Connection system for electrically connecting two conductors

Abstract

Connection system (1) for electrically connecting a first conductor (100) to a second conductor (200), wherein the connection system (1) comprises: a first connection device (10) associated with the first conductor (100) and comprising an electrically non-conductive insulating section (11) and an electrically conductive coupling component (12), wherein the insulating section (11) is deformable, preferably elastically deformable, between a ground state in which the insulating section (11) is at least partially arranged between the first conductor (100) and the coupling component (12) such that the first conductor (100) and the coupling component (12) are electrically separated from each other, and a contact state in which the first conductor (100) and the coupling component (12) are in electrical contact;and a second connecting device associated with the second conductor (200) and comprising a deformation section (22) configured to deform the insulating section (11) from the ground state to the contact state during the connection process of the two connecting devices (10, 20), so that the first conductor (100), the coupling component (12) and the second conductor (200) come into electrical contact.

Description

Technical area

[0001] The present invention relates to a connection system for electrically connecting a first conductor to a second conductor, wherein the connection system comprises a first and a second interconnectable connection device. The invention further relates to a connection device. State of the art

[0002] Interfaces of live components that are detachably connected, for example, by screwing, may have touch protection to protect people from direct contact with the live components. This is important and is often required by specific norms and standards to prevent accidents, electric shocks, or other health risks that can arise from contact with the electrically charged components.

[0003] The live components can be, for example, busbars, busbars, or battery module connectors. For high-voltage systems (>60 V), compliance with touch protection (e.g., according to IPXXB) is relevant for occupational safety. It is often required that touch protection be observed both before and after the interface is closed.

[0004] Interfaces or connections of electrical components with contact protection are described, for example, in DE 10 2014 017 081 A1, DE 10 2014 012 320 B3, DE 10 2013 005 109 A1 and DE 10 2016 200 451 A1.

[0005] Conventional technical solutions are often highly complex, involving numerous individual parts that require complex pre-assembly. This leads to high costs and can also have a negative impact on fault tolerance and reliability. Furthermore, plastic-molded screws and nuts are often required, which are significantly more expensive than standard parts.

[0006] DE 10 2016 225 092 A1 describes a connection area for a high-voltage component. DE 11 2015 003 297 T5 describes a connection base for connecting a coil-side terminal of an electric motor accommodated in a housing part and an inverter-side conducting element arranged outside the housing part. US 2016 / 0211627 A1 describes an electrical assembly with a removable part and a base part. US 5,248,259 A describes an electrical connector for use with a motor vehicle sliding door. Description of the invention

[0007] An object of the invention is to provide an improved connection system and an improved connection device for electrically connecting a first conductor to a second conductor, in particular to provide contact protection for current- or voltage-carrying components in a structurally simple, failure-proof and reliable manner.

[0008] The object is achieved by a connection system having the features of claim 1 and a connection device having the features of claim 12. Advantageous further developments follow from the subclaims, the following description of the invention and the description of preferred embodiments.

[0009] The connection system according to the invention serves to electrically connect a first (electrical) conductor to a second (electrical) conductor. The connection system is particularly suitable for use in the high-voltage range (>60 V).

[0010] The connection system comprises a first connecting device, also referred to herein as a "connecting device." The first conductor is assigned to the first connecting device, for example, by attaching the connecting device to the first conductor or by at least partially attaching the first conductor to the first connecting device. The first conductor and second conductor are part of the connection system.

[0011] The first connecting device comprises an electrically non-conductive insulating section and an electrically conductive coupling component. The insulating section is made entirely or at least partially of an electrically insulating material, preferably plastic, while the coupling component is made entirely or at least partially of an electrically conductive material, preferably copper.

[0012] The insulating section can be formed in one or more parts. The insulating section can be annular, for example, in the form of an insulating ring. The coupling component can be in the form of a sleeve.

[0013] The insulating section is deformable between a basic state in which the insulating section is at least partially arranged between the first conductor and the coupling component such that the first conductor and the coupling component are electrically separated from one another, and a contact state in which the first conductor and the coupling component are in electrical contact or can come into contact.

[0014] The connection system further comprises a second connection device. The second conductor is associated with the second connection device, for example, by attaching the second connection device to the second conductor or by at least partially forming part of the second connection device.

[0015] The second connecting device has a deformation section configured to deform the insulating section from the ground state to the contact state during the connection process of the two connecting devices, so that the first conductor, the coupling component, and the second conductor come into electrical contact.

[0016] The insulating section thus loses its spacing function during the intended connection process of the two connecting devices as soon as it is deformed from the basic state into the contact state by the deformation section of the second connecting device.

[0017] The connection system thus provides touch protection for current-carrying or live components with a comparatively small number of individual parts. This not only reduces resources and costs but also simplifies the pre-assembly of the connecting devices that make up the connection system. The connection system is fail-safe and reliable.

[0018] The nature of the individual parts, including geometry, material, etc., is structurally comparatively simple, resulting in a robust design and low installation space requirements.

[0019] The structural simplification of the connection system compared to conventional connection systems results, among other things, from the fact that the coupling component of the first connection device creates a synergy effect by assuming a dual function.

[0020] It acts both as contact protection when the two connecting devices are separated and as a current conductor when connected.

[0021] When reference is made here to electrical contact between two components, the electrical contact can be made directly, i.e. by direct mechanical contact between the two components, or indirectly by interposing one or more other electrically conductive components.

[0022] The insulating section can be elastically deformable. In this case, the deformation to eliminate the spacing function of the insulating section is reversible, so that the spacing function can be re-established after any separation of the two connecting devices, for example, during maintenance or rework.

[0023] The deformation section can be configured to at least partially enter or retract between the insulating section and the coupling component during the connection process of the two connecting devices, thereby deforming the insulating section from the basic state into the contact state. The deformation section thus expands the insulating section outward, at least in sections, by the deformation section entering between the insulating section and the coupling component in the axial direction. The above function can be performed particularly reliably if the deformation section is sleeve-shaped.

[0024] The sleeve-shaped deformation section is arranged, for example, concentrically to the coupling component of the first connecting device when the two connecting devices are connected and during the connection process. In this way, the deformation section can contribute to guiding the connection process, thereby synergistically assuming a dual function—removing the spacing function of the insulating section and guiding the connection process.

[0025] The coupling component can be captively coupled to the insulating section, which facilitates pre-assembly of the connecting device and its application.

[0026] The captive security can be achieved by having the coupling component have a flange and the insulating section have a holder, with the flange of the coupling component engaging the holder of the insulating section. In a structurally simple implementation, the holder can comprise one or more snap-in lugs behind which the flange of the coupling component engages.

[0027] A further development can consist of a combination of captive protection and contact protection, particularly according to IPxxB. This means that the connecting device is completely pre-assembled and captive, and the insulating section cannot be deformed into the contact state by hand (or with an IPxxB standard finger).

[0028] The deformation section, particularly if it is sleeve-shaped, can be configured to enter or retract between the holder of the insulating section and the coupling component during the connection process of the two connecting devices, whereby the insulating section is deformed from the basic state into the contact state. The holder is thus released by interaction with the deformation section of the second connecting device, whereby the insulating section loses its spacing function and the conductive coupling component can come into electrical contact with the first conductor.

[0029] The insulating section can have an elliptical or oval ring shape in its initial state, with the deformation section of the second connecting device being configured to deform the insulating section into a ring shape of lesser eccentricity, preferably into a circular ring shape, during the connection process of the two connecting devices to establish the contact state. In this case, the insulating section, which is elliptical or oval in its initial state, is pressed apart at the vertices of the minor axis by the deformation section, thereby implementing the contact protection in a technically particularly simple and reliable manner.

[0030] The holder can be designed, for example, in the form of two snap-in lugs at the vertices of the minor axis, whereby the removal of the loss-proof function and the removal of the spacing function of the insulating section can be realized as one and the same process during the connection process.

[0031] The second connecting device may have a connecting portion configured to mechanically and releasably connect the two connecting devices to one another. The connecting portion may be electrically non-conductive, particularly if it is accessible from the outside.

[0032] The connecting portion may be or may comprise a screw in order to easily realize a secure and detachable mechanical connection between the connecting devices.

[0033] The screw can be configured to engage a screw hole in the first conductor, eliminating the need for separate technical means in the design of the first connecting device. The screw hole can be designed as an opening, a nut, or in another suitable manner.

[0034] The sleeve-shaped deformation section can be arranged concentrically to the connecting section, thereby further improving the directed guidance of the connecting process and thus the handling of the connecting system.

[0035] The first connecting device can comprise a protective cover and a base that sandwich the first conductor, the insulating section, and at least part of the coupling component. This protects the insulating section and the coupling component from external influences, allowing their contact protection function to be implemented with particularly low interference.

[0036] The second connecting device can have a protective covering that at least partially surrounds the second conductor and the connecting section. The protective covering and the deformation section can be formed integrally, whereby the elimination of the spacing function of the insulating section and the contact protection of the second conductor can be structurally realized in a synergistic manner.

[0037] The above-mentioned object is further achieved by an arrangement for electrically connecting two conductors, wherein the arrangement comprises a first conductor and a connecting device. The connecting device comprises an electrically non-conductive insulating section, which is preferably annular, and an electrically conductive coupling component, which is preferably designed as a sleeve.The insulating section is deformable, preferably elastically deformable, between a basic state in which the insulating section is at least partially arranged between the first conductor and the coupling component such that the first conductor and the coupling component are electrically separated from one another, and a contact state in which the first conductor and the coupling component are in electrical contact, wherein the insulating section is configured to deform from the basic state into the contact state during a connection process of the connecting device to a second connecting device which is assigned to a second conductor by interaction with a corresponding deformation section of the second connecting device.

[0038] The features, technical effects, advantages and embodiments described with regard to the connection system apply analogously to the connection device.

[0039] For the reasons stated above, the coupling component is preferably captively coupled to the insulating section. For this purpose, the coupling component can have a flange and the insulating section a holder, with the flange of the coupling component engaging the holder of the insulating section in the initial state.

[0040] For the reasons mentioned above, the insulating section may have an elliptical or oval ring shape in the basic state and may be designed to deform into a ring shape of lower eccentricity, preferably into a circular ring shape, during the connection process to establish the contact state.

[0041] For the reasons mentioned above, the connecting device may comprise a protective cover and a base sandwiching the first conductor, the insulating portion and at least a part of the coupling component.

[0042] Further advantages and features of the present invention will become apparent from the following description of preferred embodiments. The features described therein can be implemented alone or in combination with one or more of the features presented above, provided the features do not contradict each other. The following description of preferred embodiments is provided with reference to the accompanying drawings. Short description of the characters

[0043] Preferred further embodiments of the invention are explained in more detail in the following description of the figures. In the figures: Fig. 1a to 1c show a sectional view of a connection system for connecting a first electrical line to a second electrical line, shown in three assembly stages; Fig. 2a and Fig. 2b is an isometric view of a first connecting device of the connecting system in the unconnected and connected state; and Fig. 3a and Fig. 3b a plan view of the first connecting device of the connecting system in the unconnected and connected state. Detailed description of preferred embodiments

[0044] Preferred embodiments are described below with reference to the figures. Identical, similar, or equivalent elements in the different figures are provided with identical reference numerals, and a repeated description of these elements is partially omitted to avoid redundancy.

[0045] The Fig. 1a to 1c show a sectional view of a connection system 1 for connecting a first electrical conductor 100 to a second electrical conductor 200, shown in three assembly stages. The connection system 1 is particularly suitable for use in the high-voltage range (>60 V).

[0046] The connection system 1 comprises a first connection device 10, which is assigned to the first electrical conductor 100, and a second connection device 20, which is assigned to the second electrical conductor 200. The first connection device 10 is also referred to herein as the "connection device." The two connection devices 10, 20 are assemblies, preferably preassembled, which can be releasably connected to one another and thus establish or break electrical contact between the two electrical conductors 100, 200.

[0047] The first connecting device 10 has an insulating section 11 which is electrically non-conductive and is thus made entirely or at least partially of an electrically insulating material, for example plastic. The insulating section 11 is designed to be deformable, for example elastic, as is particularly clear from a comparison of the Fig. 2a and Fig. 2b and 3a and 3b. The insulating section 11 can be formed in one or more parts.

[0048] The insulating section 11 is preferably designed as an insulating ring. The insulating section 11 is then designed to be deformable, in particular with respect to its ring shape. In a basic state, i.e., in the elastic case in the absence of a deforming force, the insulating section 11 can have an elliptical or oval ring shape (cf. Fig. 2a and Fig. 3a), while in a deformed state it has a circular ring shape (cf. Fig. 2b and Fig. 3b). The thus deformed state of the insulating section 11 is also referred to herein as the contact state, since it allows electrical contact between the first conductor 100 and the coupling component 12 mentioned below. The technical function of the deformable insulating section 11 will become clear further below in the description of the functioning of the connection system 1. First, however, the structural design of the connection system 1 according to the present embodiment will be described further.

[0049] The first connecting device 10 further comprises a coupling component 12 made of a conductive material, preferably copper. The coupling component 12 is preferably a sleeve, in particular a collar sleeve, comprising a sleeve body 12a and a collar or flange 12b.

[0050] The insulating section 11 is arranged such that, in the basic state, it is at least partially arranged between the first conductor 100 and the coupling component 12. The insulating section 11 is arranged, designed and configured in the basic state such that it ensures a sufficient distance between the first conductor 100 and the coupling component 12 so that the coupling component 12 in the basic state according to the Fig. 1a, Fig. 2a and Fig. 3a, in which the two connecting devices 10, 20 are not connected to each other, is spaced apart from the first conductor 100 and is therefore not subject to current or voltage. In the basic state, the coupling component 12, together with the insulating section 11, thus functions as a contact protection device.

[0051] The coupling component 12 can be captively coupled to the insulating section 11, which facilitates pre-assembly of the connecting device 10 and its use. The captivity can be achieved by engaging the flange 12b of the coupling component 12 (if the coupling component 12 is designed as a collar sleeve) in a holder 11a of the insulating section 11. In the present embodiment, the holder 11a comprises two snap-in lugs, behind which the flange 12b of the coupling component 12 engages. However, the captivity can also be achieved in other ways, for example, by a tongue and groove connection, by engaging one or more pins in a corresponding opening, and the like.

[0052] A further development can consist of a combination of captive protection and contact protection, in particular according to IPxxB. This means that the connecting device 10 is pre-assembled in a completely captive manner and that the insulating section 11 cannot be deformed into the contact state by hand (or with an IPxxB standard finger).

[0053] In the present embodiment, the first connecting device 10 further comprises a protective cover 13 and a base 14, which sandwich the first conductor 100, the insulating section 11, and a portion of the coupling component 12, including the flange 12b. The protective cover 13 and the base 14 are electrically insulating.

[0054] For the mechanical connection of the first conductor 100 to the second conductor 200, the first conductor 100 according to the present embodiment has a screw opening 110 (cf. Fig. 1a, Fig. 1b) with a thread 111 (cf. Fig. 1c).

[0055] However, a screw connection 110 is not absolutely necessary. Alternatively, a plug connection based on a positive and / or frictional connection, a clamp connection, or another suitable connection technology can be used, which ensures a secure and detachable connection to the second conductor 200.

[0056] The second connecting device 20 has the aforementioned connecting portion 21, which is configured to mechanically and detachably connect the two connecting devices 10, 20. The connecting portion 21 can be designed as a screw or can comprise one in order to engage the thread 111 of the screw opening 110 of the first conductor 100.

[0057] The mechanical connection between the first conductor 100 and the second conductor 200 does not have to be established by direct contact between the connecting portion 21 and the first conductor 100. Rather, it is possible for a corresponding counterpart for engagement with the connecting portion 21 to be part of the first connecting device 10, for example in the form of a nut.

[0058] The second connecting device 20 further comprises a deformation section 22 configured to deform the insulating section 11 from the basic state into the contact state during the connection process of the two connecting devices 10, 20. According to the present exemplary embodiment, the deformation section 22 can be designed as a sleeve, in particular a thin-walled sleeve, which, during the connection process of the two connecting devices 10, 20, moves between the holder 11a of the insulating section 11 and the coupling component 12, thereby deforming the insulating section 11 and releasing the coupling between the insulating section 11 and the coupling component 12.In the present embodiment, the insulating section 11, which is elliptical or oval in the basic state, is pressed apart at the vertices of the minor axis by the deformation section 22, whereby the engagement of the flange 12b of the coupling component 12 with the snap lugs of the holder 11a is canceled.

[0059] The insulating section 11 loses its spacing function during the connection process of the two connecting devices 10, 20 as soon as it is deformed by the deformation section 22 of the second connecting device 20 from the basic state into the contact state.

[0060] In the present embodiment, the second connecting device 20 further comprises a protective covering 23, which at least partially surrounds the second conductor 200 and the connecting section 21. The protective covering 23 is insulating.

[0061] Preferably, the protective covering 23 and the deformation section 22 are formed in one piece, whereby the cancellation of the spacing function of the insulating section 11 and the contact protection of the second conductor 200 can be structurally realized in a synergistic manner.

[0062] The first connecting device 10, in particular its insulating section 11, is preferably designed such that the deformation of the insulating section 11 to eliminate the spacing function is not possible with a testing device, such as an IPXXB standard finger.

[0063] The deformation of the insulating section 11 to eliminate the spacing function can be reversible, in particular due to an elastic nature of the insulating section 11, so that the spacing function can be re-established after any separation of the two connecting devices 10, 20, for example in the case of maintenance or rework.

[0064] Both connecting devices 10, 20 have insulating parts, in particular plastic parts, in order to ensure contact protection both before closing or connecting and afterward.

[0065] In the case of a connecting section 21 designed as a screw connector, which interacts with a screw opening 110 of the first conductor 100 or the like, one or more washers (not shown in the figures) with insulating properties can be provided. Ideally, such washers are made of a hard material to ensure appropriate preload in the screw connection.

[0066] The connection process of the two connecting devices 10, 20 is divided into three assembly stages in the Fig. 1a to 1c shown.

[0067] In a first assembly stage according to the Fig. 1a, the two connecting devices 10, 20 are moved towards each other in a connecting direction which corresponds to the axial direction of the connecting section 21 and the coupling component 12.

[0068] In a second assembly stage according to the Fig. 1b, the connecting section 21 is inserted into the coupling component 12 and the insulating section 11, which is arranged concentrically thereto except for the elliptical or oval basic state, until the connecting section 21 engages in the screw opening 110 of the first conductor 100.

[0069] In a third assembly stage according to Fig.1c, the connecting portion 21 is further screwed into the screw hole 110 of the first conductor 100. The deformation portion 22 enters between the support 11a of the insulating portion 11 and the coupling component 12, thereby deforming the insulating portion 11 from the ground state to the contact state, thereby releasing the coupling between the insulating portion 11 and the coupling component 12. The coupling component 12 comes into electrical contact with the first conductor 100, thereby completing the connection process.

[0070] The connection system 1 provides contact protection for current-carrying or voltage-carrying components with a comparatively small number of individual parts. This not only reduces resources and costs, but also simplifies the pre-assembly of the connecting devices 10, 20 forming the connection system 1. The connection system 1 is fail-safe and reliable.

[0071] The nature of the individual parts, including geometry, material, etc., is structurally comparatively simple, resulting in a robust design and low installation space requirements.

[0072] The structural simplification of the connection system 1 results, among other things, from the fact that the coupling component 12 of the first connecting device 10 creates a synergistic effect by performing a dual function. It functions both as a contact protection device in the separated state and as a current conductor when the two connecting devices 10, 20 are connected.

[0073] Where applicable, all individual features presented in the embodiments may be combined and / or exchanged without departing from the scope of the invention. List of reference symbols 1 connection system 10 First connecting device 11 Insulation section 11a Bracket 12 coupling component 12a sleeve body 12b flange 13 Protective cover 14 Base 20 Second connecting device 21 connecting section 22 Deformation section 23 Protective cover 100 First electrical conductor 110 screw opening 111 threads 200 Second electrical conductor

Claims

[1] Connection system (1) for electrically connecting two conductors, the connection system (1) comprising: a first conductor (100) and a second conductor (200); a first connecting device (10) which is assigned to the first conductor (100) and has an electrically non-conductive insulating section (11), preferably designed as an annular insulating ring, and an electrically conductive coupling component (12), preferably designed as a sleeve-shaped electrically conductive sleeve, wherein the insulating section (11) is deformable, preferably elastically deformable, between a basic state in which the insulating section (11) is at least partially arranged between the first conductor (100) and the coupling component (12) such that the first conductor (100) and the coupling component (12) are electrically separated from one another, and a contact state in which the first conductor (100) and the coupling component (12) are in electrical contact; and a second connecting device (20) associated with the second conductor (200) and a deformation section (22) which is configured to deform the insulating section (11) from the basic state to the contact state during the connection process of the two connecting devices (10, 20), so that the first conductor (100), the coupling component (12) and the second conductor (200) come into electrical contact. [2] Connection system (1) according to claim 1, characterized by that the deformation section (22) is designed such that it enters at least partially between the insulating section (11) and the coupling component (12) during the connection process of the two connecting devices (10, 20), whereby the insulating section (11) is deformed from the basic state into the contact state. [3] Connection system (1) according to claim 1 or 2, characterized by that the coupling component (12) is captively coupled to the insulating section (11). [4] Connection system (1) according to claim 3, characterized byin that the coupling component (12) has a flange (12b) and the insulating section (11) has a holder (11a), preferably comprising one or more snap lugs, wherein the flange (12b) of the coupling component (12) engages in the holder (11a) of the insulating section (11) in the basic state. [5] Connection system (1) according to claims 2 and 4, characterized by in that the deformation section (22) is designed to enter between the holder (11a) of the insulating section (11) and the coupling component (12) during the connection process of the two connecting devices (10, 20), whereby the loss security between the insulating section (11) and the coupling component (12) is eliminated and the insulating section (11) is deformed from the basic state into the contact state. [6] Connection system (1) according to one of the preceding claims, characterized byin that the insulating section (11) has an elliptical or oval ring shape in the basic state, wherein the deformation section (22) of the second connecting device (20) is designed to deform the insulating section (11) into a ring shape of lower eccentricity, preferably into a circular ring shape, during the connection process of the two connecting devices (10, 20) in order to establish the contact state. [7] Connection system (1) according to one of the preceding claims, characterized by that the second connecting device (20) has a connecting portion (21) which is designed to releasably connect the two connecting devices (10, 20) to one another in a mechanical manner. [8] Connection system (1) according to claim 7, characterized by that the connecting section (21) is or comprises a screw, wherein the screw is preferably designed to engage in a screw opening (110) of the first conductor (100). [9] Connection system (1) according to claim 2 and 8, characterized by that the deformation section (22) is arranged concentrically to the connecting section (21). [10] Connection system (1) according to one of the preceding claims, characterized by that the first connecting device (10) has a protective cover (13) and a base (14) which sandwich the first conductor (100), the insulating section (11) and at least part of the coupling component (12). [11] Connection system (1) according to one of the preceding claims, characterized by that the second connecting device (20) has a protective covering (23) which at least partially surrounds the second conductor (200) and the connecting section (21), wherein the protective covering (23) and the deformation section (22) are preferably formed in one piece. [12] Arrangement for electrically connecting two conductors, the arrangement comprising: a first conductor (100); and a connecting device (10) comprising an electrically non-conductive insulating section (11), which is preferably annular, and an electrically conductive coupling component (12), which is preferably sleeve-shaped, wherein the insulating section (11) is deformable, preferably elastically deformable, between a basic state in which the insulating section (11) is at least partially arranged between the first conductor (100) and the coupling component (12) such that the first conductor (100) and the coupling component (12) are electrically separated from one another, and a contact state in which the first conductor (100) and the coupling component (12) are in electrical contact, wherein the insulating section (11) is configured to deform from the basic state into the contact state during a connection process of the connecting device (10) with a second connecting device (20) associated with a second conductor (200) by interaction with a corresponding deformation section (22) of the second connecting device (20). [13] Arrangement according to claim 12, characterized by that the coupling component (12) is captively coupled to the insulating section (11), wherein preferably the coupling component (12) has a flange (12b) and the insulating section (11) has a holder (11a), wherein the flange (12b) of the coupling component (12) engages in the holder (11a) of the insulating section (11) in the basic state. [14] Arrangement according to claim 12 or 13, characterized bythat the insulating section (11) has an elliptical or oval ring shape in the basic state and is designed to deform into a ring shape of lower eccentricity, preferably into a circular ring shape, during the connection process to establish the contact state. [15] Arrangement according to one of claims 12 to 14, characterized by that the connecting device (10) has a protective cover (13) and a base (14) which sandwich the first conductor (100), the insulating section (11) and at least part of the coupling component (12).

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