WO2021001093A1

WO2021001093A1 - Actively cooled charging connector part

Info

Publication number: WO2021001093A1
Application number: PCT/EP2020/064817
Authority: WO
Inventors: Thomas Führer; Marius PRAIS
Original assignee: Phoenix Contact E-Mobility Gmbh
Priority date: 2019-07-01
Filing date: 2020-05-28
Publication date: 2021-01-07
Also published as: DE102019117649A1; DE112020003189A5

Abstract

The invention relates to a connector part (1) for connecting to a mating connector part (3), comprising at least one bridge element (10A, 10B) with a cooling line receiving part (103) for heat-conducting contact with a coolant line (22) of a cable (2), a plug contact (11) that can be electrcially connected to an electrical line (21) of the cable (2) and is provided on a bridge element (10A, 10B), and a cooling body (12) which is connected in a heat-conducting manner to the bridge element (10A, 10B) and which forms a coolant channel (120) to which the coolant line (22) can be connected.

Description

Actively cooled charging connector part

The invention relates to a connector part for electrical connection to a mating connector part according to claim 1, a connector arrangement and a bridge element.

Particularly in the field of e-mobility, there are particularly high requirements for connector parts and associated charging cables with regard to their functional performance, stability and safety. With high direct current charging currents, e.g. around 500 A, considerable electrical heat is regularly released in all components of the guide path.

In particular through standards, narrow limits are set with regard to the permissible heating of the components in the wiring harness, e.g. with a temperature limit of 90 ° C. In addition, the dimensions of plug-in connections are regularly limited, so that in terms of design the challenge arises to conduct the highest possible electrical power, in particular in the sense of high charging currents, over existing geometries and at the same time to keep the heating within the specified limits.

For this purpose, charging connectors and charging cables are e.g. liquid-cooled, see DE 10 2016 105 31 1 A1 and DE 10 2016 107 409 A1.

In addition to being exposed to high currents, contacts in charging connectors are also regularly operated at voltages of up to 1500 V DC. This can mean that any type of cooling on live components which are to be thermally well coupled must also be sufficiently well insulated electrically in order to avoid insulation faults in power contacts to the coolant circuit. In the case of water-based cooling liquids, in particular, the coolant circuit is generally at ground potential in its entirety. As part of an insulation coordination, it is usually ensured that specified air and creepage distances are maintained and that insulating components have at least a specified dielectric strength.

A good thermal connection with good electrical insulation at the same time poses a particular challenge. The object of the present invention is to enable a plug connector part that can be cooled as effectively as possible with a limited installation space.

This object is achieved by an object having the features of claim 1.

Thereafter, a plug connector part for electrical connection to a mating connector part is provided, which comprises at least one bridge element, at least one plug contact and a heat sink. The bridge element is optionally designed for the electrical connection of an electrical line of a cable and has a cooling line receptacle for the heat-conducting system with a coolant line of the cable. The plug contact is provided on the bridge element (e.g. adjoins it) and can (e.g. via the bridge element) be electrically connected (and optionally connected) to an electrical line of the cable. The heat sink is in a thermally conductive connection with the bridge element and forms a coolant channel to which the coolant line of the cable is or can be connected.

In this way, a connector part is provided in which the parts carrying the load current (e.g. the bridge element) can be cooled both by the cooling line and by the heat sink. This enables particularly efficient cooling in a particularly small space. The bridge element and the heat sink are separate components from one another.

The connector part can be a high-current and / or high-voltage connector part. For example, the bridge element is designed to conduct electrical currents with a power of 10 kW or more, in particular of 50 kW or more, 135 kW or more, or 350 kW or more. For example, the bridge element is designed to conduct electrical currents with currents of 100 A or more, 200 A or more, 300 A or more, in particular 500 A or more.

Optionally, the bridge element is connected to the plug contact in an electrically conductive and / or thermally conductive manner. The bridge element can thus fulfill several functions at the same time, namely, in particular, conduction of heat and conduction of electrical current.

The bridge element can be formed in one piece, for example from copper, which enables particularly good electrical and thermal conduction. The bridge element and the plug contact can be constructed in several parts and are in contact with one another, be attached to each other, for example. Alternatively, the bridge element and the plug contact are formed integrally with one another. The bridge element and the plug contact are optionally connected to one another in a materially bonded manner, for example welded and / or soldered.

The cooling line receptacle of the bridge element can be concave and / or elongated. For example, the cooling line receptacle is designed in the form of a recess. This enables particularly good heat conduction over a large contact surface. The cooling line receptacle is optionally designed in the form of a groove.

The cooling line receptacle can be aligned perpendicular to the plug contact. This enables a small installation depth, as is often necessary, for example, for installation in a vehicle.

The bridge element optionally has a base body and a thermal bridge protruding from the base body. The thermal bridge protrudes from the base body, for example, in a direction that runs parallel or essentially parallel to the longitudinal extension of the cooling line receptacle.

An electrically insulating heat-conducting element can be arranged on the bridge element. The heat-conducting element can be designed in such a way that it receives the heat bridge of the bridge element. The heat conducting element is optionally in flat contact with the heat sink. Such a heat-conducting element can achieve particularly reliable electrical insulation of the bridge element from the heat sink. An electrically insulating plastic or an electrically insulating ceramic with high thermal conductivity can be used as the material for the heat-conducting element.

The connector part can (precisely) comprise two bridge elements, in particular two bridge elements as described above. Both bridge elements are in a thermally conductive connection with the heat sink. One of the bridge elements can serve as the positive conductor of a direct current connection, the other as the negative conductor.

The heat sink has, for example, (precisely) one inlet and (precisely) one outlet, with coolant introduced through the inlet in an inlet direction flowing out of the outlet in an outlet direction. It can be provided that the inlet direction and the outlet direction are opposite. The heat sink can thus fulfill a double function, namely contribute to cooling the bridge element (s) and the Divert the coolant flow by 180 °. The coolant channel extends from the inlet to the outlet.

The connector part is designed, for example, as a vehicle charging socket, in particular for high-current charging using direct current.

According to one aspect, a plug connector arrangement is provided which comprises a plug connector part according to any configuration described herein, and a cable which comprises an electrical line and a coolant line. The electrical line is electrically connected to the connection surface of the bridge element. The coolant line is in contact with the cooling line receptacle of the bridge element and is connected to the coolant channel of the heat sink (in particular with another, e.g. adjacent section).

The bridge element can be cooled on the cooling line receptacle and over the thermal bridge by means of coolant flowing through the coolant line.

The electrical line and the coolant line can be coaxial. No separate lines are necessary. For example, the electrical line surrounds the coolant line. The electrical line comprises, for example, a layer of litz wires, in particular copper litz wires. This enables particularly efficient cooling of the electrical line, which can be used at the same time to cool the bridge element.

The electrical line can be connected to the connection surface via a welded connection. This enables a particularly secure connection with a low transition resistance.

Optionally, the connector part comprises two bridge elements of the type described. Both bridge elements are in a thermally conductive connection with the heat sink, the cable or cables comprising two electrical lines and two coolant lines. The electrical lines are each electrically connected to the connection surface of one of the bridge elements. The coolant lines are each in contact with the cooling line receptacle of one of the bridge elements and are connected to the coolant channel of the heat sink. In this way, both conductors of a direct current connection can be cooled particularly well. According to one aspect, a bridge element is provided, in particular for the plug connector part according to any configuration described herein. The bridge element comprises a base body which has a connection surface for the electrical connection of an electrical line of a cable and a cooling line receptacle for receiving a coolant line of the cable in a thermally conductive manner. The bridge element further comprises a connecting section (eg in the form of a plug contact connection) via which a plug contact for pluggable connection with a mating plug contact is or can be electrically connected to the connection surface, and a thermal bridge protruding from the base body, for example.

Such a bridge element enables heat to be dissipated both via the cooling line receptacle and via the heat bridge, which enables particularly efficient dissipation of heat.

The idea on which the invention is based is to be explained in more detail below with reference to the exemplary embodiments shown in the figures. Show it:

Fig. 1 is a view of a vehicle with a charging socket and a

Charging station with a cable arranged thereon;

FIGS. 2A and 2B are views of the connector part according to FIG. 1 with lines connected thereto;

3A and 3B parts of the connector part according to FIGS. 2A and 2B with several

Lines in a perspective view (FIG. 3A) and in an exploded view (FIG. 3B);

4A and 4B a bridge element of the plug connector part with a plug contact, and lines according to FIGS. 2A and 2B in a perspective view (FIG. 4A) and in an exploded view (FIG. 4B);

5 shows a bridge element of the connector part according to FIGS. 2A and 2B,

Cables and a plug contact;

6A and 6B are cutaway views of the bridge element according to FIG. 5; 7A to 8B are views of the bridge element of the connector part according to FIGS. 2A and 2B; and

9A to 9E are views of a heat sink of the connector part according to FIGS. 2A and

2B with heat conducting elements mounted thereon.

Fig. 1 shows an electrically powered vehicle 4, also referred to as an electric vehicle, with a connector part 1, here in the form of a charging socket, for a detachable electrical connection with a mating connector part 3. Together, the connector part 1 and the mating connector part 3 form a connector. Furthermore, FIG. 1 shows a charging station 5 which is used to charge the vehicle 4. The charging station 5 is designed to provide a charging current in the form of a direct current (alternatively or additionally an alternating current) and has a cable that connects with one end to the charging station 5 and with the other end with the mating connector part 3 in the form of a Charging connector is connected. In the example shown, the mating plug connector part 3 is designed as a manually operable charging plug for the electric vehicle 4.

2A and 2B show the connector part 1. In the present case, the connector part 1 is designed for mounting on the electric vehicle 4, specifically as a vehicle inlet, e.g. according to the CCS (Combined Charging System) type 2.

The connector part 1 is designed to transmit a charging current in the form of a direct current and / or in the form of an alternating current. It represents an actively cooled charging connector part. In the present case, the connector part 1 is connected to a coolant circuit 40 of the vehicle 4 and to a direct current network 41 of the vehicle 4.

The connector part 1 comprises a housing 16. The housing 16 forms a connection area for the mating connector part 3. Two plug contacts 1 1 are used to set up a direct current circuit. The plug contacts 11 are high-current load contacts. The plug contacts 1 1 are, for example, turned parts. You can conduct currents of 50 A or more, in particular 100 A or more, during, in particular for the duration of a charging process or discharging process. Additional plug contacts serve, for example, as protective conductors (PE) and as AC or three-phase current contacts or as data connections. For connection to the direct current network 41, cables 2 are connected to the connector part 1. One of two cables 2 is used to connect the positive and negative poles of a direct current connection. Together with the cables 2, the connector part 1 forms a connector arrangement. The cables 2 are connected to the connector part 1 in a direction which is oriented approximately perpendicular to an insertion direction of the mating connector part 3 on the connector part 1. Optionally, some of the cables, in particular the two cables 2 for direct current transmission, are combined to form a common cable or a cable bundle, as illustrated in FIG. 2A with the aid of dashed lines.

FIGS. 3A and 3B show parts of the connector part 1 which, taken by themselves, already serve as a connector part, and cables 2 connected to them.

The connector part 1 generally comprises at least one, here two bridge elements 10A, 10B for connecting an electrical line 21 of the respective cable 2 and with a cooling line receptacle 103 for heat-conducting contact with a coolant line 22 of the cable 2, the plug contact electrically connected to the bridge element 10A, 10B 11 and a heat sink 12 which is in a thermally conductive connection with the bridge element 10A, 10B and which forms a coolant channel 120 (see in particular FIGS. 9C to 9E) to which the coolant line 22 can be connected and connected. The bridge element (s) 10A, 10B is / are electrically isolated from the heat sink 12. Each bridge element 10A, 10B establishes an electrical connection between the respective plug contact 11 and the respective electrical line 21.

The cooling line receptacle 103 is aligned perpendicular to the plug contact 11. The cooling line 22 can be inserted into the cooling line receptacle 103, specifically in such a way that along the circumference of the cooling line 22 part of the cooling line 22 faces the cooling line receptacle 103 and part of the cooling line 22 faces away from the cooling line receptacle 103.

The cables 2 each include the coolant line 22, which is surrounded by the electrical line 21. The coolant line 22 is designed as a hose, for example. For example, water can be used as a coolant. The electrical line 21 is, for example, a layer of copper strands which surrounds the coolant line 22 along its length. The electric wire 21 of each of the cables 2 is electrically connected to one terminal end 23A, 23B. For the electrical connection of each of the two cables 2 to one of the two bridge elements 10A, 10B, the respective connection end 23A, 23B is electrically connected to the corresponding bridge element 10A, 10B, for example welded to it, for example by means of ultrasonic welding. Furthermore, the (exposed) coolant line 22 of each of the cables 2 lies flat on the respective bridge element 10A, 10B. In each case one of the two direct current plug-in contacts 11 also visible in FIG. 2A is fastened to one of the two bridge elements 10A, 10B and connected to it in an electrically conductive manner.

Each of the bridge elements 10A, 10B establishes an electrical connection between an electrical conductor 21 of one of the cables 2 and one of the plug contacts 11. Furthermore, each of the bridge elements 10A, 10B is in flat contact with the respective coolant line 22. The bridge elements 10A, 10B can thus be cooled by the coolant flowing in the coolant lines. In the present case, one of the coolant lines 22 serves as an inlet, the other of the coolant line 22 as an outlet.

Further details of the bridge elements 10A, 10B are explained below in connection with FIGS. 7A to 8B.

3A and 3B also show a heat sink 12 to which both coolant lines 22 are connected. Furthermore, the bridge elements 10A, 10B are each inserted into a receptacle of the cooling body 12. Further details of the heat sink 12 will be explained below in connection with FIGS. 9A to 9E.

4A and 4B show one of the two bridge elements 10A, 10B with the associated cable 2. It can be seen that the coolant line 22 of the cable 2 is attached to the bridge element 10A, in this case by means of two clamps 14, each with a screw 15 the bridge element 10A are screwed. As a result, the coolant line 22 is securely held on the bridge element 10A and also pressed against it, which enables particularly good heat conduction between the coolant lines 22 and the bridge elements 10A, 10B.

Fig. 5 shows the other of the two bridge elements 10A, 10B. In particular in comparison with FIGS. 4A and 4B, it becomes clear that in the bridge element 10A shown in FIGS. 4A and 4B, the connection end 23A and the coolant line 22 rest on opposite sides of the bridge element 10A on the bridge element 10A. In the case of the other bridge element 10B of the plug connector part 1 shown in FIG. 5, the connection end 23B is located and the coolant line 22 on the same side of the bridge element 10B on the bridge element 10B.

6A and 6B show, using the example of the bridge element 10B shown in FIG. 5, how the coolant line 22 is fastened to the bridge element 10B, specifically by means of a clamp 14 and screw 15 in the example shown. For this purpose, the bridge elements 10A, 10B have, in particular, a cooling line receptacle 103 which has essentially the same radius as the coolant line 22.

FIGS. 7A and 7B show one of the bridge elements 10A, 10B. In particular, in the views of FIGS. 7A and 7B it can be seen that the bridge elements 10A has a base body 101 on which a planar connection surface 102 for connecting the electrical line 21 of the corresponding cable 2 is formed. Specifically, the corresponding connection end 23A (e.g. made of copper) can be welded to it, whereby it is alternatively conceivable to provide a mounted socket for a crimp connection instead of a flat surface as connection surface 102. Compared to the connection surface 102, the base body 101 forms the cooling line receptacle 103. The cooling line receptacle 103 is designed as a concave, groove-like longitudinally extending recess which has the cross section of a segment of a circle. The radius of the cooling line receptacle 103 is matched to the diameter of the coolant line 22. An optional remaining gap between the coolant line 22 and the bridge element 10A can additionally be filled with a thermally conductive medium, e.g. a thermally conductive adhesive. This serves to implement a particularly efficient heat transfer for cooling between the bridge element 10A and the coolant line 22.

In the base body 101, several, here two screw holes 104 for mounting the clamps 14 are also formed. A plug contact connection 105 projects from the base body 101, in the present case in a direction perpendicular to the main mating plane of the base body 101. A through hole, here in the form of a bore 106, is formed on the plug contact connection 105. The corresponding plug contact 11 can be mounted on the bore 106, e.g. welded or screwed to it.

Furthermore, a thermal bridge 100A projects from the base body 101 at an obtuse angle. The thermal bridge 100A is rod-shaped.

Figs. 8A and 8B show the other of the bridge members 10A, 10B. This bridge element 10B is similar to the bridge element 10A according to FIGS. 7A and 7B educated. In contrast to this, the connection surface 102 of the bridge element 10B is formed on the same side as the cooling line receptacle 103. Furthermore, the thermal bridge 100B extends in the same plane as the base body 101. The plug contact connection 105 of the bridge element 10B according to FIGS Thermal bridge 100B and arranged at a distance from the cooling line receptacle 103. The plug contact connection 105 of the bridge element 10A according to FIGS. 7A and 7B is arranged at a distance from the thermal bridge 100A and adjoining the cooling line receptacle 103.

The bridge elements 10A, 10B are solid, flat parts made of thermally and electrically highly conductive material, e.g. copper. The bridge elements 10A, 10B have a cross section that allows high currents to be conducted. For example, the bridge elements have a cross section perpendicular to the direction of longitudinal extension at at least one point with a width and height whose ratio is not greater than 3: 1 or 4: 1.

FIGS. 9A to 9E show the heat sink 12 and two heat conducting elements 13.

The cooling body 12 comprises a base body 122 which has receptacles for connection to a respective hose connection 121. The receptacles are in fluid connection with a channel which, in the closed state, forms the coolant channel 120 together with a cover 123. The two coolant lines 22 can be connected to the hose connections 121, so that they are in fluid connection with one another via the coolant channel 120. A seal 124 seals the cover 123 from the base body 122. Screws 126 or other fastening elements secure the cover 123 to the base body 122.

The base body 122 and the cover 123 each have two flat surfaces 127 parallel to one another. Each of the plane surfaces 127 is in flat contact with a heat-conducting element 13. A mounting bracket 125 clamps the heat-conducting elements 13 against the base body 122 and the cover 123.

A thermal bridge 100A, 100B of one of the two bridge elements 10A, 10B is received in each of the heat-conducting elements 13. Specifically, the heat conducting elements each have a shaft section 130 for this purpose, which is closed at the end. The heat conducting elements 13 are each made of a heat conductor, which is also a electrical insulator is made of aluminum nitride ceramic, for example. The bridge elements 10A, 10B are thus electrically isolated from the heat sink 12.

Furthermore, the heat-conducting elements 13 each have a surface section 131 which extends in a plane which runs perpendicular to the direction in which the respective shaft section 130 extends. In this way, particularly reliable electrical insulation can be achieved. The heat conducting elements 13 effect a galvanic separation of the bridge elements 10A, 10B from the cooling body 12. In the present case, the heat conducting elements 13 are each designed in the form of a cap or a hat. The surface sections 131 are designed in the form of a brim.

The bridge elements 10A, 10B can thus be cooled at two points by coolant flowing through the coolant lines 22, namely both via the cooling line receptacles 103 and via the thermal bridges 100A, 100B, which enables particularly effective cooling in a small space. The entire part of the bridge elements 10A, 10B, which is located between the plug contact 11 and the connection surface 102, is permeated by the load current during operation and heated accordingly. The massive and thus good heat-conducting cross-section of the bridge elements 10A, 10B dissipates the resulting heat well to these heat transfers.

List of reference symbols

1 connector part

10A, 10B bridge element

100A, 100B thermal bridge

101 base body

102 connection surface

103 Cooling line holder

104 screw hole

105 plug contact connection (connecting section)

106 bore

11 plug contact

12 heat sinks

120 coolant duct

121 hose connection

122 base body

123 lid

124 seal

125 mounting bracket

126 screw

127 plane surface

13 heat conducting element

130 shaft section

131 area segment

14 clamp

15 screw

16 housing

2 cables

21 electrical conduction

22 coolant line

23A, 23B connection end

3 mating connector part

4 vehicle

40 coolant circuit

41 DC network

5 charging station

Claims

1. Connector part (1) for connection to a mating connector part (3), with at least one bridge element (10A, 10B) with a cooling line receptacle (103) for heat-conducting system with a coolant line (22) of a cable (2), one on the bridge element (10A) , 10B) provided and with an electrical line (21) of the cable (2) electrically connectable plug contact (11) and a heat sink (12) which is in heat-conducting connection with the bridge element (10A, 10B) and which has a coolant channel (120) forms, to which the coolant line (22) can be connected.

2. connector part (1) according to claim 1, characterized in that the

Bridge element (10A, 10B) is designed to conduct electrical currents of 200 A or more.

3. Plug connector part (1) according to claim 1 or 2, characterized in that the bridge element (10A, 10B) is electrically connected to the plug contact (11).

4. Plug connector part (1) according to one of the preceding claims, characterized in that the bridge element (10A, 10B) is formed in one piece.

5. Plug connector part (1) according to one of the preceding claims, characterized in that the cooling line receptacle (103) of the bridge element (10A, 10B) is designed as a concave, longitudinally extending recess.

6. connector part (1) according to claim 5, characterized in that the

Cooling line receptacle (103) is aligned perpendicular to the plug contact (11).

7. Plug connector part (1) according to one of the preceding claims, characterized in that the bridge element (10A, 10B) has a base body (101) and a thermal bridge (100A, 100B) projecting from the base body (101).

8. connector part (1) according to claim 7, characterized by an electrically insulating heat-conducting element (13) which receives the heat bridge (100A, 100B) of the bridge element (10A, 10B) and which is in flat contact with the heat sink (12).

9. connector part (1) according to any one of the preceding claims, characterized by two bridge elements (10A, 10B), wherein both bridge elements (10A, 10B) are in heat-conducting connection with the heat sink (12).

10. Plug connector part (1) according to one of the preceding claims, characterized in that the heat sink (12) has an inlet and an outlet, wherein coolant introduced through the inlet in an inlet direction flows out of the outlet in an outlet direction which is directed against the inlet direction is.

11. Connector part (1) according to one of the preceding claims, characterized in that the connector part (1) is designed as a vehicle charging socket for high-performance DC charging.

12. Connector arrangement with a connector part (1) according to one of the preceding claims and a cable (2) comprising an electrical line (21) and a coolant line (22), wherein the electrical line (21) is electrically connected to a connection surface (102) of the bridge element (10A, 10B) is connected and the coolant line (22) is in contact with the cooling line receptacle (103) of the bridge element (10A, 10B) and is connected to the coolant channel (120) of the heat sink (12).

13. Connector arrangement according to claim 12, characterized in that the bridge element (10A, 10B) on the cooling line receptacle (103) and over the heat bridge (100A, 100B) can be cooled by means of coolant flowing through the coolant line (22).

14. Connector arrangement according to claim 12 or 13, characterized in that the electrical line (21) surrounds the coolant line (22).

15. Connector arrangement according to one of claims 12 to 14, characterized in that the electrical line (21) is connected to the connection surface (102) via a welded connection.

16. Connector arrangement according to one of claims 12 to 15, characterized in that the connector part (1) comprises two bridge elements (10A, 10B), both bridge elements (10A, 10B) in heat-conducting connection with the heat sink (12), two electrical lines (21) and two coolant lines (22) being provided and the electrical lines (21) each being electrically connected to the connection surface (102) of one of the bridge elements (10A, 10B) and the coolant lines (22) are each in contact with the cooling line receptacle (103) of one of the bridge elements (10A, 10B) and are connected to the coolant channel (120) of the heat sink (12).

17. Bridge element (10A; 10B) for the connector part (1) according to one of claims 1 to 11, with

- A base body (101) which has a connection surface (102) for connecting an electrical line (21) of a cable (2) and a cooling line receptacle (103) for receiving a coolant line (22) of the cable (2) in a thermally conductive manner,

a connecting section (105) via which the connection surface (102) and a plug contact (11) are electrically connected to one another, and

a thermal bridge (101; 100B) protruding from the base body (101).