Contact device for double busbars, counterpart of a contact device and two contact systems for double busbars

Abstract

The invention relates to a contact device (104) for a double busbar (102), wherein the double busbar (102) has a first busbar (108) and a second busbar (110) which are separated from one another by an insulation (112) and are stacked one above the other, wherein the contact device (104) has an outer socket (114) and an inner socket (116) which is coaxially arranged in the outer socket (114), wherein an outer lamella (122) is arranged on the inside of the outer socket (114) for contacting a counter socket (120) of a counter part (106) to the contact device (104), and an inner lamella (124) is arranged on the inside of the inner socket (116) for contacting a contact pin (120) of the counter part (106), wherein the outer socket (114) is arranged on a flat side of the first busbar (108) and is in electrically conductive connection with the first busbar (108), wherein the inner socket (116) is in electrically conductive connection with the second busbar (110) and passes through the first busbar (108).

Description

Technical Field

[0001] The present invention relates to a contact device for double busbars, a mating component for the contact device, and a contact system for two 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 strips on the vehicle body can be used as grounding, thus eliminating the need for a separate return line. Therefore, nearly 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 for safety reasons. Positive and negative busbars can be designed as a double busbar configuration. Summary of the Invention

[0005] Therefore, the objective of this invention is to provide an improved contact device for double busbars, an improved mating member for the contact device, and an improved contact system for two double busbars, using means that minimize structural complexity. In this case, improvements may involve, for example, improved radiation characteristics, and in particular, reduced electromagnetic field radiation.

[0006] This task is accomplished through 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 as well, the proposed approach here is to provide a double socket with a contact sheet that allows current to be coaxially guided at the contact point as well.

[0010] A contact device for a dual busbar is proposed, wherein the dual busbar has a first busbar and a second busbar that are separated from each other by an insulator and stacked into a single stack. The contact device has an external socket and an internal socket coaxially disposed in the external socket. An external thin strip is provided on the inner side of the external socket for contacting a mating socket of a mating member to the contact device, and an inner thin strip is provided on the inner side of the internal socket for contacting a contact pin of the mating member. The external socket is disposed on the flat side of the first busbar and is electrically connected to the first busbar, and the internal socket is electrically connected to the second busbar and passes through the first busbar.

[0011] Furthermore, a mating member corresponding to the contact device according to the practice presented herein is proposed, wherein the mating member has a mating socket for contacting the outer sheet of the contact device and a stylus arranged coaxially in the mating socket for contacting the inner sheet of the contact device.

[0012] Furthermore, a contact system for two double busbars is proposed, wherein each double busbar has two busbars that are separated from each other by insulation and stacked into a stack, wherein the first busbar of the double busbar has a contact device according to the method mentioned herein, and the second busbar of the double busbar has a mating member according to the method mentioned herein, wherein an outer mating socket is arranged on the flat side of the first busbar of the second double busbar and is electrically connected to the first busbar, wherein the contact pin is electrically connected to the second busbar of the second double busbar and penetrates the first busbar, wherein the outer socket is electrically connected to the outer mating socket through an outer thin strip, and the inner socket is electrically connected to the contact pin through an inner thin strip.

[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 conductivity, are lightweight, and are inexpensive. Copper or copper alloys can have higher 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, this 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 also be very close together. 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 double busbar can also be shielded from electromagnetic 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] The socket can be made of copper. The socket can be rotationally symmetrical. The socket can be substantially hollow cylindrical. The socket can have a connection geometry for conductive connection with its respective busbar. The socket can be connected to the busbar by friction welding.

[0017] The strip can be annularly wrapped around the inner diameter of the outer or inner socket. The strip can be conductive and electrically connected to the inner surface of the respective socket. The strip can have a resilient sheath. The strip can have an inner diameter smaller than the respective socket. The sheath can be oriented substantially axially in the respective socket. The sheath can elastically deform upon contact with the mating member and press against the mating member with the resulting restoring force. Axial misalignment and / or angular misalignment between the contact device and the mating member can be compensated for by the elasticity of the strip.

[0018] The mating socket can substantially correspond to the outlet. The outer diameter of the mating socket can be smaller than the inner diameter of the outer outlet within the outer foil strip area. The outer diameter of the mating socket can be larger than the inner diameter of the outer foil strip. The mating socket can be designed without the foil strip.

[0019] The contact pin can be a solid electrical conductor. The contact pin can be made of copper. The contact pin can be rotationally symmetrical. The outer diameter of the contact pin can be smaller than the inner diameter of the inner socket within the inner sheet region. The outer diameter of the contact pin can be larger than the inner diameter of the inner sheet. The contact pin can have a connection geometry for conductive connection with a second busbar. The contact pin can be connected to the busbar by friction welding.

[0020] The sockets are electrically isolated from each other. An insulating bushing may be provided between the inner and outer sockets. Similarly, the mating socket and the contact pin are electrically isolated from each other. An insulating bushing may also be provided between the mating socket and the contact pin. The insulating bushing may be rotationally symmetrical. The insulating bushing may be substantially hollow cylindrical.

[0021] The outer socket may have an annular groove, or circumferential groove, on its inner side for the outer sheet strip. Alternatively or additionally, the inner socket may have an annular groove on its inner side for the inner sheet strip. At least a partial area or the entire sheet strip assigned to each socket may be accommodated in such a groove. The sheet strip may be axially secured in its respective socket via a groove. The sheet of the sheet strip may protrude from the groove into the inner cavity of the respective socket. The sheet strip may be inserted into the groove as a strip bent into a circle with a length corresponding to the circumference of the groove. The sheet strip may be pressed against the bottom of the groove by a restoring force.

[0022] An annular gap for a mating socket between the external and internal sockets can be provided within the area of ​​the outer thin strip. This gap can be wider than the mating socket. The gap can be defined on its inner side by the insulation. The gap can be formed through the shoulder of the external and / or internal sockets. The mating socket can be inserted between the external and internal sockets through this gap. Therefore, the contact system can have a low structural height.

[0023] An insulator positioned between the external and internal sockets may cover one end face of the internal socket. This insulator may have a hole for a contact pin, which can be centered at this hole.

[0024] The outer and / or inner sheet strips may be elongated, extending substantially parallel to the axial direction of the outer and inner sockets, and at least partially protruding radially inward beyond the inner surface of their respective sockets.

[0025] The outer and / or inner sheet strips can elastically protrude radially inward beyond the inner surface of their respective sockets.

[0026] The sheet strip can have an upper flange, a lower flange, and multiple sheets arranged laterally between the upper and lower flanges. The sheet strip can be a stamped and bent part. The sheet strip can have slits between the sheets. The slits allow the sheet strip to be easily bent. The flanges can connect the sheets to each other in a stepped manner at both ends. The sheet can be pre-bent in an arc shape.

[0027] The mating socket and pin can be centered in the contact device via a preferably arc-shaped thin sheet that protrudes radially inward. When the mating socket and pin are inserted into the socket, the thin sheet can elastically bend back by overcoming pre-bending, thus establishing a restoring force as a contact force. Attached Figure Description

[0028] An advantageous embodiment of the invention will now be explained with reference to the accompanying drawings, in which:

[0029] Figure 1 A cross-sectional view of a contact system according to one embodiment is shown.

[0030] Figure 2A perspective view of a double busbar with a contact device according to one embodiment is shown.

[0031] The figures are merely illustrative and are used only to explain the invention. Identical or functionally equivalent parts are always marked with the same reference numerals. Detailed Implementation

[0032] Figure 1 A cross-sectional view of a contact system 100 according to one embodiment is shown. Figure 2 A perspective view of a double busbar 102 with a contact device 104 is shown.

[0033] The contact system 100 electrically connects two double busbars 102. The contact system can also connect the double busbars 102 to another electrical component. The contact system 100 consists of a contact device 104 and a mating part 106 of the contact device 104.

[0034] The double busbar 102 is composed of two parallel extending busbars 108 and 110. Busbars 108 and 110 each have electrical insulation 112. Contact devices 104 and mating members 106 are arranged at the ends of the double busbar 102. Here, the contact devices 104 and mating members 106 are oriented transversely to the main extension direction of the double busbar 102 and are respectively arranged on the flat side of the corresponding double busbar 102.

[0035] The contact device 104 has two coaxially arranged sockets 114 and 116. Sockets 114 and 116 are generally hollow cylindrical. The outer socket 114 surrounds the inner socket 116. An insulation 112 is also provided between the sockets 114 and 116. The outer socket 114 is electrically connected to the first busbar 108 of the first double busbar 102. The inner socket 116 is electrically connected to the second busbar 110 of the first double busbar 102. The inner socket 116 extends electrically through the first busbar 108 to reach the second busbar 110 located behind it.

[0036] The mating member 106 has a mating socket 118 and a contact pin 120. The mating socket 118 is generally hollow cylindrical. The mating socket 118 surrounds the contact pin 120. An insulation 112 is arranged between the mating socket 118 and the contact pin 120. The mating socket 118 is electrically connected to the first busbar 108 of the second double busbar 102. The contact pin 120 is electrically connected to the second busbar 110 of the second double busbar 102. The contact pin 120 extends electrically through the first busbar 108 to reach the second busbar 110 arranged thereafter.

[0037] In one embodiment, the contact pin 120 precedes the mating socket 118. Therefore, the contact pin 120 contacts the inner socket 116 before the mating socket 118 contacts the outer socket. The contact pin 120 may have a guide bevel at its end. The contact device 104 and the mating member 106 can be aligned with each other and axially engaged together via the guide bevel.

[0038] When the contact system 100 is in the contact-on state, the mating socket 118 is disposed in the external socket 114. The outer thin strip 122 of the contact device 104 is disposed between the external socket 114 and the mating socket 118. When the mating socket 118 is inserted into the external socket 114, the outer thin strip 122 is clamped and electrically connects the external socket 114 and the mating socket 118.

[0039] When the contact system 100 is in the contact-connected state, the contact pin 120 is arranged within the inner socket 116. The inner sheet strip 124 of the contact device 104 is disposed between the inner socket 116 and the contact pin 120. When the contact pin 120 is inserted into the inner socket 116, the inner sheet strip 124 is clamped and electrically connects the inner socket 116 and the contact pin 120.

[0040] In one embodiment, the sheet strips 122 and 124 are both made of trapezoidal strip metal sheets. Due to the presence of numerous parallel slits formed by cutting or stamping within the strip, the sheet strips 122 and 124 have an upper flange 126, a lower flange 128, and numerous sheets 130 formed between these slits. The sheets 130 are curved around the longitudinal axis of the strip. For insertion into the sockets 114 and 116, these strips are cut to a certain length and spirally wound. Within the sockets 114 and 116, the winding is unwound, and the strips are then circumferentially abutted against the inner surfaces of the sockets 114 and 116 by the restoring force of the upper and lower flanges 126 and 128.

[0041] In one embodiment, busbars 108 and 110 are made of aluminum, while sockets 114 and 116, mating receptacle 118, and contact pin 120 are made of copper. Sockets 114 and 116, mating receptacle 118, and contact pin 120 are connected to busbars 108 and 110 by friction welding to obtain a reliable conductive connection.

[0042] In one embodiment, the strips 122, 124 are arranged in a ring around the surrounding groove 132 of the sockets 114, 116 on the inner side. The strips 122, 124 are fixed axially by the groove 132 and cannot move axially when the mating socket 118 is inserted into the outer socket 114 or when the contact pin 120 is inserted into the inner socket 116.

[0043] In one embodiment, the mating socket 118 is arranged in an annular gap 134 between the outer socket 114 and the insulator 112. The inner socket 116 has a surrounding retracted portion that recedes with the material thickness of the mating socket 118 to provide space for the gap 134. The contact device 104 and the mating member 106 are nested through the gap 134 and have a reduced structural height.

[0044] In one embodiment, the insulator 112 covers one end face of the inner socket 116. Therefore, electrical contact between the mating socket 118 and the inner socket 116 can be reliably avoided.

[0045] In one embodiment, the contact device 104 and the mating member 106 each have an electrically insulated housing 136. The housing 136 also surrounds the ends of the double busbar 102. The two housings 136 are sealed to each other by a seal surrounding the external socket 114.

[0046] In other words, a dual-socket design with contact plates is proposed as a contact system for a dual-bus power transmission system.

[0047] 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 advantages related to lower electromagnetic field radiation due to field elimination. Field elimination arises from the geometric arrangement of rectangular buses that overlap in the same manner 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.

[0048] This method proposes a contact system geometrically composed of two concentric nested but electrically insulated plug contacts. It features thin strips arranged as contact surfaces on the inner surfaces of the plugs. These strips can be pre-stamped, cut to length, and inserted into annular grooves provided in the plugs. The required contact force is applied via external screws on the housing. This contact system maintains a degree of freedom in the insertion direction, eliminating the need for, for example, wave springs to further pre-tighten the inner plug components to achieve tolerance compensation between the contact pairs on the positive and negative sides. The contact system can be tightened or locked on the housing side. Applications include charging socket interfaces, switch box or battery interfaces, and suspension points for segmented busbars in challenging structural spaces where their entire length cannot be utilized.

[0049] 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 busbar systems can transmit large amounts of power while maintaining low electromagnetic field radiation. This busbar system requires suitable outdoor-compatible interfaces. Through the provided contact system, the dual busbar can be installed in a space as an interface for a switch box or battery. This contact system can also serve as an interface for a charging socket, a switch box or battery interface, and a suspension separation point for segmented dual busbars installed in challenging structural spaces where their entire length cannot be utilized.

[0050] The contact is not generated through the end face of the socket geometry, but through a contact sheet embedded inside the socket. This contact system retains a certain degree of freedom in the insertion direction and does not require the use of a spring to preload one of the sockets in a pair.

[0051] The drawing shows a cross-sectional view of a dual-pin contact system with a flanged busbar connection. The housing shown is conceptual only. In the completed structure, the connector and plug housing are screwed or locked together. The inner pin, which contacts the inner socket, is clearly visible in the cross-section. The outer contact system is represented by a socket (surrounding the pin) located in the connector, which contacts the upper outer socket's contact plate. If the dual-busbar system cannot be installed as a single piece (e.g., for installation purposes), the contact system can also be used as a suspension disconnect point on the connector side. The contact system can also be used as an interface for a charging socket, where it can be directly screwed into one of the DC pins or connected to the charging socket contacts via the busbar assembly (screwed in, inserted).

[0052] To ensure protection against touch and electrical isolation, the two sockets are covered by plastic geometric shapes that retract during insertion.

[0053] Since the apparatus described above is an embodiment, those skilled in the art can make extensive modifications to it 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.

[0054] List of reference numerals

[0055] 100 contact system

[0056] 102 Double busbar

[0057] 104 Contact device

[0058] 106 mating parts

[0059] 108 First busbar

[0060] 110 Second busbar

[0061] 112 Insulation

[0062] 114 External Socket

[0063] 116 Internal socket

[0064] 118 Matching Socket

[0065] 120 styluses

[0066] 122 outer thin strip

[0067] 124 inner thin strip

[0068] 126 Upper wing edge

[0069] 128 Lower flange

[0070] 130 thin slices

[0071] 132 slots

[0072] 134 gap

[0073] 136 Casing

Claims

1. A contact device (104) for a double busbar (102). in, The double busbar (102) has a first busbar (108) and a second busbar (110) that are separated from each other by an insulator (112) and stacked into a single stack. The contact device (104) has an external socket (114) and an internal socket (116) coaxially disposed in the external socket (114). The outer thin strip (122) is provided on the inner side of the outer socket (114) to connect the mating socket (120) of the mating member (106) to the contact device (104), and the inner thin strip (124) is provided on the inner side of the inner socket (116) to connect the contact pin (120) of the mating member (106). The external socket (114) is located on the flat side of the first busbar (108) and is electrically connected to the first busbar (108). The inner socket (116) is electrically connected to the second busbar (110) and passes through the first busbar (108).

2. The contact device (104) according to claim 1, wherein, The outer socket (114) has a circumferential groove (132) on its inner side, and the outer sheet strip (122) is at least partially accommodated in the groove (132); and / or wherein, The inner side of the inner socket (116) has a surrounding groove (132) and the inner sheet strip (122) is at least partially accommodated in the groove (132).

3. The contact device (104) according to claim 1, wherein, An annular gap (134) is arranged in the region of the outer thin strip (122) to accommodate the mating socket (118) between the outer socket (114) and the inner socket (116).

4. The contact device (104) according to any one of claims 1 to 3, wherein, An insulator (112) disposed between the external socket (114) and the internal socket (116) covers one end face of the internal socket (116).

5. The contact device (104) according to any one of claims 1 to 3, wherein, The outer sheet strip (122) has an upper flange (126), a lower flange (128) and a plurality of sheets (130) arranged laterally between the upper flange (126) and the lower flange (128), and / or the inner sheet strip (124) has an upper flange (126), a lower flange (128) and a plurality of sheets (130) arranged laterally between the upper flange (126) and the lower flange (128).

6. The contact device (104) according to any one of claims 1 to 3, wherein, The outer sheet (122) and / or the inner sheet (124) sheet (130) are elongated and extend substantially parallel to the axial direction of the outer and inner sockets (114, 116), and at least locally protrude radially inward beyond the inner surface of the respective socket (114, 116).

7. The contact device (104) according to any one of claims 1 to 3, wherein, The outer sheet (122) and / or the sheet (130) of the inner sheet (124) protrude radially inward beyond the inner surface of their respective sockets (114, 116) in an elastic manner.

8. A mating member (106) for a contact device (104) according to any one of claims 1 to 7, wherein, The mating member (106) has a mating socket (118) for contacting the outer sheet (122) of the contact device (104) and a stylus (120) coaxially disposed in the mating socket (118) for contacting the inner sheet (124) of the contact device (104).

9. A contact system (100) for two double busbars (102), wherein, The dual busbars (102) each have two busbars (108, 110), which are separated from each other by an insulator (112) and stacked into a stack. The first double busbar (102) has a contact device (104) according to any one of claims 1 to 7, and the second double busbar (102) has a mating member (106) according to claim 8. The mating socket (118) is arranged on the flat side of the first busbar (108) of the second double busbar (102) and is electrically connected to the first busbar (108) of the second double busbar (102). The stylus (120) is electrically connected to the second busbar (110) of the second double busbar (102) and passes through the first busbar (108) of the second double busbar (102). The external socket (114) is electrically connected to the mating socket (118) through the external thin strip (122), and the internal socket (116) is electrically connected to the contact pin (120) through the internal thin strip (124).

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