Cooling fluid guiding housing and electrical connector system with cooling fluid guiding housing

Abstract

The invention relates to a cooling fluid guiding housing for guiding a cooling fluid around an electrical connector system, and to an electrical connector system comprising a connector and a mating connector and a cooling fluid guiding housing. The cooling fluid guiding housing comprises a first portion in which at least one support element is arranged with which the cooling fluid guiding housing can contact a connector housing of the connector, and a second portion in which an inner wall of the cooling fluid guiding housing is adapted such that, after receiving the connector, the inner wall of the cooling fluid guiding housing follows an outer wall of the connector housing at a predetermined distance. The inner wall of the cooling fluid guiding housing in the second portion defines at least one cooling channel which at least partially surrounds the outer wall of the connector housing. Furthermore, the cooling fluid guiding housing comprises at least one cooling fluid connection through which cooling fluid can be introduced into the at least one cooling channel.

Description

Technical Field

[0001] This invention relates to a cooling fluid guiding housing for guiding cooling fluid around an electrical connector system, and to an electrical connector system comprising a connector, a mating connector, and a cooling fluid guiding housing. The invention also relates to a method for mounting an electrical connector system having a cooling fluid guiding housing for guiding cooling fluid around the electrical connector system, preferably for use in the automotive industry. Background Technology

[0002] In the electrical field (electronics, electrical engineering, power systems, power engineering, etc.), a large number of electrical connector devices or apparatuses, sockets, pins, and / or hybrid connectors—hereinafter referred to as (electrical) connectors (also known as mating connectors)—are known for transmitting current, voltage, signals, and / or data with high current, voltage, frequency, and / or data rate bandwidth. In low, medium, or high voltage and / or current ranges, particularly in the automotive field, such connectors must ensure the permanent, repetitive, and / or rapid transmission of power, signals, and / or data after relatively long periods of inactivity under mechanical stress, warmth, potentially hot, contaminated, humid, and / or chemically corrosive environments. Due to the wide range of applications, a large number of specially designed connectors are known.

[0003] Such connectors, and housings that may be associated with them (e.g., in the case of connector equipment or connector assembly) or higher (e.g., in the case of connector assembly), may be attached to wires, cables, cable bundles, etc.—hereinafter referred to as (electrical) pre-assembled cables—or attached to electrical equipment or apparatus (e.g., at the housing, at the lead frame, at the printed circuit board, etc.), (electrical) electrical, electro-optical or electronic components, or corresponding assemblies, etc. (electrical entities).

[0004] If a connector (with or without a housing) is mounted on a cable, line, or cable harness, it is called a floating (plug) connector or plug, socket, or coupling. If it is mounted on or within an electrical, electro-optical, or electronic component, assembly, etc., it is called a connector assembly, such as a (panel / addition) connector, (panel / addition) plug, or (panel / addition) socket. Furthermore, connectors on such assemblies are often referred to as (connector) receptacles, header sockets, pin headers, or headers. In the context of electrical technology (generating, converting, storing, transporting, and transmitting high currents, preferably three-phase high-voltage transmission, in the power grid), due to its relatively complex construction, it is currently referred to as a cable fitting.

[0005] Such connectors must ensure defect-free power transmission, wherein corresponding and partially complementary connectors (connectors and mating connectors) typically include locking and / or fastening devices for permanently and generally releasably locking and / or securing the connector to / within the mating connector, and vice versa. Furthermore, the electrical connection device for the connector, such as having or including actual contact devices (terminals; largely formed as a single part or integrally in the material, e.g., contact elements) or contact devices (terminals; largely formed as several parts, two parts, a single part, a single piece or integrally in the material, e.g., single-part or multi-part (crimp-fit) contact devices), must be securely housed therein. In the case of (pre)assembled cables, such connection devices can be provided as connectors (see above), i.e., without a housing, e.g., in a floating manner.

[0006] Efforts have been made to improve electrical connectors and their terminals, particularly to design them more efficiently and to construct and / or manufacture them more cost-effectively. The increasing hybridization and electrification of vehicle powertrains, as well as the electrification of auxiliary units, places significant demands on thermal loads, which, if not addressed, can have negative consequences. This is especially true for electrical plug connections in vehicles. As is known for cable fittings in the field of electrical engineering, the need for cooling is constantly growing.

[0007] US Patent 8,926,360A1 discloses an electrical connection to an active cooling device, wherein the electrical connection includes at least one electrical connection consisting of a female terminal and a male terminal. At least one female terminal is optionally surrounded by heat-resistant electrical insulation and is constructed within the wall of the electrical device along with a heat sink with relatively good thermal conductivity. Furthermore, the female terminal includes an opening so that heat generated in the female terminal can be dissipated from the female terminal. Heat generated between the female and male terminals can be dissipated by a fan through ambient air from the heat sink and the opening in the female terminal.

[0008] Furthermore, US Patent 9,287,646B2 discloses an electrical connection in which an electrical connector is attached to a wire assembly, such as a cable. The electrical connector or wire assembly is actively cooled thereby by a heat transfer medium that flows substantially along the wire assembly and through the electrical connector.

[0009] However, known electrical connector systems have the drawback that coolant flowing through the interior of the connector housing leaves behind impurities, such as dust particles or moisture, which can deposit on the contact elements of the electrical connector system. This contamination can lead to corrosion and other damage to the contact elements, thereby shortening the service life of the electrical connector system. Summary of the Invention

[0010] Therefore, one object of the present invention is to provide cooling for electrical connector systems that overcomes the disadvantages of known solutions, making the produced connector systems safe and reliable, yet still inexpensive to manufacture and requiring very little installation space.

[0011] This objective is satisfied by the subject matter of the independent claims. Advantageous embodiments of the invention are the subject matter of the dependent claims.

[0012] This invention is based on the idea that by providing a separate cooling fluid guiding housing through which cooling fluid can flow, and which can be attached to the electrical connector system, active cooling can be achieved with minimal additional space requirements. The cooling fluid guiding housing advantageously conducts the cooling fluid along the outer wall of the connector housing near the contact point (hereinafter also referred to as a hot spot), absorbing heat generated in the electrical connector system and transferred to the connector housing via the electrical connection, and transferring the heat along the outer wall of the connector housing to the corresponding heat sink. As a result, particularly efficient thermal management and therefore efficient energy transfer can be achieved.

[0013] A cooling fluid guiding housing for guiding cooling fluid around an electrical connector system includes a connector and a mating connector, particularly including a first portion and a second portion, wherein at least one support element is arranged in the first portion, through which the cooling fluid guiding housing can contact the connector housing of the connector, and in the second portion, the inner wall of the cooling fluid guiding housing is adapted such that after receiving the connector, the inner wall of the cooling fluid guiding housing follows the outer wall of the connector housing at a predetermined distance.

[0014] According to the invention, the inner wall of the cooling fluid guiding housing defines at least one cooling channel in a second portion, the at least one cooling channel at least partially surrounding the outer wall of the connector housing, wherein the cooling fluid guiding housing includes at least one cooling fluid connection through which cooling fluid can be introduced into the at least one cooling channel.

[0015] In this way, the cooling fluid guide housing can be securely attached to the electrical connector by means of a support element. Furthermore, the formed cooling channels allow the cooling fluid to be guided around the outside of the connector housing, eliminating the need for the cooling fluid to pass through the inside of the connector housing, which could lead to contamination and thus damage to the wires or contact elements.

[0016] The distance between the outer walls of the cooling fluid guide housing and the connector housing can be selected such that the inner wall of the cooling fluid guide housing is tightly against the outer wall of the connector housing in order to improve cooling efficiency. This distance defines the guide cross-section or effective volume of the cooling channel used for fluid transport.

[0017] The preferred cooling fluid is air, but it can also be a different gas, such as nitrogen. Nitrogen can be separated from ambient air via a pressure swing adsorption (PSA) process on the vehicle. The term gas, of course, also includes the term gas mixture (see air). Alternatively, the cooling fluid can be a coolant, such as a coolant already present in the vehicle's cooling circuitry. The cooling fluid can be, for example, a pre-cooled cooling fluid from an air conditioning unit or an unpre-cooled cooling fluid originating from a fan or compressor and possibly a radiator.

[0018] The cooling fluid guide housing can preferably be configured as a connection port, connection flange, or connection socket. The cooling fluid guide housing can have one, exactly two, or more cooling fluid connections, allowing cooling fluid to be supplied to the cooling channels at several points. Alternatively, different cooling fluid connections can each supply cooling fluid to one or more cooling channels, allowing the cooling fluid guide housing to define several cooling channels that are separate from each other.

[0019] To selectively guide cooling fluid along the outer wall of the connector housing as much as possible near the contact point, the cooling fluid guiding housing preferably includes at least one cooling fluid guiding wall adapted to define a portion of the at least one cooling channel. Not only the contact point to which the cooling fluid is guided will act as a hot spot; for example, other hot spots along the connector housing can be predefined by simulation. The cooling fluid guiding wall can then define the at least one cooling channel such that it is guided as effectively as possible to these other hot spots.

[0020] According to an advantageous embodiment, the cooling channel begins at a cooling fluid connection in the cooling fluid guide housing and opens outward along the outer wall of the connector housing through a channel opening for a cooling fluid outlet, wherein, in addition to the channel opening, the cooling channel is configured to be permeable to gas at at least one additional point along the inner wall of the cooling fluid guide housing.

[0021] The heated cooling fluid can be delivered from the cooling channel through the point of permeable gas in a particularly simple manner. The point of permeable gas cooling channel can also be formed, for example, through an additional cooling fluid connection through which the heated cooling fluid is delivered to the corresponding radiator of the cooling circuit.

[0022] The present invention also relates to an electrical connector system, including a connector and a mating connector, having a cooling fluid guiding housing according to the invention.

[0023] The mating connector is specifically configured as a low-voltage mating connector, preferably as a vehicle mating connector for vehicle electrical systems. Voltages below 5kV are considered low voltages. Therefore, the electrical connector system according to the invention can be configured for low voltages up to 1kV to 5kV, and may have short-term currents up to 500A.

[0024] This specifically means that the connector lacks external shielding (conductive layer, protective cover, etc.) on its connector housing for removing surface charge, for field distribution, for electromagnetic shielding, etc. This means that the connector housing is particularly non-conductive externally. Preferably, there is no specially constructed Faraday cage inside the connector housing; except for applications involving shielded coaxial or twisted-pair cables, which exhibit Faraday cage characteristics due to their special structure, but do not include a Faraday cage separately as cable fittings.

[0025] Furthermore, the electrical connector system according to the invention particularly includes the absence of field control components, grounding devices, capacitive voltage dividers, capacitive test points, sealed plugs, protection for use in underground (especially buried) locations, UV protection, and / or occupancy protection. Additionally, the contact elements of the connector according to the invention preferably have no threads. Vehicles can be understood as land vehicles (road vehicles, off-road vehicles, and / or rail vehicles), boats (displacers and / or gliders), and / or aircraft (propeller-driven aircraft, jet aircraft, helicopters, and / or airships).

[0026] In a preferred embodiment, the at least one cooling channel is guided along the outer wall of the connector housing, such that the at least one cooling channel can be guided in the direction of a heat source within the connector housing. The heat source can be a contact point in the electrical connector system or any other hot spot generated when current flows through the electrical connector system, as determined by simulation results.

[0027] The cooling fluid guide housing advantageously includes at least one second cooling fluid connection for downstream delivery of cooling fluid. This allows heated cooling fluid to be delivered particularly easily to the corresponding radiator in the cooling circuit. Cooling fluid that has been recooled can then be fed back into the interior of the cooling fluid guide housing.

[0028] According to another advantageous embodiment, the predetermined distance between the inner wall of the cooling fluid guide housing and the outer wall of the connector housing in the second part differs in the inlet portion of the at least one cooling channel from that in the outlet portion.

[0029] In this way, the guide cross-section or effective volume of the cooling channel for fluid transport in the inlet portion of the cooling channel (e.g., the cooling fluid connection of the cooling channel or the adjacent downstream portion) can differ from the guide cross-section or effective volume of the cooling channel for fluid transport in the outlet portion of the cooling channel (e.g., the cooling fluid connection or the gas-permeable opening in the cooling fluid guide housing or the adjacent upstream portion of the cooling channel). Preferably, the guide cross-section or effective volume in the inlet portion of the cooling channel is smaller than the guide cross-section or effective volume in the outlet portion of the cooling channel, for example, in a similar portion located downstream thereafter.

[0030] In the direction of the contact element inlet for the mating connector, the cooling fluid guide housing can advantageously terminate flush with the outer wall of the connector housing. The end of the cooling fluid guide housing and the outer wall of the connector housing can be constructed in a sealed manner. In this way, the cooling channels in the cooling fluid guide housing are directed away from the terminal inlets for the mating connector. This prevents cooling fluid, already heated by hot spots in the connector housing, from overflowing towards the mating connector, thereby heating the mating connector.

[0031] According to another advantageous embodiment, the cooling fluid guiding housing may also be adapted to receive a mating connector, wherein the cooling fluid guiding housing includes a third portion, in which an inner wall of the cooling fluid guiding housing is adapted such that the inner wall of the third portion follows the outer wall of the mating connector housing of the mating connector at a predetermined distance, wherein the inner wall of the cooling fluid guiding housing in the third portion defines at least one cooling channel that at least partially surrounds the outer wall of the mating connector housing.

[0032] In this way, in addition to the connector housing, the mating connector housing can also be cooled, thereby further improving cooling efficiency. The cooling channels at least partially surround the outer wall of the connector housing and the outer wall of the mating connector housing.

[0033] To ensure the simplest attachment of the cooling fluid guide housing to the electrical connector or plug connection, the cooling fluid guide housing may include multiple cooling housings, each of which includes a fastening element by means of which the respective cooling housing can be fastened to at least one other cooling housing.

[0034] However, alternatively, the cooling fluid guide housing can of course be formed integrally or integrally on the material. The at least one cooling fluid connection can also be an integral part of the cooling fluid guide housing. The cooling fluid guide housing can be manufactured from a single raw material (e.g., a blank) or a single raw block (e.g., molten plastic).

[0035] The cooling fluid guiding housing can be advantageously configured such that the inner wall of the cooling fluid guiding housing in the second part and the outer wall of the connector housing each form multiple individual cooling channels. This configuration is particularly advantageous if the connector housing has a modular structure and includes multiple connector modules, in which electrical terminals can be formed or shaped. In this case, only the cooling channel associated with the inserted connector module may be supplied with cooling fluid, while other cooling channels are closed, for example, by blind plugs or blind flanges. Therefore, cooling efficiency can be further improved, while standardized cooling fluid guiding housings can be manufactured.

[0036] To effectively direct cooling fluid to a heat source in an electrical connector system, the outer wall of the connector and / or mating connector may include at least one fluid guiding element defining the at least one cooling channel. The fluid guiding element may be complementary to an additional cooling fluid guiding wall of a cooling fluid guiding housing, which is also adapted to guide cooling fluid along the outer wall of the connector housing.

[0037] The present invention also relates to a method for mounting an electrical connector system having a cooling fluid guiding housing for guiding cooling fluid around the electrical connector system, the method comprising the steps of:

[0038] Provides electrical connector systems including connectors and mating connectors.

[0039] Attached cooling fluid guide housing, wherein:

[0040] The connector housing, in which the cooling fluid is guided, contacts the connector housing in the first part, and at least one support element is arranged in the first part.

[0041] In the second part, the inner wall of the cooling fluid guiding housing follows the outer wall of the connector housing at a predetermined distance, wherein the inner wall of the cooling fluid guiding housing defines at least one cooling channel that at least partially surrounds the outer wall of the connector housing.

[0042] The cooling fluid guiding housing includes at least one external cooling fluid connection, through which cooling fluid can be introduced into the at least one cooling channel.

[0043] The active cooling according to the invention can also be advantageously extended to mating connectors. The method further includes attaching a cooling fluid guiding housing in such a way that the inner wall of the cooling fluid guiding housing in a third portion follows the outer wall of the mating connector housing of the mating connector at a predetermined distance, wherein the inner wall of the cooling fluid guiding housing in the third portion defines at least one cooling channel that at least partially surrounds the outer wall of the mating connector housing. Attached Figure Description

[0044] To better understand the invention, it will be explained in more detail with reference to the embodiments shown in the following figures. Identical components have the same reference numerals and the same component names. Furthermore, some features or combinations of features from the different embodiments shown and described may themselves represent independent, inventive, or solutions according to the invention, as illustrated in the figures:

[0045] Figure 1 A schematic perspective view of an electrical connector system according to a first example is shown;

[0046] Figure 2 Another schematic perspective view of the electrical connector system according to the first example is shown;

[0047] Figure 3 Another schematic perspective view of the electrical connector system according to the first example is shown;

[0048] Figure 4 A schematic exploded view of an electrical connector system according to a first example is shown;

[0049] Figure 5 A schematic perspective view of the cooling housing of the cooling fluid guiding housing is shown;

[0050] Figure 6 A schematic cross-sectional view of an electrical connector system according to a first example is shown;

[0051] Figure 7 A schematic exploded view of an electrical connector system according to the second example is shown;

[0052] Figure 8 A further schematic exploded view of the electrical connector system according to the second example is shown;

[0053] Figure 9 A schematic cross-sectional view of an electrical connector system according to the second example is shown. Detailed Implementation

[0054] The present invention will be explained in more detail below with reference to the accompanying drawings, and in particular with reference to... Figure 1 and 2 Schematic perspective views. Note that dimensional ratios, especially layer thickness ratios, in all figures are not necessarily shown to scale. Furthermore, parts not necessary for understanding or that may obstruct it are not shown. The terms connector and mating connector, terminal and mating terminal, etc., will be interpreted as synonyms and are interchangeable.

[0055] Figure 1A schematic perspective view of two (electrical) connectors 102 and 104 of an electrical connector system 100 according to a first advantageous embodiment of the invention is shown, which are mated to each other. Electrical connector 102 is preferably configured as a floating receptacle connector 102, while connector 104, hereinafter referred to as mating connector 104, is currently configured as a connector receptacle 104, a receptacle socket 104, a pin receptacle 104, or a receptacle 104. Connector 102 may be part of an assembled cable or electrical entity.

[0056] Electrical connector 102 includes connector housing 110, in which at least one electrical contact element (not shown) is formed or can be formed. Electrically mating connector 104 also includes mating connector housing 112, in which at least one electrical contact element (not shown) is formed or can be formed. Both connector housing 110 and mating connector housing 112 are made of an insulating material such as plastic.

[0057] By inserting the connector housing 110 into the mating connector housing 112, at least one contact element can make conductive contact with at least one mating contact element at the contact point, thereby allowing current to flow through the electrical connector system 100.

[0058] Figure 2 A schematic perspective view of connector 102 is shown, which is surrounded by a cooling fluid guiding housing 106. Electrically mating connector 104 is not shown in this figure. This makes contact element receiving chamber 116 visible, through which connector 102 receives the contact element of mating connector 104.

[0059] To cool the electrical connector system 100 by dissipating the heat generated when current is transmitted through it, the connector housing 110 is largely surrounded by a cooling fluid guiding housing 106, such as Figure 1 and 2 As illustrated in the example, the cooling fluid guiding housing 106 is adapted to guide cooling fluid 114, preferably air, at least partially around the exterior of the connector housing 110 to remove heat generated inside the connector housing 110. For this purpose, the cooling fluid guiding housing includes a cooling section (second section) wherein cooling channels are defined by the inner wall of the cooling fluid guiding housing, thus forcing the cooling fluid 114 introduced into the cooling channels in the cooling section to flow around the outer wall of the connector housing 110. The cooling section is not necessarily continuous but may consist of multiple sub-sections, for example, each sub-section defining a separate cooling channel.

[0060] like Figure 1 and 2As further shown, the cooling fluid guiding housing may include an upper housing 118 and a lower housing 120, which can be connected to each other by a fastening element 122. In this way, simple assembly of the cooling fluid guiding housing 106 to the electrical connector system 100 can be ensured. However, the two-part design of the cooling fluid guiding housing is not important to the present invention. The cooling fluid guiding housing may also be alternatively formed as a single component (or integrally formed), or assembled from multiple separate housings.

[0061] The fastening element 122 is shown here as a protrusion, in which a recessed hole 124 may be provided, by means of which the upper housing 118 and the lower housing 120 can be fastened to each other using rivets or screws. Alternatively, the fastening element 122 may also have a latching device, by means of which the upper housing 118 and the lower housing 120 can be securely connected to each other. Furthermore, the upper housing 118 and the lower housing 120 may also be glued to each other.

[0062] In order to attach the cooling fluid guide housing 106 to the electrical connector system 100 in a stable manner, the cooling fluid guide housing has a support element (shown later) that is made to contact the connector housing 110, mate the connector housing 112, or both, and supports the cooling fluid guide housing 106.

[0063] To introduce cooling fluid 114 into the cooling fluid guide housing 106, the cooling fluid guide housing 106 includes a cooling fluid connection 108, which is preferably configured as a connection port 108 such that a hose-like cooling fluid supply line can be easily pushed onto or inserted into the corresponding connection port 108 and may be further secured there (not shown). Of course, different fluid connections can be chosen instead of the connection port 108, such as connection flanges, connection sockets, etc. Gas sealing is available in all embodiments.

[0064] Starting from the inlet opening in the region of the cooling fluid connection 108, the introduced cooling fluid can flow along the outer wall of the connector housing 110 until it exits the interior of the cooling fluid guide housing 106 again at the outlet opening 126. As shown here, the outlet opening can be formed, for example, by an opening in the connection region of a cable or electrical device (e.g., an electrical unit). The outlet 126 can also be provided in other regions of the cooling fluid guide housing 106. In particular, the transitions between the upper housing 118 and the lower housing 120 can be configured to be fluid-permeable, such that these transitions provide additional ventilation options for the heated cooling fluid inside the cooling fluid guide housing 106.

[0065] However, the transition between the upper housing 118 and the lower housing 120 may alternatively include seals to prevent cooling fluid from overflowing from these transitions.

[0066] In addition, the cooling fluid guide housing 106 may include at least one additional cooling fluid connection, which can serve as an alternative outlet opening to allow heated cooling fluid to be transported downstream.

[0067] As described below, the inlet opening and outlet opening 126 in the region of the cooling fluid connection 108 are connected by a cooling channel that surrounds at least a portion of the outer wall of the connector housing 110. The cooling channel is defined on one side by at least a portion of the outer wall of the connector housing 110 and on the other side by at least the inner wall of the cooling fluid guiding housing 106, together forming the cooling channel. Therefore, the guiding cross-section or effective volume of the cooling channel for fluid transport can be largely determined by the distance between the outer wall of the connector housing 110 and the inner wall of the cooling fluid guiding housing 106.

[0068] The cooling fluid guiding housing 106 may be made of a conductive material, such as aluminum, to dissipate the heat absorbed by the cooling fluid into the environment as efficiently as possible. Alternatively, the cooling fluid guiding housing 106 may also be made of a plastic material, such as silicone, polytetrafluoroethylene (PTFE), polyethylene (PE), or polypropylene (PP), in order to keep the weight caused by the cooling fluid guiding housing 106 as low as possible.

[0069] Figure 3 A schematic perspective view of an electrical connector system according to a first example is shown, which lacks a mating connector 104 and an upper housing 118 that guides cooling fluid to the housing 106. Consequently, particularly the support element 130... Figure 3 As can be seen in the figure, the cooling fluid guide housing 106 is formed to contact the connector housing 110, thereby stabilizing the cooling fluid guide housing 106 on the connector housing 110. A support element 130 is arranged in the first portion of the cooling fluid guide housing 106, which serves as a support portion. As can be seen from the figure, this support portion is not necessarily continuous, but may include multiple smaller support portions. The support element 130 can advantageously be attached near the fastening element 122, such that the force transmission path between the fastening element 122 and the support element 130 can be kept short.

[0070] Furthermore, the outer edge 128 of the cooling fluid guide housing 106 may contact the connector housing 110 to increase the stability of the attachment of the cooling fluid guide housing. Specifically, the outer edge 128 of the cooling fluid guide housing 106 may terminate flush with the connector housing 110, thereby preventing the connector housing 110 from protruding in this area. A tight termination, as close as possible, between the outer edge 128 and the connector housing 110 in the direction of the contact element receiving chamber 116 prevents heated cooling fluid from escaping from the cooling fluid guide housing in the direction of the mating connector 104 and heating the mating connector 104.

[0071] As can be seen in the illustrated embodiment, the connector housing 110 can have a modular structure, meaning it can include several connector modules 132 that can be plugged together, wherein at least one contact element is formed in or can be formed in each of the pluggable connector modules 132. Each connector module 132 can be, for example, pushed into a retaining element 133 and connected to each other by a connecting element 134 (e.g., a clamp).

[0072] In this configuration, the cooling fluid guide housing 106 may include a separate cooling channel for each connector module 132. An associated cooling fluid connection 108 may be provided for each individual cooling channel, allowing each connector module 132 to be cooled as needed by the cooling fluid flowing through the corresponding individual cooling channel. Furthermore, cavities accommodating the retaining element 133 and the connecting element 134 may be provided within the cooling fluid guide housing 106.

[0073] Figure 4 A schematic exploded view of an electrical connector system 100 without mating connector 104 according to a first example is shown. It can be clearly seen from this view that a connector housing 110 can be inserted between an upper housing 118 and a lower housing 120 to mount an assembly, wherein the outer edge 128 of a cooling fluid guiding housing 106 and a support element 130 contact the connector housing 110. The upper housing 118 and the lower housing 120 can be fastened to each other in a closed manner by means of a fastening element 122. The cooling fluid guiding housing 106 can then be attached to the connector 102 before or after the electrical connector system 100 is closed.

[0074] Similarly, Figure 4 As shown, the upper housing 118 and the lower housing 120 each include a cooling fluid connection 108, which can provide a common cooling passage or two separate cooling passages within the cooling fluid guiding housing. Alternatively, one of the two cooling fluid connections 108 can serve as an upstream cooling fluid inlet, while the other of the cooling fluid connections 108 serves as a downstream cooling fluid outlet.

[0075] Figure 5 A schematic perspective view of the lower housing 120 of the cooling fluid guiding housing 106 is shown. Figure 5 As schematically shown by the middle arrow 114, the cooling channel opens inside the cooling fluid guiding housing 106, starting from inlet 136 in the region of cooling fluid connection 108, and extending along the inner wall of the lower housing 120 of the cooling fluid guiding housing 106. The cooling channel is defined thereby by the inner wall of the lower housing 120 and the outer wall of the connector housing 110, such that cooling fluid 114 flows along the outer wall of the connector housing 110 through the cooling channel to outlet opening 126. The inner wall of the lower housing 120 is advantageously shaped to conform to the shape of the outer wall of the connector housing 110.

[0076] A cooling fluid guiding wall 138 may be attached to the lower housing 120 of the cooling fluid guiding housing 106, and the cooling fluid guiding wall 138 additionally guides the fluid flow within the cooling fluid guiding housing 106. The cooling fluid guiding wall 138 may be integrally formed with the cooling fluid guiding housing 106. The cooling fluid guiding wall 138 is primarily used to guide the cooling fluid 114 as effectively as possible in the direction of heat sources or hot spots appearing within the connector housing 110. Secondly, the cooling fluid guiding wall 138 may also serve as a partition wall separating several individual cooling channels from each other. The individual cooling channels may be symmetrically shaped, but may also have different configurations; for example, the distance between the inner wall of the cooling fluid guiding housing 106 and the outer wall of the connector housing 110 may vary between the different cooling channels.

[0077] The upper shell 118 can be constructed in a similar manner to the lower shell 120.

[0078] Figure 6 A schematic cross-sectional view of connector 102 is shown, which is surrounded by a cooling fluid guiding housing. As schematically indicated by the arrows in the figure, cooling fluid 114 flows through a cooling fluid connection 108 (not shown) into a cooling channel defined by the inner wall of the cooling fluid guiding housing 106. The cooling fluid flows along the outer wall 140 of connector housing 110, allowing one or more heat sources within the connector housing to be cooled by heat removal. Heat from heat sources inside connector 102 is first transferred through connector housing 110 to the outer wall 140 of connector housing 110, where cooling fluid 114 flows around the outer wall 140. The cooling fluid cools the outer wall 140 of connector housing 110 there, and thus indirectly cools heat sources within connector 102, thereby absorbing heat transferred through connector housing 110.

[0079] The heated cooling fluid can then exit the cooling channel through outlet opening 126 and be conveyed away from the cooling fluid guide housing. Even though the primary flow direction is currently shown as axial in the direction of outlet opening 126, the cooling fluid 114 can of course also flow radially around the outer wall. An air guide wall can be attached to the inner wall of the cooling fluid guide housing 106 and optionally to the outer wall of the connector housing 110, thus extending axially and radially around the connector housing 110.

[0080] like Figure 6 As shown, the guide cross-section or effective volume of the cooling channel used for fluid transport can be largely determined by the distance between the outer wall 140 of the connector housing 110 and the inner wall of the cooling fluid guide housing 106. Therefore, it is advantageous to reduce the distance between the outer wall 140 of the connector housing 110 and the inner wall of the cooling fluid guide housing 106 in the region where the cooling fluid 114 flows around the connector housing 110 around a heat source (“hot spot”) to increase the flow velocity and thereby improve the efficiency of the cooling fluid in cooling the hot spot region. As described above, such a heat source appears in the region, for example, the contact point, when current flows through the connector and the contact elements of the mating connector.

[0081] Even though only one embodiment has been shown so far, in which the cooling fluid guide housing 106 at least partially surrounds the connector 102, the cooling fluid guide housing 106 may also at least partially surround the mating connector 104, such that cooling fluid for cooling can flow through the cooling fluid guide housing 106 on the outside of the mating connector housing 110. Furthermore, the connector 102 and the mating connector 104 may each be equipped with separate cooling fluid guide housings. Once the two connectors 102 and 104 have been mated together, the two separate cooling fluid guide housings may each form a common, higher-order cooling fluid guide housing with a shared cooling channel, allowing the connectors 102 and 104 to be cooled together. Alternatively, after the two connectors 102 and 104 have been mated together, the cooling channels formed in the two separate cooling fluid guide housings 106 may also remain separate, allowing each of the connectors 102 and 104 to be cooled individually.

[0082] Figure 7 and 8 Schematic exploded views of an electrical connector system 200 according to a second advantageous embodiment are shown. Figure 7 An electrical connector system 200 without mating connector 204 is shown. Figure 8 An electrical connector system 200 with mating connector 204 is shown. Figure 9 A corresponding schematic cross-sectional view of the electrical connector system 200 according to the second embodiment is shown.

[0083] Of course, all aspects and advantages described with respect to the first embodiment also apply to the second embodiment. The only difference between the second embodiment and the first embodiment is that the cooling fluid guiding housing 206 includes a receiving portion 242 (third portion) in which the cooling fluid guiding housing can receive the mating connector 104.

[0084] After receiving the mating connector 104, by Figure 7 and 8 The cooling fluid guiding housing 206 formed by the upper housing 218 and lower housing 220 defines a cooling channel that at least partially surrounds the outer wall of the mating connector housing 112. This cooling channel may be in fluid communication with a cooling channel surrounding the outer wall of the connector housing 110. However, in an embodiment, the two cooling channels may also be formed separately.

[0085] The cooling fluid connection 208 can be attached to the cooling fluid guide housing 206, for example, in the region of the receiving portion 242, such that the cooling fluid 114, after entering the cooling fluid guide housing, first flows around the outer wall of the mating connector housing 112. The cooling fluid 114 is then guided along the outer wall of the connector housing 110 through external cooling channels until it can exit the cooling fluid guide housing 206 again at one or more outlet openings 226, carrying away the absorbed heat. The outlet openings 226 can again be formed by openings in the connection area of, for example, cables or electrical devices (e.g., electrical units), so that heat can be effectively carried away from the contact point between the connector 102 and the mating connector 104.

[0086] Of course, the cooling fluid connection 208 and the outlet opening 226 can also be attached so that the cooling channel surrounds the connector housing 110 upstream and the mating connector housing 112 downstream.

[0087] like Figure 8 As schematically shown, the electrical connector system 200, including connector 102 and mating connector 104, can be initially closed to install components. The cooling fluid guide housing 206 can then contact the connector housing 110 or mating connector housing 112 (or both) via the support element 230, allowing the cooling fluid guide housing to be securely attached to the electrical connector system 200. The upper housing 218 and lower housing 220 can then be fastened to each other in a closed manner by means of the fastening element 222.

[0088] Alternatively, before the electrical connector system 200 is closed, the cooling fluid guide housing 206 may also be integrally formed and already mounted on the connector 102 (or mating connector 104) such that when the electrical connector system 200 is closed, the mating connector 104 (or connector 102) is accommodated in the cooling fluid guide housing 206.

[0089] exist Figure 9 In this example, the mating connector 104 includes conductive pin-shaped contact units 144, which are immersed in the socket-shaped base 146 of the connector 102. In the currently shown insertion state, current can flow through the contact portion 148. Heat generated in the contact portion 148 can be carried away by a cooling fluid 114, such as... Figure 9 As indicated by the middle arrow, cooling fluid 114 flows around the outer wall 150 of the mating connector housing 112 and the outer wall 140 of the connector housing 110. The cooling channel through which the cooling fluid flows is defined by the inner wall of the cooling fluid guiding housing 206, and is thus guided along the outer wall 150 of the mating connector housing 112 and the outer wall 140 of the connector housing 110. In addition to the outlet opening 226, ventilation openings may also be provided on the cooling fluid guiding housing 206, for example, in the connection area for cables or electrical devices on the mating connector 104.

[0090] Furthermore, all cross-sectional diameters or dimensions of the cooling channels are selected such that the corresponding portions of the cooling channels (branches, throttling points, etc.) can allow cooling fluid 114 to flow through as needed. In particular, the distance between the inner wall of the cooling fluid guide housing 206 and the outer wall of the connector housing 110 or mating connector housing 112 is selected such that the achievable flow rate, achievable flow resistance, and achievable cooling volume for the cooling fluid flowing around the electrical connector system 200 are dominant in each portion, provided that the fluid pressure and fluid temperature do not exceed acceptable limits.

[0091] List of reference numerals

[0092] 100, 200 electrical connector system

[0093] 102 connector

[0094] 104 mating connector

[0095] 106, 206 Cooling fluid guide housing

[0096] 108, 208 Cooling fluid connection

[0097] 110 connector housing

[0098] 112 mating connector housing

[0099] 114 Cooling fluid

[0100] 116 Contact Element Receiving Chamber

[0101] 118, 218 upper shell

[0102] 120, 220 lower shell

[0103] 122 Fastening Components

[0104] 124 recess

[0105] 126 Exit Opening

[0106] 128 outer edge

[0107] 130 support element

[0108] 132 connector module

[0109] 133 Holding Element

[0110] 134 connecting elements

[0111] 136 entrance opening

[0112] 138 Cooling Fluid Guide Wall

[0113] 140 connector housing outer wall

[0114] 144-pin contact unit

[0115] 146 socket-shaped base

[0116] 148 contact parts

[0117] 150 mating connector housing outer wall

[0118] 242 Receiver Section (Part Three)

Claims

1. Cooling fluid guiding housing (106) for guiding a cooling fluid (114) around an electrical connector system (100), the electrical connector system comprising a connector (102) and a mating connector (104), the cooling fluid guiding housing (106) comprising: a first portion in which at least one support element (130) is arranged with which the cooling fluid guiding housing (106) can be brought into contact with a connector housing (110) of the connector (102), a second portion in which an inner wall of the cooling fluid guiding housing (106) is provided such that, after receiving the connector (102), the inner wall of the cooling fluid guiding housing (106) follows an outer wall (140) of the connector housing (110) at a predetermined distance, wherein the inner wall of the cooling fluid guiding housing in the second portion defines at least one cooling channel which at least partially surrounds the outer wall (140) of the connector housing (110), wherein the cooling fluid guiding housing (106) comprises at least one cooling fluid connection (108) through which the cooling fluid (114) can be introduced into the at least one cooling channel; wherein the cooling fluid guiding housing (106) comprises at least one cooling fluid guiding wall (138) which is adapted to define a portion of the at least one cooling channel and which guides the cooling fluid (114) along the outer wall (140) of the connector housing (110); wherein the cooling fluid guiding housing (106) comprises a plurality of cooling shell parts (118, 120) and wherein each of the cooling shell parts (118, 120) comprises a fastening element (122) by means of which the respective cooling shell part (118, 120) can be fastened to at least one other cooling shell part (118, 120) in order to attach the cooling fluid guiding housing (106) to the electrical connector system (100).

2. The cooling fluid directing housing (106) of claim 1, wherein, The cooling fluid connection (108) is configured as a connection port, a connection flange or a connection socket.

3. The cooling fluid directing housing (106) according to claim 1 or 2, wherein, The cooling fluid (114) is air or nitrogen.

4. The cooling fluid directing housing (106) according to claim 1 or 2, wherein, The cooling channel opens outwards along the outer wall (140) of the connector housing (110) through a channel opening for a cooling fluid outlet, wherein, in addition to the channel opening, the cooling channel is configured to be permeable to gas at at least one further point along the inner wall of the cooling fluid guiding housing (106).

5. Electrical connector system (100) comprising a connector (102) and a mating connector (104), the electrical connector system having a cooling fluid guiding housing (106) according to any one of the preceding claims.

6. The electrical connector system (100) of claim 5, wherein, The at least one cooling channel is guided along the outer wall (140) of the connector housing (110) such that it can be guided in the direction of a heat source within the connector housing (110).

7. The electrical connector system (100) of claim 5 or 6, wherein, The cooling fluid guiding housing (106) comprises at least one second cooling fluid connection (108) for downstream transport of the cooling fluid.

8. The electrical connector system (100) of claim 5 or 6, wherein, In the second portion, a predetermined distance between the inner wall of the cooling fluid guiding housing (106) and the outer wall of the connector housing (110) differs in an inlet portion of the at least one cooling channel from an outlet portion.

9. The electrical connector system (100) of claim 5 or 6, wherein, The cooling fluid guiding housing (106) terminates flush with the outer wall (140) of the connector housing (110) in the direction of a contact element inlet (116) for the mating connector (104).

10. The electrical connector system (100) of claim 5 or 6, wherein, The cooling fluid guiding housing (106) is further adapted to receive the mating connector (104), wherein the cooling fluid guiding housing (106) comprises a third portion in which the inner wall of the cooling fluid guiding housing (106) is arranged such that in the third portion the inner wall follows the outer wall (150) of a mating connector housing (112) of the mating connector (104) at a predetermined distance, wherein in the third portion the inner wall of the cooling fluid guiding housing (106) defines at least one cooling channel which at least partially surrounds the outer wall (150) of the mating connector housing (112).

11. The electrical connector system (100) of claim 5 or 6, wherein, The cooling fluid guiding housing (106) is configured such that the inner wall of the cooling fluid guiding housing in the second portion and the outer wall (140) of the connector housing (110) each form a plurality of individual cooling channels.

12. The electrical connector system of claim 5 or 6, wherein, The outer wall (140) of the connector housing (110) comprises at least one fluid guiding element defining the at least one cooling channel.

13. A method for installing an electrical connector system (100) having a cooling fluid guiding housing (106) for guiding a cooling fluid (114) around the electrical connector system (100), the method comprising the steps of: providing the electrical connector system (100) comprising a connector (102) and a mating connector (104), attaching the cooling fluid guiding housing (106), wherein: the cooling fluid guiding housing (106) contacts a connector housing (110) of the connector (102) in a first portion in which at least one support element (130) is arranged, in a second portion, an inner wall of the cooling fluid guiding housing (106) follows an outer wall (140) of the connector housing (110) at a predetermined distance, wherein in the second portion the inner wall of the cooling fluid guiding housing (106) defines at least one cooling channel which at least partially surrounds the outer wall (140) of the connector housing (110), wherein the cooling fluid guiding housing (106) comprises at least one cooling fluid connection (108) through which the cooling fluid (114) can be introduced into the at least one cooling channel; wherein the cooling fluid guiding housing (106) comprises at least one cooling fluid guiding wall (138) adapted to define a portion of the at least one cooling channel and guiding the cooling fluid (114) along an outer wall (140) of the connector housing (110); wherein the cooling fluid guiding housing (106) comprises a plurality of cooling housing parts (118, 120) and wherein each of the cooling housing parts (118, 120) comprises a fastening element (122) by means of which the respective cooling housing part (118, 120) can be fastened to at least one other cooling housing part (118, 120) in order to attach the cooling fluid guiding housing (106) to the electrical connector system (100).

14. The method of claim 13, wherein, The cooling fluid guiding housing (106) is attached such that in a third portion the inner wall of the cooling fluid guiding housing (106) follows an outer wall (150) of a mating connector housing (112) of the mating connector (104) at a predetermined distance, wherein in the third portion the inner wall of the cooling fluid guiding housing (106) defines at least one cooling channel at least partially surrounding the outer wall (150) of the mating connector housing (112). The cooling fluid guiding housing (106) is attached such that in a third portion the inner wall of the cooling fluid guiding housing (106) follows an outer wall (150) of a mating connector housing (112) of the mating connector (104) at a predetermined distance, wherein in the third portion the inner wall of the cooling fluid guiding housing (106) defines at least one cooling channel at least partially surrounding the outer wall (150) of the mating connector housing (112).

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