention are in the dependent Claims, the description and the accompanying figures.

In an electrically driven vehicle, large electrical current flows are required, even at high voltage, in order to transmit drive power or braking or recuperation power. The current flows generate electromagnetic fields around current-carrying vehicle conductors. In order to reduce or prevent radiation of the fields, the conductors can be shielded. Alternatively or additionally, the conductors for the forward and return lines can be arranged as parallel and as 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 outgoing line and the busbar for the return line can be arranged very close together by stacking the two busbars congruently on top of each other. The stacked busbars are individually electrically insulated. This arrangement can be referred to as a double busbar.

In order to maintain the effect of extinction also at contact points, the approach presented here proposes a double socket with a contact lamella, which enables coaxial guidance of the current flows at the contact point as well.

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

Furthermore, a second double busbar with a counterpart to the contact device according to the approach presented here is proposed, the counterpart having a mating socket for contacting the outer lamella band of the contact device and a contact pin arranged coaxially in the mating socket for contacting the inner lamella band of the contact device. The second double busbar has a first busbar and a second busbar, which are separated from each other by insulation and stacked one on top of the other to form a stack. The counter socket is arranged on a flat side of the first busbar and is electrically connected to the first busbar, the contact pin being electrically connected to the second busbar and penetrating the first busbar.

Furthermore, a contact system comprising two double busbars is proposed, the double busbars each having two busbars, each of which is separated from one another by insulation and stacked one on top of the other to form a stack, a first of the double busbars having a contact device according to the approach presented here, and a second of the Double busbars have a counterpart according to the approach presented here, wherein the outer counter socket is arranged on a flat side of a first busbar of the second double busbar and is electrically connected to the first busbar, wherein the contact pin is electrically connected to a second busbar of the second double busbar and penetrates the first busbar, the outer contact socket being electrically conductively connected to the outer mating socket via the outer lamella strip and the inner contact socket being electrically conductively connected to the contact pin via the inner lamella strip.

A busbar can be understood as a solid strip of sheet metal. The busbar 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 busbar can have a rectangular cable cross section. The busbar can be elongated 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 busbar can also have a thickness of, for example, between 1 mm and 10 mm. The busbar can have insulation on all sides, that is, it can be covered by insulation. The insulation can be made of a plastic material, for example. The plastic material can be a thermoplastic. The busbar can be encapsulated with the thermoplastic. The insulation can have properties that are designed for high-voltage automotive voltages of up to 1000 volts direct current. In particular, a material thickness of the insulation can ensure dielectric strength against the vehicle high-voltage 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 wrapped around the double busbar as a fabric tape. The double busbar can also be additionally shielded against the radiation 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 vehicle's high-voltage voltage. The other busbar of the double busbar can be connected to a negative potential of the vehicle high-voltage voltage. Current flows through the two busbars flow in opposite directions and are the same size. Due to the spatial proximity of the busbars in the double busbar, the resulting electromagnetic fields essentially completely compensate for each other.

A contact socket can be made of a copper material. The contact socket can be rotationally symmetrical. The contact socket can be essentially hollow cylindrical. 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 lamella band can run in a ring shape along an inner diameter of the outer or inner contact socket. The lamella strip can be electrically conductive and can be electrically conductively connected to the inside of the respective contact socket. The slat band can have resilient slats. The lamella strip can have a smaller inner diameter than the respective contact socket. The slats can be aligned essentially axially to the respective contact socket. The slats can be elastically deformed when they come into contact with the counterpart and press against the counterpart with a resulting restoring force. Due to the elasticity of the slats, an axial offset and/or an angular offset between the contact device and the counterpart can be compensated for.

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 lamella band. The outside diameter of the mating bushing can be larger than the inside diameter of the outer lamella band. The counter bushing can be designed without a lamella band.

A contact pin can be a solid electrical conductor. The contact pin can consist 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 band. The outer diameter of the contact pin can be larger than the inner diameter of the inner lamella 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 socket can be arranged between the inner contact socket and the outer contact socket. The mating socket and the contact pin are also electrically insulated from each other. An insulating socket can also be arranged between the mating socket and the contact pin. The insulating bushing can be rotationally symmetrical. The insulating bushing can essentially be hollow cylindrical.

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

In the area of the outer lamella band, 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. On the inside, the gap can be limited 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 through the gap between the outer contact socket and the inner contact socket. The contact system can therefore 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 may have a hole for the contact pin. The contact pin can center on the hole.

Slats of the outer lamella band and/or the inner lamella band can be elongated, extend essentially parallel to an axial direction of the outer and inner contact socket and at least partially protrude radially inwards over an inner surface of the associated contact socket.

Slats of the outer slat band and/or the inner slat band can protrude radially inwards in an elastically resilient manner over an inner surface of the associated contact socket.

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

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

Short character description

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

An advantageous 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 exemplary embodiment.
• 2 a perspective view of a double busbar with a contact device according to an exemplary embodiment.

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

Detailed description

1 shows a sectional view of a contact system 100 according to an exemplary 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 dual bus bar 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 busbars 108, 110. The busbars 108, 110 each have electrical insulation 112. The contact device 104 and the counterpart 106 are arranged at end regions of the double current bars 102. 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. Insulation 112 is also arranged between the contact sockets 114, 116. 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 is electrically insulated through the first busbar 108 to reach the second busbar 110 arranged behind it.

The counterpart 106 has a mating socket 118 and a contact pin 120. The counter bushing 118 is essentially hollow cylindrical. The mating bushing 118 encloses the contact pin 120. An insulation 112 is arranged between the mating bushing 118 and the contact pin 120. The counter socket 118 is electrically 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 electrically insulated through the first busbar 108 in order to reach the second busbar 110 arranged behind it.

In one exemplary embodiment, the contact pin 120 leads the 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 plugged together axially via the insertion bevel.

When the contact system 100 is in the contacted state, the mating socket 118 is arranged in the outer contact socket 114. An outer lamellar band 122 of the contact device 104 is arranged between the outer contact socket 114 and the mating socket 118. The outer lamellar band 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 within the inner contact socket 116. An inner lamellar strip 124 of the contact device 104 is arranged between the inner contact socket 116 and the contact pin 120. The inner lamellar band 124 is clamped into the inner contact socket 116 when the contact pin 120 is inserted and connects the inner contact socket 116 and the contact pin 120 in an electrically conductive manner.

In one exemplary embodiment, the lamella strips 122, 124 each consist of a ladder-shaped strip of sheet metal. Through a plurality of parallel slots cut or punched into the strip, the slat bands 122, 124 have an upper belt 126, a lower belt 128 and the slats 130 formed between the slots. The slats 130 are bent in an arc around a longitudinal axis of the strip. To insert into the contact sockets 114, 116, the strips are cut to length and wound in a spiral. The winding is released within the contact sockets 114, 116 and the strips lie in a ring shape against the insides of the contact sockets 114, 116 due to a restoring force of the upper and lower straps 126, 128.

In one embodiment, the busbars 108, 110 are made of an aluminum material, while the contact sockets 114, 116, the mating socket 118 and the contact pin 120 are made of a copper material. The contact sockets 114, 116, the mating socket 118 and the contact pin 120 are connected to the busbars 108, 110 by friction welding in order to obtain a secure electrically conductive connection.

In one exemplary embodiment, the lamellar bands 122, 124 are arranged in a ring shape on the inside of grooves 132 surrounding the contact sockets 114, 116. The lamellar bands 122, 124 are axially fixed by the grooves 132 and cannot be axially displaced when the counter bushing 118 is inserted into the outer contact socket 114 or when the contact pin 120 is inserted into the inner contact socket 116.

In one embodiment, the mating bushing 118 is arranged in an annular gap 134 between the outer contact bushing 114 and the insulation 112. The inner contact bushing 116 has a circumferential recess by a material thickness of the mating bushing 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 exemplary embodiment, the insulator 112 covers an end face of the inner contact socket 116. In this way, electrical contact between the mating socket 118 and the inner contact socket 116 can be safely 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 against one another via a seal surrounding the outer contact socket 114.

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

In addition to classic round conductor and single rail systems, double ones can also be used to transmit electrical energy in the field of e-mobility Rail systems are used because they have advantages in terms of lower electromagnetic field radiation due to field cancellation. The field extinction results from a geometric arrangement of rectangular rails lying congruently one above 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 geometrically consists of two concentrically nested but electrically insulated socket contacts. The characteristic feature is the lamellar strips installed as contact surfaces on the inner surfaces of the sockets. These can be pre-punched as an endless strip, cut to length and inserted into an annular groove provided in the bushing. 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 using z. B. a wave spring for tolerance compensation between the contact pairs on the plus and minus sides of the contact is not required. The contact system can be screwed or locked on the housing side. Areas of application include the interface to the charging socket, the interface to the switch box or battery as well as the use as a floating separation point of a segmented double rail in difficult installation spaces in which its entire length seems unmanageable.

As part of the increasing electrical performance requirements in the context of e-mobility, the aspect of occupant protection against electromagnetic stress (ICNIRP) is becoming increasingly important. High-voltage (HV) double rail systems can transport high amounts of energy with low electromagnetic field radiation. 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, as well as as a floating separation point of a segmented double rail in difficult installation spaces in which the entire length seems unmanageable.

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

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

To ensure contact protection and 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 in the usual way by those skilled in the art to a wide extent 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 examples.

REFERENCE SYMBOL LIST

100

Contact system

102

Double busbar

104

Contact facility

106

counterpart

108

first busbar

110

second busbar

112

insulation

114

external contact socket

116

inner contact socket

118

Counter bushing

120

Contact pin

122

outer slat band

124

inner slat band

126

top strap

128

lower strap

130

lamella

132

Nut

134

gap

136

Housing

Claims (9)

First double busbar (102) with a contact device (104), the first double busbar (102) having a first busbar (108) and a second busbar (110), which are separated from each other by insulation (112) and stacked one on top of the other 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), wherein on an inside of the outer contact socket (114) there is an outer lamellar strip (122) for contacting a Counter socket (120) of a counterpart (106) to the contact device (104) is arranged and on an inside of the inner contact socket (116) an inner lamellar strip (124) for contacting a contact pin (120) of the counterpart (106) is arranged, 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) being electrically conductively connected to the second busbar (110) and the first Busbar (108) penetrates. First double busbar (102) according to Claim 1 , in which the outer contact socket (114) has a circumferential groove (132) on the inside and the outer lamella band (122) is accommodated at least partially in the groove (132), and / or in which the inner contact socket (116) on the Inside has a circumferential groove (132), and the inner lamella band (122) is accommodated at least partially in the groove (132). First double busbar (102) according to one of the preceding claims, in which an annular gap (134) for receiving the mating socket (118) between the outer contact socket (114) and the inner contact socket (116) is arranged in the area of the outer lamella band (122). . First double busbar (102) according to one of the preceding claims, in which an 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). A first double busbar (102) according to any one of the preceding claims, wherein the outer slat band (122) has an upper belt (126), a lower belt (128) and a plurality of transverse belts between the upper belt (126) and the lower belt (128 ) arranged slats (130) and / or the inner slat band (124) has an upper belt (126), a lower belt (128) and a plurality of slats arranged transversely between the upper belt (126) and the lower belt (128). (130). First double busbar (102) according to one of the preceding claims, in which slats (130) of the outer slat band (122) and/or the inner slat band (124) are elongated, substantially parallel to an axial direction of the outer and inner contact socket (114 , 116) and protrude radially inwards at least in some areas over an inner surface of the associated contact socket (114, 116). First double busbar (102) according to one of the preceding claims, in which slats (130) of the outer slat band (122) and/or the inner slat band (124) protrude radially inwards in an elastically resilient manner over an inner surface of the associated contact socket (114, 116). Second double busbar (102) with a counterpart (106) to the contact device (104) of the first double busbar (102) according to one of Claims 1 until 7 , wherein the second double busbar (102) has a first busbar (108) and a second busbar (110), which are separated from each other by insulation (112) and stacked one on top of the other to form a stack, the counterpart (106) having a mating socket (118). for contacting the outer lamellar band (122) of the contact device (110) and a contact pin (120) arranged coaxially in the mating bushing (118) for contacting the inner lamellar band (124) of the contact device (104), the mating bushing (118) being on a Flat side of the first busbar (108) is arranged and is electrically conductively connected to the first busbar (108), the contact pin (120) being electrically conductively connected to the second busbar (110) and penetrating the first busbar (108). Contact system (100) comprising the first double busbar (102) according to one of Claims 1 until 7 and the second double busbar (102) according to Claim 8 , where the outer Contact socket (114) is electrically conductively connected to the outer mating socket (118) via the outer lamella band (122) and the inner contact socket (116) is electrically conductively connected to the contact pin (120) via the inner lamella band (124).

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