Plug-in component

Abstract

The invention relates to a plug-in part for mechanically and electrically connecting to a mating plug-in part, in particular a motor vehicle-side charging socket (1), for coupling to a charging plug as a component of a charging system for an electric or hybrid vehicle, or vice versa, for mechanically and electrically connecting to a mating plug-in part, in particular a motor vehicle-side charging socket (1), for coupling to a charging plug as a component of a charging system for an electric or hybrid vehicle. The plug part has a plastic housing (2) and at least one electrical contact element (3) arranged in the housing (2). In addition, a cooling element (5) is provided which is in thermal contact with the electrical contact element (3). According to the invention, the contact element (3) and the cooling element (5) are electrically insulated from each other.

Description

Technical Field

[0001] The invention relates to a plug-in component, which is used to be mechanically and electrically connected to a mating plug-in component, in particular a charging socket on the motor vehicle side, for connecting to a charging plug as a component of a charging facility for an electric vehicle or a hybrid vehicle, or vice versa. The plug-in component has a plastic housing and at least one electrical contact element arranged in the housing, and has a cooling element in thermal contact with the electrical contact element. Background Art

[0002] In motor vehicles, plug-in components are generally charging sockets that can be connected to corresponding charging plugs that are present, for example, on an electrical charging post. Like the charging socket, the charging plug belongs to the charging facility, with the help of which the rechargeable storage device or battery of an electric or hybrid vehicle can be charged. In principle, the plug-in component on the motor vehicle can also be a charging plug instead of a charging socket. In this case, the charging post is equipped with a corresponding charging socket. However, in general, electric vehicles or hybrid vehicles have a charging socket with a plurality of electrical contact elements arranged in a housing, into which a charging plug connected to the charging post is inserted for charging the relevant motor vehicle.

[0003] For this purpose, on the one hand, in order to be able to supply the electric motor present in the relevant motor vehicle with high electrical power using the required electrical energy, and on the other hand, in order to provide a sufficient driving range, a high-voltage battery or high-voltage storage battery is currently used, which is typically charged with a high-voltage direct current voltage. In addition to this DC charging process (direct current, direct current), most electric vehicles or hybrid vehicles also have the possibility of a charging process with an alternating current voltage in an AC charging process (alternate current, alternating current). However, low currents and long charging times are usually used for this purpose, whereas in the DC charging process already described above, high voltages and high currents and the resulting short charging times are observed.

[0004] Particularly during DC charging, due to the high current intensities, there is the fundamental problem that the electrical contact elements used for this purpose heat up. This results in an increase in electrical resistance, which impedes the charging process and the desired rapid charging. Furthermore, due to the heat generated on or in the charging station, it is necessary to control or regulate the charging current in order to counteract the possible increase in the temperature of the contact elements.

[0005] For this reason, a plug-in component with a temperature monitoring device is described in the prior art according to EP 3 616 270 B1. In the event of a possible overheating of the contact element, the temperature monitoring device ensures that the current is switched off or at least reduced.

[0006] In the prior art according to EP 3 433 904 B1, the contact element is provided with a heat capacity element as a cooling element. This is intended to optimize and accelerate the heat dissipation from the contact element to the environment. In this way, high current intensities can be transmitted in the most favorable case without triggering a possible and additionally provided temperature monitoring device. This has been proven in principle.

[0007] However, the prior art according to EP 3 433 904 B1 provides that a single heat capacity element or cooling element is connected to the shank section of the contact element by means of an attachment in a force-locking or form-locking manner. The cooling element is a solid metal body in the shape of a cuboid. As a result, on the one hand, the available structural space inside the plug-in component or the charging socket is reduced. On the other hand, it is observed that the weight increases while the cost increases, and the risk of electrical short circuits may still occur. For this purpose, the prior art handles it in this way: the cooling elements of different contact elements are electrically insulated from each other.

[0008] However, the problem still remains that the cooling elements may be exposed to high voltages due to their electrical connection to the contact elements, wherein, although the insulation between the individual cooling elements can ensure electrical insulation from one another, it may not provide sufficient electrical insulation from other components within the plug-in component or also towards the outside. This can be problematic in particular against the background of a continuous increase in DC voltages or high voltages in this area. The present invention seeks to solve this problem as a whole. Summary of the invention

[0009] The invention is based on the technical problem of developing a plug-in component of the generic type in such a way that good heat dissipation and cooling are achieved even when high voltages are present and reliable electrical insulation is achieved.

[0010] In order to solve this technical problem, the invention proposes, with respect to a plug component of this type for mechanical and electrical connection to a mating plug component, that the contact element and the cooling element are electrically insulated from one another.

[0011] Thus, in contrast to the prior art according to EP 3 433 904 B1, firstly and according to the invention, the cooling element and the contact element cannot be electrically connected to one another, but are instead electrically insulated from one another. In contrast, the known teaching of this type is that the cooling element is connected to the shank section of the contact element by means of an attachment in a force-locking or form-locking manner. This prior art, in other words, deliberately promotes electrical connection, which is contrary to the teaching of the invention.

[0012] The electrical insulation between the contact element and the cooling element can be implemented in different ways in detail while achieving a heat-conducting connection at the same time. That is, according to a first variant, it is basically possible for the cooling element to be designed to be electrically insulating and at the same time heat-conducting. A variant that has proven to be particularly advantageous is one in which the cooling element consists of or is made of, for example, a heat-conducting plastic or polymer. At the same time, the cooling element can thereby be designed to be electrically insulating.

[0013] The thermally conductive polymer may be a polymer in which a separate filler for heat conduction is embedded. The invention is based on the following knowledge: Typically, for the production of housings from plastic, the thermoplastic used for the plug-in components has a thermal conductivity of a maximum of 0.5 W / m·K. This means that the plastics commonly used in this context (e.g. polypropylene (PP), PA (polyamide), polyethylene terephthalate (PET), polyethylene (PE), etc.) have the above-mentioned typical thermal conductivity values.

[0014] In order to provide a cooling element which has an increased thermal conductivity and is designed to be electrically insulating, suitable fillers can be embedded in the plastic in question. Fillers which are electrically insulating and at the same time thermally conductive have proven to be particularly advantageous. These include, for example, aluminum compounds or boron compounds, specifically particularly preferably aluminum oxide or boron nitride. This can increase the thermal conductivity of the relevant plastic by at least a factor of three, so that a correspondingly designed cooling element has a thermal conductivity of at least 1.5 W / m·K.

[0015] In this regard, the relevant heat-conducting fillers in the plastic used to produce the cooling element can be provided in a grammage of up to 50 wt% (weight percentage) or more. Further details about the fillers and the associated plastics can be found in DE 10 2007 037 316 A1, which represents the relevant and related prior art. The publication relates to heat-conducting and electrically insulating thermoplastic compounds, i.e. plastics with the above-mentioned embedded special fillers. In addition, reference can also be made to DE 10 2013 208 605 A1.

[0016] In addition to the already described approach of designing the cooling element to be electrically insulating and at the same time thermally conductive, the invention discloses as a further option that the contact element and the cooling element are thermally conductively connected to one another via an electrically insulating heat transfer element. In this way, the cooling element itself can be designed to be electrically and at the same time thermally conductive, for example, it can be realized as a cooling element made of metal. In this case, metals such as steel, aluminum or zinc have proven to be particularly advantageous. In this case, it is not the cooling element itself that provides the necessary electrical insulation, but rather the electrically insulating heat transfer element, which is connected between the electrically conductive contact element and the cooling element, which is likewise electrically conductive in this case.

[0017] Of course, in the case of a non-conductive and at the same time heat-conducting cooling element made of the described plastic with embedded filler, the electrically insulating heat transfer element can also be used in addition as required. This ultimately depends on how conductive the cooling element is or how much it should be set. That is, depending on the filler embedded in the plastic in question for realizing the cooling element, an electrically insulating heat transfer element can be connected between the contact element and the cooling element as required and in addition, or it is also possible not to connect a heat transfer element.

[0018] In the case of an electrically insulating heat transfer element, it has proven to be particularly advantageous if the heat transfer element is designed as a component of the plastic housing. This eliminates the need for additional manufacturing measures and special production methods. In this context, it is particularly advantageous if the heat transfer element surrounds the contact element as a whole in cross section by means of an annular, more precisely cylindrical, wall thickness, in particular of several millimeters. Advantageously, a wall thickness of less than 1 mm can even be used.

[0019] The heat transfer element designed as a component of the housing can be defined again by a filler embedded in the plastic. In this case, the filler is embedded in the plastic only in the region of the heat transfer element. Here again, electrically insulating fillers with increased thermal conductivity, as already described at the outset, can be used. Particularly suitable for this are aluminum compounds and boron compounds, in particular aluminum oxide or boron nitride, which are embedded in the plastic of the housing provided here in the region of the heat transfer element and in this way define an electrically insulating and at the same time thermally conductive heat transfer element.

[0020] Alternatively or additionally, however, the heat transfer element can also be designed as a component independent of the housing. In this case, it is conceivable in an alternative that the heat transfer element is a filler formed, for example, from a ceramic material or a mineral material. Alternatively or additionally, the heat transfer element independent of the housing can also be designed as a hose sheath that at least largely surrounds the electrical contact element. It is also possible that the heat transfer element has such a hose sheath.

[0021] In the latter case, the heat transfer element is typically designed in two parts and usually consists of the actual transfer element, which surrounds the contact element in an annular manner, and an additional clamping sleeve. With the help of the clamping sleeve, the heat transfer element including the electrical contact element can be inserted into the hole in the housing. The clamping sleeve or also the hose sleeve is compressed here. The clamping sleeve or the hose sleeve has a high thermal conductivity, because the heat transfer element located inside mainly ensures electrical insulation and at the same time heat transfer.

[0022] In summary, a plug-in component is provided which is characterized by particularly advantageous thermal management. This is attributable to the use of a cooling element which is electrically insulated relative to the contact element. This prevents high voltages which may occur at the contact element from being transferred to the cooling element. In order to implement the above in a concrete manner, a cooling element based on plastic or polymer with embedded fillers can be used, or an electrically insulating heat transfer element can be designed to be additionally connected between the contact element and the cooling element. Of course, the two basic measures described above can also be combined with one another.

[0023] In any case it is ensured that the cooling element itself is designed to be electrically insulating and at the same time thermally conductive, or in the case of an electrically conductive cooling element, electrical insulation of the contact element is ensured by an interposed heat transfer element. Considerable advantages can be seen from the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The invention is explained in detail below with reference to the accompanying drawings which show only one exemplary embodiment; in which:

[0025] Figure 1 The plug component according to the invention, which is designed as a charging socket on the motor vehicle side, is shown in a front view.

[0026] Figure 2 Shows Figure 1 The relevant rear view,

[0027] Figure 3 The previous view shows that Figure 1 and Figure 2 objects, and

[0028] Figure 4 The side view shows the Figure 3 object.

[0029] Figure 5A , 5B , 5C shows a modified embodiment, and

[0030] Figure 6 A, 6B, and 6C show another embodiment variant of the present invention. DETAILED DESCRIPTION

[0031] The accompanying drawings show a plug-in component for mechanical and electrical connection with a mating plug-in component. Figure 1 and Figure 2 In the embodiment of FIG. 1 , the plug component is a charging socket 1 on a motor vehicle. The charging socket 1 is configured to be connected to a charging plug, which is not shown in detail and represents a component of a charging facility for an electric vehicle or a hybrid vehicle.

[0032] For this purpose, the charging socket 1 is equipped with a housing 2 made of plastic and at least one electrical contact element 3 arranged in the housing 2. Only the two contact elements 3 required for the DC charging process are examined in detail below. In contrast, the additional electrical contact elements 4 required for the AC charging process and provided in addition are not discussed further. According to the present embodiment, the two electrical contact elements 3 are equipped with a cooling element 5 in the interior of the housing 2. The cooling element 5 is in thermal contact with the electrical contact elements 3.

[0033] Here, as a whole, Figure 3 Front view or Figure 4 . Within the scope of the invention, there are a total of two different variants for implementation. In fact, according to a first variant, it can be adopted that the cooling element 5 is designed to be electrically insulating and at the same time thermally conductive. In this case, the cooling element 5 can be a cooling element formed by a plastic or polymer, thus by a component of the housing, in which a filler designed to be electrically insulating and at the same time thermally conductive is embedded. Suitable fillers have already been described at the beginning and can be, for example, aluminum oxide and / or boron nitride. In this case, no additional and Figure 3 The electrically insulating heat transfer element 6 is indicated in FIG.

[0034] But according to Figure 3 and Figure 4 In the embodiment of the invention, an electrically insulating heat transfer element 6 is used as a whole. The contact element 3 and the cooling element 5 are connected to each other in a heat-conducting manner by means of the electrically insulating heat transfer element 6. In this case, the cooling element 5 is advantageously made of metal, such as steel, aluminum or zinc, for example. Of course, combinations are also conceivable. In order to protect the cooling element 5 made of metal from the high voltage applied to the contact element 3 in this context, the electrically insulating heat transfer element 6 ensures electrical insulation between the contact element 3 and the cooling element 5 in this case. In contrast, the variants already described above are distinguished in that no heat transfer element 6 is required, since the cooling element 5 itself provides electrical insulation.

[0035] In accordance with Figure 3 and Figure 4 In a variant, the heat transfer element 6 can consist of a heterogeneous material (ie not of plastic) and can be manufactured. Ceramic or mineral materials have proven to be particularly advantageous here, which can provide electrical insulation and still achieve thermal conductivity. A suitable ceramic material is, for example, zirconium, while sand or the like can be used as a mineral material in particular.

[0036] Furthermore, the overall design is such that the heat transfer element 6 surrounds the contact element 3 in a ring-shaped manner in cross section, which heat transfer element in cross section has, in particular, a wall thickness S of several millimeters. In practice, the wall thickness S of the heat transfer element 6 can be several millimeters and can even be less than 1 mm. In this way, a particularly expedient and rapid heat transfer from the contact element 3 to the cooling element 5 is achieved and implemented, which corresponds to a particularly effective cooling.

[0037] According to this embodiment, it can be seen that the cooling element 5 is designed as a strip as a whole and has cooling ribs 5a on the end side. Here, the cooling ribs 5a can protrude laterally from the housing 2 in the front view. This depends on the installation and space conditions for the charging socket 1. In addition, it can be seen that the cooling element 5 only surrounds the contact element 3 for the DC charging process in a strip shape, while the other contact element 4 for the AC charging process is not covered due to the small current.

[0038] Based on the above description Figure 3 and Figure 4 The variants are designed in such a way that the heat transfer element 6 is made of a foreign material (ie not of plastic). In this case, the heat transfer element 6 is designed as a separate component from the housing 2 or the cooling element 5. Figure 6 Variants are also shown in which the heat transfer element 6 is designed as a component separate from the housing 2 or the cooling element 5 .

[0039] In fact, according to Figure 5A It can be seen that in this case the heat transfer element 6 is designed as a hose sleeve which at least substantially surrounds the electrical contact element 3. Here, it can be handled in such a way that after preassembly of the electrical contact element 3 and the housing 2 or after the electrical contact element or the housing cooling element 5, the heat transfer element 6 shown in each case, which is designed as a double-ear hose sleeve, is deformed in the air gap of the housing 2 or the cooling element 5 and largely eliminates or closes the air gap. The same applies to Figure 5B According to another variant shown in , a screw 7 or another clamping element ensures that any remaining air gaps after preassembly are eliminated, so that a continuous heat flow is observed and exists through the heat transfer element 6 from the contact element 3 to the housing 2 or the cooling element 5 of the housing.

[0040] according to Figure 6 Another variant is characterized in that a two-part heat transfer element 6 is provided. 1 , 6 2 , the heat transfer element is also designed as a component independent of the housing 2 or its cooling element 5. Here, firstly a primary heat transfer element 6 is realized which completely surrounds the electrical contact element 3. 1The primary heat transfer element ensures electrical insulation between the contact element 3 and the housing 2 or the cooling element 5. 1 The electrical contact element 3 may be coated with a plastic or polymer with an embedded potting compound, which is designed to be electrically insulating and at the same time thermally conductive.

[0041] In addition to the primary heat transfer element 6 1 In addition, a secondary heat transfer element 6 designed as a clamping sleeve is provided. 2 Here, the primary heat transfer element 6 1 In comparison, the clamping bushing can be provided with a significantly improved thermal conductivity. This results in assembly advantages, such as Figure 6 As shown in the perspective view additionally shown in FIG.

[0042] In fact, the clamping sleeve or the secondary heat transfer element 6 in this regard 2 and comprising a primary heat transfer element 6 1 The electrical contact element 3 can be installed in the pre-assembled position in the associated hole or recess in the partially shown cooling element 5 practically without assembly forces. In the process, the clamping sleeve or the secondary heat transfer element 6 1 It is compressed and, with a slight transition fit, pressed into the hole in the cooling element 5. This can be done overall without tools and thus results in a cost-effective and lightweight, yet still functionally reliable variant.

[0043] List of reference numerals:

[0044] 1 Charging socket

[0045] 2 Shell

[0046] 3 Contact elements

[0047] 4 Additional contact elements

[0048] 5 Cooling element

[0049] 5a Cooling ribs

[0050] 6Heat transfer elements

[0051] 6 1 , 6 2 Heat transfer elements

[0052] Wall thickness

Claims

1. A plug-in component, which is used to be mechanically and electrically connected to a mating plug-in component, in particular a charging socket (1) on the motor vehicle side, for connecting to a charging plug as a component of a charging facility for an electric vehicle or a hybrid vehicle, or vice versa, the plug-in component has a plastic housing (2) and at least one electrical contact element (3) arranged in the housing (2), the plug-in component has a cooling element (5) in thermal contact with the electrical contact element (3), characterized in that The contact element (3) and the cooling element (5) are electrically insulated from one another.

2. The plug-in component according to claim 1, characterized in that: The cooling element (5) is designed to be electrically insulating and at the same time thermally conductive.

3. The plug-in component according to claim 2, characterized in that: The cooling element (5) is formed from a thermally conductive polymer.

4. The plug-in component according to any one of claims 1 to 3, characterized in that: The contact element (3) and the cooling element (5) are connected to each other in a heat-conducting manner via an electrically insulating heat transfer element (6).

5. The plug-in component according to claim 4, characterized in that: The heat transfer element (6) surrounds the contact element (3) in an annular manner in cross section, the wall thickness (S) of the heat transfer element in cross section being in particular a few millimeters.

6. The plug-in component according to claim 5, characterized in that: The wall thickness (S) is less than 1 mm.

7. The plug-in component according to any one of claims 4 to 6, characterized in that: The heat transfer element (6) is designed as a component of the housing (2).

8. The plug-in component according to claim 7, characterized in that: The heat transfer element (6) has a filler material embedded in the plastic of the housing (2), which filler material is formed, for example, from aluminum oxide or boron nitride.

9. The plug-in component according to any one of claims 4 to 8, characterized in that: The heat transfer element (6) is designed as a component separate from the housing.

10. The plug-in component according to claim 9, characterized in that: The heat transfer element (6) is designed as a filling made of a ceramic material or a mineral material or comprises such a filling and / or is designed as a hose sheathing which at least largely surrounds the contact element (3) or comprises such a hose sheathing.

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