EP2649684A1

EP2649684A1 - High-current plug connector

Info

Publication number: EP2649684A1
Application number: EP11785336.6A
Authority: EP
Inventors: Hubertus Goesmann; Philipp Petz; Axelle Hauck
Original assignee: Bayerische Motoren Werke AG
Current assignee: Bayerische Motoren Werke AG
Priority date: 2010-12-08
Filing date: 2011-11-11
Publication date: 2013-10-16
Anticipated expiration: 2031-11-11
Also published as: DE102010062580A1; CN103181032A; WO2012076101A1; EP2649684B1; CN103181032B

Abstract

The invention describes a high-current plug connector for currents of more than 100 A, in particular more than 200 A. The high-current plug connector of the invention comprises a first connection element (10) which comprises a first contact section (11) and a first connection section (12), and also a second connection element (20) which comprises a second contact section (21) and a second connection section (22). The high-current plug connector also has a spring element (30), which is arranged between the first and the second contact section (11, 21), for establishing an electrical connection between the first and the second connection element (10, 20), wherein the first and the second connection section are each connected to an electrical conductor (13, 23). The first and the second contact section (11, 21) are each in the form of flat pieces. A first, planar contact area (11 A) is formed on a front face of the first contact section, and a second, planar contact area (21 A) is formed on a front face of the second contact section (21), wherein the spring element (30) is clamped exclusively between the first and the second contact areas (11A, 21A) in order to electrically connect the first and the second contact section (11, 21).

Description

High Current Connectors

The invention relates to a high current (HS) connector for currents of more than 100 amperes, in particular of more than 200 amps. Such a HS connector comprises a first connection element comprising a first contact section and a first connection section. Furthermore, the HS connector has a second connecting element, which comprises a second contact portion and a second connecting portion. Furthermore, a spring element arranged between the first and the second contact section is provided for establishing an electrical connection between the first and the second connection element. The first and second connecting portions are each connected to an electrical conductor.

High current connectors are used for example for the electrical connection of energy storage modules of an energy storage in motor vehicles. Such energy storage are used, inter alia, in battery-powered motor vehicles and in such vehicles, which can be operated both electrically and by internal combustion engine. Due to the high power required by drive motors and a not arbitrarily high voltage of the energy storage can occur in such energy storage very high currents during operation. For reasons of manufacturing efficiency, but also for reasons of reliability not only screwed connections are used for the electrical connection of individual components, but also those in which two connecting elements are connected by a plug connection.

Known high-current connectors include in the first connection element a round or rectangular metal housing into which a corresponding second connection element, which is formed as a circular bolt or rectangular sword, can be introduced. To produce a sufficiently large contact surface between the metal housing and the bolt or the sword, a spring element, for example in the form of a contact blade, is arranged between these contact partners. Often, the spring element is mechanically mechanically connected to one of the two contact partners. Attached to the connecting elements are respective cables which at their respective other end are connected to an electrical component of the energy supply. Memory, a powered by the energy storage electrical component or another connection element are connected.

However, the known HS connectors have due to the metal housing used, which receives the bolt or the sword, the disadvantage that they always have a three-layer construction in cross section when inserted pin or sword. Since the HS connector still has to be provided with insulation to the outside to ensure contact protection and protection against malfunctions, the required installation space of the HS connectors is very large.

It is therefore an object of the present invention to provide a high-current connector, which requires a smaller space with comparable current carrying capacity and thus allows a reduction of the installation space of the electrical component in which the high-current connector is used.

This object is achieved by a high current (HS) connector according to the features of claim 1. Advantageous embodiments will be apparent from the dependent claims.

The invention provides a high current (HS) connector for currents greater than 100 amperes, more particularly greater than 200 amperes, with a first connection element, a second connection element and a spring element. The first spring element comprises a first contact portion and a first connection portion. The second connection element comprises a second contact section and a second connection section. The spring element is arranged between the first and the second contact section for establishing an electrical connection between the first and the second connecting element. The first and second connecting portions are each connected to an electrical conductor.

The HV connector is characterized in that the first and the second contact portion are each formed as flat pieces. On a front side of the first contact portion is a first, planar contact surface and on a front side of the second contact portion, a second, planar contact surface is formed. It is Finally, between the first and second contact surface, the spring element clamped to the electrical connection of the first and the second contact portion.

Characterized in that an electrical contact takes place only in the region of the opposing first and second contact portions of the first and second connecting element, the HV connector - in cross-section - can be constructed with only two layers, whereby the required space compared to conventional HS connectors are reduced can. In a HS connector according to the invention is compared to the known HS connectors, a reduced (in the worst case, half) contact surface of the first and second contact portion available. This is compensated by the fact that almost the entire theoretically possible contact area between the first and second contact surfaces of the first and second contact sections is used for producing an electrical connection by a corresponding shape of the spring element.

According to an advantageous embodiment, the first and the second contact portion are connected to each other by a positive engagement, which is produced by a displacement of the first contact portion relative to the second contact portion parallel to the planes of the first and the second contact surface, wherein by a force generated by the spring element perpendicular to the planes of the first and second contact surface, a release of the two contact portions is prevented. This ensures that on the one hand a simple connectivity of the two connecting elements is made possible by the clamping force of the spring element is overcome. On the other hand, the spring element provided between the first and second connecting elements not only provides the area required for the current carrying capacity, but at the same time also provides a clamping force which prevents unintentional detachment of the second connecting element from the first connecting element.

According to a further expedient embodiment, the first and / or the second contact section has at least one recess into which associated first tabs of the other contact section project, which lie in the plane or parallel to the plane of the other contact section. Through the recess and the associated first tabs, a positive connection is provided outside the contact surfaces or sections, which provide the desired two-day structure of the invention. suitable HS connector allows. At the same time it is ensured by this structural design that a force acting on the spring element is generated, whereby the spring element itself prevents the unintentional release of the two contact portions by a movement parallel to the planes of the contact surfaces by the generated opposing force.

According to a further expedient embodiment, the second and / or the first contact portion has at least one second tab, which engage around the other contact portion in a form-fitting manner, the second tabs lying in a parallel plane of the associated contact portion. As a result, the same conditions are achieved Wirku as they are caused by the recess and the insertion of the associated tabs of the other contact portion.

A further embodiment provides that the clamping of the first and second contact portion for producing the electrical connection of the first and second contact portion is effected by a housing surrounding the connector.

Through this housing, an insulation of the HS connector can be provided simultaneously. The use of a housing surrounding the connector also has the consequence that configurations for the positive connection of the first and second contact portion can optionally be omitted.

In a further embodiment, the first and / or the second connecting part can be produced by a punch-bending process or equivalent methods. Such manufacturing methods have the advantage that the HS connectors can be manufactured in a simple and cost-effective manner.

Conveniently, the first connecting part is made of aluminum (Al) or alloys thereof. The second connection part is preferably made of copper (Cu) or nickel (Ni) or alloys thereof. In principle, other materials or material combinations are conceivable. However, the aforementioned preferred materials have already proven themselves in HS connectors, so that no contact deterioration is to be expected even over long periods of use. A further embodiment provides that the electrical conductors are welded to a respective connecting portion of the first and / or the second connecting part or are connected by means of a crimp connection. The electrical conductors may be formed, for example, in the form of cables or strands or foils.

It is also expedient if the spring element has a number of fins. By the fins, the spring properties of the spring element are favored. Furthermore, a secure and large-area contact between the contact portions of the first and second connecting element can be ensured by the number of fins, whereby the desired current carrying capacity is provided. Another advantage of a lamella having spring element consists in the simple

Manufacturability.

In a particularly simple and preferred embodiment, the spring element is a. stamped sheet metal. As a result, the spring element can be provided with particularly favorable production costs.

r

Expediently, the spring element extends at least in sections substantially parallel to the planes of the first and the second contact surface. In this way, a very large-area contact between the contact surfaces of the contact portions of the connecting elements can be provided. The larger the contact surfaces can be formed, the greater the current carrying capacity of the HS connector.

It is further provided that the spring element is mechanically connected to the first contact portion or the second contact portion. This favors the production of the connector by a relative movement of the first and second connecting element to each other.

The invention will be explained in more detail below with reference to exemplary embodiments in the drawing. Show it:

1 is a schematic, perspective view of a first embodiment of an HS connector according to the invention, 2 is a cross-sectional view of the HS connector of FIG. 1,

3 is a schematic, perspective view of a second embodiment of an HS connector according to the invention,

Fig. 4 is a cross-sectional view of the HS connector of Fig. 3, and

Fig. 5 is a schematic, perspective view of a third embodiment of an HS connector according to the invention.

Fig. 1 shows a schematic, perspective view of a high current (HS) plug connector according to the invention. The HV connector is suitable for currents in excess of 100 amperes, or even more than 200 amperes. Currents of this magnitude occur, for example, in energy stores for drive machines in motor vehicles. The HV connector comprises a first connection element 10 and a second connection element 20 corresponding thereto. The first connection element 10 has a first contact section 11 and a first connection section 12. Connected to the first connection section 12 is an electrical conductor 13, which is not shown in greater detail in the figure and is designed, for example, in the form of a flat cable or a foil. In a corresponding manner, the second connecting element 20 comprises a second contact section 21 and a second connecting section 22. The second connecting section 22 is connected, for example, on its front side to an electrical conductor 23 in the form of a foil.

The manner in which the electrical conductors 13, 23 are connected to the respective connecting sections 12 and 22 and in which way the electrical conductors are structurally constructed is of secondary importance for the present invention. In principle, it is known to use cables, consisting of one or more layers of films, metal strips, Litzenpakete, etc. as electrical conductors.

While the first connection part 10 is made of aluminum or an aluminum alloy, the second connection part 20 is preferably made of copper or nickel or an alloy of one or both materials thereof. This material combination for connectors is proven in terms of contact transition and durability. 2, which shows the HS connector shown in FIG. 1, both the first contact portion 11 and the second contact portion 21 have respective first and second contact surfaces 11A, 21A. The contact surfaces 11A, 21A are, when the first and the second connection element 10, 20 are connected to each other, facing each other. The production of an electrical connection is made exclusively via the mutually facing contact surfaces 1 1 A, 21 A, between which a trained as a contact blade spring element 30 is arranged. Via the spring element 30 there is a large-area connection of the two contact surfaces 1 1A, 21A, whereby the required currents of more than 100 amps or more than 200 amps can be transmitted with only slight losses between the contact sections 1 1, 21.

The spring element 30 preferably has a multiplicity of lamellae for simultaneous good current transmission and for exercising a force perpendicular to the planes of the contact surfaces 11A, 21A. The plurality of lamellae can be designed, for example, essentially parallel to one another. The lamellae can be produced, for example, by a punching process of a sheet-metal part which is flat as a starting material. In order to be able to provide the spring action of the spring element, the stamped sheet metal can be shaped by means of corresponding bending operations into, for example, a wave-like or otherwise suitable shape.

In order to ensure the most intimate possible contact of the spring element 30 with the contact surfaces 11A, 21A of the contact portions 1 1, 21, the spring element in cross-section (ie in a side view according to Figures 2 and 4) has a substantially curved configuration in which For example, "feet" of the spring element are supported on the contact surface 21A of the contact section 21, while a "belly" connecting the feet rests as long as possible on the contact surface 11A of the contact section 11 of the first connection element 10. The area proportions of feet and stomach are about the same. In order to simultaneously ensure the longest possible contact in the region of the curvature (belly) between the spring element and the contact surface 1 1 A, the individual contact blades of the spring element 30 may be formed wave or meandering. The wave- or meander-shaped sections in this case run parallel to the plane of the contact surface 1 1A. In order to be able to ensure a simple connectability of the first and the second connecting element 10, 20, the first and the second contact section 11, 21 of the connecting elements 10, 20 are connected to one another by a positive connection. The positive connection is made by a displacement of the first contact portion 1 1 relative to the second contact portion 21 parallel to the planes of the first and second contact surfaces 1 1 A, 21 A. Due to the fact that the spring element 30 or its individual contact blades extend at least partially substantially or approximately perpendicular to the planes of the first and second contact surfaces 11A, 21A, a force is generated by the spring element which is perpendicular to the planes of the first and second Contact surfaces 11A, 21A is directed. This clamping force prevents loosening of the two contact portions, since for this purpose a predetermined by the shape of the spring element 30 and the prevention elements 10, 20 tensile force must be overcome. If this is chosen to be sufficiently large, an unintentional release, for example due to permanent vibrations, is almost impossible.

In order to ensure, when the first contact section is displaced relative to the second contact section, that the spring element 30 located between the contact surfaces 1A, 21A does not shift into an undefined position, the spring element 30 is preferably mechanically connected to the first contact section 11 or to the second Contact portion 21 of the respective connecting element connected. Such a connection can be realized for example by a clip or Crimpverbindung. Also positive connections of spring element and one of the contact portions 11, 21 are in principle conceivable.

Due to the fact that an electrical connection can only be made via the mutually facing contact surfaces 11A, 21A, the mechanical connection of the connecting elements 10, 20 takes place laterally of the contact sections 11, 21. This ensures that the HV connector has only two Layers, ie the contact portions 11, 21, can be formed. As a result, a space-optimized connector is created, which takes up less space compared to the previously known three-layer connectors. In order to ensure contact protection, but also protection against malfunction, the high-current connector is surrounded by an insulating housing, for example made of plastic, at least in the region of the contact sections, and optionally the connecting sections.

In order to be able to produce the positive fit provided laterally by the contact sections 11, 21, the first and the second connecting elements 10, 20 are bent by reshaping such that a first tab 25 of the second connecting element 20 is formed by a recess (not explicitly recognizable) of the first Connecting element 10 protrudes. The recess of the first connection element 10 is arranged in a transition section 17 which connects the contact section 11 with the connection section 12. Connecting portion 12 and contact portion 11 lie in mutually parallel planes. On the other, opposite side of the contact portion 11 is a over the entire width of the contact portion 11 extending tab 15 of the second tabs 26-1, 26-2 of the second connecting element 20 embraced. The second tabs 26-1, 26-2 emerge from the plane of the contact section 21 in the direction of the first contact section 11 in such a way that the first tab 15 is acted upon by a force in the direction of the second connection element 20, which passes through the contact surface 11, 21 arranged spring element is caused.

In this embodiment, the connecting portions 12, 22 of the first and second connecting element 10, 20 are arranged in mutually parallel, but different planes. Another characteristic of this HS connector is that the electrical conductor 23 contacting the connecting portion 22 of the second connecting member is disposed laterally of the connection, while the electrical conductor 13 of the first connecting member 10 contacts the connecting portion 12 along a direction in which the Connecting portion and the contact portion 12, 11 extend.

Figures 3 and 4 show a second embodiment of an HS connector according to the invention. The second embodiment of the HS connector according to the invention differs from the first embodiment by the different nature of the bends of the first connecting element 10. As in the previous embodiment, the first and the second contact portion are connected by a positive connection, which by a displacement of the first Kontaktab- Section relative to the second contact portion parallel to the planes of the first and the second contact surface 11 A, 21 A can be produced. The positive connection takes place concretely in turn laterally of the contact sections 11, 21.

4, the second connecting element 20 is L-shaped. At a short portion 27, which extends perpendicular to the plane of the contact portion 21 and is arranged at one end of the contact portion 21, two recesses 24-1, 24-2 are provided, in which first tabs 15-1, 15-2 of first connecting element 10 protrude. The first tabs 15-1, 15-2 are inclined out of the plane of the contact section 11 at an acute angle in the direction of the second connecting element 20. A first tab 25 of the second connecting element projects through a recess in the transition section 17 of the first connecting element 10. As a result, a simple production of the connection is also ensured at the same time low volume.

A third embodiment is shown in FIG. Fig. 5 shows an HV connector in a schematic, perspective view. In this embodiment, the second connecting element 20 has two juxtaposed second tabs 26-1, 26-2, which clasp the contact portion 11 of the first connecting element 10. This means that the second tabs 26 - 1, 26 - surround the contact section 11 of the first connecting element, the ends of the second tabs 26 - 1, 26 - 2 lying in a parallel plane of the associated contact section 21 of the second connecting element 20. Between the first and the second connecting element 10, 20, a spring element 30 is arranged. Slats 31 of the spring element 30 extend in the direction of the tab receptacles of the second tabs 26-1, 26-2.

As a material for the spring 30 is - in all three embodiments - CuNi ₃ Si, CuCrAgFeTiSi, CuBe ₂ , CuCoBe ₂ or CuCrZr into consideration. The tension of the first and second contact portion 11, 21 for the preparation of the electrical connection is effected by a not shown in Fig. 5, the connector surrounding housing. The housing, which is formed, for example, from an insulating plastic and at the same time provides for insulation of the plug connection, ensures a force absorption of the pushed into the housing interior contact portion 1 1 of the connecting element 10. The housing is in this case with the exemplary tubular connection formed section 22 latched. The connecting portion 22 is put over a correspondingly designed battery terminal of a memory cell 40 only for illustrative purposes and may be welded thereto, for example.

The invented HS connectors which are capable of carrying currents in excess of 100 or even 200 amperes are smaller and lighter than known HS connectors and can be manufactured at a lower cost.

Reference numeral list first connection element

first contact section

A flat contact surface

first connection section

electrical conductor

recess

first tab

-1 first tab

-2 ^" first tab

Overcast

second connecting element

second contact section

A flat contact surface

second connection section

electrical conductor

-1 recess

-2 recess

first tab

-1 second tab

-2 second tab

short section

spring element

lamella

memory cell

Claims

claims

1. High current (HS) connector for currents greater than 100 A, in particular greater than 200 A, comprising:

a first connection member (10) comprising a first contact portion (1 1) and a first connection portion (12),

a second connecting member (20) including a second contact portion (21) and a second connecting portion (22); a spring member (30) disposed between the first and second contact portions (11, 21) for establishing an electrical connection between the first and the second connection member (10, 20), the first and second connection portions being respectively connected to an electrical conductor (13, 23);

characterized in that

the first and the second contact section (1 1, 21) are each designed as flat pieces,

wherein on a front side of the first contact portion, a first, planar contact surface (1 1 A) and on a front side of the second contact portion (21) a second, planar contact surface (21 A) are formed, wherein exclusively between the first and the second contact surface (1 1 A, 21 A), the spring element (30) is clamped to the electrical connection of the first and the second contact portion (1 1, 21).

2. Connector according to claim 1, characterized in that the first and the second contact portion (11, 21) are interconnected by a positive connection, by a displacement of the first contact portion (11) relative to the second contact portion (21) parallel to the Layers of the first and the second contact surface (11A, 21A) can be produced, wherein a release of the two contact portions is prevented by a force generated by the spring element perpendicular to the planes of the first and second contact surface (1 1A, 21A).

3. Connector according to claim 1 or 2, characterized in that the first and / or the second contact portion (11, 21) has at least one recess (14, 24-1, 24-2), in which associated first tabs (25; 15-1, 15-2) of the other contact portion (21, 11) protrude, which lie in the plane or parallel to the plane of the other contact portion.

Connector according to one of the preceding claims, characterized in that the second and / or the first contact portion (21, 1 1) has at least one second tab (26-1, 26-2), which the other contact portion (1 1, 21) encompass positively, wherein the second tabs (26-1, 26-2) lie in a parallel plane of the associated contact portion (21).

Connector according to one of the preceding claims, characterized in that the clamping of the first and second contact portion (1 1, 21) for producing the electrical connection of the first and second contact portion (11, 21) is effected by a housing surrounding the connector.

Connector according to one of the preceding claims, characterized in that the first and / or the second connecting part (10, 20) by a punch-bending process or equivalent processes can be produced.

Connector according to one of the preceding claims, characterized in that the first connecting part (10) made of Al or alloys thereof and the second connecting part (20) made of Cu or Ni or alloys thereof.

Connector according to one of the preceding claims, characterized in that the electrical conductors to a respective connecting portion (12, 22) of the first and / or the second connecting part (10, 20) are welded or connected by means of a crimped connection.

Connector according to one of the preceding claims, characterized in that the spring element (30) has a number of lamellae (31).

Connector according to one of the preceding claims, characterized in that the spring element (30) is a stamped sheet metal. Connector according to one of the preceding claims, characterized in that the spring element (30) extends at least in sections substantially parallel to the planes of the first and the second contact surface (11A, 21A).

Connector according to one of the preceding claims, characterized in that the spring element (30) is mechanically connected to the first contact portion (11) or the second contact portion (21).