阅读说明：本技术 用于连接器元件的冷却装置和用于高压应用的连接器元件 (Cooling device for connector element and connector element for high voltage applications ) 是由 E.T.卢埃利希 M.利斯廷 于 2021-05-18 设计创作，主要内容包括：本发明涉及用于连接器元件的冷却装置以及用于高压(HV)应用的相关连接器元件。本发明还涉及一种用于安装高压连接器元件的方法。冷却装置(114)包括：冷却通道,冷却流体(126)在操作期间可以流过该冷却通道,以及支承元件(122),其保持冷却通道,其中冷却通道是与支承元件分开的部件,并且具有至少一个中空管道(210)的形状,中空管道(210)至少在支承元件(122)的圆周的一部分中围绕支承元件(122)接合。(The present invention relates to a cooling device for a connector element and an associated connector element for High Voltage (HV) applications. The invention also relates to a method for mounting a high-voltage connector element. The cooling device (114) comprises: a cooling channel through which a cooling fluid (126) may flow during operation, and a support element (122) holding the cooling channel, wherein the cooling channel is a separate component from the support element and has the shape of at least one hollow duct (210), the hollow duct (210) being joined around the support element (122) at least in a part of the circumference of the support element (122).)

1. A cooling device for a connector element (102), the cooling device (114) comprising:

a cooling channel through which a cooling fluid (126) can flow during operation, an

A support element (122) holding the cooling channel,

the cooling channel is a separate component from the support element and has the shape of a hollow duct (210), which hollow duct (210) engages around the support element (122) at least in a part of the circumference of the support element (122).

2. The cooling device according to claim 1, wherein the hollow conduit (120) is engaged around the support element (122) in a plurality of turns.

3. The cooling device according to claim 1 or 2, wherein the hollow conduit (120) comprises an electrically conductive material.

4. A cooling device according to any one of the foregoing claims, in which the support element (122) is at least partly made of an electrically insulating material.

5. A cooling device according to any one of claims 1-3, wherein the support element (322) is configured as an integral part of a base body (318) of the connector element (302).

6. Cooling arrangement according to claim 5, wherein the hollow duct (120) is at least partially electrically non-conductive.

7. Cooling device according to any of claims 1-4, wherein the support element (122) has a tubular shape and the hollow duct (120) forming the cooling channel is held in a radial circumferential groove (124).

8. The cooling device according to any one of the preceding claims, wherein the hollow conduit (120) is at least partially made of copper or silicone.

9. Connector element with an electrically conductive base body (118) and a cooling device (114) according to one of the preceding claims, wherein the support element (122) at least partially surrounds the base body (118) such that the cooling channel is in heat-conducting connection with the base body.

10. Connector system having a first connector element (102) and a mating second connector element (104), wherein the first and the second connector element (102, 104) are connectable to each other in an electrically conductive manner, and at least one of the connector elements (102, 104) comprises a cooling device (114) according to any one of claims 1 to 8.

11. A method for mounting a high voltage connector element (100), the method comprising the steps of:

providing a support element (122) for the base body (118);

attaching a cooling channel held by the support element (122), wherein the cooling channel is a separate component from the support element and has the shape of a hollow duct (210), which hollow duct (210) engages around the support element (122) at least in a part of the circumference of the support element (122).

12. The method according to claim 11, wherein the support element (122) comprises a sleeve-like collar that is slid onto the base body (118).

13. The method according to claim 11, wherein the support element (322) is formed by a receptacle (330) configured as an integral part of the base body (318) of the connector element (302).

14. The method of any of claims 11 to 13, wherein the step of attaching the cooling channel comprises winding at least one turn of the hollow conduit (120) around the support element (122).

15. The method according to any one of claims 11 to 14, further comprising the step of connecting the hollow conduit (120) to a cooling circuit.

Technical Field

The present invention relates to a cooling device for a connector element and an associated connector element for High Voltage (HV) applications. The invention also relates to a method for mounting a high-voltage connector element.

Background

In an electric vehicle, an HV connector with a large cable cross section is required to drive and charge the high voltage battery. In order to shorten the charging time or to obtain the required power from the battery, a high current density is partially required in the HV system. As a result, under adverse conditions, the temperature in the connector may rise unacceptably. However, reaching the maximum allowable temperature limits the energy that can be transferred. Passive cooling and providing a sufficiently large cable cross-section can solve this problem, but generally results in an oversized connector and excessive material costs.

Active cooling by means of a cooling fluid, for example a cooling liquid, is therefore advantageous. However, the known connector elements with integrated cooling channels have the following disadvantages: firstly, they are not suitable for retrofitting existing connector systems, and secondly, they are complex parts which are difficult to manufacture.

There is therefore a need for a cooling device for a connector element and a related connector element which overcome the disadvantages of the known solutions such that the produced connector element is safe and reliable, but can still be manufactured inexpensively and requires little installation space.

Disclosure of Invention

This object is met by the objects of the independent claims. Advantageous embodiments of the invention are the object of the dependent claims.

The idea on which the invention is based is: active cooling with minimal additional space requirement is achieved by providing separate hollow conduits through which cooling fluid may flow during operation and which are attached to the connector element. The hollow ducts, which are also referred to below as cooling lines and form cooling channels, are advantageously placed in the vicinity of the contact points (also referred to below as "hot spots"). A cooling fluid, for example a cooling liquid, as is already available in the motor vehicle absorbs the heat generated in the connector and transfers it to the corresponding radiator. As a result, particularly effective thermal management and thus effective energy transfer can be achieved without increasing installation space and costs.

The cooling device for the connector element comprises in particular: a cooling channel through which a cooling fluid may flow during operation; and a support element holding the cooling channel, wherein the cooling channel is a separate component from the support element and has the shape of at least one hollow duct engaging around the support element at least in a part of the circumference of the support element. Such hollow conduits are designed, for example, as hoses or tubes and are placed as close as possible to hot spots around the connector element.

The hollow conduit may be wound around only a part of the circumference of the cooling device connector element, or it may be wound around the support element and thus around the circumference of the connector element a plurality of turns. If the hollow pipe engages around the support element in a plurality of turns, the heat dissipation can be improved, since a larger area of the connector element can be brought into a heat-conducting connection with the cooling fluid. Furthermore, a plurality of separate hollow conduits may also be operated in parallel.

According to an advantageous embodiment, the hollow conduit comprises an electrically conductive material. For example, the hollow conduit may comprise a metallic material, such as copper, and optionally have other coatings. The metallic material has the advantage that a particularly efficient heat transfer between the connector element and the cooling fluid is obtained.

In order to ensure electrical insulation between the connector element and the hollow duct, it can be provided that the support element is at least partially made of an electrically insulating material. This is particularly advantageous when the hollow conduit comprises a metallic material, such as copper, and the cooling fluid is electrically conductive. For example, the support element may be formed by a plastic sleeve that is slid onto the connector element.

According to an advantageous development of the invention, it can be provided that the support element is designed as an integral part of the base body of the connector element. The cooling line is wound directly on the contact body, for example for moderate cooling capacity. In particular, if the base body is a conductive part of a connector element, such as a contact receptacle, this configuration has the following advantages: a particularly effective heat dissipation can be ensured in a particularly simple and space-saving manner. The hollow conduit should be non-conductive.

In particular, when the support element is at least partially electrically conductive, it is advantageous to make the hollow conduit from an electrically insulating but thermally conductive material.

According to an advantageous development of the invention, it can be provided that the supporting element has a tubular shape and that the hollow ducts forming the cooling channels are held in the radial circumferential groove. This ensures that the hollow conduit is securely retained even under harsh environmental conditions, such as vibration and strong temperature fluctuations.

Depending on whether electrically insulating properties are required, the hollow conduit may be made, for example, at least partially of copper or silicone. Of course, all other materials suitable for producing a separate cooling line, such as Polytetrafluoroethylene (PTFE), Polyethylene (PE) or polypropylene (PP), can also be used. Of course, composite hoses, such as linings made of metal, fiberglass or woven braids, are also contemplated for reinforcement.

The cooling device according to the invention is advantageous in particular when used in connection with a connector element having an electrically conductive base body, wherein the support element at least partially surrounds the base body such that the cooling channel is in heat-conducting connection with the base body. The base body may be, for example, a contact element of a connector element, such as a socket element.

The invention also provides a connector system with a first connector element and a mating second connector element, wherein the first and second connector elements can be connected to each other in an electrically conductive manner and at least one connector element comprises a cooling device according to the invention.

Furthermore, the invention relates to a method for mounting a high-voltage connector element, comprising the steps of:

providing a support element for the substrate;

attaching a cooling channel held by the support element, wherein the cooling channel is a separate component from the support element and has the shape of a hollow pipe engaging around the support element at least in a part of the circumference of the support element.

The existing high-pressure connector element can be retrofitted in a particularly simple manner if the support element has a sleeve-like collar, which can also be referred to as adapter, and which is slid onto the base body. The collar may also fulfill an electrical insulating function if the base body is an electrically conductive contact element of a high voltage connector element and the hollow tube is also made of an electrically conductive material, such as copper.

Alternatively, it can also be provided that the support element is formed by a receptacle which is formed as an integral part of the base body of the connector element. This embodiment has the advantage of a particularly small installation size and an optimum heat dissipation.

The existing connector element can be retrofitted particularly easily if the step of attaching the cooling channel comprises winding at least one turn of the hollow conduit around the support element.

The active cooling according to the invention advantageously uses a cooling circuit provided in the superordinate unit in which the connector element is located. The method then comprises the step of connecting the hollow conduit to a cooling circuit, for example of a motor vehicle or at the charging post. The cooling solution can also work simply according to the heat pipe principle and provide closed hollow ducts filled with coolant to end at the cooling element, so that the coolant evaporates on the connector element and condenses again on the cooling element acting as a heat sink.

Drawings

For a better understanding of the present invention, reference will now be made in detail to the embodiments illustrated in the following drawings. Like elements are referred to herein by like reference numerals and like part names. Furthermore, some features or combinations of features of the different embodiments shown and described may also be present in the invention itself or in a solution according to the invention, wherein,

fig. 1 shows a schematic cross-sectional view of a high-voltage connector system according to a first example;

fig. 2 shows a schematic perspective view of a high-voltage connector system according to a first example;

fig. 3 shows a schematic exploded view of a high voltage connector system according to a first example;

figure 4 shows a schematic cross-sectional view of a high-voltage connector system according to a second example;

fig. 5 shows a schematic perspective view of a high-voltage connector system according to a second example;

fig. 6 shows a schematic cross-sectional view of a high-voltage connector system according to a third example;

fig. 7 shows a schematic perspective view of a high-voltage connector system according to a third example.

Detailed Description

The invention will now be explained in more detail with reference to the drawings, and in particular first to the schematic sectional view of fig. 1 and the perspective view of fig. 2. It should be noted that the size ratio, and in particular the layer thickness ratio in all figures, is not necessarily true to scale. Furthermore, components which are not necessary or are not obstructive for the understanding, in particular the electrically insulating housing element and the protective cover, are not shown.

These figures illustrate examples of active cooling solutions used in high pressure (HV) circular connectors (e.g., 12mm diameter). Of course, other connector geometries may be configured with cooling devices in accordance with the principles of the present invention. Furthermore, the cooling device may also be provided on both connector elements or only on the second connector element, although this is not shown in the figures. In other words, the cooling device does not necessarily have to be (only) associated with the socket element.

Fig. 1 shows, in cross-section, a connector system 100 according to a first advantageous embodiment of the invention. Fig. 2 shows a corresponding perspective view of the connector system 100 according to the first embodiment.

The connector system 100 includes a first connector member 102 configured as a receptacle member. As shown in fig. 1, the first connector member 102 is mounted in the housing member 132. Furthermore, the connector system 100 comprises a second connector element 104, which may also be referred to as a mating connector element. The second connector element 104 includes electrically conductive pin contact elements 128 immersed in the socket-shaped base 118 of the first connector element. In the presently illustrated assembled state, current may flow through the contact region 108, as indicated by arrow 106. The base 118 is typically connected to a busbar, which is arranged in the lower region of the base in fig. 1 (not shown) to draw current.

In the assembled state, the second connector element 104 is pressed against the base body 118 in the contact region 108. As a result, current (current arrows 106) may enter the base 118 of the first connector element 102 between the conductive second connector elements 104.

In order to prevent contact with the live part of the first connector element 102 in the unmated state, a contact protection element 116 is arranged on the first connector element 102. The contact protection member 116 is made of a non-conductive material. In interaction with a plastic housing (not visible in the figures), the contact protection element 116 prevents objects of a size larger than the defined test fingers from being able to contact the live part.

According to the present invention, the connector system 100 includes a cooling device 114 for dissipating heat generated when current flows.

The cooling device 114 comprises, inter alia, a cooling channel formed by a hollow duct 120. The hollow conduit 120 is held in a support element 122. The support element 122 according to the embodiment shown in fig. 1 to 3 is a plastic sleeve comprising a groove 124 for holding the hollow conduit 120.

As is apparent from fig. 2, the coolant 126 may flow through the hollow conduit 120. This may be, for example, a cooling fluid, in particular a cooling liquid. Since the hollow conduit 120 is in heat-conducting contact with the base body 118 at a relatively small distance from the contact region 108, the coolant 126 passing through the hollow conduit 120 can effectively carry away the generated heat. The cooling fluid 126 may, for example, be connected to a coolant circuit of the motor vehicle.

In the illustrated embodiment, the support element 122 made of an insulating material may ensure electrical insulation between the hollow conduit 120 and the base body 118 of the first connector element 102. Thus, the material of the hollow conduit 120 need not be electrically insulating. For example, the hollow conduit 120 may be made of a metal such as copper. This has the advantage of particularly good thermal conductivity. In addition, the copper tubing is relatively stable and robust even under adverse environmental conditions.

Fig. 3 shows an exploded view of the connector system 100 according to the first example. It is evident from this view that the support element 122 can be slid onto the base body 118 in the axial direction for assembly of the assembly. The hollow conduit 120 may be inserted into the groove 124 before or after being mounted on the substrate. The cooling device 114 is arranged in a region 130 with a reduced cross section. This ensures that the installation space required in the radial direction can be kept as small as possible.

In the embodiment shown in fig. 1 to 3, the hollow conduit 102 surrounds the support element 122 in only a single turn. The advantage of this variant is that the hollow conduit 120 can be mounted in a simple manner and requires little additional space in the axial direction.

On the other hand, if a large heat-conducting contact surface is provided between the hollow pipe and the first connector element, it can also be provided that the hollow pipe surrounds the bearing element in a plurality of turns. Examples of such solutions are shown in fig. 4 and 5.

Fig. 4 shows a connector system 200 according to a second advantageous embodiment of the invention in cross-section. Fig. 5 shows a corresponding perspective view of a connector system 200 according to a second embodiment.

The connector system 200 comprises a first connector element 202 configured as a socket element. The first connector member 202 is mounted in a busbar (not visible in the drawings). Further, the connector system 200 comprises a second connector element 204, which may also be referred to as a mating connector element. In the presently illustrated assembled state, current may flow through the contact region 208.

The first connector element 202 includes a conductive base 218. In the assembled state, the second connector element 204 is pressed against the inner wall of the base body 218 in the contact region 208. As a result, current may enter the base 218 of the first connector element 202 between the conductive second connector elements 204.

To prevent contact with the live portion of the first connector member 202 in the unmated state, a contact protection member 216 is disposed on the first connector member 202. The contact protection element 216 is made of a non-conductive material. In interaction with a plastic housing (not visible in the figures), the contact protection element 216 prevents objects having a size larger than the defined test fingers from being able to contact the live part.

According to the present invention, the connector system 200 includes a cooling device 214 for dissipating heat generated when current flows.

The cooling device 214 comprises, inter alia, a cooling channel formed by a hollow duct 220. The hollow conduit 220 is held in a support element 222. The support element 222 according to the embodiment shown in fig. 4 and 5 is a plastic sleeve comprising a groove 224 for holding the hollow conduit 220. The groove 224 extends far enough in the axial direction so that the hollow conduit 220 can be wound around the support element 222 several times. As a result, the heat conduction transition between the base 218 and the cooling pipe is enlarged as compared with the first embodiment, with the result that the heat dissipation efficiency is increased.

As described with reference to fig. 1 to 3, the coolant flows through the hollow conduit 220 during operation. This may be, for example, a cooling fluid, in particular a cooling liquid. Since the hollow conduit 220 is in thermally conductive contact with the substrate 218 at a relatively small distance from the contact region 208, the coolant passing through the hollow conduit 220 may effectively carry away the generated heat. The cooling fluid may for example be connected to a cooling fluid circuit of the motor vehicle.

Also in the second embodiment shown, the support element 222 made of insulating material may ensure electrical insulation between the hollow conduit 220 and the base body 218 of the first connector element 202. Thus, the material of the hollow conduit 220 need not be electrically insulating. For example, the hollow conduit 220 may be made of a metal such as copper. This has the advantage of particularly good thermal conductivity. In addition, the copper tubing is relatively stable and robust even under adverse environmental conditions.

On the other hand, if an electrically insulating (but thermally conductive) material is used for the hollow duct, the support element may also be constructed as an integral part of the electrically conductive base body of the first connector element. Examples of such a third embodiment are shown in fig. 6 and 7.

Fig. 6 shows, in a sectional view, a connector system 300 according to a third advantageous embodiment of the invention. Fig. 7 shows a corresponding perspective view of a connector system 300 according to a third embodiment.

The connector system 300 includes a first connector member 302 configured as a receptacle member. The first connector member 302 is mounted in a busbar (not visible in the figures). Further, the connector system 300 comprises a second connector element 304, which may also be referred to as a mating connector element. In the presently illustrated assembled state, current may flow through the contact region 308.

The first connector element 302 includes a conductive base 318. In the assembled state, the second connector element 304 is pressed against the inner wall of the base body 318 in the contact region 308. As a result, current may enter the body 318 of the first connector element 302 between the conductive second connector elements 304.

In order to prevent contact with the live part of the first connector element 302 in the unmated state, a contact protection element 316 is arranged on the first connector element 302. The contact protection element 316 is made of a non-conductive material. In interaction with a plastic housing (not visible in the figures), the contact protection element 316 prevents objects of a size larger than the defined test fingers from being able to contact the live parts.

According to the present invention, the connector system 300 includes a cooling device 314 for dissipating heat generated when current flows.

The cooling means 314 particularly comprise a cooling channel formed by a hollow duct 320. The hollow conduit 320 is held in a support element 322. The support element 322 according to the embodiment shown in fig. 6 and 7 is a region 330 of reduced cross-section, which forms a groove 324 for holding the hollow conduit 320. The region 330 of reduced cross-section extends far enough in the axial direction that the hollow conduit 320 can be wound around the support element 322 multiple times. As a result, the heat conduction transition between the base 318 and the cooling pipe is enlarged as compared with the first embodiment, with the result that the heat radiation efficiency is increased. Since the mounting of the hollow conduit 320 is integrally formed with the base 318, a significantly tighter heat conducting contact with the cooling fluid may be established, which may further improve the heat management. In addition, the mounting of a separate supporting element, which is configured, for example, as a sleeve, is omitted.

As described with reference to fig. 1 to 5, coolant flows through the hollow conduit 320 during operation. This may be, for example, a cooling fluid, in particular a cooling liquid. Since the hollow conduit 320 is in thermally conductive contact with the substrate 318 at a relatively small distance from the contact region 308, the coolant passing through the hollow conduit 320 may effectively carry away the generated heat. The coolant can be connected, for example, to a coolant circuit of the motor vehicle.

In the third illustrated embodiment, the material of the hollow conduit 320 must be at least partially electrically insulated to ensure electrical insulation between the cooling fluid and the base 318 of the first connector element 302. For example, the hollow conduit 320 may be made of a plastic material such as silicone. Polytetrafluoroethylene (PTFE), Polyethylene (PE) or polypropylene (PP) may be used as further possible materials. Of course, composite hoses, such as linings made of metal, fiberglass or woven braids, are also contemplated for reinforcement.

Fig. 6 and 7 show that hollow conduit 320 is wrapped around substrate 318 multiple times to form multiple turns. Of course, only a single turn (similar to that shown in figures 1 to 3) may be provided.

List of reference numerals

100. 200, 300 connector system

102. 202, 302 first connector element

104. 204, 304 second connector element; mating connector element

106 current arrow

108. 208, 308 contact area

114. 214, 314 cooling device

116. 216, 316 contact protection element

118. 218, 318 base of the first connector element

120. 220, 320 hollow pipeline

122. 222, 322 support element

124. 224 groove

126 cooling fluid

128. 228, 328 needle contact unit

130. 330 region of reduced cross-section

132 housing element.