Plug-in connector element and plug-in connector for high-voltage applications

Abstract

The invention relates to a plug-in connector element for high voltage (HV) applications and to a related plug-in connector. A plug-in connector element (102) for removably electrically contacting a mating plug-in connector element (104) comprises at least one electrically conductive contact element (134), a housing (136) and a contact protection element (116). The contact protection element (116) is arranged such that, between the housing (136) and the contact protection element (116), access to the electrically conductive contact element (134) is prevented for objects having a diameter greater than a defined value. The plug-in connector element (102) has at least one temperature sensor (112) which is at least partially accommodated within the contact protection element (116) and which is operable to detect a temperature of the electrically conductive contact element (134).

Description

Technical Field

[0001] This invention relates to insert connector elements and related insert connectors for high voltage (HV) applications. Background Technology

[0002] In electric vehicles, propulsion and charging of HV batteries require HV plug-in connectors with large conductive cross-sections. Temperature sensors are used in HV systems to reduce charging time. Temperature sensors are also increasingly needed in HV plug-in connectors. The more accurate the temperature measurement in the plug-in connector, the better the HV system can regulate charging parameters, thereby reducing charging time. In conventional HV plug-in connectors, it is difficult to position the temperature sensor near the contact point (hereinafter referred to as a "hot spot"). Typically, the only options are to mount the temperature measurement sensor in the crimp area or on the current guide rail (away from the hot spot).

[0003] Figures 14 to 16 A known HV plug connector arrangement is shown. Figure 14 A schematic cross-sectional view of a plug-in connector 200 in an inserted state is shown. The plug-in connector 200 includes a plug-in connector element 202 and a mating plug-in connector element 204. As shown, the plug-in connector element 202 is a receptacle element with a conductive spring-loaded contact element 210, while the mating plug-in connector element 204 is a plug-in element with a conductive blade contact 206.

[0004] Figure 15 The insertion connector element 202 is shown in perspective. Figure 16 The mating insert connector element 204 is shown in perspective. Additionally, Figure 15 and 16 The function of contact protection in the two connecting elements 202 and 204 is shown, wherein test probes 214 (referred to as test fingers) that are not allowed to contact conductive parts are schematically shown.

[0005] Electrical contact between insert connector element 202 and mating insert connector element 204 occurs in contact region 208, where a conductive spring-loaded contact element 210 presses against the blade contact 206. To monitor the temperature of contact region 208, temperature sensors 212A and 212B should be mounted as close as possible to contact region 208. However, in the known arrangement shown, due to space constraints, this is only possible in the connection region of the blade contact 206 (temperature sensor 212A) and / or in the crimping region of the socket element (temperature sensor 212B). However, for this reason, the distance to the actual area where potential temperature rise occurs is too large to react quickly enough to overheating. As a result, for example, the battery must be charged for a longer time with a lower charging current.

[0006] Therefore, there is a need for a plug-in connector element that overcomes the shortcomings of known solutions, making the closed plug-in connection safe and reliable in operation, while still being inexpensive to manufacture. Summary of the Invention

[0007] This objective is achieved through the subject matter of the independent claims. Advantageous embodiments of the invention are the subject matter of the dependent claims.

[0008] This invention is based on the idea of ​​embedding at least one temperature sensor in an HV plug-in connector, rather than in a housing element, or placing it on the surface of the contact protection element. In this way, the temperature sensor can be directly positioned in the electrical contact area between the plug-in connector element and the mating plug-in connector element, and is thermally connected to the area where potential overheating occurs at the shortest possible distance.

[0009] Specifically, the plug-in connector element for detachably electrically mating plug-in connector elements includes at least one conductive contact element, a housing, and a contact protection element configured such that objects with a diameter greater than a predetermined value are prevented from approaching the conductive contact element between the housing and the contact protection element. To measure the temperature of the conductive contact element, at least one temperature sensor, at least partially housed within the contact protection element, can be operated.

[0010] The advantage of this arrangement is that the temperature sensor can be positioned flexibly and independently of installation space, even near hot spots. Regarding the contact layout, the sensor is positioned optimally within the contact protection element. Depending on the installation location, the necessary contact pressure on the measuring surface is generated by the insertion process or when assembling the contact protection. The sensor's connecting wires can also be reliably mounted within the contact protection element and led out. This solution makes temperature measurement in HV plug-in connectors more accurate and flexible.

[0011] It is important to note that, of course, not only single temperature sensors but also a large number of temperature sensors can be arranged in and / or at contact protection elements. Furthermore, temperature sensors with more than one sensitive area can also be deployed.

[0012] In order to monitor temperature in real time as much as possible, according to an advantageous embodiment, at least one temperature sensor is arranged such that it measures the temperature of the conductive contact element in the contact area, in which the conductive contact element can make electrical contact through conductive mating contact elements that mate with plug-in connector elements.

[0013] Advantageously, the housing has a generally cylindrical inner surface on which conductive contact elements are disposed, wherein the conductive contact elements at least partially surround the contact protection element. This allows for a particularly compact structure.

[0014] Here, the contact protection element can have a columnar structure, and the temperature sensor is arranged on the outer wall of the contact protection element. Then, the temperature sensor makes a particularly tight thermally conductive contact with the contact area, in which the conductive contact element can make electrical contact through the conductive mating contact element of the plug-in connector element, and the response time to temperature rise can be particularly short.

[0015] Alternatively or additionally, it may be specified that the contact protection element has a columnar structure and the temperature sensor is arranged inside the contact protection element. Here, the temperature sensor is particularly well protected against mechanical stress during insertion.

[0016] According to another advantageous embodiment of the invention, the conductive contact element comprises a cylindrical body and a spring element (also referred to as a spring contact) for spring-loaded contact with the conductive mating contact element. Therefore, when the insert connector is connected to the mating insert connector, the necessary contact pressure between the electrical contact elements and with the temperature sensor can be generated in a simple manner.

[0017] Spring elements can, in particular, have a basic annular shape and a large number of bidirectionally fastened flexible tongues that bend radially inward at their center to contact conductive mating contact elements. This ensures uniform and firm contact pressure, guaranteeing reliable electrical and mechanical contact even in the presence of vibration and over a wide temperature range.

[0018] To provide special protection for the connection wires, it may be stipulated that the electrical connection wire of at least one temperature sensor passes through the contact protection element.

[0019] According to an advantageous further improvement of the invention, the contact protection element is implemented as an electrically insulating composite component pressed into the conductive contact element. Thus, the temperature sensor can be directly overmolded, for example, so that its housing simultaneously forms the contact protection element. This reduces manufacturing costs and ensures a compact structure.

[0020] The present invention also relates to a plug connector having a plug connector element according to the invention and an associated mating plug connector element.

[0021] According to an exemplary embodiment, the mating plug-in connector element has a conductive mating contact element with a cylindrical contact area, wherein, in the inserted state of the plug-in connector, the contact area of ​​the conductive mating contact element surrounds a contact protection element. When the connector element is inserted, this concentric structure offers the advantages of a particularly compact structure and symmetrical force distribution.

[0022] To achieve particularly good heat transfer and therefore a short response time, it can be specified that at least one temperature sensor is pressed into the conductive mating contact element in the inserted state of the plug connector.

[0023] To ensure that both connector elements meet the contact safety requirements of HV components, the mating insert connector element may also have a second housing and a contact protection cover. The contact protection cover is positioned between the second housing and the cover to prevent access to the conductive mating contact element by objects with a diameter larger than a specified value. For example, the contact protection cover is formed of a generally annular electrically insulating composite component disposed on the front end region of the conductive mating contact element. Such a composite component can be manufactured cost-effectively and can be clamped or injection molded onto the metal contact element.

[0024] The advantageous features of the plug-in connector of the present invention are particularly effective when the plug-in connector is implemented as a high-voltage plug-in connector for electric vehicles. Attached Figure Description

[0025] To better understand the present invention, it will be described in more detail with reference to the embodiments shown in the following figures. Here, the same parts are given the same reference numerals and the same component symbols. Furthermore, some features or combinations of features from the various illustrated and described embodiments may represent individual, innovative, or inventive solutions. The figures show:

[0026] Figure 1 This is a schematic perspective view of a contact protection element according to one aspect of the present invention;

[0027] Figure 2 It has Figure 1 A schematic perspective view of a plug-in connector element with contact protection components;

[0028] Figure 3 yes Figure 2 A schematic cross-sectional view of a plug-in connector element;

[0029] Figure 4 It has Figure 2 A schematic perspective view of the insert connector element before insertion;

[0030] Figure 5 yes Figure 4 A schematic cross-sectional view of a plug-in connector;

[0031] Figure 6 yes Figure 5 Details;

[0032] Figure 7-10 These are cross-sectional views of various examples of plug connectors with different contact protection elements;

[0033] Figure 11 It has Figure 2 A schematic perspective view of the insert connector element after insertion;

[0034] Figure 12 yes Figure 2 A schematic perspective view of a plug-in connector used to illustrate the contact protection function;

[0035] Figure 13 yes Figure 4 A schematic perspective view of the mating insert connector, used to illustrate the contact protection function;

[0036] Figure 14 This is a schematic cross-sectional view of a known HV plug connector;

[0037] Figure 15 yes Figure 14 A schematic perspective view of the plug-in connector element;

[0038] Figure 16 yes Figure 14 A schematic perspective view of the mating insert connector element. Detailed Implementation

[0039] In the following text, reference is made to the accompanying drawings, and especially to the references to... Figure 1 The perspective views illustrate the invention in more detail. Note that dimensional relationships, particularly layer thickness relationships, are not necessarily reproduced to scale in all the figures.

[0040] Figure 1 The contact protection element 116, for a high-voltage (HV) circular plug (e.g., 12 mm in diameter), is shown in a schematic perspective view. Of course, according to the principles of the invention, the geometry of other plug-in connectors can also be designed to have temperature detection.

[0041] According to one aspect of the invention, the contact protection element 116 has an electrically insulating body 118 having an elongated columnar shape in the assembled state. For example, the body 118 may be made of a synthetic material.

[0042] According to the present invention, the temperature sensor 112 is embedded in the body 118 of the contact protection element 116. The temperature sensor 112 may be, for example, an NTC thermistor, a thermocouple, a resistance temperature sensor (e.g., Pt), or any other suitable temperature sensor.

[0043] NTC stands for "Negative Temperature Coefficient". An NTC thermistor is a temperature sensor that utilizes the resistive properties of ceramic-metal composite materials for temperature measurement. NTC sensors offer many advantages in temperature measurement, such as small size, good stability, and high accuracy and precision.

[0044] A thermocouple sensor consists of two unequal metals connected at one end. Temperature is measured at this junction. The voltage generated by the two metals is very small and can be measured and evaluated by a control system. The unequal metals are individually insulated and held together by a sheath to maintain a tight biwire construction. The advantages of thermocouple sensors include a wide operating temperature range, constant sensitivity throughout the temperature range, and a suitable small size.

[0045] A resistance sensor (called an RTD (resistance temperature detector)) is a sensor used for temperature measurement because resistance changes proportionally with temperature. RTD temperature sensors can be used even in harsh or hazardous environments with various official permits.

[0046] The temperature sensor 112 has a sensitive area 120 for performing actual temperature detection and an electrical connection line 122 that connects the temperature sensor 112 to the necessary power supply and the acquisition of the measured signal (not shown).

[0047] According to one aspect of the invention, the connecting wire 122 passes through the body 118 and exits the body 118 at the base region 124. Thus, the temperature sensor 112 and the connecting wire 122 are optimally protected from mechanical stress.

[0048] From the following Figure 3 As can be clearly seen, the contact protection element 116 has a radially circumferential latching lug 126 at the base region 124, which engages with an associated latching groove 128 for securing the contact protection element 116 in the insert connector element. The flange 130 serves for sealing and mechanical support of the contact protection element 116 in the assembled state.

[0049] Advantageously, this contact protection element 116, which is fitted with the temperature sensor 112, can be manufactured as a separate component, for example, by overmolding the temperature sensor 112, and is ready for final assembly. This greatly simplifies the installation of the temperature sensor in the plug-in connector.

[0050] Figure 2The HV plug-in connector element 102 mounted on the current rail 132 is shown in perspective view. Figure 3 As can be clearly seen from the summary of the cross-sectional view, the contact protection element 116 is arranged inside the conductive receptacle contact 134, making it impossible for an object with a diameter larger than the defined test probe to approach the conductive part from the outside. The insertion connector element 102 includes an electrically insulating housing 136 that radially covers the receptacle contact 134 around and on the front side in the insertion region.

[0051] The receptacle contact 134 includes a conductive contact body 138 that establishes an electrical connection with the current rail 132. This is for electrical contact mating with a plug-in connector (see [link]). Figure 5 and 6 The socket contact 134 includes a spring contact 140. The spring contact 140 includes a plurality of bidirectionally fastened, radially inwardly bent flexible tongues 142 that apply contact pressure to the contact elements of the mating insert connector. The inwardly bent regions of the flexible tongues 142 form the actual electrical contact area 144 in the inserted state of the insert connector, where undesirable heat accumulation first occurs.

[0052] In order to quickly detect overheating, according to a first advantageous aspect of the invention, the temperature sensor 112 is arranged such that its sensitive area 120 is adjacent to the contact area 144.

[0053] Figures 4 to 6 It is explained that the insert connector element 102 is inserted together with the mating insert connector element 104 to form the insertion state of the insert connector 100.

[0054] According to the embodiment shown, the mating plug-in connector element 104 includes a hollow cylindrical conductive mating contact element 146 that, when plugged together along direction 148, surrounds the contact protection element 116 and simultaneously makes external electrical contact with it via a spring contact 140.

[0055] For electrical insulation, the mating plug connector 104 has an electrically insulating second housing 152 and an electrically insulating contact protection cover 154. The contact protection cover 154 is formed such that, between the second housing and the contact protection cover, it prevents access to the conductive mating contact element 146 by objects with a diameter greater than a predetermined value.

[0056] If the temperature sensor 112 is specified to protrude slightly from the smooth outer surface of the contact protection element 116 at least in the sensitive area 120, the temperature sensor is pressed against the inner surface of the conductive mating contact element 146 in the inserted state. This ensures a particularly tight thermal contact, and the temperature sensor 112 can respond particularly quickly and reliably to overheating in the critical area 150 indicated by the dashed line.

[0057] Figures 7 to 10 This demonstrates how to modify the temperature detection function of an otherwise unmodified plug connector 100 by using different variations of the contact protection element 116.

[0058] For comparison, Figure 7 References were shown again. Figures 1 to 6 The arrangement is explained.

[0059] like Figure 8 As shown, the temperature sensor can also be arranged closer to the base region 124 of the contact protection element 116 in order to monitor the temperature near the current rail.

[0060] In addition, it can be specified that the temperature sensor passes through the contact protection element 116 in the center, so that symmetrical temperature detection can be achieved on the one hand, and the temperature sensor can be mechanically protected on the other hand.

[0061] Finally, each of the shown contact protection elements 116 (preferably as follows) Figure 8 (As shown) It can also be used simply without the temperature sensor 112. Figure 10 This variant is shown in the figure.

[0062] By using more than one temperature sensor 112 or a sensor having more than one sensitive area 120, Figures 7 to 9 All the variations shown can also be combined with each other.

[0063] Figure 11 The insert connector 100 of the present invention in the inserted state is shown again in perspective view.

[0064] exist Figure 12 The figure illustrates the contact protection function of the plug-in connector element 102. As shown, the test probe 114 cannot penetrate the free space between the contact protection element 116 and the housing 136, nor can it penetrate the contact conductive parts, i.e., the socket contact 134.

[0065] Similarly, as Figure 13 As shown, the interaction between the second housing 152 and the contact protection cover 154 prevents the test probe 114 (and therefore all objects with a diameter larger than the test probe) from contacting the conductive mating contact element 146.

[0066] In summary, according to an exemplary aspect of the invention, a novel arrangement of the contact components, such as a 12mm circular contact with finger protection, allows for flexible and space-independent positioning of the temperature sensor, even near hot spots. Regarding the contact layout, the sensor is positioned optimally within the contact protection element. Depending on the mounting location, the necessary contact pressure on the measuring surface is generated by the insertion process or when assembling the contact protection. The sensor's connecting wires can also be reliably mounted within and led out from the contact protection element. This solution makes temperature measurement in HV plug-in connectors more accurate and flexible.

[0067] It should also be noted that although the above description always uses a circular contact as an example, other contact cross-sections and multiple contacts can of course be designed according to the principles of the present invention.

[0068] List of reference numerals

[0069] 100, 200 plug connectors

[0070] 102, 202 Insert-type connector elements

[0071] 104 and 204 mating insert connector elements

[0072] 206 blade contact

[0073] Contact areas of 108 and 208

[0074] 110, 210 spring-loaded contact elements

[0075] 112, 212A, 212B temperature sensors

[0076] 114, 214 test probes

[0077] 116 Contact Protection Components

[0078] 118 main body of contact protection element

[0079] 120 Sensitive Areas

[0080] 122 connecting cable

[0081] 124 base area

[0082] 126 latch lugs

[0083] 128 latch grooves

[0084] 130 flange

[0085] 132 current rails

[0086] 134 socket contacts; contact elements

[0087] 136 (First) Shell

[0088] 138 Contact Subject

[0089] 140 spring contact

[0090] 142 Flexible tongue

[0091] 144 contact area

[0092] 146 mating contact element

[0093] 148 Insertion Direction

[0094] 150 key areas

[0095] 152 mating insert connector housing; second housing

[0096] 154 Contact Protective Cover

Claims

1. A plug-in connector element for detachably electrically mating with a plug-in connector element (104), wherein, The insert connector element (102) includes: At least one conductive contact element (134) includes a cylindrical body (138) and a spring contact (140), the spring contact being disposed on the inner surface of the cylindrical body (138). Shell (136). A contact protection element (116), which is surrounded by the cylindrical body (138), is configured such that, between the housing (136) and the contact protection element (116), it prevents access to the conductive contact element (134) for objects with a diameter greater than a predetermined value. At least one temperature sensor (112) is at least partially housed within a contact protection element (116) and is operable to measure the temperature of a conductive contact element (134), the temperature sensor (112) being surrounded by the spring contact (140).

2. The insertion connector element according to claim 1, wherein, The at least one temperature sensor (112) is arranged such that it detects the temperature of the conductive contact element (134) in the contact area (144), in which the conductive contact element (134) can make electrical contact through the conductive mating contact element (146) of the mating insert connector element (104).

3. The insertion connector element according to claim 1 or 2, wherein, The housing (136) has a generally cylindrical inner surface on which the conductive contact element (134) is disposed, and wherein the conductive contact element (134) at least partially surrounds the contact protection element (116).

4. The insertion connector element according to claim 1 or 2, wherein, The contact protection element (116) has a columnar structure, and the temperature sensor (112) is arranged on the outer wall of the contact protection element (116).

5. The insertion connector element according to claim 1 or 2, wherein, The contact protection element (116) has a columnar structure, and the temperature sensor (112) is arranged inside the contact protection element (116).

6. The insertion connector element according to claim 1, wherein, The spring contact (140) has a basic annular shape and includes a large number of bidirectional fastening flexible tongues (142) that are radially inwardly bent at their center to contact the conductive mating contact element (146) of the mating insert connector element (104).

7. The insertion connector element according to claim 1 or 2, wherein, The electrical connection wire (122) of the at least one temperature sensor (112) passes through the contact protection element (116).

8. The insertion connector element according to claim 1 or 2, wherein, The contact protection element (116) is implemented as an electrically insulating composite component pressed into the conductive contact element (134).

9. A plug-in connector comprising a plug-in connector element (102) according to any one of the preceding claims and an associated mating plug-in connector element (104).

10. The insertion connector according to claim 9, wherein, The mating plug-in connector element (104) has a conductive mating contact element (146) with a cylindrical contact area, wherein, in the inserted state of the plug-in connector (100), the contact area of ​​the conductive mating contact element (146) surrounds the contact protection element (116).

11. The insertion connector according to claim 9 or 10, wherein, When the insert connector (100) is inserted, at least one temperature sensor (112) is pressed into the conductive mating contact element (146) of the mating insert connector element (104).

12. The plug-in connector according to claim 10, wherein, The mating insert connector element (104) further includes a second housing (152) and a contact protection cover (154), wherein the contact protection cover (154) is configured such that objects with a diameter greater than a predetermined value are prevented from approaching the conductive mating contact element (146) between the second housing (152) and the contact protection cover (154).

13. The insertion connector according to claim 12, wherein, The contact cover (154) is formed of a generally annular electrically insulating composite component arranged on the front end region of the conductive mating contact element (146).

14. The insertion connector according to claim 9 or 10, wherein, The insert connector (100) is implemented as a high-voltage insert connector for electric vehicles.

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