Vehicle with on-board power supply and electrical connector inside

Abstract

The invention relates to a vehicle (4) comprising an on-board power supply (3) with at least one electrical connector (15, 2; 17, 2; 1, 19; 1, 21; 23, 2; 1, 25; 1, 28), comprising a first connector element (1; 15; 17; 23) into which a second connector element (2; 19; 21; 25; 28) can be inserted, wherein the first connector element (1; 15; 17; 23) has a receptacle (5) for the second connector element (2; 19; 21; 25; 28) into which at least one first contact element (6; 24) designed as a blade projects, the second connector element has a contact housing (9; 28) that can be inserted into the receptacle and is open in the insertion direction, within which at least one spring-loaded clamping contact formed second contact element (10) into which the first contact element (6;24) is clamped in the plugged-in state, and wherein the first plug-in element and / or the second plug-in element is / are each equipped with at least one heat pipe (16; 18; 20; 22; 24; 26; 29).;

Description

[0001] The invention relates to a vehicle having an on-board power system with at least one electrical plug connection, comprising a first plug connection element that can be plugged into a second plug connection element, wherein the first plug connection element has a receptacle for the second plug connection element, into which at least one first contact element designed as a blade projects, the second plug connection element has a contact housing that can be plugged into the receptacle and is open in the plug-in direction, and within which there is at least one second contact element designed as a resilient clamping contact, into which the first contact element is clamped when plugged in. The invention is particularly advantageously applicable to fully electrically powered vehicles.

[0002] DE 10 2019 110 241 A1 discloses a connector comprising: an outer peripheral wall forming a recessed portion therein, into which a mating connector is to be inserted; a cylindrical portion provided within the outer peripheral wall, having an inner peripheral surface and configured to receive a mating terminal of the mating connector within the inner peripheral surface; a terminal having a contact portion disposed within the inner peripheral surface, the terminal being electrically connected to the mating terminal when the contact portion contacts the mating terminal; and a cooling mechanism having a heat absorption portion and a heat dissipation portion, the heat absorption portion being provided at a position opposite to the contact portion with respect to the inner peripheral surface.The cooling mechanism distributes heat generated at the contact portion at the heat dissipation portion and transfers it to the heat absorption portion via the inner peripheral surface.

[0003] US 6 602 091 B2 discloses an electrical connector. It is equipped with heat dissipation devices to reduce hot spots within the connector and efficiently dissipate heat to the surrounding atmosphere, thereby increasing the connector's current-carrying capacity.

[0004] US 8 926 360 B2 discloses an electrical connector described with an active cooling system. The electrical connector may comprise a conductor with an electrically conductive pin and a conductor receptacle slidably connected to the conductor. The conductor receptacle may comprise a wall with an electrically conductive material forming a cavity in which the pin is received. The conductor receptacle may also comprise an insulating sleeve mechanically connected to the wall. The conductor receptacle may further comprise a heat sink mechanically coupled to the insulating sleeve and a channel that collects the heat absorbed by the heat sink. The heat collected by the channel can be dissipated outside the conductor receiver. Alternatively, the wall of the conductor receptacle may be connected to an insulator and have at least one opening that dissipates heat from the cavity to the insulator.

[0005] It is the object of the present invention to at least partially overcome the disadvantages of the prior art and in particular to provide a vehicle of the type in question which can improve heat dissipation from hot zones or "hotspots" in the plug connection in a compact, low-maintenance and effective manner.

[0006] This object is achieved according to the features of the independent claims. Preferred embodiments can be found in particular in the dependent claims.

[0007] The object is achieved by a vehicle having an on-board power supply system with at least one electrical plug connection, having a first plug connection element into which a second plug connection element can be inserted, wherein - the first plug-in connection element has a receptacle for the second plug-in connection element, into which at least one first contact element designed as a sword projects, - the second plug-in connection element has a housing which can be inserted into the receptacle and is open in the insertion direction (hereinafter referred to as “contact housing” without restriction of generality), within which there is at least one second contact element designed as a resilient clamping contact, into which the first contact element is clamped in the inserted state, and wherein - the first plug-in connection element and / or the second plug-in connection element is / are each equipped with at least one heat pipe.

[0008] This vehicle has the advantage that, thanks to the use of a heat pipe in an electrical connector of an on-board power system, potentially damaging hot spots, particularly those occurring at the contact surface of the contact elements, can be reduced or even completely eliminated. In particular, thermal aging (e.g., corrosion or oxidation) at the contact surface can be advantageously prevented. Furthermore, mechanical and / or electrical properties at the contact surface, such as clamping force, electrical contact resistance, etc., can be stabilized, which in turn stabilizes the on-board power system and eliminates the need for potential current-limiting functions.

[0009] The vehicle can be a motor vehicle (e.g., a motor vehicle such as a passenger car, truck, bus, etc., or a motorcycle), a railway, a watercraft (e.g., a boat or a ship), or an aircraft (e.g., an airplane or a helicopter). The vehicle can have an internal combustion engine or be an electric vehicle. The electric vehicle can, for example, be a plug-in hybrid vehicle (PHEV), or a fully electric vehicle, e.g., a battery-powered vehicle (BEV). Electrical consumers of the electric vehicle are supplied with electrical energy via the on-board power system. The on-board power system can have an on-board power system voltage, e.g., of 12 V, 24 V, 48 V, etc., or can have two or more sub-systems with different on-board power system voltages, for example, a low-voltage (NV) sub-system with an on-board power system voltage of, for example, 12 V and a high-voltage (NV) sub-system with an on-board power system voltage of, for example,60 V, 120 V, 400 V, 800 V, etc. The use of the plug connection with heat pipe tends to be more advantageous the higher the associated current strength or power density in the plug connection or through its contact surface.

[0010] The fact that the first contact element is clamped into the second contact element in the inserted state includes, in particular, that the first contact element elastically bends the second contact element during insertion so that the second contact element, in the inserted state, presses on the first contact element or blade due to the elastic spring force, in particular with a sufficiently high normal force.

[0011] A blade is understood to be a substantially elongated and flat contact element. It is electrically conductive and can be made of metal, for example.

[0012] A further development is that the spring-loaded terminal contact has a pair of opposing springs whose springs press against each other when not plugged in. When plugged in, the blade is inserted between the two springs, thereby elastically pushing them apart. This creates two contact areas or contact surfaces on opposite sides of the blade, namely between each of the two springs and the blade.

[0013] The at least one second contact element is typically electrically connected to a respective electrical line (e.g., a stranded wire or core of a single- or multi-core cable) that extends from the contact housing. The stranded wire can be connected to the second contact element, for example, by crimping, ultrasonic welding, soldering, and / or an insulation displacement connection.

[0014] A further development is that at the end of the contact housing of the second contact element opposite the insertion direction (rear or rear), a grommet, optionally provided with a sealing layer, is provided, which seals the transition between the rear end of the contact housing and the cable. The grommet can be in the form of a heat-shrink tube, for example.

[0015] A heat pipe is, as is generally known, a heat exchanger that utilizes the evaporation enthalpy of a working medium housed in a closed, typically highly thermally conductive heat pipe housing to achieve a high heat flux density. In both designs relevant here, namely the so-called "heat pipe" and the two-phase thermosiphon, the basic operating principle is that heat is supplied from the outside in an evaporator or heating zone of the heat pipe, causing the working medium to evaporate and flow back to a condensation or cooling zone. In a two-phase thermosiphon, the backflow occurs through the effect of gravity, while in a heat pipe, it is achieved through the wick or capillary action. Therefore, the heat pipe design is advantageous because it is largely independent of spatial orientation. In both designs, the return transport occurs passively and therefore without the need for auxiliary means such as a circulation pump.The heat pipe allows heat generated in the contact area of ​​the plug connection to be passively dissipated to cooler areas without the need for additional measures. In particular, the heat pipe can be designed so compactly that the dimensions of the plug connection elements can be retained, making it virtually interchangeable with conventional plug connection elements.

[0016] It is a further development that the heat pipe in the area of ​​the cooling zone is equipped with an active cooling element such as a fan and / or a Peltier element, etc. or a passive cooling element such as a heat sink.

[0017] It is a further development that the heat pipe in the area of ​​the cooling zone is connected to a mass with a high specific heat capacity, in particular to the vehicle body.

[0018] One embodiment provides that the receptacle of the first plug-in connection element is designed or covered on the inside, at least in part, with at least one heat pipe. This offers the advantage that the contact elements and their geometry do not need to be adapted, and the heating zone can be designed to be particularly large.

[0019] One embodiment is such that, in the plugged-in state, an outer surface of the contact housing of the second plug-in connection element rests flatly on the heat pipe, in particular practically completely on its outer surface. This advantageously enables a particularly large heat transfer surface.

[0020] In one embodiment, the second connector element has a typically metallic cage that laterally surrounds the at least second contact element. This facilitates mating of the two connector elements and protects the second contact elements. In another embodiment, the cage protrudes forward in front of the contact housing of the second contact element.

[0021] One embodiment provides for the heat pipe to be arranged in the receptacle such that, when plugged in, it contacts a portion of the cage protruding from the contact housing on the outside. This enables effective heat dissipation from the at least one contact surface via the cage.

[0022] In a further development, the heat pipe contacts a front edge of the contact housing of the second plug-in connector element when plugged in. The heat pipe can then advantageously also serve as a stop for the second plug-in connector element.

[0023] In the case where the second plug-in connection element has a cage laterally surrounding the at least one second contact element, it is advantageous to have at least one heat pipe attached to an outer side of the cage in contact with the cage. This enables large-area heat dissipation while maintaining a short distance from the contact surface of the at least one pair of contact elements.

[0024] In one embodiment, at least one heat pipe attached to an outer side of the cage is housed at least partially within the contact housing. This can include both the heat pipe being housed entirely within the contact housing, as well as the heat pipe being housed partially within the contact housing and partially protruding forward from the contact housing. This provides the advantage that the external form factor of the second plug-in connection element does not need to be changed.

[0025] One embodiment includes at least one heat pipe attached to an outer side of the cage, which protrudes through the contact housing in the opposite direction to the insertion direction of the second connector element or to the rear. This provides the advantage that the cooling zone of the heat pipe is located in the particularly cool environment outside the contact housing and can thus dissipate heat particularly effectively.

[0026] One embodiment is for the cage to be designed as a heat pipe, meaning the entire cage itself or parts of it are designed as a heat pipe. The cage or heat pipe can then be housed entirely within the contact housing or protrude rearward from the contact housing.

[0027] One embodiment involves the first contact element being designed as a heat pipe. This then has a sword shape. This provides the advantage that the contact surface of this contact element can be cooled directly and thus particularly effectively.

[0028] One embodiment includes at least one heat pipe integrated into the contact housing. This is advantageously particularly easy to implement, e.g., by encapsulating it with the same material as the contact housing.

[0029] A further development is that at least one heat pipe is completely embedded in the contact housing. This has the advantage that the form factor of the contact housing needs to be maintained or at least only slightly modified.

[0030] A further development is that at least one heat pipe protrudes rearward from the contact housing. This provides the advantage that the heat pipe's cooling zone is located in the particularly cool environment outside the contact housing, allowing heat to be dissipated particularly effectively.

[0031] One embodiment includes the first connector element being integrated into a functional component of the vehicle electrical system. This enables a particularly compact and robust connector. For example, the first connector element can be integrated into a housing of the functional component. The second connector element can, in particular in this case, represent an end piece of a connecting cable.

[0032] In one embodiment, the functional component is a power distributor. This can have a plurality of first plug-in connection elements. However, the functional component is not limited to this and can also be, for example, a control unit, a charging unit, or a drive unit (e.g., a power steering unit, a steering system, etc.).

[0033] A further development is that the first connector element is protected by an electronic fuse or "E-fuse." This can, for example, prevent the contact surfaces of the contact elements from burning out. A further development is that the electronic fuse is equipped with or coupled to a temperature sensor, so that the electronic fuse interrupts the flow of current through the connector if a specified temperature limit is reached or exceeded in the connector area.

[0034] The above-described properties, features and advantages of this invention, as well as the manner in which they are achieved, will become clearer and more readily understood in connection with the following schematic description of embodiments, which are explained in more detail in connection with the drawings. Fig. 1 shows a sectional side view of an electrical connector in an on-board power system of a vehicle without heat pipe(s); Fig. 2 shows a sectional side view of an electrical plug connection with at least one heat pipe according to a first embodiment; Fig. 3 shows a sectional side view of an electrical plug connection with at least one heat pipe according to a second embodiment; Fig. 4 shows a sectional side view of an electrical plug connection with at least one heat pipe according to a third embodiment; Fig. 5 shows a sectional side view of an electrical plug connection with at least one heat pipe according to a fourth embodiment; Fig. 6 shows a sectional side view of an electrical plug connection with at least one heat pipe according to a fifth embodiment; Fig. 7 shows a sectional side view of an electrical plug connection with at least one heat pipe according to a sixth embodiment; and Fig. 8 shows a sectional side view of an electrical plug connection with at least one heat pipe according to a seventh embodiment.

[0035] Fig. 1 shows a sectional side view of an electrical plug connection 1, 2 in an on-board power system 3 of a vehicle 4 without heat pipe(s).

[0036] The plug connection 1, 2 comprises a first plug connection element 1 with a receptacle 5, into which at least one stationary first contact element, designed as a blade 6, projects. In particular, several blades 6 can be provided, which are arranged parallel to one another at a distance perpendicular to the image plane. Here, the first plug connection element 1 is integrated into a component housing 7 of a functional component such as a power distributor 8 or the like. The at least one blade 6 is electrically connected at the rear to at least one current path in the power distributor 8.

[0037] A second plug-in connection element 2 can be inserted into the receptacle 5. It has a contact housing 9 that is open in its insertion direction and within which at least one second contact element designed as a spring-loaded clamping contact 10 is located.

[0038] The clamping contact 10 comprises an opposing pair of springs, whose contact springs 10a, 10b press against each other when not plugged in. A corresponding blade 6 is inserted between the two contact springs 10a, 10b upon insertion, elastically pushing them apart. This creates two contact surfaces K on opposite sides of the blade 6, namely between each of the two contact springs 10a and 10b and the blade 6. Typically, there is one opposing clamping contact 10 per blade 6.

[0039] The terminal contact 10 is electrically connected to a respective electrical line (e.g., a stranded wire or core) of a single- or multi-core cable 11, which extends rearwardly from the contact housing 9. The connection of the stranded wire to the associated terminal contact 10 can be achieved, for example, by means of a connection 12 in the form of a crimp connection, an ultrasonic welding connection, a solder connection, and / or an insulation displacement connection.

[0040] At the rear end of the contact housing 9 opposite its insertion direction, a grommet 13, optionally provided with a sealing surface, may be provided, which seals the transition between the rear end of the contact housing 9 and the cable 11. The grommet 13 may, for example, be in the form of a shrink tube.

[0041] The second connector element 2 can have a metallic cage 14 surrounding the at least one terminal contact 10. As shown, one variant is that the cage 14 protrudes forward in front of the contact housing 9.

[0042] Fig. 2 shows an electrical plug connection 15, 2 which is constructed similarly to the plug connection 1, 2 and has the same second plug connection element 2. However, the receptacle 5 of the first plug connection element 15 is now designed on the inside, at least in some regions, with at least one heat pipe 16. The heat pipe 16 can, for example, follow the cross-section of the receptacle 5 and then have, for example, a tubular outer contour. In an alternative, the at least one heat pipe 16 can have a plurality of heat pipes 16 extending along the receptacle 5 and arranged distributed around the cross-section of the receptacle 5. Such heat pipes 16 can, for example, each have a rod- or plate-shaped basic shape. In particular, in the plugged-in state, an outer surface of the contact housing 9 rests flat on the at least one heat pipe 16.

[0043] If the plug connection 15, 2 heats up in the area of ​​the contact surfaces K, the end region of the at least one heat pipe 16 located near the contact surfaces K and serving as heating zone 16a is noticeably heated by heat diffusion and generates a flow of the heated working medium to the more distant end region serving as cooling zone 16b (in Fig. 2 (shown on the left). In the cooling zone 16b, the working fluid cools, releasing heat, and then flows toward the heating zone 16a. As a result, heat is dissipated from the area of ​​the contact surfaces K to the cooling zone 16b, where it is released into the typically cooler environment.

[0044] Fig. 3 shows a sectional side view of an electrical plug connection 17, 2, which is constructed similarly to the plug connection 15, 2 and has the same second plug connection element 2. However, the at least one heat pipe 18 of the first plug connection element 17 is now arranged in the receptacle 5 such that, when plugged in, it contacts a section of the cage 14 protruding from the contact housing 9 on the outside. For this purpose, the at least one heat pipe 18 protrudes into the receptacle 5 in a stepped manner with respect to the section of the receptacle 5 occupied by the second plug connection element 2, so that the at least one heat pipe 18 can also serve as a stop for the second plug connection element 2.

[0045] Fig. Figure 4 shows a sectional side view of an electrical plug connection 1, 19, which is constructed similarly to the plug connection 1, 2 and has the same first plug connection element 1. However, the second plug connection element 19 has at least one heat pipe 20, which is attached to an outer side of the cage 14, in particular in a planar contact with the cage, in particular practically completely on its outer surface. The at least one heat pipe 20 is advantageously accommodated in sections within the contact housing 9 and protrudes forward in sections from the contact housing 9.

[0046] Fig. Figure 5 shows a sectional side view of an electrical plug connection 1, 21, which is constructed similarly to the plug connection 1, 19. However, the at least one heat pipe 22 of the second plug connection element 21, which is attached to an outer side of the cage 14, in particular in a planar contact, is additionally designed to project rearward through the contact housing 9.

[0047] Fig. Figure 6 shows a sectional side view of an electrical connector 23, 2, which is constructed similarly to the connector 1, 2. However, the blade of the first connector element 23 is now designed as a heat pipe 24.

[0048] Fig. Figure 7 shows a sectional side view of an electrical connector 1, 25, which is constructed similarly to connector 1, 2. However, at least one heat pipe 26 of the second connector element 25 is now integrated into the contact housing 27, in this case completely.

[0049] Fig. Figure 8 shows a sectional side view of an electrical plug connection 1, 28, which is constructed similarly to the plug connection 1, 25. However, the at least one heat pipe 29 of the second plug connection element 28 now protrudes rearward through the contact housing 30.

[0050] Of course, the present invention is not limited to the embodiment shown.

[0051] Thus, the cage 14 itself can be designed at least partially as a heat pipe.

[0052] Furthermore, a plug-in connection can also have the heat pipes shown in basically any combination.

[0053] In general, “a”, “an”, etc. can be understood as a singular or a plural, in particular in the sense of “at least one” or “one or more”, etc., unless this is explicitly excluded, e.g. by the expression “exactly one”, etc.

[0054] A numerical value may also include the exact number stated as well as a usual tolerance range, as long as this is not explicitly excluded. List of reference symbols 1 First connector element 2 Second connector element 3 On-board power system 4 vehicle 5 Recording 6 Sword 7 component housings 8 power distributors 9 Contact housing 10 terminal contact 10a Contact spring 10b Contact spring 11 cables 12 Connection 13 spout 14 cage 15 First connector element 16 heat pipe 16a Heating zone 16b Cooling zone 17 First connector element 18 heat pipe 19 Second connector element 20 heat pipe 21 Second connector element 22 Heat pipe 23 First connector element 24 heat pipe 25 Second connector element 26 Heat pipe 27 contact housings 28 Second connector element 29 Heat pipe 30 contact housings K Contact area QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2019 110 241 A1

[0002] US 6 602 091 B2

[0003] US 8 926 360 B2

[0004]

Claims

[1] Vehicle (4), comprising an on-board power supply system (3) with at least one electrical plug connection (15, 2; 17, 2; 1, 19; 1, 21; 23, 2; 1, 25; 1, 28), comprising a first plug connection element (1; 15; 17; 23) into which a second plug connection element (2; 19; 21; 25; 28) can be inserted, wherein - the first plug-in connection element (1; 15; 17; 23) has a receptacle (5) for the second plug-in connection element (2; 19; 21; 25; 28), into which at least one first contact element (6; 24) designed as a blade projects, - the second plug-in connection element (2; 19; 21; 25; 28) has a contact housing (9; 28) which can be inserted into the receptacle (5) and is open in the insertion direction, within which there is at least one second contact element (10) designed as a resilient clamping contact, into which the first contact element (6; 24) is clamped in the inserted state, and wherein - the first plug-in connection element (1; 15; 17; 23) and / or the second plug-in connection element (2; 19; 21; 25; 28) is / are each equipped with at least one heat pipe (16; 18; 20; 22; 24; 26; 29). [2] Vehicle (4) according to claim 1, wherein the receptacle (5) of the first plug-in connection element (15; 17) is covered on the inside at least in regions with at least one heat pipe (16; 18). [3] Vehicle (4) according to one of the preceding claims, wherein in the plugged-in state an outer surface of the contact housing (9) rests flatly on the at least one heat pipe (16). [4] Vehicle (4) according to one of the preceding claims, wherein the second plug connection element (2) has a cage (14) which laterally surrounds the at least second contact element (10) and projects forwards in front of the contact housing (9) of the second contact element (10), and the heat pipe (18) is arranged in the receptacle (5) such that, in the plugged-in state, it contacts a section of the cage (14) which projects from the outside of the contact housing (9). [5] Vehicle (4) according to one of the preceding claims, wherein the second plug connection element (19; 21) has a cage (14) laterally surrounding the at least second contact element (10) and at least one heat pipe (20; 22) is attached to an outer side of the cage (14) in surface contact with the latter. [6] Vehicle (4) according to claim 5, wherein at least one heat pipe (20; 22) attached to an outer side of the cage (14) is accommodated at least in sections within the contact housing (9). [7] Vehicle (4) according to one of claims 5 to 6, wherein at least one heat pipe (22) attached to an outer side of the cage (14) projects rearwardly through the contact housing. [8] Vehicle (4) according to one of the preceding claims, wherein the cage (14) is designed as a heat pipe. [9] Vehicle (4) according to one of the preceding claims, wherein the first contact element (24) is designed as a heat pipe. [10] Vehicle (4) according to one of the preceding claims, wherein at least one heat pipe (26; 29) is integrated into the contact housing (27; 30). [11] Vehicle (4) according to one of the preceding claims, wherein the first plug connection element (1; 15; 17; 23) is integrated into a functional component (8) of the vehicle electrical system (3). [12] Vehicle (4) according to claim 11, wherein the functional component (8) is a power distributor.

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