Contact device, contact and contact system for double busbars

Abstract

The invention relates to a contact device (104) for a double busbar (102), wherein the double busbar (102) has two busbars (108) which are stacked in a stack, wherein the contact device (104) of each busbar (108) has an even number of plug connectors (110) which are arranged symmetrically with respect to an axis of symmetry (112) of the contact device (104), wherein the plug connectors (110) of the two busbars (108) are oriented in one and the same plug-in plane (114).

Description

Technical Field

[0001] This invention relates to a contact device for double busbars, a connector for double busbars, and a contact system for double busbars. Background Technology

[0002] The invention will be described below primarily in the context of vehicle power supplies. However, the invention can be used in any application that transmits electrical loads, particularly large electrical loads with, for example, high power greater than 10kW or high voltage greater than 100V.

[0003] In a vehicle's low-voltage power supply, the conductive metal plates on the vehicle body can be used as grounding, thereby shortening the length of the return cable. Therefore, almost half of all the cabling within the vehicle can be discarded.

[0004] For example, high voltage in motor vehicles, exceeding 300V or even 700V, can be used to transmit large electrical loads. Busbars made of solid metal materials can be used for high voltage in motor vehicles. If busbars are used, separate positive and negative busbars may be required to ensure the necessary safety (protection against touch, arcing, or voltage breakdown, etc.). Positive and negative busbars can be designed as dual busbars, i.e., formed by flat stacking with a small pitch (<5mm). Summary of the Invention

[0005] Therefore, the object of the present invention is to provide an improved contact device for double busbars, an improved connector for double busbars, and an improved contact system for double busbars, using means that are as simple as possible in design. In this case, the improvement may, for example, involve improved radiation characteristics, and in particular, reduced electromagnetic field radiation.

[0006] This task is accomplished by the subject matter of the independent claims. Advantageous improvements of the invention are described in detail in the dependent claims, the specification, and the drawings.

[0007] In electric vehicles, even under the high voltage conditions of motor vehicles, a large current is required to transmit drive power, braking power, or regenerative power. The current generates an electromagnetic field around the current-carrying conductors of the vehicle. The conductors can be shielded to reduce or even prevent field radiation. Alternatively or additionally, the feeder and return conductors can be arranged as parallel and close to each other as possible, because the electromagnetic fields caused by opposing currents cancel each other out.

[0008] Even in the case of busbars, the feeder busbar and the return busbar can be arranged very close together by stacking the two busbars equally. The stacked busbars are electrically isolated individually. This arrangement can be called a double busbar.

[0009] In order to maintain the elimination effect at the contact point, the proposed approach here proposes a double parallel contact that also allows current to be guided in a manner that is adjacent to each other at the contact point.

[0010] A contact device for a dual busbar is proposed, wherein the dual busbar has two busbars stacked in a stack, wherein the contact device for each busbar has an even number of plug connectors arranged symmetrically with respect to the axis of symmetry of the contact device, and wherein the plug connectors of the two busbars are oriented in the same mating plane.

[0011] A connector for dual busbars is also proposed, wherein the connector is designed to contact a contact device according to the practice proposed herein, wherein the connector for each busbar has an even number of plug connectors arranged symmetrically with respect to the axis of symmetry, wherein the plug connectors of the two busbars are oriented in the same mating plane.

[0012] Finally, a contact system for a dual busbar is proposed, wherein the dual busbar has a contact device according to the practice described herein and the busbar is electrically connected to the plug connector, wherein the plug connector of the contact device is electrically connected to a connector according to the practice described herein.

[0013] A busbar can refer to a solid, elongated metal strip. For example, a busbar can be made of aluminum or copper. Aluminum or aluminum alloys have good electrical conductivity, are lightweight, and are inexpensive. Copper or copper alloys can have higher electrical conductivity than aluminum or aluminum alloys. Furthermore, copper or copper alloys may be oxidation-resistant and have low contact resistance. The busbar can have a rectangular conductor cross-section. Here, the busbar can be elongated and have a length, for example, greater than 0.5 m, preferably greater than 1 m, and a width, for example, between 0.5 cm and 10 cm, preferably between 1 cm and 5 cm. The busbar can also have a thickness, for example, between 1 mm and 10 mm. The busbar can be insulated on all sides, i.e., wrapped with an insulating layer. For example, the insulation can be made of a plastic material. The plastic material can be thermoplastic. The busbar can be encapsulated in thermoplastic injection molding. This insulation can have characteristics designed for high voltage applications in motor vehicles up to 1000 volts DC. In particular, the thickness of the insulation material ensures insulation strength against high voltage applications in motor vehicles.

[0014] A double busbar can consist of two busbars of the same size. These two busbars can be stacked on top of each other on their flat sides. The busbars can be arranged equally. The double busbar can be covered with a plastic material. Alternatively or additionally, the double busbar can be covered with a fabric material. For example, the fabric material can be wrapped around the double busbar as a fabric strip. The busbar can be exposed at one end, i.e., for example, the insulation and sheath can be removed at least partially. The double busbar can also be shielded from electromagnetic field radiation by a conductive sleeve.

[0015] In the installed state, one busbar of the dual busbar system can be connected to the positive potential of the vehicle's high voltage. The other busbar can be connected to the negative potential of the vehicle's high voltage. The currents flowing through the two buses therefore flow in opposite directions and are of equal magnitude. The spatial adjacency of the buses in the dual busbar system causes the resulting electromagnetic fields to essentially cancel each other out.

[0016] Plug connectors can be pluggable electrical connectors. Plug connectors can be lockable. Plug connectors can also be disassembled. Plug connectors can be axially inserted. Plug connectors can have mechanical and / or motion mechanisms designed to generate contact pressure on the two mating contacts to allow for low contact resistance. Plug connectors can have limited current-carrying capacity. The current-carrying capacity of a single plug connector can be less than the current-carrying capacity of the busbar to which it is connected. To reach or exceed the busbar's current-carrying capacity, multiple plug connectors can be connected in parallel. For example, in the practice mentioned here, two, four, six, eight, or ten plug connectors can be connected in parallel. The plug connectors here can all be of the same type. The total current of the busbar is thus distributed to multiple load paths. In particular, the current is evenly distributed to the load paths. The current-carrying capacities of the plug connectors are then added together.

[0017] The axis of symmetry of the contact device can be oriented in the axial insertion direction of the plug connector. The axis of symmetry can extend through the geometric center of the contact device within its plug connector region. The plug connectors of the busbars can be paired and opposed to each other about the axis of symmetry. When current flows through the contact device, electromagnetic fields appear around each load path. Due to the symmetry of the load paths about the axis of symmetry, the rectified individual electromagnetic fields combine to form a resultant electromagnetic field along the axis of symmetry. Because the plug connectors and, consequently, the load paths of the two busbars are arranged symmetrically about the axis of symmetry, there are two resultant electromagnetic fields of equal intensity but opposing forces along the axis of symmetry, which cancel each other out.

[0018] The mating plane can extend through all the plug connectors. The axis of symmetry can extend within the mating plane. Because they are arranged within the mating plane, the plug connectors can be arranged in series and side by side.

[0019] A connector can be a mating part of a contact device. A connector can be a mating part of a plug connector. A connector can be designed to correspond to a contact device.

[0020] Plug connectors can be designed as circular plug connectors and / or flat plug connectors. In the case of flat plug connectors, two flat conductors with flat sides can be pressed together, resulting in a large contact area. In the case of circular plug connectors, the circumference of the circular conductor can be placed in a socket. Here, a large contact area can also be obtained. Flat plug connectors are easier to install than circular plug connectors because the flat conductor can be integrally connected to the inserted flat conductor. In circular plug connectors, a transition from the flat cross-section of the busbar to the circular cross-section of the plug connector is required.

[0021] Flat plug connectors can be connected to their respective busbars via flat contacts. The flat contacts can be arranged symmetrically with respect to a plane of symmetry passing through the axis of symmetry. The plane of symmetry can be oriented perpendicular to the mating plane. The flat contacts can be small busbars. The number of flat contacts can correspond to the number of plug connectors. In particular, this number can be even. Individual flat contacts can be metal strips. Flat contacts can be made of copper. Individual flat contacts can have a smaller conductor cross-section than the busbar. Individual flat contacts can form mating contacts directly within the flat plug connector. The plane of symmetry of the flat contacts can correspond to a central plane of symmetry along the dual busbars. Due to the symmetry with respect to the plane of symmetry, electromagnetic field destructiveness is also guaranteed in the flat contact region.

[0022] The flat contact can be designed as a stamped and bent part. Each flat contact can have a mating area oriented on its respective busbar and a plug area oriented on its respective plug connector. The flat contact can be soldered to its respective busbar at the mating area. The mating area can be arranged in its respective flat plug connector. The mating area and the plug area can be oriented at an angle to each other.

[0023] The engagement area and plug area can be bent relative to each other at 90°. The engagement areas are oriented on their respective busbars. The plug area and, consequently, the flat plug connector can be oriented perpendicular to the busbars. The plug areas of the flat contacts can be oriented parallel to each other. The flat plug connector can be oriented parallel to a plane of symmetry. Thus, the flat plug connectors can be placed side-by-side and the contact device occupies very little space.

[0024] The plug connectors of the first busbar can be arranged between the plug connectors of the second busbar. The plug connectors of the first busbar can be arranged closer to each other than the plug connectors of the second busbar. Attached Figure Description

[0025] Advantageous embodiments of the invention are explained below with reference to the accompanying drawings, in which:

[0026] Figure 1 A diagram of a contact system according to one embodiment is shown.

[0027] This diagram is for illustrative purposes only and is intended to explain the invention. Identical or functional components are always marked with the same reference numerals. Detailed Implementation

[0028] Figure 1 A diagram of a contact system 100 according to one embodiment is shown. The contact system 100 is arranged at the interface between a double busbar 102 and a component (not shown) of a high-voltage system in a motor vehicle. Alternatively, the contact system 100 may also be arranged at the interface between two double busbars 102. The contact system 100 consists of a contact device 104 and a connector 106. The connector 106 is a mating part that mates with the contact device 104. The contact device 104 is connected to the double busbar 102. The connector 106 is connected to the component.

[0029] The double busbar 102 has two busbars 108. Each busbar 108 is a metal strip with a rectangular conductor cross-section. The busbars 108 are made of aluminum. The busbars 108 of the double busbar 102 are stacked and extend parallel to each other. The busbars 108 are electrically isolated from each other and from the environment. The busbars transmit direct current during operation. Here, one busbar 108 is at a positive potential of the vehicle's high voltage. The other busbar 108 is at a negative potential of the vehicle's high voltage. The currents flowing through the busbars 108 are opposite in direction but equal in magnitude. The parallel orientation and close proximity of the busbars 108 in the double busbar 102 cause the electromagnetic fields generated by the current to cancel each other out.

[0030] To maintain this elimination at the interface, the contact system 100 has four parallel-arranged plug connectors 110. Here, the plug connectors 110 are flat plug connectors. Alternatively, the plug connectors 110 can also be circular plug connectors. The plug connectors 110 are arranged in pairs symmetrically with respect to the axis of symmetry 112 of the contact system 100. The plug connectors 110 form an inner pair and an outer pair. Each pair of plug connectors 110 is electrically connected in parallel. The inner pair is connected to one busbar 108. The outer pair is connected to another busbar 108. The current in each busbar 108 is split into two identical load paths through the parallel plug connectors 110.

[0031] All plug connectors 108 are arranged in a mating plane 114 of the contact system 100. The mating plane 114 is oriented perpendicular to the plane of symmetry 116 of the double busbars 102. The axis of symmetry 112 is the intersecting line of the mating plane 114 and the plane of symmetry 116.

[0032] In one embodiment, a plurality of flat contacts 118 are arranged between the busbar 112 of the dual busbar 102 and the plug connector 110. The flat contacts 118 are made of copper. The flat contacts 118 are stamped and bent. The stamped profiles of the flat contacts 118 are L-shaped. The flat contacts 118 are arranged symmetrically with respect to the plane of symmetry 116. Each flat contact 118 has a conductor cross-section smaller than that of the busbar 108. Each flat contact 118 has a mating region 120 and a plug region 122. The mating region 120 is oriented parallel to and electrically connected to its respective busbar 108. The plug region 122 is oriented along its respective plug connector 110.

[0033] In one embodiment, the plug regions 122 are each at a 90° angle to the engagement region 120. Thus, the plug regions are perpendicular to the mating plane 114 and parallel to the plane of symmetry 116. Consequently, the four plug regions 122 of all the flat contacts 118 are oriented parallel to each other.

[0034] In one embodiment, the flat contact 118 directly forms the mating contact of the plug connector 110. Here, the plug connector 110 each has a cage 124 surrounding one end of the plug region 122 of its respective flat contact 118. The mechanism for pressing the plug region 122 against the corresponding contact piece 126 of the connector 106 is arranged in the cage 124.

[0035] Connector 106 has two contacts 128, each with two contact tabs 126. Contacts 128 are made of copper. Like the flat contact 118, contacts 128 are stamped and bent. The stamped profile of contacts 128 is T-shaped. Contact tabs 126 are oriented perpendicular to the center area of ​​contacts 128. For the mating plug connector 110, the contact tabs 126 are bent more than 90° and then bent back to vertical to allow for small pitch in the mating plug connector 110.

[0036] In other words, a contact system for a series flat plug for a dual-bus power transmission system is proposed.

[0037] Besides the classic circular conductor and single busbar systems used in electric vehicles, dual busbar systems can also be used for power transmission because they offer the advantage of less electromagnetic field radiation due to field elimination. Field elimination originates from the geometric arrangement of equally overlapping rectangular buses with minimal spacing between them. Interfaces with contact systems are required to connect these dual busbar systems to components such as charging sockets, switch boxes, or batteries.

[0038] This approach proposes a contact system that connects two potentials using conventional plug contacts, such that the contacts are arranged in pairs symmetrically with respect to the center of the flat conductor and from the inside out, thereby canceling out electromagnetic fields.

[0039] Current transfer between two potentials is typically achieved through side-by-side contacts using insert contacts. As a result, the electromagnetic fields in the contact area are shifted relative to each other and can no longer completely cancel each other out.

[0040] Because of the paired symmetrical arrangement, the field displacements cancel each other out, thus the fields in the entire insertion region are completely canceled out.

[0041] With the ever-increasing power requirements in the electric vehicle sector, the protection of occupants from electromagnetic inrush (ICNIRP) is receiving growing attention. High-voltage (HV) dual-bus systems can transmit large amounts of energy while maintaining low electromagnetic field radiation. This bus system requires suitable outdoor-compatible interfaces. Through the proposed contact system, the dual bus can be installed in space as an interface for switch boxes or batteries.

[0042] The approach presented here can be scaled in principle by selecting the number of mating contacts and contact pairs and can be used for any power range. Electromagnetically, the contact system is neutral in the mating region.

[0043] Electrical connection is made through conventional plug connectors, which are of the same structure and arranged in pairs symmetrically in the plane of contact symmetry. In this sense, all flat and round plug connectors are applicable as conventional plug connectors; they are axially connected together and generate an electrical connection in the connected state, with or without additional measures such as locking mechanisms.

[0044] The plane of symmetry of the busbar is perpendicular to the busbar and extends through its neutral line. In the contact area, the center point of each contact lies on a plane perpendicular to the plane of symmetry of the busbar. Within the plane of symmetry of the contact, all contact pairs are arranged symmetrically with respect to the axis of symmetry of the load path.

[0045] Because of this configuration, the center of mass of the contact pair and the center of the electromagnetic field are both located on the axis of symmetry, so these fields completely cancel each other out. Therefore, the contact area itself does not generate an electromagnetic field.

[0046] As long as the two planes of symmetry are perpendicular to each other, the plane of symmetry of the contact and, consequently, the axis of the load path can be at any angle relative to the axis of symmetry of the busbar, determined by the principle. This allows for the formation of a 90° plug-in variant, just like the 180° variant (and thus, for example, an inline connector).

[0047] Since the apparatus and methods described above are embodiments, those skilled in the art can make extensive modifications to them in a common manner without departing from the scope of the invention. In particular, the mechanical arrangement and dimensional relationships of the various components are merely exemplary.

[0048] List of reference numerals

[0049] 100 contact system

[0050] 102 Double busbar

[0051] 104 Contact device

[0052] 106 connector

[0053] 108 busbar

[0054] 110 Plug Connector

[0055] 112 Axis of Symmetry

[0056] 114 Insertion plane

[0057] 116 Symmetrical planes

[0058] 118 Flat Contact

[0059] 120 Joint Area

[0060] 122 Plug Area

[0061] 124 cages

[0062] 126 contact pieces

[0063] 128 contacts

Claims

1. A contact device for double busbars, wherein, The dual busbars have two busbars stacked together, wherein the contact device of each busbar has an even number of plug connectors symmetrically arranged about the axis of symmetry of the contact device, and wherein the plug connectors of the two busbars are oriented in the same mating plane. The insertion plane is perpendicular to the extension directions of the two busbars. At least one of the busbars has a plug connector designed as a flat plug connector. The flat plug connector is connected to a corresponding busbar via flat contacts, wherein the flat contacts are arranged symmetrically about a plane of symmetry passing through the axis of symmetry, wherein the plane of symmetry is perpendicular to the insertion plane, and the axis of symmetry is a straight line intersecting the plane of symmetry and the insertion plane. The two busbars include a first busbar and a second busbar, wherein the plug connector of the first busbar is arranged between the plug connectors of the second busbar.

2. The contact device according to claim 1, wherein, When the plug connector of one of the two busbars is designed as a flat plug connector, the plug connector of the other of the two busbars is designed as a round plug connector.

3. The contact device according to claim 1, wherein, The flat contacts are designed as stamped and bent parts, wherein each flat contact has a mating area oriented along its respective busbar and a plug area oriented along its respective plug connector.

4. The contact device according to claim 3, wherein, The engagement area and the plug area are bent at 90° relative to each other.

5. The contact device according to any one of claims 1 to 4, wherein, The flat plug connector is oriented parallel to the plane of symmetry.

6. A connector for a double busbar, wherein, The connector is designed to engage the contact device according to any one of claims 1 to 5, and the connector includes a contact piece for engaging with the plug connector.

7. A contact system for double busbars, wherein, The dual busbars include a contact device according to any one of claims 1 to 5, wherein the two busbars are electrically connected to the plug connector, wherein the plug connector of the contact device is electrically connected to the contact piece of the connector according to claim 6.

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