Contact system

Abstract

Contact system (25), the contact system the contact socket (1) comprising: ---- an electrically conductive receptacle (3) designed to receive a connector pin (17); ----- a main electrical line (5) electrically connected to the receptacle (3); wherein the contact socket (1) further comprises an electrically insulating first heat-conducting element (7); wherein the first heat-conducting element (7) is designed to dissipate heat from the contact socket (1); -- the contact plug (15) comprising: ---- the electrically conductive plug pin (17) which is designed to be inserted into the receptacle (3) of the contact socket (1); wherein an electrically insulating second heat-conducting element (19) is provided on the connector pin (17); wherein the second heat-conducting element (19) is designed to dissipate heat from the plug pin (17); wherein the first heat-conducting element (7) of the contact socket (1) is connectable to a second heat sink (23) of the contact plug (15) when electrical contact is established between the contact socket (1) and the contact plug (15); and / or wherein the second heat-conducting element (19) of the contact plug (15) is connectable to a first heat sink (9) of the contact socket (1) when electrical contact is established between the contact socket (1) and the contact plug (15).

Description

State of the art

[0001] In electrical connections, such as plug connectors, heat is generated when current is applied. High current, i.e., high applied voltage or current, can cause the connector to overheat. This can also lead to malfunction or failure of the electrical connector.

[0002] With known connectors, heat can only be dissipated from the connector via the functional elements intended for power transmission, such as the power line.

[0003] From JP 2000-208177 A, a connector is known that comprises a connecting unit provided with a busbar on an insulating plate. The busbar includes a connecting portion connecting a plurality of pressure-welded portions of the busbar, to which wires can be pressure-welded. The connecting connector also includes a connecting plate with a plurality of pressure-welded slots into which connecting units can be inserted to establish a connection between the connecting plate and the connecting portions of the connecting units. By stacking a plurality of pressure-welded connecting units and pressing their insulating plates into the pressure-welded slots of a connecting plate, the wires pressure-welded to the upper and lower connecting units are connected to each other.

[0004] From DE 10 2011 013 711 B3 a high-current plug is known with at least two current-carrying conductors, wherein the conductors have at least one design-related overheating section and with a carrier for receiving the conductors with at least one insulating section running between the conductors for insulating the conductors and with a heat sink provided on the carrier, wherein the insulating section has a thermal conductivity greater than 0.5 W / mK and / or a thermal conductivity a > 0.3 x 10 -6 m 2 / s.

[0005] An electrical connector is known from US 2003 / 0 082 945 A1. It is designed to incorporate heat-dissipating devices to reduce hot spots within the connector and efficiently dissipate heat to the environment, thereby increasing the connector's current-carrying capacity.

[0006] A connector is known from US 2012 / 0 184 152 A1. It comprises a first terminal housing for receiving a plurality of aligned first connection terminals, a second terminal housing for receiving a plurality of aligned second connection terminals, a plurality of aligned insulating elements housed in the first or second terminal housing, and a connecting element for jointly securing and electrically connecting the plurality of first connection terminals and the plurality of second connection terminals at each contact point by pressing the plurality of first connection terminals and the plurality of second connection terminals.The connecting member includes an annular support fixed to the first terminal housing, a rotary portion of which an upper portion is inserted into a cavity formed within the annular support so as to be pivotally supported by the support, and a pressing portion that moves relative to the rotary portion by rotating the rotary portion in a vertical direction. Disclosure of the invention

[0007] There may therefore be a need for an improved electrical plug connection, in particular a contact socket on a contact plug and a contact system, which in particular ensure a safer functionality of the electrical connection.

[0008] This need can be met by the subject matter of the present invention according to claim 1. Advantageous embodiments of the present invention are described in the dependent claims. Features, details, and possible advantages of a device according to embodiments of the invention are discussed in detail below.

[0009] According to one aspect of the invention, a contact system for electrical contacts is presented. The contact system comprises a contact socket, described below, and a contact plug, described below. A first heat-conducting element of the contact socket can be connected to a second heat sink of the contact plug when electrical contact is established between the contact socket and the contact plug. Additionally or alternatively, a second heat-conducting element of the contact plug can be connected to a first heat sink of the contact socket when electrical contact is established between the contact socket and the contact plug. In other words, the first heat-conducting element of the contact socket can be connected both to a first heat sink arranged directly on the contact socket and to a second heat sink arranged on the contact plug when the plug pin is inserted into the receptacle of the contact socket. Furthermore, the second heat-conducting element, which is in thermal contact with the plug pin, can be connected both to the second heat sink arranged directly on the contact plug and to a first heat sink provided on the contact socket when electrical contact is established between the contact socket and the contact plug.

[0010] The contact socket has an electrically conductive receptacle and an electrical main line. The electrically conductive receptacle is designed to accommodate a plug pin of the contact plug described below. The electrical main line is electrically connected to the receptacle. Furthermore, the contact socket has at least one electrically insulating first heat-conducting element. The first heat-conducting element is designed to dissipate heat from the contact socket.

[0011] The contact plug has an electrically conductive plug pin. The plug pin is designed to be inserted into the receptacle of the contact socket described above. An electrically insulating second heat-conducting element is provided on the plug pin. The second heat-conducting element is designed to dissipate heat from the plug pin.

[0012] In other words, the idea of ​​the present invention is based on enabling or accelerating heat dissipation from the contact socket and the corresponding plug connection by providing additional heat-conducting elements made of an insulating material. The improved heat dissipation using the heat-conducting elements enables higher current flow to the electrical plug connection. This means that higher currents can be transmitted or higher voltages applied using the described contact socket. Furthermore, the service life of the contact socket can be increased by designing the contact socket with a heat-conducting element.

[0013] The contact socket can be provided, for example, on a wiring harness. In particular, the contact socket can be provided on a wiring harness of an electric vehicle or a hybrid vehicle. For example, the contact socket can be designed to be connected to a high-current plug or a plug pin. The contact socket can be used for an electric drive, for example, in connection with the drive of an electric motor.

[0014] The electrically conductive receptacle can, for example, be designed as a cylindrical hollow body into which a connector pin can be inserted. Furthermore, the receptacle can comprise an electrically conductive material, such as a metal.

[0015] The main line is electrically connected to the receptacle. For example, a connector pin can be inserted into the receptacle through a recess at a first end of the receptacle. The main electrical line can be connected to a second end of the receptacle. The main electrical line can be connected to a power source, such as a voltage source.

[0016] At least one electrically insulating first heat element is provided on the contact socket. In particular, a plurality of electrically insulating first heat-conducting elements can be provided. The first heat-conducting element can be in direct contact with the electrically conductive receptacle and / or with the main electrical line. The first heat-conducting element comprises an electrically insulating material, such as ceramic. The first heat-conducting element can have the largest possible surface area, which is in direct contact with the heat-producing points, i.e., with the electrically conductive receptacle and with the main electrical line. For example, the first heat-conducting element can be designed in a meandering shape.

[0017] The first heat-conducting element is designed to dissipate heat from the contact socket. This means that the first heat-conducting element comprises a material with high thermal conductivity that is also electrically insulating. For example, the first heat-conducting element can comprise silicone oil and zinc oxide. Furthermore, the first heat-conducting element can comprise thermoplastics. Heat generated, for example, by electrical resistance, is absorbed by the first heat-conducting element at its source and conducted, for example, to the surface of the contact socket.

[0018] According to one embodiment of the invention, the contact socket further comprises a first heat sink for dissipating heat to the surroundings of the contact socket. The first heat sink is arranged on the outside of the contact socket. The first heat-conducting element is thermally or thermally conductively connected to the first heat sink.

[0019] The first heat sink can, for example, comprise a material with high thermal conductivity, such as a metal. In particular, the first heat sink can comprise aluminum. Furthermore, the first heat sink can be made of sheet metal. The first heat sink can have the largest possible surface area, which is, for example, in contact with the surrounding air or with a coolant. The first heat sink can, for example, run in a meandering shape on the surface of the contact socket. Alternatively, the first heat sink can run flat. The first heat sink is provided on the outside of the contact socket. This means that the first heat sink is provided, for example, on the surface of the contact socket. The first heat-conducting element is directly thermally connected to the first heat sink.

[0020] According to a further embodiment of the invention, the contact socket further comprises a housing. The electrically conductive receptacle, the main electrical line, and the first heat-conducting element are arranged in the housing. This means that the housing surrounds these elements. The first heat sink is integrated into the housing.

[0021] The housing can, for example, comprise an electrically insulating material such as plastic, or alternatively, a metal. Furthermore, the housing can be open on at least one side to allow the insertion of a connector pin into the electrically conductive receptacle.

[0022] The first heat sink is integrated directly into the housing. This means that the first heat sink can be designed as part of the housing. For example, an existing part of a metal housing can be used as a heat sink. This allows existing components of the contact socket to be used for heat dissipation. This can reduce manufacturing costs and labor.

[0023] According to a further embodiment of the invention, the first heat-conducting element is in direct contact with the main electrical line and / or with the electrical receptacle. This means that the first heat-conducting element is thermally connected to the main electrical line or to the electrically conductive receptacle. Furthermore, the first heat-conducting element can be thermally connected to both the main electrical line and the electrically conductive receptacle. In other words, the first heat-conducting element is in direct heat-exchange contact with the main electrical line and / or with the electrically conductive receptacle.

[0024] According to a further embodiment of the invention, the contact socket further comprises a shielding line for shielding an electromagnetic field of the main electrical line. The shielding line surrounds the main electrical line and is electrically connected to it. The first heat-conducting element is in direct thermal contact with the shielding line.

[0025] The shielded cable can serve to protect the surrounding electrical components from an electromagnetic field generated by the main electrical cable. For this purpose, the shielded cable can, for example, surround the main electrical cable in a cylindrical shape and be electrically conductive. A current can be induced in the shielded cable parallel to the main electrical cable. The shielded cable is electrically connected to the main electrical cable so that the induced current can flow away. During operation of the contact socket, heat can also be generated in the shielded cable. This heat is dissipated from the shielded cable by the first heat-conducting element.

[0026] According to a further embodiment of the invention, the first heat-conducting element comprises a heat-conducting foil, a heat-conducting adhesive, a heat-conducting gel, a heat-conducting paste and / or a ceramic material.

[0027] A thermally conductive foil can, for example, be designed as a flexible or elastic foil with a thickness between 0.01 mm and 0.1 mm. In addition to providing good thermal conductivity, a thermally conductive adhesive can also bond the components of the contact socket together. A thermally conductive gel and a thermally conductive paste, for example, can contain particles with particularly high thermal conductivity. A ceramic material can, for example, be provided in the form of a ceramic disc. All of these materials can be thermally bonded directly to the points where heat is generated.

[0028] The electrically conductive connector pin can, for example, comprise an electrically conductive material such as a metal. For example, the connector pin can be connected to an electric machine, in particular an electric motor or an electric generator. In particular, the connector pin can, for example, be arranged on a housing of an electric machine in a hybrid or electric vehicle. The second heat-conducting element can be designed analogously to the first heat-conducting element. For example, the second heat-conducting element can have the same material and the same geometric shape as the first heat-conducting element. Alternatively, the second heat-conducting element can be made of a different material and have a different shape than the first heat-conducting element.

[0029] According to one embodiment of the invention, the contact plug comprises a plug collar and a second heat sink. The plug pin is arranged in the plug collar, and the second heat-conducting element is connected to the second heat sink. The second heat sink is integrated into the plug collar.

[0030] For example, the connector collar can be designed as a cylindrical housing for the connector pin and surround it. The connector collar can, for example, be made of a plastic and be arranged at a distance from the connector pin. The second heat sink can be designed analogously to the first heat sink, i.e., with the same materials and in the same shape as the first heat sink. The second heat sink can be integrated into the connector collar. This means that the second heat sink is designed as part of the connector collar. If the connector collar is made of metal, for example, the metal area can act as a second heat sink. The heat generated at the connector pin can be conducted away from the connector pin by the second heat-conducting element and passed on, for example, to an outer surface of the connector collar or to the second heat sink.

[0031] Furthermore, a method for producing a contact socket described above is presented. The method comprises the following steps: providing an electrically conductive receptacle designed to accommodate a connector pin; electrically connecting the receptacle to a main electrical line; and providing an electrically insulating first heat-conducting element on the contact socket. The first heat-conducting element is designed to dissipate heat from the contact socket.

[0032] Furthermore, a method for producing a contact plug described above is presented. The method comprises the following steps: providing an electrically conductive plug pin designed to be inserted into a receptacle of a contact socket; providing an electrically insulating second heat-conducting element on the plug pin. The second heat-conducting element is designed to dissipate heat from the plug pin.

[0033] Further features and advantages of the present invention will become apparent to those skilled in the art from the following description of exemplary embodiments, which, however, are not to be construed as limiting the invention, with reference to the accompanying drawings. Fig. 1 shows a cross section through a contact system with a contact socket and a contact pin Fig. 2 shows a cross section through the contact socket along the line AA

[0034] All figures are merely schematic. In particular, distances and size relationships are not shown to scale. Corresponding elements in the different figures are provided with the same reference numbers.

[0035] In Fig. Figure 1 shows a contact system 25 with a contact socket 1 and a contact plug 15. Both the contact socket 1 and the contact plug 15 are designed to enable accelerated heat dissipation from the plug connection and from the contact system 25, respectively. This makes the contact system 25 suitable for higher currents than known plug connections.

[0036] More efficient heat dissipation from the contact socket 1 and the contact plug 15 is enabled by heat-conducting elements 7, 19. For this purpose, the heat-conducting elements 7, 19 are directly thermally connected to heat sources of the contact system 25. Heat sources can be, for example, the electrical contact, i.e., the electrically conductive receptacle 3 of the contact socket 1 and the electrically conductive plug pin 17, or the main electrical line 5 and the shielding line 13. The heat is conducted via the respective heat-conducting element 7, 19 to the surface of the contact system 25, where it is dissipated to the environment via a heat sink 9, 23.

[0037] The structure of the contact socket 1 and the contact plug 15 is described in detail below. The contact socket 1 has an electrically conductive receptacle 3. The receptacle 3 is designed to accommodate an electrically conductive plug pin 17 of the contact plug 15. Furthermore, the contact socket 1 has a main electrical line 5, which is connected, for example, to the receptacle 3 at one end and to a power or voltage source at another end.

[0038] Furthermore, the contact socket 1 has at least one electrically insulating first heat-conducting element 7. In the embodiment in Fig. 1, three first heat conducting elements 7 are shown. These can be designed, for example, in a meandering shape or as a flat surface. The first heat conducting elements 7 are in direct thermal contact with the main line 5. Furthermore, the first heat conducting elements 7 can be connected directly to the receptacle 3 (see Fig. 1 not shown). The first heat-conducting elements 7 are designed to dissipate the heat generated, for example, on the main line 5 during operation of the contact socket 1 to an outer region of the contact socket 1.

[0039] The contact socket 1 may further comprise a housing 11 in which the receptacle 3, the main line 5, and the first heat-conducting elements 7 are integrated. A first heat sink 9 may also be provided on the surface of the housing 11. As shown in Fig. As shown in Figure 1, the first heat-conducting elements 7 are integrated into the housing 11 or lead through the housing to the first heat sink 9. The first heat sink 9 can have a large surface area that is in contact with the environment and can thus dissipate a large amount of heat. The first heat-conducting elements 7 can be integrated into a portion of the housing 11. Alternatively, an entire portion of the housing 11 can be used for heat dissipation. In other words, the first heat sink 9 can be configured as part of the housing 11.

[0040] Furthermore, the contact socket 1 can have a shielding cable 13. This is in Fig. 1 not shown. Fig. 2 shows an alternative embodiment of a contact socket 1. The geometric orientation of the representation in Fig. 2 corresponds to a section through the line AA of the Fig. 1. In the example shown in Fig. 2, the contact socket has a shielding line 13. The main line 5 is concentrically surrounded by the shielding line 13. The shielding line 13 can contribute to shielding the electromagnetic field induced by the main line 5. For this purpose, the shielding line 13 can be electrically connected to the main line 5. The shielding line 13 is, for example, embedded in the housing 11. Both the main line 5 and the shielding line 13 can each be connected to a first heat sink 9 on the surface of the contact socket 1 by first heat-conducting elements 7.

[0041] In Fig.1 further shows the design of a contact plug 15 of the contact system 25. The contact plug 15 has an electrically conductive plug pin 17. The plug pin 17 is designed to be inserted into the receptacle 3 of the contact socket 1 and to establish an electrical connection there. The plug pin 17 also has an electrically insulating second heat-conducting element 19. The second heat-conducting element is in direct thermal contact with the plug pin 17 and also with a second heat sink 23 arranged on the surface of a plug collar 21. The plug collar 21 is arranged around the plug pin 17 and can protect it from unwanted influences. The second heat sink 23 can be designed as part of the plug collar 21.

[0042] With the help of the additional heat conducting elements 7, 19, the heat dissipation from the contact system 25 can be accelerated so that higher currents and / or higher voltages are permissible.

[0043] Finally, it is noted that expressions such as "comprising" or similar are not intended to exclude the possibility of further elements or steps being provided. Furthermore, it should be noted that "a" or "an" does not exclude a plurality. Furthermore, features described in connection with the various embodiments may be combined with one another in any desired manner. It is further noted that the reference signs in the claims are not intended to limit the scope of the claims.

Claims

[1] Contact system (25), the contact system the contact socket (1) comprising: ---- an electrically conductive receptacle (3) designed to receive a connector pin (17); ----- a main electrical line (5) electrically connected to the receptacle (3); wherein the contact socket (1) further comprises an electrically insulating first heat-conducting element (7); wherein the first heat-conducting element (7) is designed to dissipate heat from the contact socket (1); -- the contact plug (15) comprising: ---- the electrically conductive plug pin (17) which is designed to be inserted into the receptacle (3) of the contact socket (1); wherein an electrically insulating second heat-conducting element (19) is provided on the connector pin (17); wherein the second heat-conducting element (19) is designed to dissipate heat from the plug pin (17); wherein the first heat-conducting element (7) of the contact socket (1) is connectable to a second heat sink (23) of the contact plug (15) when electrical contact is established between the contact socket (1) and the contact plug (15); and / or wherein the second heat-conducting element (19) of the contact plug (15) is connectable to a first heat sink (9) of the contact socket (1) when electrical contact is established between the contact socket (1) and the contact plug (15). [2] Contact system (25) according to claim 1, wherein the contact socket (1) further comprises a first heat sink (9) for dissipating heat to an environment of the contact socket (1); wherein the first heat sink (9) is provided on the outside of the contact socket (1); wherein the first heat-conducting element (7) is connected to the first heat sink (9). [3] Contact system (25) according to claim 2, the contact socket (1) further comprising a housing (11); wherein the electrically conductive receptacle (3), the main electrical line (5) and the first heat-conducting element (7) are arranged in the housing (11); wherein the first heat sink (9) is integrated into the housing (11). [4] Contact system (25) according to one of claims 1 to 3, wherein the first heat conducting element (7) is in direct contact with the main electrical line (5) and / or with the receptacle (3). [5] Contact system (25) according to one of claims 1 to 4, the contact socket (1) further comprising a shielding line (13) for shielding an electromagnetic field of the main electrical line (5); wherein the shielding line (13) surrounds the main electrical line (5) and is electrically connected thereto; wherein the first heat conducting element (7) is in direct contact with the shielding line (13). [6] Contact system (25) according to one of claims 1 to 5, wherein the first heat-conducting element (7) comprises a heat-conducting foil, a heat-conducting adhesive, a heat-conducting gel, a heat-conducting paste and / or a ceramic material. [7] Contact system (25) according to one of claims 1 to 6, the contact plug (15) further comprising a connector collar (21); a second heat sink (23) or the second heat sink (23); wherein the connector pin (17) is arranged in the connector collar (21); wherein the second heat conducting element (19) is connected to the second heat sink (23); wherein the second heat sink (23) is integrated into the connector collar (21).

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