EP4089853A1 - Contact system for two busbars and busbar connection for two dual busbars - Google Patents

Abstract

The present invention relates to a contact system (100) for two busbars (306), the contact system (100) having a first contact (102) for the first busbar (306) and a second contact (104) for the second busbar (306 ), and a clamping element (106) that can be rotated between a plugging position (110) and a clamping position (112), the contact system (100) being pluggable when the clamping element (106) is arranged in the plugging position (110), the first Contact (102) and the second contact (104) are arranged coaxially in one another when the contact system (100) is in a plugged-in state and the clamping element (106) is designed to move from the plugging position (110) into the clamping position ( 112) clamping at least one of the contacts (102, 104) and elastically deforming it radially, the contacts (102, 104) being electrically conductively connected to one another in the plugged-in state as a result of the radial deformation.

Description

technical field

The present invention relates to a contact system for two busbars and a busbar connection for two double busbars.

State of the art

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

In a vehicle's low-voltage vehicle electrical system, electrically conductive sheet metal of a body can be used as ground, as a result of which a line length of return lines can be shortened. In this way, approximately half of all cables in the vehicle can be dispensed with.

Motor vehicle high voltage with, for example, more than 300V or even more than 700V can be used to transmit large electrical loads. Busbars made of solid metal material can be used for high-voltage motor vehicles. If busbars are used, separate plus and minus busbars can be used to ensure the required safety (protection against accidental contact, protection against arcing or voltage breakdown, etc.). The plus and minus rails can be designed as a double rail, ie superimposed over a small area (<5mm).

Description of the invention

It is therefore an object of the invention to provide an improved contact system for two busbars and an improved busbar connection for two double busbars using means that are as simple as possible in terms of design.

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

In an electrically driven vehicle, large electrical current flows are required, even with motor vehicle high-voltage of up to 1000 volts DC, in order to transmit drive power or braking or recuperation power. These current flows generate electromagnetic fields around current-carrying conductors of the vehicle. The conductors can be shielded to reduce or even prevent the fields from being radiated. Alternatively or additionally, the conductors for plus and minus can be arranged as parallel and close together as possible, since the electromagnetic fields caused by the opposing current flows cancel each other out.

In the case of busbars, too, the busbar for the positive pole or the plus potential and the busbar for the negative pole or the negative potential can be arranged very close together by stacking the two busbars congruently one on top of the other. The stacked busbars are individually electrically insulated. This arrangement can be referred to as a double busbar.

In order to maintain the effect of cancellation at contact points as well, the approach presented here proposes a coaxial contact that also enables the current flows to be guided closely at the contact point.

A contact system for two busbars is proposed, the contact system having a first contact for the first busbar and a second contact for the second busbar, as well as a clamping element that can be rotated between a plugging position and a clamping position, the contact system being pluggable when the clamping element is in is arranged in the plugged-in position, with the first contact and the second contact being arranged coaxially within one another when the contact system is in a plugged-in state, and the clamping element is designed to clamp at least one of the contacts during a rotational movement from the plugged-in position into the clamping position and to elastically close it radially deform, the contacts being connected to one another in an electrically conductive manner in the plugged-in state as a result of the radial deformation.

Furthermore, a busbar connection for two double busbars is proposed, with the double busbars each having two busbars that are isolated from one another by insulation and are stacked one on top of the other, with the busbars being connected using two concentrically arranged contact systems according to the approach presented here.

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

A double busbar can consist of two busbars with the same dimensions. The two busbars can be stacked on top of each other on flat sides. The busbars can be arranged congruently. The double busbar can be covered with a plastic material. Alternatively or additionally, the double busbar can be covered with a fabric material. The fabric material can, for example, be wrapped around the conductor rail as a fabric tape. The busbar can be exposed in a contact area, i.e. the insulation and sheathing can have been removed at least in certain areas. The double busbar can also be additionally shielded against the emission of electromagnetic fields by an electrically conductive jacket.

Contacts can be made of a metal material. The contacts can in particular be made of a copper material. The contacts can have an essentially axisymmetric basic shape. At least the first contact can have two different diameters. For example, the first contact can be oval-cylindrical. An insertion direction of the contact system can correspond to an axis of symmetry of the contacts. The first contact and the second contact of a contact system can be referred to as a contact pair.

A clamping element can also have an essentially axisymmetric basic shape. The clamping element can also have two different diameters. The clamping element can have at least one point of attack for rotating the clamping element. Depending on the embodiment, the point of application can be arranged on an outside of the clamping element or on an inside of the clamping element. An axis of rotation of the clamping element can coincide with the axis of symmetry of the contacts.

In the plugged-in state, the first contact can be arranged between the clamping element and the second contact. The clamping element can be designed to change a diameter of the first contact during the rotary movement from the plugged-in position into the clamping position. The first contact can be pressed against the second contact by changing the diameter. In this case, the first contact can be electrically conductively connected to the second contact. In a matable state, there may be a gap between the first contact and the second contact. The gap can be closed by changing the diameter. By changing the diameter, the first contact can be pressed against the second contact with a defined contact pressure in order to achieve a low contact resistance.

The second contact can be arranged inside the first contact in the plugged-in state. The clamping element can enclose the first contact from the outside. The clamping element can be designed to reduce the diameter of the first contact during the rotary movement from the plugged-in position into the clamping position and to press the first contact against the second contact. Alternatively, the second contact can enclose the first contact from the outside in the plugged-in state and the clamping element can be arranged inside the first contact. The clamping element can then be designed to increase the diameter of the first contact during the rotational movement from the plugged-in position into the clamping position and to press the first contact against the second contact.

When the first contact is arranged outside of the second contact and the clamping element is arranged on the outside of the first contact, a small inner diameter of the clamping element can be smaller than a large outer diameter of the first contact. However, the small inner diameter of the clamping element can be larger than a small outer diameter of the first contact. A large inner diameter of the clamping element can be larger than the large outer diameter of the first contact.

When the first contact is arranged inside the second contact and the clamping element is arranged on the inside of the first contact, a large outer diameter of the clamping element can be larger than a small inner diameter of the first contact. However, the large outside diameter of the clamping element can be smaller than a large inside diameter of the first contact. A small outside diameter of the clamping element can be smaller than the small inside diameter of the first contact.

The first contact may be axially slotted to facilitate changing the diameter. A slot of the first contact may prevent transmission of tensile forces when the first contact is pushed apart or provide space for the first contact to be pushed together. The first contact may also be wound from sheet material leaving a gap open between ends of the sheet material. In particular, the first contact can be slotted twice. The slots may be diametrically opposed. The second contact can be closed in a ring, to resist tensile forces or compressive forces when changing the diameter of the first contact.

The clamping element can be electrically conductive and can be arranged between the first contact and the second contact in the plugged-in state. The clamping element can be designed to press against the first contact and the second contact during the rotary movement from the plugged-in position into the clamping position and to electrically conductively connect the first contact to the second contact. The clamping element can be ring-shaped. The clamping element can have its point of application for initiating the rotational movement on the outside and/or on the inside. If the point of attack is arranged on the outside, the first contact can have at least one opening for the point of attack. If the point of attack is arranged on the inside, the second contact can have at least one opening for the point of attack. The clamping element can also have several points of application. The points of attack and openings for the points of attack can then be distributed evenly over the circumference of the clamping element.

The clamping element can have two diametrically opposite thickenings, which are moved between the first contact and the second contact during the rotary movement from the plugged-in position into the clamping position. The bulges can be moved into a gap between the first contact and the second contact and bridge the gap. The thickenings can be slightly wider than the gap in order to generate a contact pressure via elastic deformation of the contacts.

The clamping element can be rotated through 90° during the rotary movement from the plugged-in position into the clamping position. The clamping element can thus assume two distinct, easily verifiable positions.

Brief character description

• Fign. 1 und 2 Darstellungen eines Kontaktsystems gemäß Ausführungsbeispielen; und
• Fig. 3 eine Darstellung einer Stromschienenverbindung gemäß einem Ausführungsbeispiel.

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

• Figs. 1 and 2 Representations of a contact system according to exemplary embodiments; and
• 3 a representation of a busbar connection according to an embodiment.

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

Detailed description

For easier understanding, in the following description, the reference numerals to the Figures 1-3 retained for reference.

Figs. 1a to 1c show an illustration of a contact system 100 according to an embodiment. The contact system 100 consists of two pluggable contacts 102, 104 and a rotatable clamping element 106. The clamping element 106 is designed to clamp and deform the first contact 102 during a rotational movement 108 from a plugging position 110 into a clamping position 112. As a result of the deformation, the first contact 102 is pressed against the second contact 104 and a secure electrically conductive connection is established between the first contact 102 and the second contact 104 .

The contacts 102, 104 have an essentially hollow-cylindrical basic shape. The contacts 102, 104 are shown in a mated state and are arranged coaxially with one another or nested in one another in the mated state. The clamping element 106 also has at least an annular or hollow-cylindrical basic shape. Here the first contact 102 is arranged between the clamping element 106 and the second contact 104 . The clamping element 106 encloses the first contact 102 on an outside.

The clamping element 106 has different inner diameters over its circumference. The clamping element 106 has two opposite flattened areas 114 on its inside. The flats 114 reduce the inner diameter of the clamping element 106 at this point. The first contact 102 has different outer diameters over its circumference. An outside of the first contact 102 is oval. An inner diameter of the uncompressed first contact 102 remains the same over the circumference. The second contact 104 here has a circumference over its circumference constant outer diameter. The outside diameter of the second contact 104 is smaller than the uncompressed inside diameter of the first contact 102.

A large inner diameter of the clamping element 106 is larger than a large outer diameter of the first contact 102. The large outer diameter of the first contact 102 can at most be equal to the large inner diameter of the clamping element 106, since the first contact 102 then rests against the clamping element 106. A small inside diameter of the clamping element 106 at the flats 114 is smaller than the large outside diameter of the first contact 102. A small outside diameter of the first contact 102 is smaller than the small inside diameter of the clamping element 106 at the flats 114. The small outside diameter of the first contact 102 can be at most equal to the small inner diameter of the clamping element 106, since the first contact 102 then rests against the flattened areas.

On its outside, the clamping element 106 has a drive geometry 116 for initiating a rotational movement 108 from the plugged-in position 110 into the clamped position 112 . Here, the drive geometry 116 has two opposite parallel surfaces for applying an open-end wrench or other tool.

In one embodiment, the first contact 102 is slotted. The first contact 102 has two diametrically opposed slots 118 on its small outside diameter. The slots 118 provide space for the deformation of the first contact 102 and allow the deformation by a defined clamping force.

In Fig. 1a the clamping element 106 is arranged in the plugged-in position 110 . The large inside diameter of the clamping element 106 is aligned with the large outside diameter of the first contact 102 . The small inside diameter of the clamping element 106 is aligned with the small outside diameter of the first contact 102 . The first contact 102 is not in contact with the second contact 104 or only slightly. The contact system 100 can be plugged in easily.

In Fig. 1b the clamping element 106 is shown during the rotary movement 108 from the plugged-in position 110 into the clamping position 112. In the process, the flat areas 114 of the clamping element slide onto the outer surface of the first contact 102 and begin to deform the first contact 102 . Due to the deformation, the large outer diameter of the first contact 102 reduced. As a direct consequence, the inner diameter of the first contact 102 is also reduced in the area of the large outer diameter and the inner surface of the first contact 102 is pressed against the outer surface of the second contact 104 .

When the first contact 102 is slotted, the slots 118 narrow due to the deformation of the first contact 102. The first contact 102 begins to touch the second contact 104 in contact areas 120. FIG.

In 1c the clamping element 106 is arranged in the clamping position 112. The small diameter of the clamping element 106 is aligned with the former large outer diameter of the first contact 102 . The former large outer diameter of the first contact 102 is now equal to the current small inner diameter of the clamping element 106. The current small inner diameter of the clamping element 106 can be larger than the former small inner diameter in the plugged-in position 110 due to elastic deformation of the clamping element 106 during the rotary movement 108. The first contact 102 and the second contact 104 lie firmly against one another in the contact areas 120 in the area of the former large outer diameter of the first contact 102 and are securely connected to one another in an electrically conductive manner.

In one exemplary embodiment, the clamping element 106 has been rotated through 90° between the mating position 110 and the clamping position 112 .

That in the Figures 1a to 1c The contact system 100 shown can also be constructed in reverse. The second contact 104 can enclose the first contact from the outside. The clamping element 106 is then arranged inside the first contact 102 . During the rotary movement 108 from the plugged-in position 110 into the clamping position 112, the clamping element 106 pushes the first contact 102 apart until the first contact 102 rests against the inside of the second contact and makes electrical contact with it.

the Figs. 2a to 2c show an illustration of a contact system 100 according to an embodiment. The contact system 100 consists as in 1 of the two pluggable contacts 102, 104 and the rotatable clamping element 106. The clamping element 106 is electrically conductive and designed to clamp the first contact 102 and the second contact 104 during the rotary movement from the plugged position 110 into the clamping position 112 and to be electrically conductive associate.

In contrast to the embodiment in 1 the clamping element 106 is arranged between the first contact 102 and the second contact 104 here. The first contact 102 is arranged within the clamping element 106 . The second contact 104 is arranged outside of the clamping element 106 .

The first contact 102 and the clamping element have as in 1 two different diameters. In the mating position 110, the small inside diameter of the contact element 106 is aligned with the small outside diameter of the first contact 102, while the large inside diameter of the clamping element 106 is aligned with the large outside diameter of the first contact 102. When the clamping element 106 is rotated to the clamping position 112, the small inside diameter of the clamping element 106 clamps on the large outside diameter of the first contact 102. As a result, the clamping element 106 is deformed and pressed against the inside of the second contact 104.

In one exemplary embodiment, the clamping element 106 also has different outer diameters. The clamping element 106 has a large outer diameter at its small inner diameter. The small inner diameter and the large outer diameter result in a thickening of 200.

In one embodiment, the second contact 104 also has different diameters. A small inner diameter of the second contact 104 is located at the large outer diameter of the first contact 102 . During the rotary movement 108 from the plugged-in position 110 to the clamped position 112, the thickening 200 is inserted between the small inside diameter of the second contact 104 and the large outside diameter of the first contact 102, thereby clamping both the first contact 102 and the second contact 104.

In one embodiment, the second contact 104 is segmented. In this case, the second contact 104 has a segment 202 in the area of the large outer diameter of the first contact 102 or in the area of the small inner diameter of the second contact 104 . The second contact 104 has windows 204 between the diametrically opposite segments 202 . In the windows 204 are is the drive geometry 116 of the contact element 106 is arranged and is thus accessible from the outside.

In one exemplary embodiment, the contact element 106 has two diametrically opposite points of action 206 or levers as the drive geometry. Using the contact points 206, the contact element 106 can be rotated back and forth between the plugged-in position 110 and the clamped position without tools.

In Figure 2a the clamping element is arranged in the plugged-in position 110.

In Figure 2b the clamping element is rotated by the rotary movement 108 from the plugged-in position 110 into the clamping position 112 and begins to clamp the first contact 102 and the second contact 104 .

In Figure 2c the clamping element 106 is arranged in the clamping position 112 and clamps the first contact 102 and the second contact 104 in contact regions 120.

3 shows a representation of a busbar connection 300 for two double busbars 302, 304. The busbar connection 300 is shown in an unplugged state. A first of the dual busbars 302 is shown as being at the top and may also be referred to as the upper dual busbar for convenience. The second of the dual busbars 304 is located at the bottom of the illustration and may be referred to as the lower dual busbar for convenience.

The double busbars 302, 304 each have two busbars 306 stacked one on top of the other to form a stack. The busbars 306 of the upper double busbar are electrically insulated from one another by insulation 308 . Insulation 308 also insulates upper dual bus bar 302 from an environment.

The double busbars 302, 304 have two contact systems 100 arranged coaxially to one another in accordance with the approach presented here. The outer contact system 100 corresponds to the contact system 1 . The inner contact system 100 corresponds to the contact system from FIG 2 . The outer contact system 100 is designed to the two facing busbars 306 of the two To connect double busbars 302, 304 electrically conductive to each other. The inner contact system 100 is designed to electrically conductively connect the two busbars 306 of the double busbars 302, 304 facing away from one another through the busbars 306 facing one another.

In the illustrated, unplugged state, the first contacts 102 and second contacts 104 of the two contact systems 100 are arranged axially offset from one another.

In one exemplary embodiment, the first double busbar 302 has the respective first contacts 102 of the two contact systems 100 . The second double power supply 304 has the respective second contacts 104 of the contact systems 100 . The clamping element 106 of the outer contact system 100 is arranged on the first double busbar 302 . The clamping element 106 of the second contact system 100 is arranged on the second double busbar 304 .

In one embodiment, the first contact 102 and the second contact 104 of the outer contact system 100 are arranged on opposite flat sides of the two double busbars 302, 304. The outer contact system 100 is designed to connect the opposite busbars 306 of both double busbars 302, 306. The inner contact system 100 is designed to connect the busbars 306 arranged on opposite sides of the double busbars 302, 304.

In one exemplary embodiment, the second contact 104 and the clamping element 106 of the inner contact system 100 are arranged on a rear side of the second double busbar 304 which faces away from the first double busbar 302 (facing downwards in the illustration). The first contact 102 of the inner contact system 100 therefore protrudes axially out of the essentially hollow-cylindrical first contact 102 of the outer contact system 100 . The first contact 102 is so long that, when the busbar connection 300 is plugged in, it protrudes into the second contact 104 arranged on the back. Except for a tip area, the first contact 102 is surrounded by insulation 308 in the form of a hollow cylinder. In the mated state, the insulation insulates the first contact 102 of the inner contact system 100 from the second contact of the outer contact system 100.

In other words, a contact system of a rotary clamping plug for a dual-rail power transmission system is presented.

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

The present approach presents a contact system that establishes, improves and/or secures the electrical connection by rotating certain components around the longitudinal axis of the contact.

For EMC reasons, the two potentials of the superimposed rails are routed concentrically into one another. The geometry of the cross-sections is designed in such a way that the potentials to be contacted do not or only minimally touch during the plugging process or when being guided into one another, so that no force is required due to friction between the contact partners. After the contact partners have been brought together and have reached their final position in relation to one another, the qualified electrical contact is established by rotating separate components.

Different functional principles can be used here. In one exemplary embodiment, at least one of the contact partners can be deformed by a component that is moved by rotation, such as a spring or a bolt. In an alternative exemplary embodiment, the contact partners can be electrically contacted by an electrically conductive component that is moved by rotation. The electrically conductive component can be referred to as a mediator.

In the context of the increasing electrical performance requirements in the context of e-mobility, the aspect of occupant protection against electromagnetic pollution (ICNIRP) is increasingly coming into focus. High-voltage (HV) double rail systems can handle large amounts of energy with low electromagnetic field emissions transport. The rail system requires suitable interfaces suitable for outdoor use. Thanks to the contact system presented, the double rail can be used in the installation space as an interface to the switch box or battery.

The approach presented here enables (almost) effortless positioning of the connector including rail and, when locking, establishes contact and fixation of the connection without additional tools.

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

REFERENCE LIST

100

contact system

102

first contact

104

second contact

106

clamping element

108

rotary motion

110

mating position

112

clamping position

114

flat areas

116

drive geometry

118

slot

120

contact area

200

thickening

202

segment

204

window

206

attackpoint

300

busbar connection

302

first double track

304

second double track

306

power rail

308

insulation

Claims (9)

Contact system (100) for two busbars (306), wherein the contact system (100) has a first contact (102) for the first busbar (306) and a second contact (104) for the second busbar (306), and between a plug-in position (110) and a clamping position (112) has a rotatable clamping element (106), the contact system (100) being pluggable when the clamping element (106) is arranged in the plugging position (110), the first contact (102) and the second Contact (104) are arranged coaxially in one another when the contact system (100) is in a plugged-in state and the clamping element (106) is designed to move at least one of the contacts ( 102, 104) and to elastically deform it radially, the contacts (102, 104) being electrically conductively connected to one another in the plugged-in state as a result of the radial deformation. Contact system (100) according to Claim 1, in which the first contact (102) is arranged between the clamping element (106) and the second contact (104) in the plugged-in state, the clamping element (106) being designed to, during the rotary movement (108 ) to change a diameter of the first contact (102) from the plugging position (110) to the clamping position (112), the first contact (102) being pressed against the second contact (104) by the change in diameter and the first contact ( 102) is electrically conductively connected to the second contact (104). Contact system (100) according to Claim 2, in which the second contact (104) is arranged inside the first contact (102) in the plugged-in state and the clamping element (106) encloses the first contact (102) from the outside, the clamping element (106) is designed to reduce the diameter of the first contact (102) during the rotary movement (108) from the plugging position (110) into the clamping position (112) and to press the first contact (102) against the second contact (104). Contact system (100) according to Claim 2, in which the second contact (104) in the plugged-in state encloses the first contact (102) from the outside and the clamping element (106) is arranged inside the first contact (102), the Clamping element (106) is designed to increase the diameter of the first contact (102) during the rotary movement (108) from the plugging position (110) to the clamping position (112) and to press the first contact (102) against the second contact (104) to press. A contact system (100) as claimed in any preceding claim, wherein the first contact (102) is axially slotted to facilitate changing the diameter. Contact system (100) according to Claim 1, in which the clamping element (106) is electrically conductive and, in the plugged-in state, is arranged between the first contact (102) and the second contact (104), the clamping element (106) being designed for this purpose of the rotary movement (108) from the plugging position (110) into the clamping position (112) against the first contact (102) and the second contact (104) and to electrically conductively connect the first contact (102) to the second contact (104). associate. Contact system (100) according to Claim 6, in which the clamping element (106) has two diametrically opposite thickenings (200) which, during the rotary movement (108) from the plugging position (110) into the clamping position (112) between the first contact (102) and the second contact (104) are moved. Contact system (100) according to one of the preceding claims, in which the clamping element (106) can be rotated through 90° during the rotary movement (108) from the plugging position (110) into the clamping position (112). Busbar connection (300) for two double busbars (302, 304), the double busbars (302, 304) each having two busbars (306) which are insulated from one another by insulation (308) and are stacked one on top of the other to form a stack, the busbars (306) using two concentrically arranged contact systems (100) according to one of claims 1 to 8 are connected.

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