Contact device, method for manufacturing the contact device and method for dismantling the contact device

Abstract

The invention relates to a contact device (40), a method for manufacturing the contact device (40), and a method for disassembling the contact device (40), wherein the contact device (40) comprises a housing (45), a first contact element (55), and a sealing element (60), wherein the housing (45) comprises a contact housing (95) and an outer housing (90) with a housing interior (100), wherein the contact housing (95) is arranged in a first partial region (215) of the housing interior (100) and has a first contact receptacle (150) in which the first contact element (55) is arranged, wherein a sealing chamber (225) is arranged in the housing interior (100) between the contact housing (95) and the outer housing (90), wherein the sealing element (60) is arranged in the sealing chamber (225), wherein the sealing element (60) comprises a phase-change material, and wherein the sealing element (60) is in a normal state of the contact device (40). is in a fixed phase stateand mechanically connects the outer housing (90) to the contact housing (95), wherein the housing (45) has a contact side (104) arranged at its end face, wherein the sealing chamber (225) is formed circumferentially, wherein a gap (235, 240) is arranged between the outer housing (90) and the contact housing (95), wherein the gap (235, 240) extends between the contact side (104) and the sealing chamber (225) and fluidically connects the sealing chamber (225) to the contact side (104).

Description

[0001] The invention relates to a contact device according to claim 1, a method for manufacturing the contact device according to claim 10 and a method for disassembling the contact device according to claim 11.

[0002] From DE 10 2018 108 181 A1 a high-voltage connector system with a recess or seal of high-voltage contacts in a phase-change material is known.

[0003] A waterproof connection part of this type is known from DE 101 44 315 A1.

[0004] Furthermore, a waterproof connector and a method for manufacturing the waterproof connector are known from US 2006 / 0 240 710 A1.

[0005] The object of the invention is to provide an improved contact device, an improved method for manufacturing the contact device and an improved method for disassembling the contact device.

[0006] This problem is solved by means of a contact device according to claim 1, a method for manufacturing the contact device according to claim 10, and a method for disassembling the contact device according to claim 11. Advantageous embodiments are specified in the dependent claims.

[0007] It was recognized that an improved contact device, in particular a second maintenance contact device, for a high-voltage system of an electric vehicle can be provided by the contact device comprising a housing, at least one first contact element, and at least one sealing element. The housing comprises a contact housing and an outer housing with an interior. The contact housing is arranged in a first partial region of the interior and has a first contact receptacle in which the first contact element is arranged, at least partially. A sealing chamber is arranged in the interior between the contact housing and the outer housing, wherein the sealing element is arranged in the sealing chamber, which fluidically seals a second partial region of the interior.The sealing element comprises a phase-change material, wherein the sealing element is in a fixed phase state in a normal state of the contact device and mechanically connects the outer housing to the contact housing.

[0008] The housing has a contact surface arranged at its end face, to which the first contact element can be connected. The sealing chamber extends completely around the contact housing. A gap is arranged between the outer housing and the contact housing, with the gap extending between the contact surface and the sealing chamber and fluidically connecting the sealing chamber to the contact surface.

[0009] This design has the advantage that the mechanical connection of the outer housing to the contact housing via the sealing element allows for a particularly simple geometric design of both the outer housing and the contact housing. In particular, additional locking mechanisms can be omitted, thus simplifying the molds for manufacturing both the outer housing and the contact housing. Furthermore, the material required for manufacturing both the outer housing and the contact housing is reduced.

[0010] This design also has the advantage that the sealing element can be poured in through the gap in liquid state, or the liquefied sealing element can be poured out of the sealing chamber through the gap along with the liquid phase change material.

[0011] In a further embodiment, the contact device comprises an electrical safety device and at least one second contact element, wherein the contact housing has a second contact receptacle. The second contact element is arranged at least partially within the second contact receptacle, with the outer housing sealing the housing interior on one side opposite the contact side. The safety device is arranged in the second section of the housing interior. The safety device electrically connects the first contact element to the second contact element. This design has the advantage that the sealing element reliably protects the safety device from environmental influences. In particular, the sealing element has the advantage of withstanding even high pressure differentials between the second section and the contact side.

[0012] In a further embodiment, the sealing element is thermally connected to the first contact element, wherein the sealing element is configured to absorb heat from the first contact element, and wherein the first contact element is configured to heat up when an electrical power surge is transmitted, particularly in a fault condition that differs from normal operation. In the event of a fault, the sealing element is configured to remain in a solid phase state. This ensures that an unintended mechanical separation of the outer housing from the contact housing does not occur and preferably that the safety device remains fluidically sealed against the contact side even in the event of a fault.

[0013] In a further embodiment, the sealing element comprises at least one of the following phase-change materials: wax, microencapsulated paraffin, paraffin, hard paraffin, microencapsulated hard paraffin, LDPE, HDPE, thermoplastic polymer, bio-based wax, lipids, fatty acid, alcohol, ethylene bis-stearamide, erucamide, stearamide, behenamide, amide, carnauba, polyethylene. The phase-change material has the advantage of exhibiting a high heat capacity compared to plastics, even when remaining in the solid phase. Furthermore, when heated above its melting point, the phase-change material can exhibit a viscosity that can also be described as low-viscosity. In particular, the viscosity can be between XX and XX and is significantly lower than, for example, the viscosity of molten thermoplastics.This allows for a complex geometry of the sealing chamber and ensures essentially complete emptying of the chamber even when the phase-change material is heated above its melting point. This, in turn, ensures that the individual materials of the contact device can be separated from each other in a largely pure manner during recycling or disassembly.

[0014] In a further embodiment, the sealing element comprises at least one of the following filler materials: carbon, aluminum, fibers, bio-based fibers, wool fibers, flax fibers, hemp fibers, glass fiber, carbon powder, micro- and / or nano-fibrillated cellulose, shellac, natural protein fibers, or jute fibers. The filler material is embedded in the phase-change material of the sealing element. Embedding in this context means that the filler material is essentially completely enclosed by the phase-change material. Embedding the filler material in the phase-change material allows for easy adjustment of the sealing element's stiffness within the sealing chamber. Furthermore, the use of bio-based filler materials offers the advantage of reduced CO2 emissions during the manufacture and recycling of the contact element.

[0015] In a further embodiment, the first contact element of the contact device is configured to transmit an electric current in a range of 50 A to 1000 A inclusive, in particular from 100 A to 800 A inclusive, and especially from 200 A to 600 A inclusive, during normal operation. The electrical voltage can be in a range of 300 V to 1000 V inclusive, and this can be a direct current (DC) voltage. This design has the advantage that the contact device can be used, in particular, in a high-voltage system of a vehicle, especially an electric vehicle.

[0016] In a further embodiment, the phase-change material has a first melting point, and the housing has a housing material with a second melting point and / or glass transition temperature. The second melting point and / or glass transition temperature is higher, in particular by at least 30 °C, than the first melting point of the phase-change material of the sealing element. This ensures that when the contact device is heated, the housing retains its shape and does not melt, thus enabling the ejection, in particular the pouring, of the molten phase-change material from the sealing chamber.

[0017] In a further embodiment, the sealing element has a circumferentially arranged outer contour, wherein the outer contour, preferably substantially completely, abuts an inner contour of the sealing chamber. Preferably, the outer contour is materially bonded to the inner contour of the sealing chamber. Due to the materially bonded connection of the sealing element with the housing, in particular the outer housing, and / or the contact housing, the sealing element serves not only for sealing but also for mechanical connection, so that further mechanical connecting means, for example snap-fit ​​or click connections between the outer housing and the contact housing, can be dispensed with.

[0018] It is particularly advantageous if the sealing element is cast, especially injection-molded, within the sealing chamber. This ensures that the sealing chamber is essentially completely filled by the sealing element.

[0019] It was recognized that an improved method for manufacturing the contact device described above can be provided by first supplying the housing with the contact housing and outer housing. In a second process step, the contact housing is inserted into a first section of the housing interior to form the sealing chamber. In a third process step, the phase-change material of the sealing element is melted, and in a fourth process step, the molten phase-change material is introduced into the sealing chamber. In particular, the phase-change material can be poured into the sealing chamber in its molten state. In a fifth process step, the phase-change material is cooled and solidifies to form the sealing element. It is particularly advantageous if the specified process steps are carried out according to their numbering.The method has the advantage that additional molds for manufacturing the sealing element can be dispensed with and, by pouring the phase change material into the sealing chamber of the contact device, a mechanical connection between the outer housing and the inner housing is additionally created by the sealing element when the phase change material cools down.

[0020] An improved method for disassembling the contact device described above can be provided by first disassembling the contact device as described above. In a second disassembly step, the sealing element is melted in the sealing chamber of the housing. The melting can take place partially, preferably completely, in the sealing chamber. In a third disassembly step, the liquid phase-change material is removed from the sealing chamber and collected. In particular, the liquid phase-change material can be poured out of the sealing chamber. In a fourth disassembly step, the contact housing is separated from the outer housing.

[0021] This design has the advantage that, by melting the phase change material, the sealing element can be collected separately and recycled from the contact housing and / or the outer housing.

[0022] The invention is explained in more detail below with the aid of figures. These show: Fig. 1 a section of an electric vehicle with a high-voltage system; Fig. 2 a perspective view of a contact facility; Fig. 3 an exploded view of the in Fig. 2 contact devices shown; Fig. 4 a perspective view of the outer casing; Fig. 5 a sectional view along a Fig. Section plane AA shown in 4 through the in Fig. 4 outer casings shown; Fig. 6 a sectional view along a Fig. Section BB shown in section 4 through the in Fig. 4 outer casings shown; Fig. 7 a perspective view of the outer casing of the in the Fig. 1 to 6 shown contact device; Fig. 8 a perspective view of the in Fig. 7 contact housing shown; Fig. 9 a sectional view along a Fig. 2 section plane CC shown through the in Fig. 2 contact devices shown; Fig. 10 a sectional view along a in Fig. 2 shown section plane DD through the in Fig. 2 contact devices shown; Fig. 11. A flowchart of a process for producing the in the Fig. 1 to 10 of the contact devices shown; and Fig. 12. A flowchart of a dismantling procedure for dismantling the components in the Fig. 1 to 10 of the contact devices shown.

[0023] For ease of understanding, the following figures refer to a coordinate system. This coordinate system has an x-axis (longitudinal direction), a y-axis (transverse direction), and a z-axis (vertical direction). The coordinate system can be right-handed.

[0024] Fig. Figure 1 shows a section of an electric vehicle 10 with a high-voltage system 15.

[0025] The high-voltage system 15 of the vehicle 10 connects at least two high-voltage components of the vehicle 10. In particular, the high-voltage system 15 can, for example, electrically connect a high-voltage battery to a vehicle drive of the vehicle 10.

[0026] The vehicle 10 has a vehicle housing 20 in which the high-voltage system 15 is sealed off from the environment of the vehicle 10 during normal operation.

[0027] The high-voltage system 15 has a first maintenance contact device 30 and a second maintenance contact device 35. In the operational state of the vehicle 10, the first maintenance contact device 30 is connected to the second maintenance contact device 35. Fig. 1 schematically indicated by dashed lines, electrically contacted, so that a current flow in the high-voltage system 15, for example between the electrical energy storage device and a drive motor, is ensured.

[0028] For maintenance work, especially on the high-voltage system 15, the vehicle housing 20 is opened and the first maintenance contact device 30 is separated from the second maintenance contact device 35, thus mechanically interrupting current transmission within the high-voltage system 15.

[0029] Fig. Figure 2 shows a perspective view of a contact facility 40.

[0030] It is pointed out that the in Fig. The contact device 40 shown in Figure 2 is an exemplary design of the contact device 40. Of course, it is also possible that the contact device 40 is designed differently.

[0031] In this embodiment, for example, the in Fig. 2 shown contact device 40 which is in Fig. 1 form the second maintenance contact device 35 shown. It would also be possible, for example, that the one in Fig. 2 shown contact device 40 which is in Fig. 1 shows the first maintenance contact device 30.

[0032] In this embodiment, the contact device 40 comprises a housing 45, a contact element arrangement 50 with at least one first contact element 55, and a sealing element 60. The contact element arrangement 50 may additionally comprise at least one second contact element 65, wherein the second contact element 65 is arranged, for example, offset in a transverse direction relative to the first contact element 55. Furthermore, the contact element arrangement 50 may, by way of example, also comprise a third contact element 70 and, for example, a fourth contact element 75, wherein, for example, the third and fourth contact elements 70 and 75 are arranged in a transverse direction between the first contact element 55 and the second contact element 65.

[0033] In this embodiment, for example, the first to fourth contact elements 55, 65, 70, 75 are designed as plug contacts. Of course, it would also be possible for the first and / or second and / or third and / or fourth contact elements 55, 65, 70, 75 to be designed as socket contacts.

[0034] In this embodiment, at least one contact section 80 of the first contact element 55 extends along a mounting axis 85, wherein the mounting axis 85 is aligned, for example, parallel to the longitudinal direction (x-axis).

[0035] The housing 45 further comprises an outer housing 90 and a contact housing 95. The outer housing 90 encloses an inner housing chamber 100 arranged inside the outer housing 90, wherein, for example, the contact housing 95, the sealing element 60, and the contact element assembly 50 are arranged in the inner housing chamber 100 of the outer housing 90. The outer housing 90 is open at a contact side 104, which is arranged on the end face of the outer housing 90. In the longitudinal direction, for example, opposite this, the outer housing 90 closes the inner housing chamber 100 at the rear.

[0036] In the configuration as a second maintenance contact device 35, for example no cables are inserted into the interior of the housing 100 and the second maintenance contact device 35 contacts the first maintenance contact device 30 and also seals the first maintenance contact device 30.

[0037] Fig. Figure 3 shows an exploded view of the in Fig. 2 shown contact device 40.

[0038] The contact device 40, in particular in its configuration as a second maintenance contact device 35, can additionally have a safety device 105, wherein the safety device 105 is arranged in the interior of the housing 100.

[0039] The safety device 105, for example, has a safety element 110. The safety element 110 can be designed, for example, as an electronic fuse or as a fusible link.

[0040] The locking device 105 is connected to the first contact element 55 and the second contact element 65 by means of a connecting element 115. The connecting element 115 connects the locking element 105 both mechanically and electrically to the first contact element 55 on one side and to the second contact element 65 on the other side. The connecting element 115 can, for example, be designed as a screw with a nut, with which the locking element 105 is mechanically and electrically connected to the first and second contact elements 55 and 65, respectively.

[0041] In this embodiment, for example, the first and second contact elements 55, 65 are spaced as far apart as possible so that sufficient installation space can be provided in the interior of the housing 100 to provide the locking device 105 for contacting the first and second contact elements 55, 65.

[0042] Fig. Figure 4 shows a perspective view of the outer casing 90.

[0043] The outer housing 90 has an inner surface 120. The inner surface 120 adjoins the housing interior 100 and radially delimits the housing interior 100 on its outer side. The outer housing 90 has a first groove 125 extending circumferentially along the inner surface 120. The first groove 125 is preferably arranged longitudinally spaced from the contact side 104. The first groove 125 can have one or more recesses 130, which are also preferably formed completely circumferentially.

[0044] Furthermore, the outer housing 90 has at least one first recess 135 extending longitudinally away from the contact side 104. The first recess 135 can extend to a rear housing surface 140 of the outer housing 90, which is located opposite the contact side 104.

[0045] The first recess 135 leads into the first groove 125. The first recess 135 can, for example, only extend circumferentially over a partial area of ​​the outer housing 90.

[0046] In this embodiment, for example, a second recess 145 is arranged on the inner side 120 of the outer housing 90, opposite the first recess 135 in the z-direction, with the second recess 145 extending longitudinally from the contact side 104 towards the rear of the housing 140. Advantageously, the second recess 145 opens into the first groove 125.

[0047] The second recess 145, like the first recess 135, can be groove-shaped, in particular as a longitudinal groove, formed on the inner side 120. Of course, it is also possible to omit the second recess 145 and / or to have the first recess 135, for example, wider in the circumferential direction.

[0048] Fig. 5 shows a sectional view along a Fig. Section plane AA shown in 4 through the in Fig. 4 shown outer casings 90.

[0049] It is clear in Fig. 5 to recognize that the first recess 135 extends from the contact side 104 towards the rear of the housing 140, but, for example, the first recess 135 ends at a distance from the rear of the housing 140.

[0050] For example, the first groove 125 and the first recess 135 can be formed with approximately the same depth on the inside 120.

[0051] Fig. Figure 6 shows a sectional view along a [unclear] in Fig. Section BB shown in section 4 through the in Fig. 4 shown outer casings 90.

[0052] In this embodiment, for example, the second recess 145 is identical to the first recess 135, so that what is described above regarding the first recess 135 also applies to the second recess 145.

[0053] Fig. Figure 7 shows a perspective view of the outer casing 90 of the in the Fig. 1 to 6 shown contact device 40.

[0054] The outer housing 90 has at least one first contact receptacle 150. The first contact receptacle 150 extends along the mounting axis 85. The first contact receptacle 150 corresponds to at least a partial area of ​​the first contact element 55, and in the assembled state of the contact device 40, the first contact element 55 is arranged in the first contact receptacle 150. The first contact element 55 can be fixed in the first contact receptacle 150 by a material-fit, a positive-fit, and / or a force-fit connection.

[0055] Additionally, the contact housing 95 can further comprise a second contact receptacle 155 and / or a third contact receptacle 160 and / or a fourth contact receptacle 165. In the transverse direction, the second contact receptacle 155 is, by way of example, arranged opposite the first contact receptacle 150 at a distance. Furthermore, the third and / or fourth contact receptacle 160, 165 can be arranged between the first contact receptacle 150 and the second contact receptacle 155.

[0056] In this embodiment, the contact receptacle 150, 155, 160, 165 is designed, for example, as a through-opening with a slot-shaped profile in the contact housing 95 and extends longitudinally, for example, completely through the contact housing 95. When the contact device 40 is assembled, the respective associated contact element 55, 65, 70, 75 is arranged in the associated contact receptacle 150, 155, 160, 165. The contact housing 95 and the respective associated contact element 55, 65, 70, 75 are designed such that the contact housing 95 seals around the circumference of the associated contact element 55, 65, 70, 75 in the contact receptacle 150, 155, 160, 165.

[0057] The contact housing 95 further comprises a circumferential side 170. The circumferential side 170 is shaped, for example, in its basic form similarly to, essentially identically to, the inner surface 120 of the outer housing 90. In this embodiment, the circumferential side 170 can, for example, be essentially elongated in the transverse direction, with each transverse end being rounded, for example, with a 180° radius. Of course, other configurations of both the circumferential side 170 and the inner surface 120 of the outer housing 90 are also possible.

[0058] In this embodiment, for example, the contact housing 95 has at least one second groove 175, wherein the second groove 175 is formed circumferentially on the peripheral side 170. In this embodiment, two second grooves 175, which are arranged longitudinally spaced apart from each other on the peripheral side 170, can also be provided.

[0059] On the rear side of the contact housing 95, facing away from contact side 104, the contact housing 95 has a first protrusion 180. The first protrusion 180 is rib-shaped and projects vertically beyond the remaining circumferential side 170. On an end face facing away from contact side 104, the first protrusion 180 has a first stop surface 185, which extends, for example, in an xy-plane. Furthermore, the first protrusion 180 has a first contact surface 190 on its outer side, the first contact surface 190 projecting vertically beyond the circumferential side 170. In this embodiment, the first protrusion 180 is formed correspondingly, particularly in the transverse direction, to the first recess 135.

[0060] In this embodiment, the first protrusion 180 is integrally formed on the contact housing 95, so that the contact housing 95 and the first protrusion 180 are formed in one piece and of a single material.

[0061] Fig. Figure 8 shows a perspective view of the in Fig. 7 shown contact housing 95.

[0062] In the vertical direction opposite the first protrusion 180, a second protrusion 195 can also be arranged on the contact housing 95, which is, for example, essentially identical to the first protrusion 180.

[0063] The second protrusion 195 can be formed corresponding to the second recess 145 of the outer housing 90. The second protrusion 195 has a second stop surface 200 on its end face facing away from the contact side 104. On its outer side, the second protrusion 195 has a second contact surface 205. Preferably, the second protrusion 195 is formed corresponding to the second recess 145 in the outer housing 90. The second contact surface 205 can be aligned parallel to the first contact surface 190, and both the first and second contact surfaces 190, 205 can extend in a yz-plane.

[0064] The first stop surface 185 and the second stop surface 200 are arranged in a common xy-plane, for example.

[0065] The circumferential side 170 of the contact housing 95 is shaped essentially corresponding to the inner side 120 and has essentially the same shape as the inner side 120.

[0066] Fig. Figure 9 shows a sectional view along a [unclear] in Fig. 2 section plane CC shown through the in Fig. 2 shown contact device 40.

[0067] For example, the first contact element 55 is arranged in the first contact receptacle 150, and the second contact element 65 is arranged in the second contact receptacle 155. The first contact element 55 is electrically connected to the second contact element 65 via the locking device 105.

[0068] The third contact element 70 and the fourth contact element 75 are, for example, electrically connected to each other via a bridge 210. In particular, the third and fourth contact elements 70, 75, and the bridge 210 can be manufactured in one piece and from a single piece of electrically conductive material, especially sheet metal. The third contact element 70 is sealed in the third contact receptacle 160, and the fourth contact element 75 is sealed in the fourth contact receptacle 165.

[0069] When the contact device 40 is assembled, the contact housing 95 is arranged in a first sub-section 215 of the housing interior 100, which adjoins the contact side 104. A second sub-section 220 of the housing interior 100 is arranged longitudinally between the rear of the housing 140 and the contact housing 95. The locking device 105 and the bridge 210 are arranged in the second sub-section 220.

[0070] The first groove 125, together with the circumferential side 170 and optionally the second groove 175, defines a sealing chamber 225. The sealing chamber 225 is filled by the sealing element 60. The first recess 135 forms a first gap 235 with the circumferential side 170 of the contact housing 95, and the second recess 145 forms a second gap 240 with the circumferential side 170 of the contact housing 95. The first gap 235 and / or the second gap 240 can open into the sealing chamber 225 or, together with the circumferential side 170, extend the sealing chamber 225 longitudinally, preferably to the contact side 104.

[0071] The sealing chamber 225 has an inner contour 230. The inner contour 230 is defined by the geometric design of the first and second recesses 135, 145, the circumferential side 170, the second groove 175 (if applicable) arranged in the circumferential side 170, and the first groove 125 arranged in the inner side 120.

[0072] Due to the cast sealing element 60, an outer contour 231 of the sealing element 60 essentially corresponds to the inner contour 230 of the sealing chamber 225 and is in substantial contact, preferably completely, with the inner contour 230 of the sealing chamber 225. The material bond can form primarily between the outer contour 231 and the inner contour 230. The sealing element 60 is arranged on the outside of the circumferential side 170, between the contact housing 95 and the outer housing 90. The sealing element 60 fluidically seals the second sub-area 220 of the housing interior 100 against the contact side 104 and the surrounding area of ​​the contact device 40.

[0073] The sealing element 60 is cast into the first groove 125 and the second groove 175. Preferably, the sealing element 60 not only forms a positive-locking connection between the outer housing 90 and the contact housing 95, but also positively connects the outer housing 90 to the contact housing 95 at the first groove 125.

[0074] In its cast state, the sealing element 60 rests not only on the second groove 175, but also on the circumferential side 170 of the contact housing 95, which connects to the first groove 125 on the inside.

[0075] The cast sealing element 60 preferably completely fills the first groove 125 and the second groove 175, in addition to the sealing chamber 225. This allows the sealing element 60 to completely seal the second sub-area 220 of the housing interior 100 fluidically against the environment. Furthermore, the sealing element 60 can also fill the first gap 235 and the second gap 240.

[0076] In this embodiment, the first to fourth contact elements 55, 65, 70, 75 are preferably designed as high-current contact elements. Each of the contact elements 55, 65, 70, 75 is configured to transmit an electric current in the range of 50 A to 1000 A inclusive, in particular 100 A to 800 A inclusive, and especially 200 A to 600 A inclusive, during normal operation of the contact device 40. The electrical voltage applied, in particular between the first contact element 55 and the third contact element 70 or between the second contact element 65 and the fourth contact element 75, can, for example, be in the range of 300 V to 1000 V inclusive.

[0077] During operation of the contact device 40, particularly as a second maintenance contact device 35, electrical power is transmitted, for example, to charge the electrical energy storage device and / or to drive a traction motor of the vehicle 10. In this process, the first to fourth contact elements 55, 65, 70, 75 can heat up. The contact elements 55, 65, 70, 75 are thermally coupled to the sealing element 60 via the contact housing 95. The sealing element 60 is designed, particularly during a power peak of electrical power to be transmitted via the contact elements 55, 65, 70, 75 and the associated heat peak, to absorb and buffer some of the heat from the contact element arrangement 50, thus providing short-term cooling of the contact element arrangement 50 and preventing thermal overload of the respective contact elements 55, 65, 70, 75 of the contact element arrangement 50.

[0078] It is particularly advantageous if the sealing element 60 comprises a phase change material. Specifically, the sealing element 60 can comprise at least one of the following phase change materials: wax, microencapsulated paraffin, paraffin, hard paraffin, microencapsulated hard paraffin, LDPE, HDPE, thermoplastic polymer, bio-based wax, lipids, fatty acid, alcohol, ethylene bis-stearamide, erucamide, stearamide, behenamide, amide, carnauba, polyethylene, synthetic molding material.

[0079] Additionally, the sealing element 60 can comprise at least one of the following filler materials: carbon, aluminum, fibers, bio-based fibers, wool fibers, flax fibers, hemp fibers, glass fiber, carbon powder, micro- and / or nano-fibrillated cellulose, shellac, natural protein fibers, jute fibers. The filler material is preferably completely embedded in the phase-change material of the sealing element. The filler stiffens the sealing element 60 and increases the positive locking force in the first and second grooves 125, 175.

[0080] The phase-change material has a first melting point. The housing 45, in particular the contact housing 95 and / or the outer housing 90, each have a second melting point and / or glass transition temperature. The second melting point and / or glass transition temperature is higher, in particular significantly higher, in particular at least 30 °C higher, than the first melting point of the phase-change material of the sealing element 60.

[0081] The sealing element 60 is thermally connected to the first contact element 55 and the subsequent contact elements 65, 70, 75 via the contact housing 95. The sealing element 60 can absorb heat from the contact elements 55, 65, 70, 75 and cool them during operation. It should be noted that in the design of the contact assembly 40, the contact elements 55, 65, 70, 75 are dimensioned such that even in the event of a fault, i.e., if the contact elements 55, 65, 70, 75 are heated far beyond normal operating temperatures, the sealing element 60 does not melt and remains in a solid state.

[0082] It should be noted that, of course, the outer housing 90 and the contact housing 95 can each have a different housing material; however, it is advantageous if the outer housing 90 and the contact housing 95 each have the same housing material. Should the contact housing 95 and the outer housing 90 have different housing materials, the housing material of the respective contact housing 95 and the outer housing 90 is selected such that the aforementioned condition, namely that the second melting point of the housing material and / or the glass transition temperature of the respective housing material is at least 30 °C higher than the first melting point of the phase change material, is met.

[0083] Fig. Figure 10 shows a sectional view along a [unclear] in Fig. 2 shown section plane DD through the in Fig. 2 shown contact device 40.

[0084] It is clear in Fig. It can be seen that the sealing element 60 not only fills the groove 125, 175, but also the first recess 135 and the second recess 145. In particular, the sealing element 60 fills the groove 125, 175 and the recess 135, 145 to at least 90%, and in particular to at least 95%, of the volume of the groove 125, 175 and the recess 135, 145. A sealing element end face 226 can be arranged substantially at the level of the contact face 104.

[0085] In Fig. On the underside, and thus on one of the sides facing the rear of the housing 140, the first recess 135 is closed by the first protrusion 180. The first contact surface 190 rests against the outside of the first recess 135. The position along the mounting axis 85, and thus in the longitudinal direction, is determined by the first stop surface 185 bearing against a base of the first recess 135.

[0086] In the vertical direction opposite, on the side facing the rear of the housing 140, the second recess 145 is closed by the second protrusion 195, and further movement of the contact housing 95 relative to the outer housing 90 is blocked by the second stop surface 200 abutting the bottom of the second recess 145. In the vertical direction, the second contact surface 205 rests against the inside of the second recess 145.

[0087] Fig. Figure 11 shows a flowchart of a process for producing the [item] in the Fig. 1 to 10 of the contact devices shown 40.

[0088] In a first process step 305, the components of the contact device 40, with the exception of the sealing element 60, are provided. For example, the provided outer housing 90 and / or the provided contact housing 95 may be injection-molded. Furthermore, the respective contact elements 55, 65, 70, 75 may already be arranged in the respective contact receptacles 150, 155, 160, 165 of the provided contact housing 95. The locking device 105 may also already be mounted on the first and second contact elements 55, 65.

[0089] In a second process step 310, which follows the first process step 305, the contact housing 95 is inserted into the first sub-area 215 of the housing interior 100 of the outer housing 90 along the mounting axis 85 until the first stop surface 185 abuts the bottom of the first recess 135 and the second stop surface 200 abuts the bottom of the second recess 145. This forms the sealing chamber 225 between the outer housing 90 and the contact housing 95 in the area of ​​the first and second grooves 125, 175 and the first and second recesses 135, 145, in conjunction with the respective associated inner surface 120 and the circumferential side 170.

[0090] In a third process step 315, which is carried out in parallel to or after the second process step 310, the phase change material is heated to a temperature above its first melting point, so that the phase change material transitions from a solid to a liquid phase state. Additionally, the filler can already be incorporated into the phase change material and heated along with it.

[0091] In a fourth process step 320 following the third process step 315, the contact device 40 is preferably oriented such that the contact side 104 is located on the upper side and above the rear of the housing 140. Furthermore, in the fourth process step 320, the liquid phase change material, preferably containing the filler material, is introduced, particularly poured, from the contact side 104 via the first recess 135 and / or the second recess 145. The liquid phase change material fills the sealing chamber 225, so that the sealing chamber 225 acts as a mold for the sealing element 60 to be produced. During the pouring of the phase change material, the filler material is also introduced into the sealing chamber 225 along with the liquid phase change material and distributed within the sealing chamber 225.

[0092] Preferably, sufficient phase change material, preferably with filler material, is cast into the sealing chamber 225 such that a casting surface is arranged substantially at the level of the contact side 104. This ensures that a sufficient amount of phase change material is arranged in the sealing chamber 225.

[0093] In a fifth process step 325 following the fourth process step 320, the liquid phase change material is cooled below its first melting point, causing it to solidify and form the sealing element 60 in the sealing chamber 225. As the phase change material poured into the sealing chamber 225 solidifies, the sealing element 60 assumes a geometric shape that essentially corresponds to the inner contour 230 of the sealing chamber 225. During solidification, the phase change material can cross-link.

[0094] The cooling of the phase change material can occur passively or by forced cooling. Furthermore, a certain amount of shrinkage of the phase change material of the sealing element 60 can occur during solidification, so that the sealing element face 226 (cf. Fig. 10) moves towards the rear of the housing 140 and is arranged only essentially at the level of the contact side 104, but possibly with a small distance in the longitudinal direction.

[0095] During the solidification of the phase change material of the sealing element 60, the phase change material can form a material-bonded connection to the housing material of the outer housing 90 and / or the contact housing 95, so that in addition to the positive locking, the sealing element 60 is also materially bonded to the outer housing 90 and / or the contact housing 95.

[0096] The material-fit connection between the contact housing 95 and the outer housing 90 via the sealing element 60 has the advantage that further mechanical connecting means for the mechanical connection of the contact housing 95 to the outer housing 90 can be dispensed with, so that the contact device 40 is designed to be particularly simple and robust. The sealing element 60 thus not only performs the function of sealing the second sub-area 220 of the housing interior 100 from the environment of the contact device 40, but the sealing element 60 also secures the contact housing 95 in the housing interior 100 of the outer housing 90 by means of a positive fit, and in particular by material fit.

[0097] This allows the outer housing 90 and / or the contact housing 95 to be manufactured with a particularly simple geometric design, making both the molds used for manufacturing the outer housing 90 and / or the contact housing 95, especially injection molds, particularly easy to produce, and facilitating the removal of the outer housing 90 and / or contact housing 95 produced by the molds from the respective mold. In particular, this eliminates the need for detent devices, such as detent springs and / or corresponding recesses, in the outer housing 90 and / or the contact housing 95.

[0098] It is pointed out that in the assembled state of the contact device 40, in particular in the assembled state of the contact device 40 as the second maintenance contact device 35 on the first maintenance contact device 30, the sealing element 60 serves primarily to seal the second sub-area 220 by means of the sealing element 60.

[0099] Due to the different material used for the first sealing element compared to conventional materials, the sealing element 60 is essentially spaced apart from the contact side 104 by the design of the first and second recesses 135, 145 and, in addition to the sealing on the first maintenance contact device 30, a further sealing element (not shown in the figures) can usually be arranged to seal the contact sections of the contact elements 55, 65, 70, 75 in the contacting.

[0100] To the in the Fig. To dismantle the contact device 40 shown in Figures 1 to 10, in particular to dismantle it in a recycling process, the dismantling procedure described below is used.

[0101] Fig. Figure 12 shows a flowchart of a dismantling procedure for dismantling the components in the Fig. 1 to 10 of the contact devices shown 40.

[0102] In a first disassembly step 405, the part in the Fig. 1 to 10 shown contact device 40 in detached and separated state from the first maintenance contact device 30 provided.

[0103] In a second disassembly step 410, the sealing element 60 in the sealing chamber 225 of the housing 45 is heated to such an extent that the temperature of the phase change material is above the first melting point and the phase change material melts.

[0104] To melt the sealing element 60, heat can be introduced into the sealing element 60 from the contact side 104 via the first and / or second recess 135, 145. For this purpose, a nozzle can be placed on the contact side 104, the nozzle being essentially corresponding to the first and second recess 135, 145, and a hot air stream can be directed towards the sealing element end face 226, melting the sealing element 60 from the sealing element end face 226.

[0105] Alternatively, it is also possible that, for example, heat in the form of electromagnetic radiation, in particular thermal radiation, for example laser radiation, is introduced into the sealing element 60 from the sealing element face 226 via the first recess 135 and / or second recess 145 and that the phase change material of the sealing element 60 is melted with the heat introduced into the sealing element 60.

[0106] It is advantageous if, during the melting of the sealing element 60, the contact device 40 is aligned such that the contact side 104 is arranged above the rear of the housing 140 and, in particular, the contact side 104 is oriented upwards and the rear of the housing 140 downwards.

[0107] In a third disassembly step 415 following the second disassembly step 410, which is preferably carried out when the phase change material is completely heated and melted, the contact device 40 is rotated, for example above a collection container, by, for example, 180° so that the contact side 104 is arranged below the rear of the housing 140 and the melted phase change material, preferably with the filler embedded in the phase change material, flows out of the sealing chamber 225 via the first recess 135 and / or the second recess 145 on the contact side 104.

[0108] Once the molten sealing element 60 has been substantially completely poured out of the sealing chamber 225, the contact housing 95 can be easily pulled out of the first section 215 along the mounting axis 85 from the housing interior 100 and separated from the outer housing 90. Along with the contact housing 95, the locking device 105 and the contact elements 55, 65, 70, 75 arranged on the contact housing 95 can also be removed from the housing interior 100.

[0109] The disassembled components of the contact device 40 can each be fed into a separate recycling process in a further fourth disassembly step 420. In particular, the contact elements 55, 65, 70, 75 and the safety device 105 can be separated from the contact housing 95.

[0110] Alternatively, it is also possible that, after disassembling the contact device 40, for example a melted fuse element 110 of the fuse device 105 is replaced and then the second to fifth process steps 310 to 325 are carried out to reassemble the contact device 40.

[0111] The above-described design of the contact device 40 has the advantage that the circumferential first and second grooves 125, 175 create an undercut with which the sealing element 60 can mechanically fix the contact housing 95 in the outer housing 90. Furthermore, by casting the phase-change material through the first and second recesses 135, 145, it can be ensured that the second sub-area 220 of the housing interior 100 is fluid-tightly sealed off from the contact side 104.

[0112] The protrusions 180, 195 further ensure that, in particular, the recess 135, 145 is wide enough to allow the liquid phase change material to be poured in together with any fillers embedded in the phase change material, without the fillers clogging the recess 135, 145 and thereby unintentionally introducing too little phase change material into the sealing chamber 225.

[0113] Furthermore, the protrusion 180, 195 also ensures that sufficient heat can be partially introduced into the sealing element 60 for the disassembly of the contact device 40 in order to completely melt the phase change material of the sealing element 60.

[0114] Additionally, when the contact housing 95 is inserted with the first and second protrusions 180, 195 into their respective recesses 135, 145, the protrusions 180, 195 are slightly pivoted inwards and tensioned, so that the protrusions 180, 195 form a kind of beam spring and, in the pre-assembled state (in the second process step 310), the contact housing 95 is reliably positioned relative to the outer housing 90. Furthermore, this prevents the contact housing 95 from unintentionally slipping out of the housing interior 100.

[0115] It should be noted that of course further locking mechanisms or other mechanical means may be provided to mechanically connect the contact housing 95 to the outer housing 90.

[0116] Furthermore, the embodiment shown in the figures has the advantage that by using the phase change material as the basis for the sealing element 60, plasticizer hardening, which often occurs with conventional plastic sealing elements, can be avoided, and thus a reliable seal of the second sub-area 220 of the housing interior 100 is ensured over the lifetime of the contact device 40.

[0117] Furthermore, in a total emergency, it is possible that the sealing element 60 will be heated to such an extent by the electrical energy transmitted via the contact device 40 that it will melt and thereby briefly cool the contact elements 55, 65, 70, 75. Reference symbol list 10 vehicles 15 High-voltage system 20 vehicle bodies 30 first maintenance contact device 35 second maintenance contact device 40 Contact device 45 cases 50 Contact element arrangement 55 first contact element 60 sealing element 65 second contact element 70 third contact element 75 fourth contact element 80 Contact section 85 Mounting axis 90 Outdoor housings 95 contact housings 100 Housing interior 104 Contact page 105 Safety device 110 safety element 115 Fasteners 120 inside 125 first groove 130 In-depth study 135 first recess 140 Rear of case 145 second recess 150 first contact 155 second contact 160 third contact 165 fourth contact 170 perimeter page 175 second groove 180 first protrusion 185 first stop surface 190 first planting area 195 second protrusion 200 second stop surface 205 second planting area 210 Bridge 215 first sub-area 220 second sub-area 225 sealing chamber 226 Sealing element face 230 inner contour 231 Outer contour 235 first gap 240 second gap 305 first procedural step 310 second procedural step 315 third procedural step 320 fourth process step 325 fifth procedural step 405 First disassembly step 410 second disassembly step 415 third disassembly step 420 fourth disassembly step

Claims

[1] Contact device (40), in particular a second maintenance contact device (35), for a high-voltage system (15) of an electric vehicle (10), - wherein the contact device (40) comprises a housing (45), a first contact element (55) and a sealing element (60), - wherein the housing (45) comprises a contact housing (95) and an outer housing (90) with a housing interior (100), - wherein the contact housing (95) is arranged in a first partial area (215) of the housing interior (100) and has a first contact receptacle (150) in which the first contact element (55) is arranged at least section by section, - wherein a sealing chamber (225) is arranged in the interior of the housing (100) between the contact housing (95) and the outer housing (90), - wherein the sealing element (60) is arranged in the sealing chamber (225), which fluidically seals a second sub-area (220) of the housing interior (100), - wherein the sealing element (60) comprises a phase change material, - wherein the sealing element (60) is in a fixed phase state in a normal state of the contact device (40) and mechanically connects the outer housing (90) to the contact housing (95), characterized by , that - the housing (45) has a contact side (104) arranged on the front face, on which the first contact element (55) can be contacted, - wherein the sealing chamber (225) is formed completely around the contact housing (95) on its circumference, - wherein a gap (235, 240) is arranged between the outer housing (90) and the contact housing (95), - wherein the gap (235, 240) extends between the contact side (104) and the sealing chamber (225) and fluidically connects the sealing chamber (225) to the contact side (104). [2] Contact device (40) according to claim 1, - wherein the contact device (40) comprises an electrical safety device (105) and a second contact element (65), - wherein the contact housing (95) has a second contact receptacle (155), - wherein the second contact element (65) is arranged at least section by section in the second contact point (155), - wherein the outer casing (90) closes the casing interior (100) on one side opposite the contact side (104), - wherein the safety device (105) is arranged in the second sub-area (220) of the housing interior (100), - wherein the safety device (105) electrically connects the first contact element (55) to the second contact element (65). [3] Contact device (40) according to any of the preceding claims, - wherein the sealing element (60) is thermally connected to the first contact element (55), - wherein the first contact element (55) is designed to heat up when an electrical power peak is transmitted, particularly in a fault condition different from normal operation, - wherein in the event of a fault the sealing element (60) is designed to remain in the solid phase state. [4] Contact device (40) according to any of the preceding claims, - wherein the sealing element (60) comprises at least one of the following phase change materials: wax, microencapsulated paraffin, paraffin, hard paraffin, microencapsulated hard paraffin, LDPE, HDPE, thermoplastic polymer, bio-based wax, lipids, fatty acid, alcohol, ethylene bis-stearamide, erucamide, stearamide, behenamide, amide, carnauba, polyethylene. [5] Contact device (40) according to claim 4, - wherein the sealing element (60) comprises at least one of the following filling materials: Carbon, aluminum, fibers, bio-based fibers, wool fibers, flax fibers, hemp fibers, glass fiber, carbon powder, micro- and / or nano-fibrillated cellulose, shellac, natural protein fibers, jute fibers, - wherein the filling material is embedded in the phase change material of the sealing element (60). [6] Contact device (40) according to any of the preceding claims, - wherein the first contact element (55) is configured to transmit an electric current in a range from 50 A inclusive to 1000 A inclusive, in particular from 100 A inclusive to 800 A inclusive, in particular from 200 A inclusive to 600 A inclusive, during normal operation, - where the electrical voltage is in a range from 300 V inclusive to 1000 V inclusive. [7] Contact device (40) according to any of the preceding claims, - where the phase change material has a first melting point, - wherein the housing (45) has a housing material with a second melting point and / or glass transition temperature, - wherein the second melting point and / or the glass transition temperature is greater, in particular by at least 30 °C greater, than the first melting point of the phase change material of the sealing element (60). [8] Contact device (40) according to any of the preceding claims, - wherein the sealing element (60) has a circumferentially arranged outer contour (231), - wherein the outer contour (231) rests against an inner contour (230) of the sealing chamber (225), - wherein preferably the outer contour (231) is materially bonded to the inner contour (230) of the sealing chamber (225). [9] Contact device (40) according to any of the preceding claims, - wherein the sealing element (60) is formed in the sealing chamber (225) by casting, in particular by injection molding. [10] Method for manufacturing a contact device (40) according to any one of the preceding claims, - wherein in a first process step (305) the housing (45) with the contact housing (95) and outer housing (90) is provided, - wherein in a second process step (310) the contact housing (95) is inserted into a first sub-area (215) of the housing interior (100) to form the sealing chamber (225), - wherein in a third process step (315) the phase change material of the sealing element (60) is melted, - wherein in a fourth process step (320) the molten phase change material is introduced into the sealing chamber (225), - wherein in a fifth process step (325) the phase change material is cooled and solidifies to form the sealing element (60). [11] Method for disassembling a contact device (40) according to any one of claims 1 to 9, - wherein in a first disassembly step (405) a contact device (40) according to one of claims 1 to 9 is provided, - wherein in a second disassembly step (410) the sealing element (60) is melted in the sealing chamber (225) of the housing (45), - wherein in a third disassembly step (415) the liquid phase change material is removed from the sealing chamber (225) and collected, - wherein in a fourth disassembly step (420) the contact housing (95) is separated from the outer housing (90).

Images