EP1965467B1 - High current plug contact and high current plug device - Google Patents

Abstract

The high current plug contact (1) is electrically connected with a female contact element (2) containing plug-in opening (4), a conductor (9) comprising conducting layer. A sleeve shaped casing (13) covering a female contact element, which is accommodated between the female contact element and sleeve shaped shroud (21), and is arranged with an axial gap to the female contact element. The support sleeve (24) envelops the conductor coaxially around a section of conductor shielding (26).

Description

The invention relates to a high-current contact according to claim 1 and to a high-current plug-in device having at least one such high-current contact according to claim 11.

In the technical field of electrical contacting of electrical and / or electronic devices for the realization of a (partial) electric drive, in particular a hybrid drive in vehicles are used because of the high power requirements and harsh environmental conditions plug connectors only in individual cases. The few known connectors are application-specific developments, which can be difficult or impossible to adapt to other applications in the vehicle due to the high demands on the electrical shielding and the seal against media, especially against moisture. Such a high current plug contact is in the WO 2006013027 A disclosed.

The invention is therefore based on the object to propose an alternative plug contact for high-current applications, on the one hand equipped with a high electrical shield and on the other hand, optionally after a small modification, for a variety of contacting tasks, especially in vehicles with an electric or electrically assisted drive is. In particular, the high-current plug-in contact should be used as a scalable component in high-current plug-in devices. Furthermore, the object is to propose a scalable high-current plug-in device with at least one high-current plug-in contact.

This object is achieved with regard to the high-current plug-in contact with the features of claim 1 and with regard to the high-current plug-in device with the features of claim 11. Advantageous developments of the invention are specified in the subclaims.

The invention is based on the idea of proposing a preferably at least approximately cylindrical high-current plug contact with a female contact element for contacting an interface in which the female contact element is at least partially, preferably completely, surrounded by a sleeve-shaped enclosure, wherein radially outside the enclosure is in an axial Direction extending, sleeve-shaped shield plate is provided, which is connected by crimping with axial distance to the radially inner socket contact element with the cable shielding of the female contact element contacting line. On the one hand, the casing has the function of fixing the socket contact element and the electrical connection produced therewith, especially against vibration, to protect and on the other hand to ensure electrical insulation of the female contact element against the electrically conductive shielding plate. In order to ensure the crimping of the sleeve-shaped shielding plate with the radially inner cable shielding, which is preferably designed as a shield braid, a support sleeve providing the counterforce is provided. This is arranged coaxially to the line contacting the female contact element, wherein the cable shield is folded around the support sleeve, that is sandwiched between the shield plate and the support sleeve. In addition, the support sleeve prevents a disadvantageous for the crimping process sinking the cable shield in an intermediate insulation of the line surrounding the at least one current-carrying wire of the line. Due to the crimping of the cable shielding with the shield plate, on the one hand, the mechanical stability of the high-current plug-in contact is improved and, on the other hand, a good transfer of the shielding from the line to the shielding plate is ensured. In turn, as will be explained later, the shielding plate is passed on to the interface to be contacted by the shielding plate. The support sleeve in turn rests radially on the outside either on the outer insulation of the line and / or on the exposed cable shielding. The described high-current plug-in contact ensures optimal shielding for improving the EMC due to the sleeve-shaped shielding plate and the optimal shield propagation of the cable shielding to the shielding plate in an offset axially to the female contact element crimping. Furthermore, any number of the described high-current plug contacts can be combined in a surrounding housing as a high-current plug-in device, whereby a multiplicity of different application requirements can be met. Under high current in the context of the invention are electrical currents with a current of more than 60 A, in particular of about 100 A or understood about it.

In an embodiment of the invention is advantageously provided that the high-current plug contact is cylindrical. This distinguishes the high-current plug-in contact from a large number of especially L-shaped high current plug contacts of the prior art. The line is guided on the insertion opening of the female contact element opposite side in the high current plug contact for contacting the female contact element.

It is particularly advantageous if the envelope surrounding the female contact element is provided as an encapsulation, i. by encapsulation of the female contact element, preferably formed of an electrically insulating plastic. In particular, the choice of an encapsulation as wrapping an optimal, shape-dependent mechanical fixation of the female contact element is ensured throughout the high-current plug-in contact. The choice of electrically insulating plastic additionally ensures the insulation of the socket contact and preferably also of the otherwise exposed terminal area.

As an alternative, it is conceivable to form the envelope in shell construction, in particular from injection-molded parts, wherein the shell parts are preferably locked together. To ensure a mechanical fixation of the female contact element, it is advantageous if the envelope thus formed is provided with radial stops or radial fixings for the received female contact element. Preferably, even in such an embodiment, the sheath, i. the at least two shell parts, formed of an electrically insulating plastic.

In a further development of the invention is advantageously provided that the Support sleeve for the fixation, preferably with axial distance to the crimping of the shield plate, is crimped with the line shield with the line. Preferably, the support sleeve, in particular made of metal, is crimped with the outer jacket insulation of the line. Also conceivable is an embodiment in which the support sleeve is not crimped or only with an axial Abschitt with the outer sheath insulation and otherwise rests directly on the cable shield and thus crimped in the latter case both with the cable shield and an intermediate insulation of the line. In particular for preventing the penetration of media into the region of the female contact element, it is advantageous if the envelope, in particular formed as an encapsulation or shell component, is led beyond the female contact element in the axial direction and rests radially outward on the intermediate insulation of the line surrounding at least one core. In particular, the wire exposed in the axial direction and contacted with the socket contact element is thus insulated, so that accidental contacting of the outer shielding plate is reliably avoided.

Preferably, the socket contact element comprises a so-called Radsok contact, which is available in different sizes. By means of a Radsok contact a shock-insensitive contacting of an interface, in particular a contact pins, can be ensured.

An advantage is an embodiment in which the shroud is not directly contacted with a shield of the contacting interface, that is not directly applied to this, but that is provided to ensure a reliable Schirmübergabe an abutting on the shield plate shield ring. Among other things, this shield ring contributes to the mechanical stabilization of the shielding plate in the area of its front side and also ensures a secure contacting of the shielding of the interface.

Advantageously, the shield ring comprises a sleeve-shaped portion, which is received radially between the shield plate and the sheath, in particular clamped between these components.

The actual contacting of the interface via a slat portion of the shield plate, which is bent backwards around the end face of the shielding plate and is resilient in the radial direction. Preferably, the slat portion takes the shield plate by clamping. The contacting of the interface takes place with the radially outer circumferential surface of a portion of the shielding plate surrounding the lamella portion of the shield ring.

The invention also relates to a high-current plug-in device having at least one high-current plug-in contact as described above, wherein the at least one high-current plug contact is surrounded by a protective housing. Preferably, the protective housing is formed as encapsulation. It is essential that the protective or surrounding housing is formed from an electrically insulating material. Alternatively, it is conceivable that the protective housing in shell construction, in particular with two mutually latchable shell elements, form. If required, the high-current plug-in device can be provided with additional functionalities, such as a pilot contact. The high-current plug-in device according to the invention is characterized in that it is scalable, i. can be manufactured or equipped with a virtually any number of high-current plug contacts. It is also conceivable to provide plug contacts in different sizes.

In development of the invention it is ensured that the Protective housing against its environment, in particular for preventing the entry of liquids, is sealed. An advantage here is an embodiment in which the seal is formed by the protective housing itself. For this purpose, it is advantageous to select for the protective housing forming encapsulation a material that connects to the outer jacket insulation of the line of the high-current plug-in contact. In this case, the sealing preferably takes place by a fusion of the encapsulation material with the insulation material of the line. Alternatively, it is conceivable to use a single or group seal to seal the line input. Sealing effect is achieved by pressing the seal. In this case, the outer diameter of the seal used is preferably greater than the diameter of the mounting opening receiving the seal. Additionally or alternatively, the inner diameter of the seal used may be less than the outer diameter of the conduit. The at least one seal used is preferably a lamellar seal with a plurality of lamellae arranged axially next to one another and each extending in the circumferential direction. Such a lamellar seal acts as a labyrinth seal, which reliably prevents the ingress of media, in particular even if individual lamellae should be damaged.

Furthermore, an embodiment is advantageous in which to dispense with a separate seal and the sealing function of the support sleeve and the shield plate are taken. In this embodiment, although it is conceivable that media can penetrate into the protective housing, a penetration to the actual socket contact is on the other hand prevented by the tight connection of the support sleeve to the line on the one hand and the tight connection of the shield plate to the support sleeve.

Fig. 1

eine geschnittene, perspektivische Darsiellung eines Hochstrom-Kontaktes, bei dem aus Übersichtlichkeitsgründen ein Schirmring zur Übergabe der Schirmung an eine Schnittstelle weggelassen wurde,

Fig. 2

eine geschnittene Darstellung eines Teilabschnitts des Hochstrom-Steckkontaktes gemäß Fig. 1,

Fig. 3a

eine Seitenansicht eines Hochstrom-Steckkontaktes mit Schirmring,

Fig. 3b

eine perspektivische Darstellung des Schirmrings in Alleinstellung,

Fig. 4a

eine perspektivische Darstellung einer dreipoligen Hochstrom-Steckverbindung mit drei Hochstrom-Steckkontakten und

Fig. 4b

eine perspektivische Darstellung einer bei der Hochstrom-Steckvorrichtung gemäß Fig. 4a zur Anwendung kommenden Lamellendichtung.

Further advantages, features and details of the invention will become apparent from the following description of preferred embodiments and from the drawings; these show in:

Fig. 1

a sectional, perspective Darsiellung a high-current contact, in which for clarity, a shield ring has been omitted for transferring the shielding to an interface,

Fig. 2

a sectional view of a portion of the high-current plug contact according to Fig. 1 .

Fig. 3a

a side view of a high current plug contact with shield ring,

Fig. 3b

a perspective view of the shield ring in isolation,

Fig. 4a

a perspective view of a three-pole high-current connector with three high-current plug contacts and

Fig. 4b

a perspective view of one of the high-current plug-in device according to Fig. 4a used for use Lamella seal.

In the figures, the same components and components with the same function with the same reference numerals.

In Fig. 1 For example, a high current plug contact for contacting applications with currents between about 60 A and about 150 A is shown.

The sleeve-shaped high-current plug-in contact 1 comprises as a core element a socket contact element 2 with a sleeve-shaped Radsok contact, for example, in the German application DE 10 2005 013 633.8 is described. Furthermore, the socket contact element 2 comprises a metallic holding element 5 with two mutually opposite blind holes 6, 7, wherein the right in the plane of the blind hole has a smaller inner diameter than that receiving the Radsok contact Blind hole 6.

In the blind hole 7 in the axial direction, the single, central core 8 of a line 9 is guided and contacted with the holding element 5 and thus also with the Radsok contact 3 electrically conductive.

In the line 9 is a coaxial cable with an outer sheath insulation 10, a radially arranged inside the outer sheath insulation 10, designed as a braided shielding shield 11, a radially located within the cable shield 11 intermediate insulation 12 and the central core. 8

The female contact element 2 is encapsulated with a sheath 13, which projects beyond the spring-shaped end face 14 of the female contact element 2 in the radial direction and projects radially inwardly over an annular end face 15 of a retaining sleeve 16 of the Radsok contact 3 and thus the Radsok contact 3 in axial Direction in the blind hole 6 secures.

The envelope 13 formed of electrically insulating material is in the axial direction of the drawing plane to the right via the socket contact element 2, in particular the holding element 5, led out and extends in the plane of the right conical and forms an opening channel 17 for the wire 8 with intermediate insulation 12. The intermediate insulation 12 lies with its outer circumferential surface directly to a peripheral wall 18 of the opening channel 17 at. The envelope 13 thus isolates not only the entire holding element 5, but also the line 9 or the wire 8, whereby a sealed chamber is formed by the blind hole 7.

The holding element 5 is provided in the region of the bottom of the blind hole 7 with an outer circumferential collar 19, which prevents axial displacement of the sheath 13 relative to the socket contact element 2. Radially outside the circumferential collar 19 of the sheath 13, an abutment collar 20 for a radially outer, sleeve-shaped shroud 21 1 is formed. Another, two-part plant collar 22 for the shroud 21 is provided in the axial direction in the plane of the right offset from the plant 20.

The shield plate 21 extends from radially outside the insertion opening 4 in the axial direction beyond the sheath 13 addition, wherein the shroud 21 is crimped with axial distance to the opening channel 17 of the sheath 13 with the cable shield 11 in a first Vercrimpungsbereich 23. For this purpose, a metallic support sleeve 24 is arranged radially inside the Vercrimpungsbereiches 23, which extends in the axial direction on the shield plate 21 addition and is crimped in a second Vercrimpungsbereich 25 with the outer sheath insulation 10 of the line 9. In this case, the second Vercrimpungsbereich is axially offset from the first Vercrimpungsbereich 23.

The pushed onto the line 9 support sleeve 24 is radially inwardly directly on the outer jacket insulation 10 of the line 9. A usually directly on the intermediate insulation 12 resting portion 26 of the cable shield 11 is in the plane of the drawing after right around the outer jacket insulation 10 and arranged on the outer jacket insulation 10 support sleeve 24 folded. In other words, the folded portion 26 of the cable shield 11 is sandwiched between the first crimping portion 23 of the shielding plate 11 and the supporting sleeve 24. The freed from the folded portion 26 of the cable shield 11 axial portion 27 of the line 9 projects beyond the support sleeve 24 in the axial direction and is guided in the direction of holding element 5, wherein the intermediate insulation 12 of the axial portion 27 extends only into the opening channel 17 inside. In the axial direction before, ie left in the plane of the drawing, the core 8 is completely stripped.

In Fig. 2 the principle of the screen transfer from the cable shield 11 to the shield plate 21 in the first Vercrimpungsbereich 23 is shown in detail. It can be seen that the cable shield 11 extends directly along the intermediate insulation 12 and is bent in the plane of the drawing to the right about the intermediate insulation 12 and the support sleeve 24 around. As a result, the annular end faces 28, 29 of the support sleeve 24 and the outer jacket insulation 10 are spanned by the line shield 1. The folded portion 26 of the cable shield 11 extends substantially parallel to the voltage applied to the intermediate insulation 12 main portion 30 of the cable shield eleventh

In Fig. 3 a complete high current plug-in contact 1 is shown. Evident is the outer shroud 21, which is crimped in the first Vercrimpungsbereich 23 with the folded portion 26 of the cable shield 11. Further, the support sleeve 24 can be seen, which is crimped in the second Vercrimpungsbereich 25 with the outer sheath insulation 10 of the line 9 and which projects beyond the shield plate 21 in the axial direction.

In the drawing plane on the left of the high-current plug-in contact 1, a shield ring 31 can be seen, by means of which the shield is passed from the shield plate 21 to an interface.

The shield ring 31 comprises an outer, radially resilient fin section 32, with which the actual screen transfer takes place. The fin section 32 is arranged radially outside of the shielding plate 21 and exerts a spring force radially inwardly on the shield plate 21. A radially inwardly located sleeve-shaped portion 33 (see Fig. 3b ) is sandwiched between the shroud 21 and the sheath 13 when assembled.

In Fig. 4a a three-pole high-current plug-in device 34 is shown in this embodiment. Within a bivalve in this embodiment, a protective housing 35 three juxtaposed high-current plug contacts 1 are added, the juxtaposed shield rings 31 are arranged on the front housing front side. To seal the protective housing 35 against the lines 9 of the high-current plug contacts 1 is in each case one in Fig. 4b Slat seal 36 shown in detail is provided, each slat seal 36 being received in a separate mounting opening 37 in the protective housing 35.

The louver seal 36 includes a plurality of circumferentially extending and axially spaced louvers 38 which together form a seal labyrinth.

LIST OF REFERENCE NUMBERS

1 High-current plug-in contact 21 shroud 2 Female contact element 22 contact collar 3 Radsok contact 23 First crimping area 4 insertion 24 support sleeve 5 retaining element 25 Second crimping area 6 blind 26 Turned section of the cable shielding 7 blind 27 axial 8th Contact Core 28 front 9 management 29 front 10 Outer jacket insulation 30 main section 11 Line shielding 31 shield ring 12 intermediate isolation 32 fin section 13 wrapping 33 Sleeve-shaped section 14 front 34 High-current plug-in device 15 front 35 housing 16 holding sleeve 36 lamellar seal 17 opening channel 37 mounting hole 18 peripheral wall 38 slats 19 circumferential collar 20 contact collar

Claims (14)

1. High-current plug-in contact (1) with at least one line (9) that comprises a line shielding (11) that makes electrical contact with at least one socket contact element (2) that has a front-side plug-in opening (4) and with a sleeve-like covering (13) that encloses the socket contact element (2), which covering (13) is received radially between the socket contact element (2) and a sleeve-like shroud (21), and with a support bushing (24) that coaxially encloses the line (9) and is arranged at an axial distance from the socket contact element (2), around which support bushing (24) one section (26) of the line shielding (11) is wrapped so that the wrapped section of the line shielding (26) is located radially between the support bushing (24) and the shroud (21), whereby the shroud (21) is crimped with the wrapped section of the line shielding (26), whereby the covering (13) is run out in the axial direction on the line side via the socket contact element (2), characterized in that the covering rests radially outside against an intermediate insulation (12) of the line.
2. High-current plug-in contact according to claim 1, wherein the high-current plug-in contact (1) is designed at least approximately cylindrically and wherein the line (9) is run in axial direction to the front side in the socket contact element (2) that is opposite the front side that has the plug-in opening (4).
3. High-current plug-in contact according to one of claims 1 or 2, wherein the sleeve-like covering (13) is formed by molding-in the socket contact element (2), in particular with an electrically insulating plastic.
4. High-current plug-in contact according to one of claims 1 or 2, wherein the sleeve-like covering (13) is formed as a multi-shell, in particular two-shell, sleeve (16), in particular made of an electrically insulating plastic.
5. High-current plug-in contact according to one of the preceding claims, wherein the support bushing (24), in particular at an axial distance from the crimping point (23) of the shielding bushing with the line shielding (11), is crimped with the line (9), in particular with an outer sheath insulation (10) of the line (9).
6. High-current plug-in contact according to one of the preceding claims, wherein the socket contact element (2) comprises a Radsok contact (3).
7. High-current plug-in contact according to one of the preceding claims, wherein a shielding ring (31), which is connected in an electrically conductive manner to the shroud (21), is provided for transferring the shielding (11) from the shroud (21) to an interface that is to make contact.
8. High-current plug-in contact according to claim 7, wherein a sleeve-like section (33) of the shielding ring (31) is received radially between the shroud (21) and the covering (13).
9. High-current plug-in contact according to one of claims 7 or 8, wherein a section of the shroud (21) is received in a clamping manner radially inside an outer, elastic layered section (32) of the shielding ring (31), which is bent around a front side of the shroud (21).
10. High-current plug-in device with at least one high-current plug-in contact (1) according to one of the preceding claims and a protective housing (35) that surrounds the latter at least in sections.
11. High-current plug-in device according to claim 10, wherein the protective housing (35) is designed as insert molding.
12. High-current plug-in device according to claim 10, wherein the protective housing (35) is designed as a shell structure.
13. High-current plug-in device according to one of claims 10 to 12, wherein the line (9) is sealed with respect to the housing (35), in particular by means of a layered seal (36).
14. High-current plug-in device according to one of claims 10 to 13, wherein several high-current plug-in contacts (1) - that are arranged beside one another and preferably run parallel to one another - are provided within the housing (35).

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