Multi-conductor cable with reduced diameter and contact device for the same
阅读说明：本技术 直径减小的多导体线缆和用于该多导体线缆的接触装置 (Multi-conductor cable with reduced diameter and contact device for the same ) 是由 R·哈贝林 于 2018-05-30 设计创作，主要内容包括：提出一种具有插拔连接器(26)的电多导体线缆(10)、尤其具有用于电动车的充电插头的导线。所述线缆(10)具有中心的线缆芯、一定数量的彼此同心地围绕线缆芯环状布置且由单线制成的导体(11、12、13)和分别在所述导体之间的绝缘部(14)。根据本发明,接触装置具有两个夹紧壳件(21A、21B),所述夹紧壳件在其内侧具有多个彼此在径向上成梯级的接收部(22-1、22-2、22-3)。在夹紧壳件的接收部中分别布置有接触体(23-1、23-2、23-3)并且触点接触所述同心的导体(11、12、13)中的一个。每个接触体(23-1、23-2、23-3)具有沟形状(24),所述沟形状具有纵向延伸部和围绕所对应的导体弯曲的横截面走向。闭锁装置(27、28)将夹紧壳件连接并且在闭合位置中将其固定,夹紧壳件使接触体(23-1、23-2、23-3)共轴地保持并且将每个接触体(23-1、23-2、23-3)为了触点接触目的而压紧在分别所对应的同心的导体(11、12、13)上。(An electrical multi-conductor cable (10) with a plug connector (26), in particular a line with a charging plug for an electric vehicle, is proposed. The cable (10) has a central cable core, a number of conductors (11, 12, 13) which are arranged concentrically around the cable core and are made of single wires, and insulation (14) between the conductors. According to the invention, the contact device comprises two clamping shells (21A, 21B) which have a plurality of radially stepped receptacles (22-1, 22-2, 22-3) on the inner side thereof. In the receiving sections of the clamping shells, contact bodies (23-1, 23-2, 23-3) are arranged in each case and contact one of the concentric conductors (11, 12, 13). Each contact body (23-1, 23-2, 23-3) has a groove shape (24) with a longitudinal extension and a cross-sectional course that is curved around the corresponding conductor. A locking device (27, 28) connects the clamping shells and fixes them in the closed position, the clamping shells holding the contact bodies (23-1, 23-2, 23-3) coaxially and pressing each contact body (23-1, 23-2, 23-3) against the respectively associated concentric conductor (11, 12, 13) for contact purposes.)
1. An electrical multiconductor cable with a contact device for plugging in and out a connector, in particular a conductor of a charging plug at a charging station of an electric vehicle, comprising:
a central cable core, a number of conductors arranged annularly concentrically around the cable core and made of single wires, and insulation between the conductors, respectively; it is characterized in that the preparation method is characterized in that,
the contact device comprises two clamping shells having on their inner side a plurality of receptacles stepped in the radial direction with respect to one another;
in each case, in the receptacle of at least one clamping shell, contact bodies are arranged, which for contact purposes correspond to concentric conductors, wherein each contact body has a groove shape with a longitudinal extension and a cross-sectional course that is curved around a circumferential portion of the corresponding conductor;
-latching means are provided for connecting the clamping shells, which latching means secure the clamping shells to each other in the closed position; and is
The clamping shells hold the contact bodies coaxially to one another in the closed position and press each contact body against the respectively corresponding concentric conductor for contact-making purposes.
2. The cable according to claim 1, characterized in that said blocking means act as:
quick-locking means that can be closed without tools, for example in the form of quick-locking tabs, clip-on connections or the like, in particular in the form of quick-locking means that cannot be released;
a rivet connection which is not releasable; or
-embodied as a releasable screw connection.
3. Cable according to claim 1 or 2, characterized in that the groove shape of the contact body is in contact with the surface-like electrical contact of the respectively corresponding conductor mainly and in particular exclusively by a clamping force applied to the circumferential surface of the respectively corresponding conductor, which clamping force is generated by the latching device and is transmitted from the clamping shell to the contact body.
4. Cable according to any one of claims 1 to 3, in particular according to claim 3, characterized in that the groove shape of the contact body extends over a circumferential portion of at least 20% to at most 80%, in particular over a circumferential angle of at least 120 ° to at most 270 °, of the circumference of the corresponding concentric conductor.
5. A cable according to any one of claims 1 to 3, in particular according to claim 3, wherein the groove shape of the contact body extends over about 60% to 95% of the circumferential portion of the circumference of the corresponding concentric conductor, and the two opposing receiving portions of the clamping shell element receive and press against such contact body, respectively.
6. Cable according to claim 4 or 5, characterized in that the groove shape of the contact body has an arcuately curved cross section, in particular an arcuately curved cross section; or have a discontinuously curved cross section.
7. Cable according to one of claims 1 to 6, in particular according to claim 6, characterized in that the contact bodies are each manufactured in one piece.
8. Cable according to any one of claims 1 to 7, characterized in that the contact has the groove shape in a first region and comprises a contact pin or a contact socket for a plug connector in an opposite second region.
9. The cable according to any one of claims 1 to 8, in particular according to claim 8, characterized in that the clamping shell of the contact device forms an integral part of a multi-part plug connector housing, wherein the plug connector housing preferably consists of the clamping shell.
10. The cable according to any one of claims 1 to 9, in particular claims 8 and 9, wherein the clamping shell part has the receptacle in a first region and forms a housing part of a plug or a coupling in an opposite second region, and in particular comprises at least one contact carrier for a contact pin or a contact socket, respectively, on one end side in the second region.
11. Cable according to claim 10, wherein the clamping shell has at least one seal at its interface and/or has a tension relief at the cable-side end of the first region.
12. Cable according to any one of claims 1 to 11, in particular according to any one of claims 9 to 11, characterized in that the contact device has exactly two clamping shell parts, in particular molded parts made of plastic, which are manufactured as half shells, in particular as identical parts.
13. A cable according to any one of claims 1 to 12, wherein at least a number of receiving portions corresponding to the number of concentric conductors is provided in each clamping shell, and at least some of the receiving portions of each clamping shell receive the groove shape of the contact and the circumferential portion of the corresponding conductor surrounded by the groove shape, respectively.
14. A cable according to any one of claims 1 to 13, wherein the cable core comprises a further conductor made of a single wire.
15. A cable according to any one of claims 1 to 14, wherein a support layer is provided for each insulation between adjacent pairs of concentric conductors, said support layer preventing a single wire from being pressed into said insulation.
16. A cable according to any one of claims 1 to 15, characterized in that the cross-section of the single wires decreases outwards from one concentric conductor to the next.
17. Cable according to any one of claims 1 to 16, characterized in that each conductor consists of stranded single wires, preferably stranded from one conductor to the next in alternating opposite twisting directions, and in particular stranded onto an insulation located in the middle.
18. A cable according to any one of claims 1 to 17, characterized in that at least three concentric conductors are arranged around the cable core, wherein two conductors, each having at least 20mm, are used as current supply conductors2In particular more than 60mm2Total ring cross section of (a).
19. Cable according to any one of claims 1 to 18, in particular according to claim 18, characterized in that at least one signal conductor for data transmission is provided having a significantly smaller overall cross section.
20. A contact arrangement for a plug connector, in particular for or as part of a charging plug at a charging station for an electric vehicle, characterized in that it has the features of the characterizing part of any of claims 1 to 13.
21. A charging station for an electric vehicle comprising a cable or contact arrangement according to any one of claims 1 to 19.
22. Use of a cable according to any one of claims 1 to 19 as a charging cable for an electric vehicle.
Technical Field
The present invention generally relates to a flexible electric multi-conductor cable having a central core and a plurality of conductors made of single wires arranged concentrically and annularly around the core. The invention relates in particular to a multiconductor cable of the type with a contact device, in particular for plugging and unplugging a connector.
Background
Such a conductor having a conductor arranged concentrically around a core is known, for example, from publication DE 4004802 a1, which has the following purposes: subjected to high dynamic stresses.
Likewise, in patent US 3261907, in a multi-conductor power supply cable for high frequencies, it is proposed that the conductors made of single wires are arranged concentrically and annularly around a core with respect to each other. In addition to the main advantage of reducing the impedance, the following advantages are also illustrated there: such a wire achieves a more compact construction.
Furthermore, in FR 2693024 a1, a diameter reduction of about 30% is produced for data cables and supply cables having concentrically or coaxially arranged conductors.
In fact, the concentric design allows a perceptible reduction in the overall diameter of the cable compared to the usual design with a bunching of conventional cable cores arranged side by side, which have corresponding conductor cross sections.
The reduction in overall diameter makes hand manipulation particularly easy. However, this is an important advantage not only in manual user applications (for example in the charging lines of charging stations for electric vehicles).
In view of the short charging times (i.e. increased charging currents in the region of several hundred amperes, which require a large conductor cross section of the individual conductors, in particular for thermal reasons), a compact cable cross section becomes particularly interesting, in particular in the case of direct current. For example, currently customary charging cables according to IEC 62196 type 2 are suitable therein for charging currents of up to 32A.
Furthermore, the aforementioned patent document does not provide any solution for the group connection (Konfektion) of multi-conductor cables, in particular for contacting the contacts of an electrical connector device, such as a plug connector.
FR 2693024 a1 clearly confirms that multi-conductor cables of this type are typically not used as power supply cables, precisely because of the difficulties in electrical connections and insulation (see
For rigid mounting systems of coaxial rigid conductors, a special contact device is proposed by US 2012/094553a1 from other fields, which, however, is also relatively expensive to assemble.
In general, the prior art also lacks up to now an efficient, cost-effective solution for contacting the concentric conductors of a multi-conductor cable.
Disclosure of Invention
A first task of the present invention is to propose an improved simplified contact contacting device for a multi-conductor cable with concentric conductors of reduced diameter. The contact arrangement should in particular reduce the outlay on cable-to-connector engagement or group connection to the connector to a perceptible extent.
This object is achieved by an electrical cable according to claim 1 having a contact device and, independently thereof, also by a contact device according to
In an electrical, preferably flexible multi-conductor cable with a central cable core, a plurality of conductors which are arranged concentrically or coaxially to one another and are insulated relative to one another around the cable core and are made of single wires, it is proposed according to the invention that the contact device comprises at least or exactly two clamping shells which have, on their inner side, a plurality of radially stepped receptacles which can be stepped relative to one another in the direction of the cable axis and which have, for example, a groove-like or trough-like configuration. Furthermore, the following steps are set: in at least some of the receptacles of at least one clamping shell, preferably in each receptacle, a separate groove-like contact body is arranged, which for the purpose of contacting corresponds to a concentric conductor. Each contact body has a longitudinal extension and a curved cross-sectional course which is intended to surround a circumferential portion of the associated conductor in order to rest against the conductor. In the receptacle of the clamping shell or shells, the contact bodies can be held coaxially to one another with their longitudinal extension, also stepwise.
In a further aspect, the invention provides a closure device for connecting the clamping shells to one another, i.e. in the closed position, the closure device mechanically fixes the clamping shells to one another. The clamping shell in the closed position thus enables each of the contact bodies provided to be pressed against the respective concentric conductor for the purpose of contacting the contacts.
With the proposed contact arrangement, a multi-conductor cable can be formed with particularly low assembly effort. For this purpose, the cable merely has to be stripped off (abmantellung) in steps corresponding to the steps in the arrangement of the contact bodies (i.e. the insulation is removed in steps) so that the different conductors are exposed in mutually successive longitudinal sections. Suitable tools or machines are provided for this purpose. In the simplest case, the electrical contact can be achieved merely by appropriately inserting or introducing the cable ends stripped off in stages into the open position of the clamping shell and then closing the clamping shell. A sufficient contact pressure between the contact body and the corresponding lateral surface of the round conductor is achieved by suitable dimensioning and locking. In particular, conventional spiral contact or solder contact is not required either.
In short, a central aspect of the invention is that the two clamping shells with the contact means arranged in steps simultaneously also effect a contact of the cable ends stripped off in steps when closed. The corresponding additional work step is omitted. In particular, rapid and error-free contact of the contacts due to the predefined correspondence is ensured. The special design of the line with concentric "round conductors" achieves a reduction of about 20% or more in the outer diameter compared to conventional lines (for the same current distribution Strombelag or with a corresponding conductor cross section). The known difficulties of such a group connection of special cables are overcome by the present invention.
Here, the term "groove shape" is also understood to mean a short longitudinal section resulting from an imaginary groove, i.e. the dimension in the longitudinal extension can be smaller than the dimension in the circumferential direction, like for example a clamping sleeve or a clamping band (Klemmschelle). In this context, a "single wire" is understood to mean, entirely in general or irrespective of the cross-section, all electrically conductive wires (in particular 151-12-28 in the IEV sense), in particular also individual wires in a stranded wire or conductor bundle.
The force required for the force-locking contact can be predetermined or adjusted, if necessary, by the dimensioning of the clamping shell, the contact body and/or by the locking device. Furthermore, as long as the position of the contact body is predetermined, a defect-free contact can naturally be ensured by a suitable correspondence of the individual steps with respect to one another. This can be ensured by suitable protection against confusion, if necessary.
In one embodiment, the locking device can be embodied as a quick locking device that can be closed without tools, for example as a quick-action chuck, a lever clamp (e.g., toggle clamp), a locking connector/clip connector, or the like.
In a preferred embodiment, the locking device is designed as a quick locking device that cannot be released (i.e., a connection that cannot be released without damage) for reasons of electrical safety. This can be achieved, for example, also by means of a toggle clamp, if the tensioning lever is sunk exactly or flush into the receptacle and is then no longer accessible to the user.
Other types of non-releasable connections, such as rivet connections or adhesive connections, can also be envisaged, however, with somewhat higher assembly expenditure.
A cost-effective solution arrangement that allows a high pressing force is provided: the locking device is embodied as a releasable screw connection. This also allows, for example, subsequent maintenance work.
The groove shape on the contact body can be brought into contact with the planar electrical contact of the respectively associated conductor primarily and, in particular, preferably exclusively by means of a clamping force generated by the latching device, which is applied to the circumferential surface of the respectively associated conductor, wherein the clamping force of the latching device can be transmitted from the clamping shell to the contact body. Preferably, all the corresponding contact bodies are pressed with substantially the same pretensioning against the respective lateral surfaces of the conductor sections exposed in steps by means of a predetermined dimensioning. The electrical contact can thus be realized surface-to-surface and force-locked without further work steps.
In particular if the contact body is received in each of the two clamping shells, it is advantageous for sufficient contact that the groove shape of the contact body extends over a circumferential portion of at least 20% to at most 80%, in particular over a circumferential angle of at least 120 ° to at most 270 °, of the circumference of the corresponding concentric conductor.
Alternatively, it is also possible for the groove shape to be embodied in the manner of a clamping sleeve, i.e. for: the groove shape of the contact body extends over more than 60% up to 95% or more of the circumferential portion of the corresponding concentric conductor. In this case, two opposite receiving portions of the clamping shell can each receive and press such a contact body, for example in such a way that the free cross section of the receiving portions has an undersize (Untermass) with respect to at least the clamping sleeve and, if appropriate, the associated conductor.
That is, the contact bodies can be present separately in each clamping shell or, for each radial step, a common contact body (similar to a clamping sleeve) is present, which is pressed onto the respective "round conductor" by the co-action of the clamping shells. The configuration of the latter (corresponding "round conductor") simplifies the assembly to a greater extent, for example when the contact body comprises a contact pin or a contact socket, as explained further below.
In a design type to be produced in a simple manner, the contact body has at least in sections a groove shape with an arcuately curved cross section, in particular with a circularly curved cross section.
It is also possible to provide a discontinuously curved cross section, for example a curved wave or zigzag course around the respective conductor. The more expensive shaping can increase the overall contact surface and can also cause, for example, a single-wire "hook" with the conductor, for example, for longitudinal restraint.
Such contacts are inexpensive: the contact body is produced in one piece, for example as a sheet metal part, for example, modified from a copper sheet, wherein the basic shape to be modified can be produced by stamping. Alternatively, the contact body can also be produced in a cutting manner, for example a copper milling.
A particularly effective and time-saving embodiment is one in which the contact body has a groove shape in a first region and comprises a contact pin or a contact socket for plugging and unplugging the connector in an opposite second region. If a contact body of this type is present in at least one clamping shell, the assembly of a special cable by means of a plug connector is significantly facilitated, since the contact contacts themselves can already be provided or produced by nature.
In one embodiment, provision is made for: the clamping shell of the contact device itself may form part of a multi-part plug connector housing with the other housing part. Preferably, the plug connector housing, which is desired for the application, can also consist essentially of the clamping shell part, so that further work steps for the plug connector assembly are dispensed with. The plug connector can be, for example, a high-current plug or a high-current ferrule (for example, according to IEC 62196 type 2 or the like).
In particular in the case of a combination of the two above embodiments, it is therefore advantageous if the clamping shell part has a receptacle in the first region and forms a housing part of the plug or the coupling in the opposite second region and in particular in the second region comprises a contact carrier for at least one end side of the contact pin or contact socket, respectively. The contact-making of the concentric conductors in one working step thus enables the plug assembly to be carried out simultaneously.
For a certain level of protection, it is practical for the clamping shell to have at least one sealing ring at its interface, for example for the watertight design of a plug connector housing. A high level of IP protection, such as IP67, can be achieved. Furthermore, the clamping shell can also have a tension relief at the cable-side end of the first region, so that at the same time a tension relief and if necessary also a sealing on the housing is achieved by means of the locking device.
A further simplification is achieved if the contact arrangement has exactly two clamping shell parts, in particular molded parts made of plastic (e.g. injection molded parts), which are produced as half shells. The clamping shells can also be produced in one and the same piece. The clamping shells can be used to bring very different cable contacts into contact and, if appropriate, to be connected in groups, wherein it is not necessary to provide a contact body in each receiving step. Thus, at least a number of receiving portions corresponding to the number of concentric conductors is provided in each clamping shell, or at least some of the receiving portions of each clamping shell are able to receive the groove shape of the contact body and the circumferential portion of the corresponding conductor surrounded thereby, respectively.
The cable core can be embodied purely as a mechanical support, but preferably for the purpose of spatial optimization itself comprises a further conductor made of a single wire. Alternatively, a support layer can be provided for each insulation between adjacent pairs of concentric conductors, which support layer prevents the individual wires from being pressed into the insulation. The support layer is mounted in particular under high contact pressure.
For the purpose of diameter optimization, it is also advantageous if the cross section of the individual wires decreases from one concentric conductor to the next. For example, the wire cross section can be reduced in accordance with the proportional relationship of the radii of one conductor to the next, since the distribution circumference (verteilengugsumfang) of the individual wires increases. The conductor cross-section is selectively matched by appropriate selection of the individual wires according to the nominal current distribution to further reduce the overall diameter. It is advantageous, for example, to arrange the protective conductor radially on the outside, since it can have a smaller cross section than the conductor that conducts the current, depending on the standard.
The type of conductor structure and the type of contact structure according to the invention are particularly advantageous when three or more concentric conductors are arranged around the cable core and have a very large cross section (for example at least 20mm each)2In particular more than 60mm2Total ring cross section) of two or more conductors are used as current supply conductors. For example, for a DC current requirement of up to 500A>90mm2Of the conductor cross section. The invention also provides significant advantages in the case of a multipurpose line in which, in addition to the supply conductors, at least one signal conductor for data transmission is also provided, which has a significantly smaller overall cross section.
The manufacture of the specialty cable can be done in a known manner. Mechanically advantageously, each conductor consists of twisted individual wires and the individual wires are preferably twisted in alternating opposite twisting directions (schlagrickhtung) from one conductor to the next. As described in DE 4004802 a1, the conductor can be twisted, for example, onto an insulation located in the middle.
The invention also relates to the contact device itself, in particular to a contact device for a plug connector, which has the features from one of the above embodiments.
A possible application of the invention can be found in the area of charging stations for electric vehicles, where particular advantages are achieved due to the desire for higher charging currents and the required hand manipulation by the end user. The invention also provides advantages in other applications with high amperage.
However, the invention can be applied to all types of electrical multiconductor cables, including pure data conductors, since a simultaneous diameter reduction with reduced assembly expenditure is desirable in a plurality of fields.
Drawings
Further advantageous features and effects of the invention are explained in more detail below with reference to the drawings according to embodiments. It shows that:
FIGS. 1A-1B: a cross section of a conventional multi-conductor cable (fig. 1B) and of a multi-conductor cable (fig. 1A) within the meaning of the invention is shown purely by way of example;
FIGS. 2A-2C: a schematic view illustrating an embodiment of a contact arrangement for a multi-conductor cable according to fig. 1A; and
FIGS. 3A-3B: schematic views of a plurality of contact bodies for a contact arrangement according to the invention in a side view (fig. 3A) and in a front view (fig. 3B); and
FIG. 4: schematic front view of further contact bodies.
Detailed Description
Fig. 1B shows a conventional multiconductor cable 1 having three cable cores 2, 3, i.e. conductors made of single wires with corresponding insulation 4. The cable wires are guided parallel next to one another in the
In contrast, the concentric cable construction according to the invention according to fig. 1A provides a perceptible reduction in the overall diameter D1 with the conductor cross section remaining constant. Fig. 1A shows a
Fig. 2A to 2C show purely by way of example a
The
Exemplary contacts 23-1, 23-2, 23-3 are shown in fig. 3-4. Each contact body 23-1, 23-2, 23-3 essentially has a
As can be seen best from fig. 2A to 2C, the two clamping
As a possible locking device for the fixed connection (for example, to form a closed housing) of the clamping
With clamping
List of reference numerals
FIGS. 1A-1B
1 conventional multiconductor cable
2. 3 cable core wire
4 insulating part
5 outer cover
10 concentric special cable
11. 12, 13 ring-shaped conductor
14 insulating part
15 outer casing
D1, D2 Total diameter
FIGS. 2A-2C and FIGS. 3-4
20 contact device
21A, 21B clamp housing
22-1, 22-2, 22-3 receiving part
23-1, 23-2, 23-3 contact body
24 groove shape
25 contact pin
26 plug connector
27. 28 locking means (clamping screw).
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