EP2732507B1 - High-current plug-in connector for motor vehicle applications - Google Patents

High-current plug-in connector for motor vehicle applications Download PDF

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Publication number
EP2732507B1
EP2732507B1 EP12781041.4A EP12781041A EP2732507B1 EP 2732507 B1 EP2732507 B1 EP 2732507B1 EP 12781041 A EP12781041 A EP 12781041A EP 2732507 B1 EP2732507 B1 EP 2732507B1
Authority
EP
European Patent Office
Prior art keywords
contact
connection
spring
connector according
sections
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
Application number
EP12781041.4A
Other languages
German (de)
French (fr)
Other versions
EP2732507A1 (en
Inventor
Hubertus Goesmann
Paul Czechanowski
Harald Heck
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Bayerische Motoren Werke AG
Diehl Metal Applications GmbH
Original Assignee
Bayerische Motoren Werke AG
Diehl Metal Applications GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bayerische Motoren Werke AG, Diehl Metal Applications GmbH filed Critical Bayerische Motoren Werke AG
Publication of EP2732507A1 publication Critical patent/EP2732507A1/en
Application granted granted Critical
Publication of EP2732507B1 publication Critical patent/EP2732507B1/en
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/15—Pins, blades or sockets having separate spring member for producing or increasing contact pressure
    • H01R13/187—Pins, blades or sockets having separate spring member for producing or increasing contact pressure with spring member in the socket
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/15—Pins, blades or sockets having separate spring member for producing or increasing contact pressure
    • H01R13/17—Pins, blades or sockets having separate spring member for producing or increasing contact pressure with spring member on the pin
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/193—Means for increasing contact pressure at the end of engagement of coupling part, e.g. zero insertion force or no friction
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/28—Clamped connections, spring connections
    • H01R4/48—Clamped connections, spring connections utilising a spring, clip, or other resilient member

Definitions

  • the invention relates to a high-current connector for currents of more than 100 amps, in particular of more than 200 amps.
  • a HS connector comprises a first connection element, which has a first contact section and a second connection element, which comprises a second contact section.
  • a spring element serves to produce an electrical connection between the first and the second connecting element.
  • the two connecting elements are each connected to an electrical conductor.
  • High current (HS) connectors are used for example for the electrical connection of energy storage modules of an energy storage in motor vehicles.
  • 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.
  • 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.
  • a spring element for example in the form of a contact blade, is arranged between the first connection element and the second connection element.
  • the spring element is mechanically connected to one of the two contact partners.
  • Respective cables or lines are attached to the connecting elements, which are connected at their respective other end to an electrical component of the energy store, an electrical component operated by the energy store or another connecting element.
  • a disadvantage of this connector is that there is a small contact area between the spring element and the connecting elements for power transmission. This results in increased contact resistance, which leads to an increase in temperature.
  • GB2228150A discloses an electrical connection device having an end connector which in turn has an end piece guide, a resilient strip integrally formed on the end piece guide, and an end piece support.
  • the contact surfaces of the connecting elements are provided with a coating.
  • the coating consists of silver, which has excellent conductivity properties.
  • the coating is formed with a thickness of at most 10 microns
  • the invention provides a high current connector for currents greater than 100 amperes, in particular greater than 200 amperes, with a first connection element, a second connection element and a spring element.
  • the first connection element comprises a first contact section.
  • the second connection element comprises a second contact section.
  • the spring element is intended to produce an electrical connection between the first and the second contact portion.
  • the spring element comprises at least two clip elements connected to one another via at least one web, wherein the web and respective first sections of the clip elements are arranged on a first outer surface of the connection formed by the first and the second contact section and second sections of the clip elements are disposed at least partially on a second, the first outer surface opposite outer surface are arranged.
  • At least one contact spring Arranged on the at least one web is at least one contact spring which generates a contact force directed towards the second outer surface on the first outer surface, whereby contact surfaces of the first and second contact sections facing one another are pressed against one another, the second sections of the clip elements serving as an abutment.
  • the invention allows the first and second contact portions to be in direct contact with each other. Characterized in that the first and the second contact portion are in direct contact with each other, resulting in a larger compared to the prior art contact surface. Due to the now occurring in the contact area lower contact resistance is associated with lower temperatures. Due to the lower operating temperatures due to the smaller contact resistance, a longer life of the connector can be made possible.
  • the spring element is in particular designed as a component that is independent of the first and / or second connecting element and that can be produced and / or processed independently of the connecting elements. This not only enables the secure provision of the electrical contact by the spring element presses the two contact portions defined on each other, but also provides in comparison for a smaller installation space volume and weight of the connector.
  • the first and the second connecting element are only one side mechanically and thus electrically in contact.
  • the mutually facing contact surfaces are formed corresponding thereto.
  • the connecting elements or their contact portions are flat and flat.
  • the connecting elements can also be spherical and dome-shaped (concave and convex). As a result, a high surface contact for power transmission is ensured.
  • the contact portions of the first and second connecting elements are non-positively connected to one another via the spring element. As a result, a solubility of the contact portions is given after removal of the contact force. At the same time, this embodiment makes it possible to produce the connection powerless.
  • At least one contact spring is arranged on the at least one web on opposite sides.
  • a contact force for clamping the contact portions of the connecting elements is applied laterally to a plug-in direction of the connecting elements.
  • the direction of insertion of the connecting elements is to be understood as a direction in which the connecting elements are (are) moved relative to one another, around the contact sections the fasteners initially bring to cover each other to then produce the contact force can.
  • the at least one contact spring on a wave profile wherein the wave profile, starting from the web, at least one wave crest and then having a standing with the first outer surface in contact trough having the contact force generated under a wave crest is one of the Compound oriented buckle understood.
  • a trough is understood to mean, in a corresponding manner, a curvature of the wave profile directed towards the connection.
  • the wave profile can be easily generated by a forming process.
  • the at least one contact spring may extend parallel to the clip elements and perpendicular to a plug-in direction of the first and the second connecting element for producing the plug connection of the plug connector. This means that the extension of successive wave crest and wave trough is parallel to the elements and approximately perpendicular to the direction of insertion of the connecting elements for the production of the connector.
  • the last wave trough of the wave profile merges into a T-shaped section, wherein the opposite arms of the T-shaped section have a deformation which points away from the connection.
  • the contact force can be varied via actuation of the arms of the T-shaped section, for example in order to establish or release the connection. In particular, this may provide a powerless connection establishment or solution.
  • the spring element comprises at least two mutually parallel clamping elements, wherein between each two clamp elements, the at least one contact spring is arranged.
  • the number of clip elements of the spring element and the distance between each two clip elements depend, inter alia, on which surface or length the contact sections are to form the electrical connection.
  • the contact force acting over the surface can be generated via the number and distribution of the contact springs.
  • respective ends of a clamping element, in particular on the second outer surface of the connection are mechanically connected to one another, in particular by a positive connection or a material connection.
  • the staple elements guided from the same side to the second outer surface may be interconnected, e.g. by opening into a respective end-side flat section.
  • the mechanical connection then takes place by means of the two lying on the second outer surface end-side flat sections.
  • the end-side flat portions are dimensioned such that they are in mechanical contact with a large part of the second outer surface. In this way, the necessary to produce the contact force abutment is reliably formed.
  • the spring element on an inner of the clamping elements on a in the direction of the contact force extending stop shoulder serves to introduce one of the two connecting elements for the purpose of establishing the connection over a defined length in the spring element, so that there is a predetermined contact surface between the two connecting elements.
  • the plug connector is surrounded by an insulating housing, in particular made of plastic. Since the high current connector is designed for high currents and high voltages, reliable isolation of the connection provided by the insulating housing is required.
  • the housing preferably serves not only to isolate the connection, but at the same time assumes a function for producing or releasing the connection from the two connection elements.
  • the housing comprises at least one guide section with a trajectory, which lifts the at least one contact spring counter to its spring force of the connection to be produced when applying the housing to the spring element in an intermediate position, in the insertion direction a powerless insertion of the non-connected to the spring element connecting element in the To allow spring element, wherein in an end position of the housing, the at least one guide portion is not engaged with the spring element to allow the generation of the contact force by the spring element.
  • the contact portions of the connecting elements are flat, in particular flat or concave or convex, formed.
  • the spring element is formed of a stainless steel, in order to be able to exert the contact force necessary for the generation on the compound can.
  • the at least one contact spring, the at least one web and the at least two clip elements in one piece, i. in one piece, are formed.
  • the spring element is preferably formed from a piece of metal, in particular stainless steel.
  • the first and / or the second connecting element made of aluminum or an aluminum alloy.
  • the first and / or the second connecting element may consist of copper or a copper alloy.
  • the material of which the first or second connecting element is manufactured results primarily from the material of another connecting partner, which must be contacted with the relevant connecting element. If the connection partner consists of aluminum, then it is expedient to provide the connecting element made of aluminum in order to be able to produce the simplest possible and safe electrical connection between these two components.
  • the first and / or the second connecting element in the region of their respective adjacent contact portions have a first and a second coating.
  • a coating can also be provided if the two connecting elements consist of the same materials or alloys.
  • An advantage of providing the coating is that the life of the connector can be increased by protecting the surface of the contact portions from oxidation. This is particularly important for aluminum connecting elements of importance, which oxidize very quickly on contact with oxygen. If the connecting elements - as explained above - consist of different materials, the provision of the coating additionally contributes to protection against contact corrosion due to an otherwise occurring electrochemical voltage series.
  • the first and / or the second coating comprise a layer of tin or a tin alloy. Tin can be provided at a lower cost than the silver otherwise used, thereby reducing the cost of making the connector.
  • the first and / or the second coating between the tin or the tin alloy as the outermost layer (surface coating) comprises a first intermediate layer of copper and / or a second intermediate layer Include nickel or their alloys. If and if one or more intermediate layers are provided, the corresponding materials can be selected depending on the material of the two connecting elements in order to avoid problems due to the electrochemical series of voltages.
  • first and / or the second coating surface coating
  • the first and / or the second coating to have a total thickness of more than 10 ⁇ m, in particular more than 20 ⁇ m, the maximum total thickness of the first and / or the second coating being 100 ⁇ m, preferably 50 ⁇ m ⁇ m.
  • the greater the thickness of the coating is chosen the lower the risk of oxidation of, in particular of aluminum and its alloys, existing fasteners.
  • the danger of such Oxidation occurs because the coating typically wears away over the life of the connector, unintentionally exposing the surface of the material of one of the connectors. This danger is greater the thinner the layer thickness. In particular, it has been shown that the problem is given when the layer thickness is less than 10 microns.
  • the layer thickness can be readily applied to the contact portions of the connecting elements up to 100 microns thick.
  • a corresponding layer thickness of silver which is used in the prior art as a coating agent to provide a high conductivity, would only increase the cost of the connector in practice unacceptably high.
  • the application of the coating can be done, for example, galvanically. Likewise, other suitable methods can be used.
  • the coating has a 1 to 20 microns, especially a 2 to 8 microns, strong Unterkupferung or Unterickelung as an intermediate layer.
  • a cover layer of copper and / or a copper alloy and / or nickel and / or a nickel alloy and / or silver and / or a silver alloy and / or gold and / or or a gold alloy preferably has a thickness of 0.01 to 5 ⁇ m, in particular a thickness of 0.1 to 0.3 ⁇ m.
  • the coating of the contact surfaces of the contact portions may e.g. be applied galvanically and / or by hot dip coating and / or by deposition from the gas phase and / or by flame and / or by plasma spraying and / or by compaction.
  • a high-current (HS) plug connector according to the invention is shown in various perspective and sectional representations.
  • the HV connector is suitable for currents of more than 100 A, or even more than 200 A. Currents of this magnitude occur, for example, in energy stores for drive machines in motor vehicles.
  • the HV connector 1 comprises a first connection element 10 and a second connection element 20.
  • the first connection element 10 has a first contact section 11
  • the second connection element 20 has a second contact section 21.
  • the first and second contact portions 11, 21 are planar in the embodiments, i. also, designed as flat pieces.
  • the contact portions may also be concave and convex.
  • the connecting elements 10, 20 are coplanar brought to the preparation of an electrical connection 5 in the region of their contact portions 11, 21 and connected to each other via a spring element 30 by applying mutually pressing contact forces. Therefore, the spring element 30 surrounds the connection 5 from the outside.
  • FIG. 3 The sectional view shown, the relative arrangement of the two connecting elements 10, 20 to each other best seen when this in a compound. 5 training position.
  • the connecting elements 10, 20 are arranged in such a way to each other, as they would be due to the 30 provided in the region of the contact portions 11, 21 spring element.
  • the spring element 30 in FIG Fig. 3 omitted.
  • Reference numeral 6 denotes a first outer surface.
  • the first outer surface 6 is that side or surface of the contact section which does not represent the electrical connection to the contact section 21 of the other connecting element 20.
  • the reference numeral 7 designates a second outer surface facing the first outer surface. How out Fig. 3 is readily apparent, the second outer surface is that surface of the contact portion 21, which does not form the electrical connection to the contact portion 11 of the first connecting member 10.
  • a contact element of an energy storage or a battery cell may be connected.
  • the connecting element 10 has the shape of a hook in a lateral view. This is only due to a specific installation situation in an energy store. In principle, the course of the connecting element 10 outside the contact section 11 could be arbitrary.
  • an electrical conductor 25 is connected via its cable connecting element 26 (FIG. Fig. 1 ). How the connecting elements 10, 20 are connected to the cable or the cable connection element 26 and the contact element, not shown, of an energy store or a battery cell, is for the present invention of minor importance.
  • the configuration of the connecting elements for contacting the contact partners is dependent on the circumstances to choose and for the present invention is not important.
  • connecting members 10, 20 including their contact portions
  • aluminum or copper or their alloys are preferably used.
  • one of the two connecting elements 10, 20 made of aluminum or an aluminum alloy and the other connecting part made of copper or a copper alloy. It is also possible that both fasteners made of aluminum or an aluminum alloy or copper or a copper alloy.
  • aluminum or an aluminum alloy is preferably used in at least one of the two connecting elements, since the contact terminals of the energy accumulator also consist of aluminum.
  • Aluminum has the advantage of lower weight over copper.
  • copper or a copper alloy is often used for the second connecting element because it can be easily and reliably connected to corresponding electrical conductors, such as e.g. the illustrated cable 25 or its cable connection element 26, can connect.
  • the connecting elements 10, 20 have a respective coating (not shown) in the region of their respective contact sections. Since the connecting elements 10, 20 are in contact with each other over a large area in the region of their contact sections 11, 21, the coating need not consist of expensive (and highly conductive) silver. Instead, the much cheaper tin can be used. On the other hand, due to the significantly lower cost of tin compared to silver, the thickness of the coating can be increased from a maximum of 10 ⁇ m up to 100 ⁇ m. Preferably, a layer thickness between 20 .mu.m and 70 .mu.m, in particular 50 .mu.m, is selected.
  • the increased layer thickness has the advantage that the life of the connector can be increased since a permanent protection of the surfaces of the contact portions is made possible before oxidation.
  • the coating (s) wear off over time.
  • the two-dimensional coating of the contact portions 11, 21 causes surface roughnesses of the coating (s) to be removed by the relative movement of the connecting elements 10, 20, whereby the contact between the contact sections 11, 21 is further improved.
  • the coating of one of the contact portions 11, 21 is completely removed, so that the oxidation effects described above can not occur.
  • the coating not shown, consists exclusively of tin.
  • the coating may comprise at least one intermediate layer of copper and / or nickel.
  • the intermediate layer (s) are then arranged between the tin as the outermost layer and the contact portion of the connecting element.
  • the layer thicknesses of a respective intermediate layer are between 2 and 8 microns. In this case, it is preferable if the total layer thickness does not become larger than 100 ⁇ m.
  • a layer of copper and / or a copper alloy and / or nickel and / or a nickel alloy and / or silver and / or a silver alloy and / or gold and / or a gold alloy may be applied.
  • the cover layer preferably has a thickness of 0.01 to 5 ⁇ m, in particular a thickness of 0.1 to 0.3 ⁇ m.
  • the coating of the contact surfaces of the contact sections takes place, for example, galvanically and / or by hot dip coating and / or by deposition from the gas phase and / or by flame and / or plasma spraying and / or by compacting.
  • the spring element 30 comprises two clip elements 32, 35 connected to one another via a web 31.
  • the clip elements 32, 35 run parallel to one another, the web 31 connecting them in a plan view approximately in the middle in the direction of a plug-in direction SR.
  • the spring element 30 has the shape of an "H".
  • the direction of insertion SR is understood to mean that direction of movement in which the one or more connecting elements 10, 20 must or must be inserted into the spring element 30 in order to produce the connection 5, or vice versa.
  • the web 31 and respective first portions 33, 36 of the clip elements are arranged on the first outer surface 6.
  • the first portions 33, 36 are guided around respective end faces of the connection 5 (ie, the superimposed contact portions 11, 21) and terminate in second portions 34, 37 of the clamp members disposed on the second outer surface 7.
  • respective ends of a clamping element 32, 35 are mechanically connected to each other, in particular by a positive connection or an adhesive bond.
  • the connection of respective ends of a clip element 32, 35 takes place on the second outer surface 7.
  • contact springs 40, 45 are arranged on its opposite sides.
  • the contact springs 40, 45 each have a wave profile (see. Fig. 2 ).
  • the wave profile initially has a wave crest 41, 46 and then a wave valley 42, 47 which is in contact with the first outer surface 6.
  • the one-piece spring element 30 is made of a spring steel. Due to the described shape design of the wave profile, the wave troughs 42, 47 generate a contact force, which is directed in the direction of the second outer surface 7. As a result, mutually facing contact surfaces of the first and second contact portions 11, 21 are pressed against each other.
  • the second sections 34, 37 of the clamp elements serve as an abutment.
  • Fig. 2 shows, starting from the web 31, the last wave trough 42, 47 of the wave profile 40, 45 in a (in plan view) T-shaped section 43, 48 via.
  • the opposite arms 44, 49 of the T-shaped section 43, 48 have a deformation which points away from the connection 5.
  • This upward-pointing deformation is better understood of the Fig. 1 in particular T-shaped section 48.
  • the deformations of the T-shaped section 43, 48 serve to enable a powerless connection or a weak connection release. This is accomplished by means of the insulating housing 70 described in more detail below.
  • a stop shoulder 50 extending in the direction of the contact force is formed. This opens into a section 53 which runs parallel to the connecting element 20 and can rest thereon.
  • 35 flags 51, 52 are formed on the inner clip member. These are attached to the second portion 37 of the inner bracket member 35 and engage around a constriction 23 of the connecting element 20. As a result, the spring element 30 is positively connected to the connecting element 20. It follows that for the preparation of the compound 5, the contact portion 11 of the first connecting element 10 in the insertion direction SR must be inserted into the spring element 30, wherein the contact portion 21 of the second connecting member 20 is already stored in this stationary.
  • FIGS. 4 to 6 show once in a perspective embodiment and in two different sectional views of the HS connector 1, which is surrounded by an insulating housing 70, in particular of a plastic. From the perspective view is the in Fig. 1 shown cable 25, wherein the cable connection element 26 is not visible below the housing 70. The housing 70 and surrounded by this HS connector 1 are "surrounded" by an insulating plate 71, which covers all live parts of the energy storage shown in the embodiment from touching. Exemplary is in the perspective Fig. 4 Also shown a contact element 2 of the energy storage.
  • Fig. 5 shows a section through the in Fig. 4 shown arrangement, wherein the housing 70 is in an intermediate position.
  • the housing 70 includes in its interior two on opposite sides arranged guide portions 72, 73, which describe a trajectory.
  • guide portion 72 In the presentation of the Fig. 5 only the guide portion 72 is shown on a side wall of the housing 70.
  • the trajectory 72 has a ramp-shaped course.
  • the second connecting element 20 is surrounded by the housing 70, wherein in particular the cable connecting element arranged on the cable connecting surface 22 26 is included. Due to the positive connection of the second connecting element 20 with the spring element 30, this is also encompassed by the housing 70.
  • the contact springs 40, 45 are lifted off the connection to be produced counter to their spring force in an intermediate position of the housing by the guide sections 72, 73. In this way, in the insertion direction, a powerless insertion of the not connected to the spring element 30 connecting element 10 are made possible in the spring element 30. If the housing is pushed further in the direction of GR into its end position, the spring contacts 40, 45 are relieved again due to the trajectory of the guide section, whereby they can exert their contact force on the contact sections of the connecting elements 10, 20. The engagement of the guide sections 72, 73 with the contact springs 40, 45 takes place in the region of the arms 44, 49 of the T-shaped sections 43, 48 of the contact springs.
  • FIG. 6 shows the housing in its end position in a sectional view, wherein due to the cutting direction now both guide portions 72, 73, which act on the T-shaped portions 48, 43 are visible.
  • the connector according to the invention has the advantage of small contact resistance. This reduces temperature increases due to current flow compared to prior art arrangements.
  • the outer spring element ensures a low volume of the connector. Due to the surface contact of the current-transmitting connecting elements results in a longer life. Due to the low complexity of the connector this has a small weight.

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  • Connector Housings Or Holding Contact Members (AREA)
  • Details Of Connecting Devices For Male And Female Coupling (AREA)

Description

Die Erfindung betrifft einen Hochstrom-Steckverbinder für Ströme von mehr als 100 Ampere, insbesondere von mehr als 200 Ampere. Ein derartiger HS-Steckverbinder umfasst ein erstes Verbindungselement, das einen ersten Kontaktabschnitt sowie ein zweites Verbindungselement, das einen zweiten Kontaktabschnitt umfasst. Ein Federelement dient zur Herstellung einer elektrischen Verbindung zwischen dem ersten und dem zweiten Verbindungselement. Die beiden Verbindungselemente sind jeweils mit einem elektrischen Leiter verbunden.The invention relates to a high-current connector for currents of more than 100 amps, in particular of more than 200 amps. Such a HS connector comprises a first connection element, which has a first contact section and a second connection element, which comprises a second contact section. A spring element serves to produce an electrical connection between the first and the second connecting element. The two connecting elements are each connected to an electrical conductor.

Hochstrom (HS)-Steckverbinder werden beispielsweise zur elektrischen Verbindung von Energiespeichermodulen eines Energiespeichers in Kraftfahrzeugen eingesetzt. Derartige Energiespeicher kommen unter anderem in batteriebetriebenen Kraftfahrzeugen sowie in solchen Kraftfahrzeugen zum Einsatz, welche sowohl elektrisch als auch verbrennungsmotorisch betrieben werden können. Aufgrund der von Antriebsmotoren benötigten großen Leistung und einer nicht beliebig hohen Spannung der Energiespeicher können in solchen Energiespeichern sehr hohe Ströme im Betrieb auftreten. Aus Gründen der Fertigungseffizienz, aber auch aus Gründen der Zuverlässigkeit werden dabei nicht nur geschraubte Verbindungen zur elektrischen Verbindung einzelner Komponenten eingesetzt, sondern auch solche, bei denen zwei Verbindungselemente durch eine Steckverbindung miteinander verbunden werden.High current (HS) 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.

Bei bekannten HS-Steckverbindern ist zwischen dem ersten Verbindungselement und dem zweiten Verbindungselement ein Federelement, beispielsweise in Gestalt einer Kontaktlamelle, angeordnet. Häufig ist das Federelement mechanisch mit einem der beiden Kontaktpartner verbunden. An die Verbindungselemente sind jeweilige Kabel oder Leitungen angebracht, welche an ihrem jeweiligen anderen Ende mit einer elektrischen Komponente des Energiespeichers, einer durch den Energiespeicher betriebenen elektrischen Komponente oder einem anderen Verbindungselement verbunden sind. Ein Nachteil dieser Steckverbindung besteht darin, dass eine geringe Kontaktfläche zwischen dem Federelement und den Verbindungselementen zur Stromübertragung besteht. Hierdurch ergeben sich erhöhte Übergangswiderstände, die zu einer Erhöhung der Temperatur führen.In known HS connectors, a spring element, for example in the form of a contact blade, is arranged between the first connection element and the second connection element. Often, the spring element is mechanically connected to one of the two contact partners. Respective cables or lines are attached to the connecting elements, which are connected at their respective other end to an electrical component of the energy store, an electrical component operated by the energy store or another connecting element. A disadvantage of this connector is that there is a small contact area between the spring element and the connecting elements for power transmission. This results in increased contact resistance, which leads to an increase in temperature.

GB2228150A offenbart eine Einrichtung zu elektrischer Verbindung, die einen Endstückverbinder aufweist, der seinerseits eine Endstückführung, einen federnden Streifen, der an der Endstückführung einstückig angeformt ist, und eine Endstückunterstützung aufweist. GB2228150A discloses an electrical connection device having an end connector which in turn has an end piece guide, a resilient strip integrally formed on the end piece guide, and an end piece support.

Um den Kontaktwiderstand gering zu halten, werden daher zumindest die Kontaktflächen der Verbindungselemente mit einer Beschichtung versehen. In der Regel besteht die Beschichtung aus Silber, welches exzellente Leitfähigkeitseigenschaften aufweist. Aus Kostengründen wird die Beschichtung mit einer Dicke von höchstens 10 µm ausgebildetIn order to keep the contact resistance low, therefore, at least the contact surfaces of the connecting elements are provided with a coating. As a rule, the coating consists of silver, which has excellent conductivity properties. For cost reasons, the coating is formed with a thickness of at most 10 microns

Es ist Aufgabe der vorliegenden Erfindung, einen Hochstrom-Steckverbinder anzugeben, welcher bei vergleichbarer Stromtragfähigkeit einen geringeren Übergangswiderstand aufweist.It is an object of the present invention to provide a high-current connector, which has a lower contact resistance with comparable current carrying capacity.

Diese Aufgabe wird gelöst durch einen Hochstrom-Steckverbinder gemäß den Merkmalen des Patentanspruches 1. Vorteilhafte Ausgestaltungen ergeben sich aus den abhängigen Patentansprüchen.This object is achieved by a high current connector according to the features of claim 1. Advantageous embodiments will be apparent from the dependent claims.

Die Erfindung schafft einen Hochstrom-Steckverbinder für Ströme von mehr als 100 Ampere, insbesondere mehr als 200 Ampere, mit einem ersten Verbindungselement, einem zweiten Verbindungselement und einem Federelement. Das erste Verbindungselement umfasst einen ersten Kontaktabschnitt. Das zweite Verbindungselement umfasst einen zweiten Kontaktabschnitt. Das Federelement bezweckt die Herstellung einer elektrischen Verbindung zwischen dem ersten und dem zweiten Kontaktabschnitt. Das Federelement umfasst zumindest zwei über zumindest einen Steg miteinander verbundene Klammerelemente, wobei der Steg und jeweilige erste Abschnitte der Klammerelemente auf einer ersten Außenfläche der aus dem ersten und dem zweiten Kontaktabschnitt gebildeten Verbindung angeordnet sind und zweite Abschnitte der Klammerelemente zumindest teilweise auf einer zweiten, der ersten Außenfläche gegenüber liegenden Außenfläche angeordnet sind. An dem zumindest einen Steg ist zumindest eine Kontaktfeder angeordnet, welche auf der ersten Außenfläche eine in Richtung der zweiten Außenfläche gerichtete Kontaktkraft erzeugt, wodurch einander zugewandte Kontaktflächen des ersten und des zweiten Kontaktabschnitts gegeneinander gepresst werden, wobei die zweiten Abschnitte der Klammerelemente als Widerlager dienen.The invention provides a high current connector for currents greater than 100 amperes, in particular greater than 200 amperes, with a first connection element, a second connection element and a spring element. The first connection element comprises a first contact section. The second connection element comprises a second contact section. The spring element is intended to produce an electrical connection between the first and the second contact portion. The spring element comprises at least two clip elements connected to one another via at least one web, wherein the web and respective first sections of the clip elements are arranged on a first outer surface of the connection formed by the first and the second contact section and second sections of the clip elements are disposed at least partially on a second, the first outer surface opposite outer surface are arranged. Arranged on the at least one web is at least one contact spring which generates a contact force directed towards the second outer surface on the first outer surface, whereby contact surfaces of the first and second contact sections facing one another are pressed against one another, the second sections of the clip elements serving as an abutment.

Die Erfindung erlaubt es, dass der erste und der zweite Kontaktabschnitt unmittelbar in Kontakt miteinander stehen. Dadurch, dass der erste und der zweite Kontaktabschnitt unmittelbar in Kontakt miteinander stehen, ergibt sich eine im Vergleich zum Stand der Technik größere Kontaktfläche. Aufgrund der nunmehr im Kontaktbereich auftretenden geringeren Übergangswiderstände gehen damit auch geringere Temperaturen einher. Durch die im Betrieb geringeren Temperaturen aufgrund der kleineren Übergangswiderstände kann eine längere Lebensdauer der Steckverbindung ermöglicht werden.The invention allows the first and second contact portions to be in direct contact with each other. Characterized in that the first and the second contact portion are in direct contact with each other, resulting in a larger compared to the prior art contact surface. Due to the now occurring in the contact area lower contact resistance is associated with lower temperatures. Due to the lower operating temperatures due to the smaller contact resistance, a longer life of the connector can be made possible.

Um die Kontaktabschnitte des ersten und des zweiten Verbindungselementes in eine, zur Herstellung des niederohmigen elektrischen Kontakts flächige Anlage zu bringen, ist das von außen auf die Kontaktabschnitte wirkende Federelement vorgesehen. Das Federelement ist insbesondere als ein von dem ersten und/oder zweiten Verbindungselement unabhängiges Bauteil ausgebildet, das unabhängig von den Verbindungselementen herstellbar und/oder verarbeitbar ist. Dies ermöglicht nicht nur die sichere Bereitstellung des elektrischen Kontakts, indem das Federelement die beiden Kontaktabschnitte definiert aufeinander presst, sondern sorgt auch im Vergleich für ein geringeres Bauraumvolumen und Gewicht des Steckverbinders.In order to bring the contact portions of the first and the second connecting element in a flat area for the production of low-resistance electrical contact, the force acting from the outside on the contact portions spring element is provided. The spring element is in particular designed as a component that is independent of the first and / or second connecting element and that can be produced and / or processed independently of the connecting elements. This not only enables the secure provision of the electrical contact by the spring element presses the two contact portions defined on each other, but also provides in comparison for a smaller installation space volume and weight of the connector.

Hierdurch ergibt sich auch eine besonders einfache Realisierung des Steckverbinders, da das erste und das zweite Verbindungselement nur einseitig mechanisch und damit elektrisch miteinander in Kontakt stehen. Die einander zugewandten Kontaktflächen sind hierzu korrespondierend ausgebildet. Bevorzugt sind die Verbindungselemente bzw. deren Kontaktabschnitte eben und flächig ausgebildet. Die Verbindungselemente können auch kugel- und kalottenförmig (konkav und konvex) ausgebildet sein. Hierdurch ist ein hoher Flächenkontakt für die Stromübertragung sichergestellt.This also results in a particularly simple realization of the connector, since the first and the second connecting element are only one side mechanically and thus electrically in contact. The mutually facing contact surfaces are formed corresponding thereto. Preferably, the connecting elements or their contact portions are flat and flat. The connecting elements can also be spherical and dome-shaped (concave and convex). As a result, a high surface contact for power transmission is ensured.

Die Kontaktabschnitte der ersten und zweiten Verbindungselemente sind über das Federelement kraftschlüssig miteinander verbunden. Hierdurch ist eine Lösbarkeit der Kontaktabschnitte nach Entfernen der Kontaktkraft gegeben. Gleichzeitig ermöglicht es diese Ausgestaltung, die Verbindung auch kraftlos herstellen zu können.The contact portions of the first and second connecting elements are non-positively connected to one another via the spring element. As a result, a solubility of the contact portions is given after removal of the contact force. At the same time, this embodiment makes it possible to produce the connection powerless.

Gemäß einer zweckmäßigen Ausgestaltung ist an dem zumindest einen Steg auf gegenüber liegenden Seiten jeweils zumindest eine Kontaktfeder angeordnet. Hierdurch wird lateral zu einer Steckrichtung der Verbindungselemente jeweils eine Kontaktkraft zur Klemmung der Kontaktabschnitte der Verbindungselemente aufgebracht. Unter der Steckrichtung der Verbindungselemente ist eine Richtung zu verstehen, in welche die Verbindungselemente relativ zueinander bewegt werden (müssen), um die Kontaktabschnitte der Verbindungselemente zunächst in Deckung zueinander zu bringen, um anschließend die Kontaktkraft herstellen zu können.According to an expedient embodiment, at least one contact spring is arranged on the at least one web on opposite sides. As a result, a contact force for clamping the contact portions of the connecting elements is applied laterally to a plug-in direction of the connecting elements. The direction of insertion of the connecting elements is to be understood as a direction in which the connecting elements are (are) moved relative to one another, around the contact sections the fasteners initially bring to cover each other to then produce the contact force can.

Gemäß einer weiteren zweckmäßigen Ausgestaltung weist die zumindest eine Kontaktfeder ein Wellenprofil auf, wobei das Wellenprofil, ausgehend von dem Steg, zumindest einen Wellenberg und dann einen mit der ersten Außenfläche in Kontakt stehendes Wellental aufweist, das die Kontaktkraft erzeugt Unter einem Wellenberg wird eine von der Verbindung weg gerichtete Wölbung verstanden. Unter einem Wellental wird in entsprechender Weise eine zu der Verbindung hin gerichtete Wölbung des Wellenprofils verstanden. Das Wellenprofil kann auf einfache Weise durch einen Umformprozess erzeugt werden.According to a further expedient embodiment, the at least one contact spring on a wave profile, wherein the wave profile, starting from the web, at least one wave crest and then having a standing with the first outer surface in contact trough having the contact force generated under a wave crest is one of the Compound oriented buckle understood. A trough is understood to mean, in a corresponding manner, a curvature of the wave profile directed towards the connection. The wave profile can be easily generated by a forming process.

Insbesondere kann sich die zumindest eine Kontaktfeder parallel zu den Klammerelementen und senkrecht zu einer Steckrichtung des ersten und des zweiten Verbindungselements zur Herstellung der Steckverbindung des Steckverbinders erstrecken. Dies bedeutet, die Erstreckung von aufeinander folgenden Wellenberg und Wellental ist parallel zu den Elementen und in etwa senkrecht zu der Steckrichtung der Verbindungselemente für die Herstellung der Steckverbindung.In particular, the at least one contact spring may extend parallel to the clip elements and perpendicular to a plug-in direction of the first and the second connecting element for producing the plug connection of the plug connector. This means that the extension of successive wave crest and wave trough is parallel to the elements and approximately perpendicular to the direction of insertion of the connecting elements for the production of the connector.

Ferner kann vorgesehen sein, dass, ausgehend von dem Steg, das letzte Wellental des Wellenprofils in einen T-förmigen Abschnitt übergeht, wobei die gegenüber liegenden Arme des T-förmigen Abschnitts eine Verformung aufweisen, welche von der Verbindung weg weist. Hierdurch kann die Kontaktkraft über Aktuierung der Arme des T-förmigen Abschnitts variiert werden, beispielsweise um die Verbindung herzustellen oder zu lösen. Insbesondere kann hiermit eine kraftlose Verbindungsherstellung oder -lösung bereitgestellt werden.Furthermore, it can be provided that, starting from the web, the last wave trough of the wave profile merges into a T-shaped section, wherein the opposite arms of the T-shaped section have a deformation which points away from the connection. As a result, the contact force can be varied via actuation of the arms of the T-shaped section, for example in order to establish or release the connection. In particular, this may provide a powerless connection establishment or solution.

Insbesondere umfasst das Federelement zumindest zwei parallel zueinander verlaufende Klammerelemente, wobei zwischen jeweils zwei Klammerelementen die zumindest eine Kontaktfeder angeordnet ist. Die Anzahl der Klammerelemente des Federelements und der Abstand zwischen jeweils zwei Klammerelementen hängen unter anderem davon ab, über welche Fläche bzw. Länge die Kontaktabschnitte die elektrische Verbindung ausbilden sollen. Über die Anzahl und Verteilung der Kontaktfedern kann darüber hinaus definiert die über die Fläche wirkende Kontaktkraft erzeugt werden.In particular, the spring element comprises at least two mutually parallel clamping elements, wherein between each two clamp elements, the at least one contact spring is arranged. The number of clip elements of the spring element and the distance between each two clip elements depend, inter alia, on which surface or length the contact sections are to form the electrical connection. In addition, the contact force acting over the surface can be generated via the number and distribution of the contact springs.

Gemäß einer weiteren zweckmäßigen Ausgestaltung sind jeweilige Enden eines Klammerelements, insbesondere auf der zweiten Außenfläche der Verbindung mechanisch, insbesondere durch einen Formschluss oder einen Stoffschluss miteinander verbunden. Weiter können die von der gleichen Seite auf die zweite Außenfläche geführten Klammerelemente miteinander verbunden sein, z.B. indem diese in einen jeweiligen endseitigen Flachabschnitt münden. Die mechanische Verbindung erfolgt dann mittels der zwei auf der zweiten Außenfläche liegenden endseitigen Flachabschnitte. Vorzugsweise sind die endseitigen Flachabschnitte derart bemessen, dass diese mit einem Großteil der zweiten Außenfläche in mechanischem Kontakt stehen. Auf diese Weise ist auch die zur Herstellung der Kontaktkraft notwendige Widerlagerung zuverlässig ausgebildet.In accordance with a further expedient embodiment, respective ends of a clamping element, in particular on the second outer surface of the connection, are mechanically connected to one another, in particular by a positive connection or a material connection. Further, the staple elements guided from the same side to the second outer surface may be interconnected, e.g. by opening into a respective end-side flat section. The mechanical connection then takes place by means of the two lying on the second outer surface end-side flat sections. Preferably, the end-side flat portions are dimensioned such that they are in mechanical contact with a large part of the second outer surface. In this way, the necessary to produce the contact force abutment is reliably formed.

Gemäß einer weiteren zweckmäßigen Ausgestaltung weist das Federelement an einem inneren der Klammerelemente eine sich in Richtung der Kontaktkraft erstreckende Anschlagschulter auf. Die Anschlagschulter dient dazu, eines der beiden Verbindungselemente zwecks Herstellung der Verbindung über eine definierte Länge in das Federelement einzuführen, so dass sich eine vorgegebene Kontaktfläche zwischen den beiden Verbindungselementen ergibt.According to a further expedient embodiment, the spring element on an inner of the clamping elements on a in the direction of the contact force extending stop shoulder. The stop shoulder serves to introduce one of the two connecting elements for the purpose of establishing the connection over a defined length in the spring element, so that there is a predetermined contact surface between the two connecting elements.

Es ist weiterhin zweckmäßig, wenn an dem inneren Klammerelement zumindest eine Fahne ausgebildet ist, welche eines der Verbindungselemente im Bereich einer Einschnürung umläuft, um das Federelement formschlüssig mit diesem Verbindungselement zu verbinden. Hierdurch wird zum einen eine definierte Position dieses Verbindungselements zu dem Federelement sichergestellt. Andererseits sorgt dies im Zusammenspiel mit der Anschlagschulter für die eben erwähnte definierte Position der Kontaktflächen der beiden Verbindungselemente zueinander.It is also expedient if at least one lug is formed on the inner clip element, which rotates one of the connecting elements in the region of a constriction in order to connect the spring element in a form-fitting manner with this connecting element. As a result, on the one hand a defined position of this connecting element is ensured to the spring element. On the other hand, this in interaction with the stop shoulder for the above-mentioned defined position of the contact surfaces of the two connecting elements to each other.

Gemäß einer weiteren zweckmäßigen Ausgestaltung ist der Steckverbinder nach Herstellung der Verbindung zwischen dem ersten und dem zweiten Verbindungselement von einem isolierenden Gehäuse, insbesondere aus Kunststoff, umgeben. Da der Hochstrom-Steckverbinder für hohe Ströme und hohe Spannungen vorgesehen ist, ist eine sichere Isolation der Verbindung erforderlich, welche durch das isolierende Gehäuse bereitgestellt wird.According to a further expedient embodiment, after the connection between the first and the second connecting element has been established, the plug connector is surrounded by an insulating housing, in particular made of plastic. Since the high current connector is designed for high currents and high voltages, reliable isolation of the connection provided by the insulating housing is required.

Das Gehäuse dient bevorzugt nicht nur der Isolation der Verbindung, sondern übernimmt gleichzeitig eine Funktion zur Herstellung oder zum Lösen der Verbindung aus den beiden Verbindungselementen. Zweckmäßigerweise umfasst das Gehäuse zumindest einen Führungsabschnitt mit einer Bahnkurve, welcher beim Aufbringen des Gehäuses auf das Federelement in einer Zwischenposition die zumindest eine Kontaktfeder entgegen ihrer Federkraft von der herzustellenden Verbindung abhebt, um in Steckrichtung ein kraftloses Einführen des nicht mit dem Federelement verbundenen Verbindungselements in das Federelement zu ermöglichen, wobei in einer Endposition des Gehäuses der zumindest eine Führungsabschnitt in keinem Eingriff mit dem Federelement ist, um die Erzeugung der Kontaktkraft durch das Federelement zu ermöglichen.The housing preferably serves not only to isolate the connection, but at the same time assumes a function for producing or releasing the connection from the two connection elements. Conveniently, the housing comprises at least one guide section with a trajectory, which lifts the at least one contact spring counter to its spring force of the connection to be produced when applying the housing to the spring element in an intermediate position, in the insertion direction a powerless insertion of the non-connected to the spring element connecting element in the To allow spring element, wherein in an end position of the housing, the at least one guide portion is not engaged with the spring element to allow the generation of the contact force by the spring element.

In einer weiteren zweckmäßigen Ausgestaltung sind die Kontaktabschnitte der Verbindungselemente flächig, insbesondere eben oder konkav oder konvex, ausgebildet.In a further expedient embodiment, the contact portions of the connecting elements are flat, in particular flat or concave or convex, formed.

Insbesondere ist vorgesehen, dass das Federelement aus einem Edelstahl gebildet ist, um die für die Erzeugung notwendige Kontaktkraft auf die Verbindung ausüben zu können.In particular, it is provided that the spring element is formed of a stainless steel, in order to be able to exert the contact force necessary for the generation on the compound can.

Es ist zweckmäßig, wenn die zumindest eine Kontaktfeder, der zumindest eine Steg und die zumindest zwei Klammerelemente einteilig, d.h. einstückig, ausgebildet sind. Mit anderen Worten bedeutet dies, dass das Federelement vorzugsweise aus einem Stück Metall, insbesondere Edelstahl, ausgebildet ist.It is expedient if the at least one contact spring, the at least one web and the at least two clip elements in one piece, i. in one piece, are formed. In other words, this means that the spring element is preferably formed from a piece of metal, in particular stainless steel.

Wahlweise bestehen das erste und/oder das zweite Verbindungselement aus Aluminium oder einer Aluminium-Legierung. Ebenso können das erste und/oder das zweite Verbindungselement aus Kupfer oder einer Kupfer-Legierung bestehen. Aus welchem Material das erste bzw. zweite Verbindungselement gefertigt wird, ergibt sich primär aus dem Material eines weiteren Verbindungspartners, welcher mit dem betreffenden Verbindungselement kontaktiert werden muss. Besteht der Verbindungspartner aus Aluminium, so ist es zweckmäßig, auch das Verbindungselement aus Aluminium bereit zu stellen, um zwischen diesen beiden Komponenten eine möglichst einfache und sichere elektrische Verbindung herstellen zu können.Optionally, the first and / or the second connecting element made of aluminum or an aluminum alloy. Likewise, the first and / or the second connecting element may consist of copper or a copper alloy. The material of which the first or second connecting element is manufactured results primarily from the material of another connecting partner, which must be contacted with the relevant connecting element. If the connection partner consists of aluminum, then it is expedient to provide the connecting element made of aluminum in order to be able to produce the simplest possible and safe electrical connection between these two components.

Es ist jedoch ebenfalls möglich, eines der beiden Verbindungselemente aus Aluminium und das andere der beiden Verbindungselemente aus Kupfer (oder jeweils deren Legierungen) bereitzustellen. Insbesondere in diesem Fall ist vorgesehen, dass das erste und/oder das zweite Verbindungselement im Bereich ihrer jeweiligen aneinander grenzenden Kontaktabschnitte eine erste bzw. eine zweite Beschichtung aufweisen. Es versteht sich, dass eine derartige Beschichtung auch dann vorgesehen werden kann, wenn die beiden Verbindungselemente aus den gleichen Materialien bzw. Legierungen bestehen. Ein Vorteil des Vorsehens der Beschichtung besteht darin, dass die Lebensdauer der Steckverbindung durch einen Schutz der Oberfläche der Kontaktabschnitte vor Oxidation erhöht werden kann. Dies ist insbesondere für aus Aluminium bestehende Verbindungselemente von Bedeutung, welche bei Kontakt mit Sauerstoff sehr schnell oxidieren. Bestehen die Verbindungselemente - wie eingangs erläutert - aus unterschiedlichen Materialien, so trägt das Vorsehen der Beschichtung zusätzlich zu einem Schutz vor Kontaktkorrosion aufgrund einer ansonsten auftretenden elektro-chemischen Spannungsreihe bei.However, it is also possible to provide one of the two aluminum fasteners and the other of the two copper interconnects (or their alloys, respectively). In particular, in this case it is provided that the first and / or the second connecting element in the region of their respective adjacent contact portions have a first and a second coating. It is understood that such a coating can also be provided if the two connecting elements consist of the same materials or alloys. An advantage of providing the coating is that the life of the connector can be increased by protecting the surface of the contact portions from oxidation. This is particularly important for aluminum connecting elements of importance, which oxidize very quickly on contact with oxygen. If the connecting elements - as explained above - consist of different materials, the provision of the coating additionally contributes to protection against contact corrosion due to an otherwise occurring electrochemical voltage series.

Es ist insbesondere zweckmäßig, wenn die erste und/oder die zweite Beschichtung eine Schicht aus Zinn oder einer Zinnlegierung umfassen. Gegenüber dem ansonsten verwendeten Silber kann Zinn zu einem kostengünstigeren Preis bereitgestellt werden, wodurch die Kosten für die Herstellung der Steckverbindung reduziert werden können. Um eine Kontaktkorrosion aufgrund der elektro-chemischen Spannungsreihe zu vermeiden, kann weiterhin vorgesehen sein, dass die erste und/oder die zweite Beschichtung zwischen dem Zinn oder der Zinnlegierung als äußerste Schicht (Oberflächenbeschichtung) eine erste Zwischenschicht aus Kupfer und/oder eine zweite Zwischenschicht aus Nickel oder deren Legierungen umfassen. Ob und falls eine oder mehrere Zwischenschichten vorgesehen sind, können die entsprechenden Materialien in Abhängigkeit des Materials der beiden Verbindungselemente gewählt werden, um Probleme aufgrund der elektro-chemischen Spannungsreihe zu vermeiden.It is particularly expedient if the first and / or the second coating comprise a layer of tin or a tin alloy. Tin can be provided at a lower cost than the silver otherwise used, thereby reducing the cost of making the connector. In order to avoid contact corrosion due to the electrochemical series of voltages, it may further be provided that the first and / or the second coating between the tin or the tin alloy as the outermost layer (surface coating) comprises a first intermediate layer of copper and / or a second intermediate layer Include nickel or their alloys. If and if one or more intermediate layers are provided, the corresponding materials can be selected depending on the material of the two connecting elements in order to avoid problems due to the electrochemical series of voltages.

Es ist weiterhin zweckmäßig, wenn die erste und/oder die zweite Beschichtung (Oberflächenbeschichtung) eine Gesamtdicke von mehr als 10 µm, insbesondere mehr als 20 µm aufweisen, wobei die maximale gesamte Dicke der ersten und/oder der zweiten Beschichtung 100 µm, bevorzugt 50 µm, beträgt. Je größer die Dicke der Beschichtung gewählt wird, desto geringer ist die Gefahr einer Oxidation von, insbesondere von aus Aluminium und deren Legierungen bestehenden, Verbindungselementen. Die Gefahr einer solchen Oxidation entsteht dadurch, dass die Beschichtung über die Lebensdauer der Steckverbindung sich typischerweise abnutzt und dabei unbeabsichtigter Weise die Oberfläche des Materials eines der Verbindungselemente freigelegt werden kann. Diese Gefahr ist umso größer, je dünner die Schichtdicke ist. Insbesondere hat sich gezeigt, dass das Problem dann gegeben ist, wenn die Schichtdicke weniger als 10 µm beträgt. Aufgrund des wesentlich geringeren Preises des bevorzugten Zinns als Beschichtung kann die Schichtdicke ohne weiteres bis zu 100 µm dick auf die Kontaktabschnitte der Verbindungselemente aufgebracht werden. Eine entsprechende Schichtdicke aus Silber, das im Stand der Technik als Beschichtungsmittel zur Bereitstellung einer hohen Leitfähigkeit verwendet wird, würde hingegen nur die Kosten der Steckverbindung für die Praxis unakzeptabel hoch ansteigen lassen. Die Aufbringung der Beschichtung kann beispielsweise galvanisch erfolgen. Ebenso sind andere geeignete Verfahren einsetzbar. Bevorzugt weist die Beschichtung eine 1 bis 20µm, insbesondere eine 2 bis 8 µm, starke Unterkupferung oder Unternickelung als Zwischenschicht auf.It is furthermore expedient for the first and / or the second coating (surface coating) to have a total thickness of more than 10 μm, in particular more than 20 μm, the maximum total thickness of the first and / or the second coating being 100 μm, preferably 50 μm μm. The greater the thickness of the coating is chosen, the lower the risk of oxidation of, in particular of aluminum and its alloys, existing fasteners. The danger of such Oxidation occurs because the coating typically wears away over the life of the connector, unintentionally exposing the surface of the material of one of the connectors. This danger is greater the thinner the layer thickness. In particular, it has been shown that the problem is given when the layer thickness is less than 10 microns. Due to the much lower price of the preferred tin as a coating, the layer thickness can be readily applied to the contact portions of the connecting elements up to 100 microns thick. By contrast, a corresponding layer thickness of silver, which is used in the prior art as a coating agent to provide a high conductivity, would only increase the cost of the connector in practice unacceptably high. The application of the coating can be done, for example, galvanically. Likewise, other suitable methods can be used. Preferably, the coating has a 1 to 20 microns, especially a 2 to 8 microns, strong Unterkupferung or Unterickelung as an intermediate layer.

Wahlweise kann auf die erste und/oder die zweite Beschichtung ferner zusätzlich eine Deckschicht aus Kupfer und/oder einer Kupfer-Legierung und/oder Nickel und/oder einer Nickellegierung und/oder Silber und/oder einer Silber-Legierung und/oder Gold und/oder einer Gold-Legierung aufgebracht sein. Vorzugsweise weist die Deckschicht eine Dicke von 0,01 bis 5 µm, insbesondere eine Dicke von 0,1 bis 0,3 µm, auf.Optionally, in addition to the first and / or the second coating, a cover layer of copper and / or a copper alloy and / or nickel and / or a nickel alloy and / or silver and / or a silver alloy and / or gold and / or or a gold alloy. The cover layer preferably has a thickness of 0.01 to 5 μm, in particular a thickness of 0.1 to 0.3 μm.

Die Beschichtung der Kontaktflächen der Kontaktabschnitte kann z.B. galvanisch und/oder durch Schmelztauchbeschichten und/oder durch Abscheidung aus der Gasphase und/oder durch Flamm- und/oder durch Plasmaspritzen und/oder durch Kompaktieren aufgebracht sein.The coating of the contact surfaces of the contact portions may e.g. be applied galvanically and / or by hot dip coating and / or by deposition from the gas phase and / or by flame and / or by plasma spraying and / or by compaction.

Die Erfindung wird nachfolgend näher anhand eines Ausführungsbeispiels in der Zeichnung erläutert. Es zeigen:

Fig. 1
eine perspektivische Darstellung eines erfindungsgemäßen Hochstrom-Steckverbinders ohne ein die Verbindung umgebendes Gehäuse,
Fig. 2
einen Schnitt durch die Verbindung, in welcher die Verbindungselemente und das Federelement zur Herstellung der Erfindung dargestellt sind,
Fig. 3
eine Schnittdarstellung der in Verbindung befindlichen Verbindungselemente, wobei zu Illustrationszwecken das Federelement weggelassen ist,
Fig. 4
eine perspektivische Darstellung eines erfindungsgemäßen Hochstrom-Steckverbinders, bei dem die Verbindung von einem isolierenden Gehäuse umgeben ist,
Fig. 5
einen Schnitt in Längsrichtung durch das auf die Verbindung aufgebrachte Gehäuse, wobei sich dieses in einer Zwischenposition befindet, und
Fig. 6
einen weiteren Schnitt in Querrichtung durch den erfindungsgemäßen HochstromSteckverbinder, bei dem das Gehäuse in seiner Endposition über der Verbindung angeordnet ist.
The invention will be explained in more detail below with reference to an embodiment in the drawing. Show it:
Fig. 1
a perspective view of a high-current connector according to the invention without a housing surrounding the compound,
Fig. 2
a section through the connection, in which the connecting elements and the spring element for producing the invention are shown,
Fig. 3
a sectional view of the connecting elements in connection, wherein for illustrative purposes, the spring element is omitted,
Fig. 4
a perspective view of a high-current connector according to the invention, in which the connection is surrounded by an insulating housing,
Fig. 5
a longitudinal section through the housing applied to the connection, wherein this is in an intermediate position, and
Fig. 6
a further cross-section through the high-current connector according to the invention, in which the housing is arranged in its end position over the connection.

In den nachfolgend beschriebenen Darstellungen ist ein erfindungsgemäßer Hochstrom (HS)-Steckverbinder in verschiedenen perspektivischen und geschnittenen Darstellungen gezeigt. Der HS-Steckverbinder ist für Ströme von mehr als 100 A, oder sogar mehr als 200 A, geeignet. Ströme in dieser Größenordnung treten beispielsweise bei Energiespeichern für Antriebsmaschinen in Kraftfahrzeugen auf.In the illustrations described below, a high-current (HS) plug connector according to the invention is shown in various perspective and sectional representations. The HV connector is suitable for currents of more than 100 A, or even more than 200 A. Currents of this magnitude occur, for example, in energy stores for drive machines in motor vehicles.

Der HS-Steckverbinder 1 umfasst ein erstes Verbindungselement 10 sowie ein zweites Verbindungselement 20. Das erste Verbindungselement 10 weist einen ersten Kontaktabschnitt 11, das zweite Verbindungselement 20 einen zweiten Kontaktabschnitt 21 auf. Der erste und der zweite Kontaktabschnitt 11, 21 sind in den Ausführungsbeispielen flächig, d.h. eben, als Flachstücke ausgebildet. Die Kontaktabschnitte können auch konkav und konvex ausgebildet sein. Die Verbindungselemente 10, 20 werden zur Herstellung einer elektrischen Verbindung 5 im Bereich ihrer Kontaktabschnitte 11, 21 koplanar in Anlage gebracht und über ein Federelement 30 durch Aufbringung von gegeneinander pressenden Kontaktkräften miteinander verbunden. Daher umgibt das Federelement 30 die Verbindung 5 von außen her.The HV connector 1 comprises a first connection element 10 and a second connection element 20. The first connection element 10 has a first contact section 11, the second connection element 20 has a second contact section 21. The first and second contact portions 11, 21 are planar in the embodiments, i. also, designed as flat pieces. The contact portions may also be concave and convex. The connecting elements 10, 20 are coplanar brought to the preparation of an electrical connection 5 in the region of their contact portions 11, 21 and connected to each other via a spring element 30 by applying mutually pressing contact forces. Therefore, the spring element 30 surrounds the connection 5 from the outside.

In der in Fig. 3 gezeigten Schnittansicht ist die relative Anordnung der zwei Verbindungselemente 10, 20 zueinander am besten ersichtlich, wenn diese in einer die Verbindung 5 ausbildenden Position sind. Die Verbindungselemente 10, 20 sind dabei derart zueinander angeordnet, wie sich diese aufgrund des im Bereich der Kontaktabschnitte 11, 21 vorgesehenen Federelements 30 befinden würden. Der Übersichtlichkeit halber und zur Erläuterung der nachfolgend weiter verwendeten Bezeichnungen ist das Federelement 30 in Fig. 3 weggelassen. Mit dem Bezugszeichen 6 ist eine erste Außenfläche gekennzeichnet. Die erste Außenfläche 6 ist dabei diejenige Seite bzw. Fläche des Kontaktabschnitts, welcher nicht die elektrische Verbindung zu dem Kontaktabschnitt 21 des anderen Verbindungselements 20 repräsentiert. Das Bezugszeichen 7 kennzeichnet eine zweite Au-ßenfläche, welche der ersten Außenfläche gegenüber liegt. Wie aus Fig. 3 ohne Weiteres ersichtlich ist, ist die zweite Außenfläche diejenige Fläche des Kontaktabschnitts 21, welcher nicht die elektrische Verbindung zu dem Kontaktabschnitt 11 des ersten Verbindungselements 10 ausbildet.In the in Fig. 3 The sectional view shown, the relative arrangement of the two connecting elements 10, 20 to each other best seen when this in a compound. 5 training position. The connecting elements 10, 20 are arranged in such a way to each other, as they would be due to the 30 provided in the region of the contact portions 11, 21 spring element. For the sake of clarity and to explain the terms used further below, the spring element 30 in FIG Fig. 3 omitted. Reference numeral 6 denotes a first outer surface. The first outer surface 6 is that side or surface of the contact section which does not represent the electrical connection to the contact section 21 of the other connecting element 20. The reference numeral 7 designates a second outer surface facing the first outer surface. How out Fig. 3 is readily apparent, the second outer surface is that surface of the contact portion 21, which does not form the electrical connection to the contact portion 11 of the first connecting member 10.

An dem von dem Kontaktabschnitt 11 abgewandten Ende 12 des Verbindungselementes 10 kann ein Kontaktelement eines Energiespeichers oder einer Batteriezelle (nicht dargestellt) verbunden sein. Entsprechend der Bauraumsituation in einem Energiespeicher weist das Verbindungselement 10 in seitlicher Ansicht die Gestalt eines Hakens auf. Dies ist lediglich einer konkreten Einbausituation in einem Energiespeicher geschuldet. Prinzipiell könnte der Verlauf des Verbindungselements 10 außerhalb des Kontaktabschnitts 11 beliebig sein. An dem von dem Kontaktabschnitt 21 abgewandten Ende 22 des Verbindungselements 20 ist ein elektrischer Leiter 25 über sein Kabelanschlusselement 26 verbunden (Fig. 1). Auf welche Weise die Verbindungselemente 10, 20 mit dem Kabel bzw. dem Kabelanschlusselement 26 sowie dem nicht dargestellten Kontaktelement eines Energiespeichers oder einer Batteriezelle verbunden sind, ist für die vorliegende Erfindung von untergeordneter Bedeutung. Die Ausgestaltung der Verbindungselemente zur Kontaktierung der Kontaktpartner ist abhängig von den Gegebenheiten zu wählen und für die vorliegende Erfindung nicht von Bedeutung.At the end 12 remote from the contact portion 11 of the connecting element 10, a contact element of an energy storage or a battery cell (not shown) may be connected. According to the installation space situation in an energy store, the connecting element 10 has the shape of a hook in a lateral view. This is only due to a specific installation situation in an energy store. In principle, the course of the connecting element 10 outside the contact section 11 could be arbitrary. At the end 22 of the connecting element 20 remote from the contact section 21, an electrical conductor 25 is connected via its cable connecting element 26 (FIG. Fig. 1 ). How the connecting elements 10, 20 are connected to the cable or the cable connection element 26 and the contact element, not shown, of an energy store or a battery cell, is for the present invention of minor importance. The configuration of the connecting elements for contacting the contact partners is dependent on the circumstances to choose and for the present invention is not important.

Als Materialien für die Verbindungselemente 10, 20 einschließlich deren Kontaktabschnitte werden vorzugsweise Aluminium oder Kupfer oder deren Legierungen verwendet. Wahlweise kann eines der beiden Verbindungselemente 10, 20 aus Aluminium oder einer Aluminium-Legierung und das andere Verbindungsteil aus Kupfer oder einer Kupfer-Legierung bestehen. Ebenso ist es möglich, dass beide Verbindungselemente aus Aluminium oder einer Aluminium-Legierung oder aus Kupfer oder einer Kupfer-Legierung bestehen.As materials for the connecting members 10, 20 including their contact portions, aluminum or copper or their alloys are preferably used. Optionally, one of the two connecting elements 10, 20 made of aluminum or an aluminum alloy and the other connecting part made of copper or a copper alloy. It is also possible that both fasteners made of aluminum or an aluminum alloy or copper or a copper alloy.

Bei Einsatz des HS-Steckverbinders 1 in einem Kraftfahrzeug zur Elektrifizierung eines Energiespeichers für eine Antriebsmaschine kommt bei zumindest einem der beiden Verbindungselemente vorzugsweise Aluminium oder eine Aluminium-Legierung zum Einsatz, da auch die Kontaktterminals des Energiespeichers aus Aluminium bestehen. Aluminium weist gegenüber Kupfer den Vorteil eines geringeren Gewichts auf. Demgegenüber wird für das zweite Verbindungselement häufig Kupfer oder eine Kupfer-Legierung eingesetzt, da sich dieses auf einfache und bewährte Weise mit entsprechenden elektrischen Leitern, wie z.B. dem dargestellten Kabel 25 bzw. dessen Kabelanschlusselement 26, verbinden lässt.When using the HS connector 1 in a motor vehicle for electrification of an energy storage device for a prime mover, aluminum or an aluminum alloy is preferably used in at least one of the two connecting elements, since the contact terminals of the energy accumulator also consist of aluminum. Aluminum has the advantage of lower weight over copper. On the other hand, copper or a copper alloy is often used for the second connecting element because it can be easily and reliably connected to corresponding electrical conductors, such as e.g. the illustrated cable 25 or its cable connection element 26, can connect.

Dadurch, dass die Kontaktabschnitte 11,21 der Verbindungselemente 10, 20 durch das Federelement 30 unmittelbar, d.h. ohne Zwischenschaltung weiterer Komponenten aufeinander gespannt werden, sind beliebige Materialkombinationen möglich. Dies resultiert insbesondere aus einem Verzicht einer Kontaktfeder zwischen den Kontaktabschnitten 11, 21 der Verbindungselemente 10, 20.Characterized in that the contact portions 11,21 of the connecting elements 10, 20 by the spring element 30 directly, i. Without the interposition of other components are stretched on each other, any combination of materials are possible. This results in particular from a waiver of a contact spring between the contact portions 11, 21 of the connecting elements 10, 20th

Es ist bevorzugt, wenn die Verbindungselemente 10, 20 im Bereich ihrer jeweiligen Kontaktabschnitte eine jeweilige Beschichtung (nicht dargestellt) aufweisen. Da die Verbindungselemente 10, 20 im Bereich ihrer Kontaktabschnitte 11, 21 großflächig in Kontakt miteinander stehen, braucht die Beschichtung nicht aus teurem (und gut leitfähigem) Silber zu bestehen. Stattdessen kann das wesentlich kostengünstigere Zinn zum Einsatz gebracht werden. Aufgrund der signifikant geringeren Kosten von Zinn gegenüber Silber kann demgegenüber die Dicke der Beschichtung von bislang maximal 10 µm auf bis zu 100 µm vergrößert werden. Bevorzugt wird eine Schichtdicke zwischen 20 µm und 70 µm, insbesondere 50 µm, gewählt.It is preferred if the connecting elements 10, 20 have a respective coating (not shown) in the region of their respective contact sections. Since the connecting elements 10, 20 are in contact with each other over a large area in the region of their contact sections 11, 21, the coating need not consist of expensive (and highly conductive) silver. Instead, the much cheaper tin can be used. On the other hand, due to the significantly lower cost of tin compared to silver, the thickness of the coating can be increased from a maximum of 10 μm up to 100 μm. Preferably, a layer thickness between 20 .mu.m and 70 .mu.m, in particular 50 .mu.m, is selected.

Die vergrößerte Schichtdicke weist den Vorteil auf, dass die Lebensdauer der Steckverbindung erhöht werden kann, da ein dauerhafter Schutz der Oberflächen der Kontaktabschnitte vor Oxidation ermöglicht wird. Im Betrieb des Steckverbinders, in dem die Verbindungselemente durch das Federelement kraftschlüssig miteinander verbunden sind, ergeben sich geringfügige Relativbewegungen zueinander, welche die Beschichtung(en) im Laufe der Zeit abtragen. Bei einer lediglich dünnen Beschichtung von bis zu 10 µm kann diese über die Lebensdauer, beispielsweise eines Energiespeichers eines Fahrzeugs, vollständig abgetragen werden, so dass es zu Oxidationserscheinungen an den Verbindungselementen kommt. Demgegenüber führt die flächige Beschichtung der Kontaktabschnitte 11, 21 dazu, dass durch die Relativbewegung der Verbindungselemente 10, 20 zueinander Oberflächenrauhigkeiten der Beschichtung(en) abgetragen werden, wodurch sich der Kontakt zwischen den Kontaktabschnitten 11,21 weiter verbessert. Dabei besteht auch keine Gefahr, dass die Beschichtung eines der Kontaktabschnitte 11, 21 vollständig abgetragen wird, so dass die oben beschriebenen Oxidationseffekte nicht eintreten (können).The increased layer thickness has the advantage that the life of the connector can be increased since a permanent protection of the surfaces of the contact portions is made possible before oxidation. In operation of the connector in which the connecting elements are non-positively connected to each other by the spring element, there are slight relative movements to each other, which the coating (s) wear off over time. With a merely thin coating of up to 10 μm, it can be completely removed over the lifetime, for example of an energy store of a vehicle, so that oxidation phenomena occur at the connecting elements. In contrast, the two-dimensional coating of the contact portions 11, 21 causes surface roughnesses of the coating (s) to be removed by the relative movement of the connecting elements 10, 20, whereby the contact between the contact sections 11, 21 is further improved. There is also no risk that the coating of one of the contact portions 11, 21 is completely removed, so that the oxidation effects described above can not occur.

In der einfachsten Ausgestaltung besteht die nicht dargestellte Beschichtung ausschließlich aus Zinn. In alternativen Ausgestaltungen kann die Beschichtung wenigstens eine Zwischenschicht aus Kupfer und/oder Nickel umfassen. Die Zwischenschicht(en) sind dann zwischen dem Zinn als äußerste Schicht und dem Kontaktabschnitt des Verbindungselements angeordnet. Die Schichtdicken einer jeweiligen Zwischenschicht betragen zwischen 2 und 8 µm. Dabei ist es bevorzugt, wenn die Gesamtschichtdicke nicht größer als 100 µm wird. Durch das Vorsehen einer oder mehrerer Zwischenschichten aus den genannten Materialien kann vorteilhaft das Problem einer elektro-chemischen Spannungsreihe (Kontaktkorrosion) gelöst werden, welches bei unterschiedlichen Materialien der beiden Verbindungselemente 10,20 besteht. Auch hierdurch kann die Zuverlässigkeit des Steckverbinders 1 über die Lebensdauer verbessert werden.In the simplest embodiment, the coating, not shown, consists exclusively of tin. In alternative embodiments, the coating may comprise at least one intermediate layer of copper and / or nickel. The intermediate layer (s) are then arranged between the tin as the outermost layer and the contact portion of the connecting element. The layer thicknesses of a respective intermediate layer are between 2 and 8 microns. In this case, it is preferable if the total layer thickness does not become larger than 100 μm. By providing one or more intermediate layers of the materials mentioned, the problem of an electrochemical series of voltages (contact corrosion) can advantageously be solved, which exists with different materials of the two connecting elements 10, 20. Again, the reliability of the connector 1 can be improved over the life.

Als Deckschicht der Beschichtung kann eine Schicht aus Kupfer und/oder einer Kupfer-Legierung und/oder Nickel und/oder einer Nickellegierung und/oder Silber und/oder einer Silber-Legierung und/oder Gold und/oder einer Gold-Legierung aufgebracht sein. Vorzugsweise weist die Deckschicht eine Dicke von 0,01 bis 5 µm, insbesondere eine Dicke von 0,1 bis 0,3 µm, auf.As a cover layer of the coating, a layer of copper and / or a copper alloy and / or nickel and / or a nickel alloy and / or silver and / or a silver alloy and / or gold and / or a gold alloy may be applied. The cover layer preferably has a thickness of 0.01 to 5 μm, in particular a thickness of 0.1 to 0.3 μm.

Die Beschichtung der Kontaktflächen der Kontaktabschnitte erfolgt z.B. galvanisch und/oder durch Schmelztauchbeschichten und/oder durch Abscheidung aus der Gasphase und/oder durch Flamm- und/oder durch Plasmaspritzen und/oder durch Kompaktieren.The coating of the contact surfaces of the contact sections takes place, for example, galvanically and / or by hot dip coating and / or by deposition from the gas phase and / or by flame and / or plasma spraying and / or by compacting.

Nachfolgend wird unter Bezugnahme auf die Figuren 1 und 2 die Ausgestaltung des Federelements 30 näher erläutert. Das Federelement 30 umfasst zwei über einen Steg 31 miteinander verbundene Klammerelemente 32, 35. Die Klammerelemente 32, 35 verlaufen zueinander parallel, wobei der Steg 31 diese in einer Draufsicht in etwa der Mitte in Richtung einer Steckrichtung SR verbindet. Von oben, d.h. der ersten Außenfläche 6 her, weist das Federelement 30 die Form eines "H" auf. Unter der Steckrichtung SR wird diejenige Bewegungsrichtung verstanden, in welcher das oder die Verbindungselemente 10, 20 in das Federelement 30 eingeführt werden muss oder müssen, um die Verbindung 5 herzustellen, oder umgekehrt. Der Steg 31 und jeweilige erste Abschnitte 33, 36 der Klammerelemente sind auf der ersten Außenfläche 6 angeordnet. Die ersten Abschnitte 33, 36 sind um jeweilige Stirnseiten der Verbindung 5 (d.h. der übereinander angeordneten Kontaktabschnitte 11, 21) herum geführt und münden in zweite Abschnitte 34, 37 der Klammerelemente, die auf der zweiten Außenfläche 7 angeordnet sind. Vorzugsweise sind jeweilige Enden eines Klammerelements 32, 35 mechanisch, insbesondere durch einen Formschluss oder einen Stoffschluss, miteinander verbunden. Insbesondere erfolgt die Verbindung jeweiliger Enden eines Klammerelements 32, 35 auf der zweiten Außenfläche 7.The following is with reference to the FIGS. 1 and 2 the embodiment of the spring element 30 explained in more detail. The spring element 30 comprises two clip elements 32, 35 connected to one another via a web 31. The clip elements 32, 35 run parallel to one another, the web 31 connecting them in a plan view approximately in the middle in the direction of a plug-in direction SR. From above, ie the first outer surface 6 ago, the spring element 30 has the shape of an "H". The direction of insertion SR is understood to mean that direction of movement in which the one or more connecting elements 10, 20 must or must be inserted into the spring element 30 in order to produce the connection 5, or vice versa. The web 31 and respective first portions 33, 36 of the clip elements are arranged on the first outer surface 6. The first portions 33, 36 are guided around respective end faces of the connection 5 (ie, the superimposed contact portions 11, 21) and terminate in second portions 34, 37 of the clamp members disposed on the second outer surface 7. Preferably, respective ends of a clamping element 32, 35 are mechanically connected to each other, in particular by a positive connection or an adhesive bond. In particular, the connection of respective ends of a clip element 32, 35 takes place on the second outer surface 7.

An dem Steg 31 sind auf seinen gegenüber liegenden Seiten Kontaktfedern 40, 45 angeordnet. Die Kontaktfedern 40, 45 weisen jeweils ein Wellenprofil auf (vgl. Fig. 2). Das Wellenprofil weist, ausgehend von dem Steg 31, jeweils zunächst einen Wellenberg 41, 46 und dann ein mit der ersten Außenfläche 6 in Kontakt stehendes Wellental 42, 47 auf. Das einteilig hergestellte Federelement 30 besteht aus einem Federstahl. Aufgrund der beschriebenen Formgestaltung des Wellenprofils erzeugen die Wellentäler 42, 47 eine Kontaktkraft, welche in Richtung der zweiten Außenfläche 7 gerichtet ist. Hierdurch werden einander zugewandte Kontaktflächen des ersten und zweiten Kontaktabschnitts 11, 21 gegeneinander gepresst. Dabei dienen die zweiten Abschnitte 34, 37 der Klammerelemente als Widerlager.At the web 31 contact springs 40, 45 are arranged on its opposite sides. The contact springs 40, 45 each have a wave profile (see. Fig. 2 ). Starting from the web 31, the wave profile initially has a wave crest 41, 46 and then a wave valley 42, 47 which is in contact with the first outer surface 6. The one-piece spring element 30 is made of a spring steel. Due to the described shape design of the wave profile, the wave troughs 42, 47 generate a contact force, which is directed in the direction of the second outer surface 7. As a result, mutually facing contact surfaces of the first and second contact portions 11, 21 are pressed against each other. The second sections 34, 37 of the clamp elements serve as an abutment.

Wie insbesondere aus der Schnittdarstellung der Fig. 2 hervorgeht, geht, ausgehend vom Steg 31, das letzte Wellental 42, 47 des Wellenprofils 40, 45 in einen (in Draufsicht) T-förmigen Abschnitt 43, 48 über. Dabei weisen die gegenüber liegenden Arme 44, 49 des T-förmigen Abschnitts 43, 48 eine Verformung auf, welche von der Verbindung 5 weg weist. Diese, nach oben weisende Verformung geht wiederum besser aus der Darstellung der Fig. 1 hervor, insbesondere T-förmiger Abschnitt 48. Die Verformungen des T-förmigen Abschnitts 43, 48 dienen dazu, eine kraftlose Herstellung der Verbindung oder ein kraftloses Lösen der Verbindung zu ermöglichen. Dies wird vermittels des nachfolgend näher beschriebenen isolierenden Gehäuses 70 bewerkstelligt.As in particular from the sectional view of Fig. 2 shows, starting from the web 31, the last wave trough 42, 47 of the wave profile 40, 45 in a (in plan view) T-shaped section 43, 48 via. In this case, the opposite arms 44, 49 of the T-shaped section 43, 48 have a deformation which points away from the connection 5. This upward-pointing deformation, in turn, is better understood of the Fig. 1 in particular T-shaped section 48. The deformations of the T-shaped section 43, 48 serve to enable a powerless connection or a weak connection release. This is accomplished by means of the insulating housing 70 described in more detail below.

An dem Klammerelement 35, das ein sog. inneres Klammerelement darstellt, ist eine sich in Richtung der Kontaktkraft erstreckende Anschlagschulter 50 ausgebildet. Diese mündet in einen Abschnitt 53, welcher parallel zu dem Verbindungselement 20 verläuft und auf diesem aufliegen kann. Darüber hinaus sind an dem inneren Klammerelement 35 Fahnen 51, 52 ausgebildet. Diese sind an dem zweiten Abschnitt 37 des inneren Klammerelements 35 befestigt und umgreifen eine Einschnürung 23 des Verbindungselements 20. Hierdurch ist das Federelement 30 formschlüssig mit dem Verbindungselement 20 verbunden. Hieraus ergibt sich, dass zur Herstellung der Verbindung 5 der Kontaktabschnitt 11 des ersten Verbindungselements 10 in Steckrichtung SR in das Federelement 30 eingeführt werden muss, wobei der Kontaktabschnitt 21 des zweiten Verbindungselements 20 bereits in diesem ortsfest gelagert ist.On the clamp element 35, which constitutes a so-called. Inner clip element, a stop shoulder 50 extending in the direction of the contact force is formed. This opens into a section 53 which runs parallel to the connecting element 20 and can rest thereon. In addition, 35 flags 51, 52 are formed on the inner clip member. These are attached to the second portion 37 of the inner bracket member 35 and engage around a constriction 23 of the connecting element 20. As a result, the spring element 30 is positively connected to the connecting element 20. It follows that for the preparation of the compound 5, the contact portion 11 of the first connecting element 10 in the insertion direction SR must be inserted into the spring element 30, wherein the contact portion 21 of the second connecting member 20 is already stored in this stationary.

Die Figuren 4 bis 6 zeigen einmal in einer perspektivischen Ausgestaltung und in zwei unterschiedlichen Schnittdarstellungen den HS-Steckverbinder 1, wobei dieser von einem isolierenden Gehäuse 70, insbesondere aus einem Kunststoff, umgeben ist. Aus der perspektivischen Darstellung ist das in Fig. 1 dargestellte Kabel 25 ersichtlich, wobei das Kabelanschlusselement 26 nicht sichtbar unterhalb des Gehäuses 70 liegt. Das Gehäuse 70 sowie der von diesem umgebene HS-Steckverbinder 1 sind von einer Isolationsplatte 71 "umgeben", welche sämtliche spannungsführenden Teile des im Ausführungsbeispiel gezeigten Energiespeichers vor Berührung abdeckt. Beispielhaft ist in der perspektivischen Fig. 4 auch ein Kontaktelement 2 des Energiespeichers dargestellt.The FIGS. 4 to 6 show once in a perspective embodiment and in two different sectional views of the HS connector 1, which is surrounded by an insulating housing 70, in particular of a plastic. From the perspective view is the in Fig. 1 shown cable 25, wherein the cable connection element 26 is not visible below the housing 70. The housing 70 and surrounded by this HS connector 1 are "surrounded" by an insulating plate 71, which covers all live parts of the energy storage shown in the embodiment from touching. Exemplary is in the perspective Fig. 4 Also shown a contact element 2 of the energy storage.

Fig. 5 zeigt einen Schnitt durch die in Fig. 4 gezeigte Anordnung, wobei sich das Gehäuse 70 in einer Zwischenstellung befindet. Das Gehäuse 70 umfasst in seinem Inneren zwei auf gegenüber liegenden Seiten angeordnete Führungsabschnitte 72, 73, welche eine Bahnkurve beschreiben. In der Darstellung der Fig. 5 ist lediglich der Führungsabschnitt 72 an einer Seitenwand des Gehäuses 70 dargestellt. Die Bahnkurve 72 weist einen rampenförmigen Verlauf auf. Von dem Gehäuse 70 ist das zweite Verbindungselement 20 umgeben, wobei insbesondere das an der Kabelanschlussfläche 22 angeordnete Kabelanschlusselement 26 enthalten ist. Aufgrund der formschlüssigen Verbindung des zweiten Verbindungselements 20 mit dem Federelement 30 ist auch dieses von dem Gehäuse 70 umfasst. Fig. 5 shows a section through the in Fig. 4 shown arrangement, wherein the housing 70 is in an intermediate position. The housing 70 includes in its interior two on opposite sides arranged guide portions 72, 73, which describe a trajectory. In the presentation of the Fig. 5 only the guide portion 72 is shown on a side wall of the housing 70. The trajectory 72 has a ramp-shaped course. The second connecting element 20 is surrounded by the housing 70, wherein in particular the cable connecting element arranged on the cable connecting surface 22 26 is included. Due to the positive connection of the second connecting element 20 with the spring element 30, this is also encompassed by the housing 70.

Wird nun das Gehäuse 70 in Richtung GR über die Verbindung geschoben, so werden in einer Zwischenposition des Gehäuses durch die Führungsabschnitte 72, 73 die Kontaktfedem 40, 45 entgegen ihrer Federkraft von der herzustellenden Verbindung abgehoben. Hierdurch kann in Steckrichtung ein kraftloses Einführen des nicht mit dem Federelement 30 verbundenen Verbindungselements 10 in das Federelement 30 ermöglicht werden. Wird das Gehäuse in Richtung GR in seine Endposition weiter geschoben, so werden aufgrund der Bahnkurve des Führungsabschnitts die Federkontakte 40,45 wieder entlastet, wodurch diese ihre Kontaktkraft auf die Kontaktabschnitte der Verbindungselemente 10, 20 ausüben können. Der Eingriff der Führungsabschnitte 72, 73 mit den Kontaktfedern 40, 45 erfolgt im Bereich der Arme 44, 49 der T-förmigen Abschnitte 43, 48 der Kontaktfedern. Um das "Gleiten" der Führungsabschnitte unter den Federkontakten zu ermöglichen, sind die Arme 44, 49 - wie beschrieben - von der Verbindung 5 weg gebogen. Fig. 6 zeigt das Gehäuse in seiner Endposition in einer geschnittenen Darstellung, wobei aufgrund der Schnittrichtung nun beide Führungsabschnitte 72, 73, welche auf die T-förmigen Abschnitte 48, 43 einwirken, ersichtlich sind.If the housing 70 is then pushed over the connection in the direction GR, the contact springs 40, 45 are lifted off the connection to be produced counter to their spring force in an intermediate position of the housing by the guide sections 72, 73. In this way, in the insertion direction, a powerless insertion of the not connected to the spring element 30 connecting element 10 are made possible in the spring element 30. If the housing is pushed further in the direction of GR into its end position, the spring contacts 40, 45 are relieved again due to the trajectory of the guide section, whereby they can exert their contact force on the contact sections of the connecting elements 10, 20. The engagement of the guide sections 72, 73 with the contact springs 40, 45 takes place in the region of the arms 44, 49 of the T-shaped sections 43, 48 of the contact springs. In order to allow the "sliding" of the guide portions under the spring contacts, the arms 44, 49 - as described - bent away from the compound 5. Fig. 6 shows the housing in its end position in a sectional view, wherein due to the cutting direction now both guide portions 72, 73, which act on the T-shaped portions 48, 43 are visible.

Der erfindungsgemäße Steckverbinder weist den Vorteil kleiner Übergangswiderstände auf. Hierdurch werden durch Stromfluss bedingte Temperaturerhöhungen im Vergleich zu Anordnungen aus dem Stand der Technik reduziert. Das außen liegende Federelement sorgt für ein geringes Bauvolumen des Steckverbinders. Aufgrund der flächigen Kontaktierung von den Strom übertragenden Verbindungselementen ergibt sich eine höhere Lebensdauer. Aufgrund der geringen Komplexität des Steckverbinders weist dieser ein kleines Gewicht auf.The connector according to the invention has the advantage of small contact resistance. This reduces temperature increases due to current flow compared to prior art arrangements. The outer spring element ensures a low volume of the connector. Due to the surface contact of the current-transmitting connecting elements results in a longer life. Due to the low complexity of the connector this has a small weight.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

11
Hochstrom-SteckverbinderHigh Current Connectors
22
Kontaktelementcontact element
55
Verbindungconnection
66
erste Außenfläche der Verbindungfirst outer surface of the connection
77
zweite Außenfläche der Verbindungsecond outer surface of the connection
1010
erstes Verbindungselementfirst connecting element
1111
erster Kontaktabschnittfirst contact section
1212
ZellanschlussflächeCell pad
2020
zweites Verbindungselementsecond connecting element
2121
zweiter Kontaktabschnittsecond contact section
2222
KabelanschlussflächeCable area
2323
Einschnürungconstriction
2525
Kabelelectric wire
2626
KabelanschlusselementCable connection element
3030
Federelementspring element
3131
Stegweb
3232
(äußeres) Klammerelement(outer) clamp element
3333
erster Abschnitt des Klammerelements 32 auf der ersten Außenfläche 6first portion of the clip member 32 on the first outer surface 6th
3434
zweiter Abschnitt des Klammerelements 32 auf der zweiten Außenfläche 7second portion of the clip member 32 on the second outer surface. 7
3535
(inneres) Klammerelement(inner) clamp element
3636
erster Abschnitt des Klammerelements 35 auf der ersten Außenfläche 6first portion of the clip member 35 on the first outer surface 6th
3737
zweiter Abschnitt des Klammerelements 35 auf der zweiten Außenfläche 7second portion of the clamp member 35 on the second outer surface. 7
4040
Kontaktfedercontact spring
4141
WellenbergWellenberg
4242
Wellentaltrough
4343
T-förmiger AbschnittT-shaped section
4444
Arm des T-förmigen Abschnitts 43Arm of the T-shaped section 43
4545
Kontaktfedercontact spring
4646
WellenbergWellenberg
4747
Wellentaltrough
4848
T-förmiger AbschnittT-shaped section
4949
Arm des T-förmigen Abschnitts 48Arm of the T-shaped section 48
5050
Anschlagschulterstop shoulder
5151
FahneBanner, flag
5252
FahneBanner, flag
5353
Abschnittsection
7070
Gehäusecasing
7171
Isolationsplatteinsulation plate
7272
Führungsabschnittguide section
7373
Führungsabschnittguide section
SRSR
Steckrichtungplug-in direction
GRGR
Bewegungsrichtung des Gehäuses beim Herstellen der VerbindungDirection of movement of the housing when establishing the connection

Claims (14)

  1. High-current plug-in connector for currents of more than 100 A, in particular more than 200 A, comprising:
    - a first connecting element (10) that comprises a first contact section (11),
    - a second connecting element (20) that comprises a second contact section (21),
    - a spring element (30) for the establishment of an electrical connection (5) between the first and second connecting elements (10, 20), on which the first contact section (11) and the second contact section (21) are arranged one on top of the other,
    - The spring element (30) comprises at least one clamping element (32, 35),
    - On the at least one crosspiece (31), at least one contact spring (40, 45) is arranged, which generates, on a first exterior surface (6) of the connection (5) formed by the first and second contact sections (11, 21), a contact force directed in the direction of a second exterior surface (7) opposite the first exterior surface (6), as a result of which contact surfaces of the first and second contact sections (11, 21) that face each other are pressed onto each other, whereby the second sections (34, 37) of the at least one clamping element (32, 35) serve as counter bearings,
    - whereby the first sections (33, 36) of the at least one clamping element (32, 35) are passed around respective front sides of the connection (5) and end in second sections (34, 37) of the at least one clamping element (32, 35), and
    - whereby the first and second contact sections (11, 21) are directly in contact with each other,
    characterised in that
    - the spring element (30) comprises at least two clamping elements (32, 35) connected with each other by at least one crosspiece (31) and running parallel to each other,
    - the crosspiece (31) and respective first sections (33, 36) of the clamping elements (32, 35) are arranged on the first exterior surface (6) and second sections (34, 37) of the clamping elements (32, 35) are arranged at least partially on the second exterior surface (7), and
    - the at least one contact spring (40, 45) is arranged between two clamping elements (32, 35) in each case.
  2. High-current plug-in connector according to claim 1, characterised in that at least one contact spring (40, 45) is arranged on the at least one crosspiece (31) on opposite sides in each case.
  3. High-current plug-in connector according to one of the claims above, characterised in that the at least one contact spring (40, 45) has a wave profile, whereby the wave profile, starting from the crosspiece (31), first displays a wave peak (41, 46) and then a wave trough which is in contact with the first exterior surface (42, 47), and the trough generates the contact force; in particular, that the at least one contact spring (40, 45) extends in parallel to the clamping elements (32, 35) and perpendicular to a plugging direction of the first and second connecting elements (10, 20) for establishing the plug connection of the plug-in connector (1).
  4. High-current plug-in connector according to claim 3, characterised in that, starting from the crosspiece (31), the last wave trough (42, 47) of the wave profile (40, 45) transitions into a T-shaped section (43, 48), whereby the opposite arms (44, 49) of the T-shaped section (43, 48) display a deformation which points away from the connection (5).
  5. High-current plug-in connector according to one of the claims above, characterised in that respective ends of a clamping element (32, 35), in particular on the second exterior surface (7) of the connection (5), are connected with each other mechanically, in particular by means of form fitting or firm bonding.
  6. High-current plug-in connector according to one of the claims above, characterised in that the spring element (30) has, on an inner one of the clamping elements (35), a stop shoulder (50) which extends in the direction of the contact force; in particular, that on the inner clamping element (35), at least one lug (51, 52) is formed, which runs around one of the connecting elements (20) in the area of a constriction in order to connect the spring element (30) form-fitting with this connecting element (20).
  7. High-current plug-in connector according to one of the claims above, characterised in that the plug-in connector (1), after establishment of the connection (5) between the first and second connecting element (10, 20), is enclosed by an insulating housing (70), in particular made of plastic; in particular, that the housing (70) comprises at least one guide section (72, 73) with a trajectory, which lifts, while the housing (70) is placed on the spring element (30) in an intermediate position, the at least one contact spring (40, 45) from the connection (5) to be established against its spring force in order to enable a forceless introduction of the connecting element (10) not connected with the spring element in the spring element (30) in the plugging direction, whereby in an end position of the housing (70), the at least one guide section (72, 73) is in no mesh with the spring element (30) in order to enable the generation of the contact force by the spring element (30).
  8. High-current plug-in connector according to one of the claims above characterised in that the contact sections (11, 21) of the connecting elements (10, 20) are designed flat, in particular even or concave and convex.
  9. High-current plug-in connector according to one of the claims above, characterised in that the spring element (30) is made of stainless steel.
  10. High-current plug-in connector according to one of the claims above, characterised in that the contact surfaces of the first and/or second contact sections (11, 21) are made of aluminium or copper or their alloys.
  11. High-current plug-in connector according to one of the claims above, characterised in that the contact surfaces of the first and/or second contact sections (11, 21) feature a surface coating made of tin and/or a tin coating in each case; in particular, that the surface coating has a thickness of 20 to 100 µm, and in particular a thickness of 20 to 70 µm.
  12. High-current plug-in connector according to claim 11, characterised in that an intermediate layer made of copper and/or a copper alloy and/or nickel and/or a nickel alloy is arranged between the base material of the first and/or second contact sections (11, 21) and the surface coating; in particular, that the intermediate layer has a layer thickness of 1 to 20 µm, in particular a thickness of 2 to 8 µm.
  13. High-current plug-in connector according to one of the claims 11 or 12, characterised in that a top layer made of copper and/or a copper alloy and/or nickel and/or a nickel alloy and/or silver and/or a silver alloy and/or gold and/or a gold alloy is applied on the surface coating; in particular, that the top layer has a thickness of 0.01 to 5 µm, in particular a thickness of 0.1 to 0.3 µm.
  14. High-current plug-in connector according to one of the claims 11 to 13, characterised in that the surface coating is applied by means of electroplating and/or hot-dip coating and/or vapour deposition and/or flame spraying and/or plasma spraying and/or compacting.
EP12781041.4A 2011-11-03 2012-10-31 High-current plug-in connector for motor vehicle applications Not-in-force EP2732507B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102011085700A DE102011085700A1 (en) 2011-11-03 2011-11-03 High current connectors for automotive applications
PCT/EP2012/004552 WO2013064249A1 (en) 2011-11-03 2012-10-31 High-current plug-in connector for motor vehicle applications

Publications (2)

Publication Number Publication Date
EP2732507A1 EP2732507A1 (en) 2014-05-21
EP2732507B1 true EP2732507B1 (en) 2017-12-13

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Family Applications (1)

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EP12781041.4A Not-in-force EP2732507B1 (en) 2011-11-03 2012-10-31 High-current plug-in connector for motor vehicle applications

Country Status (6)

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US (1) US9231326B2 (en)
EP (1) EP2732507B1 (en)
CN (1) CN104081586B (en)
DE (1) DE102011085700A1 (en)
ES (1) ES2660971T3 (en)
WO (1) WO2013064249A1 (en)

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WO2013064249A8 (en) 2013-11-28
CN104081586A (en) 2014-10-01
US20140308857A1 (en) 2014-10-16
ES2660971T3 (en) 2018-03-26
DE102011085700A1 (en) 2013-05-08
US9231326B2 (en) 2016-01-05
WO2013064249A1 (en) 2013-05-10
CN104081586B (en) 2018-04-27
EP2732507A1 (en) 2014-05-21

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